Honda BF40, BF50 Owner's Manual

C 2004 Honda Motor Co., Ltd. -All Rights Reserved	2005

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Keep this owner’s manual handy, so you can refer to it at any time. This owner’s manual is considered a permanent part of the outboard motor and should remain with the outboard motor if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.

Congratulations on your selection of a Honda outboard motor. We are certain you will be pleased with your purchase of one of the finest outboard motors on the market.

We want to help you get the best results from your new outboard motor and to operate it safely. This manual contains the information on how to do that; please read it carefully.

As you read this manual you will find information preceded by a

symbol. That information is intended to help you avoid damage to your outboard motor, other property, or the environment.

INTRODUCTION

We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership.

When your outboard motor needs scheduled maintenance, keep in mind that your Honda marine dealer is specially trained in servicing Honda outboard motors. Your Honda marine dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.

2004 Honda Motor Co., Ltd. All

Rights Reserved

1

INTRODUCTION

A FEW WORDS ABOUT SAFETY

Your safety and the safety of others are very important. And using this outboard motor safely is an important responsibility.

To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

Of course, it is not practical or possible to warn you about all the hazards associated with operating or maintaining an outboard motor. You must use your own good judgment.

You will find important safety information in a variety of forms, including:

Safety Labels on the outboard motor.

Safety Messages preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

Safety Headings such as IMPORTANT SAFETY INFORMATION.

Safety Section such as OUTBOARD MOTOR SAFETY.

Instructions how to use this outboard motor correctly and safely.

This entire book is filled with important safety information please read it carefully.

2

OUTBOARD MOTOR SAFETY...................................	. 7
IMPORTANT SAFETY INFORMATION................	. 7
SAFETY LABEL LOCATIONS................................	. 9
CONTROLS AND FEATURES ...................................	10
CONTROL AND FEATURE
IDENTIFICATION CODES .................................	10
COMPONENT AND CONTROL LOCATIONS .....	11
CONTROLS...............................................................	16
LH and LHT Types (long tiller handle)
Ignition Switch .......................................................	16
Emergency Stop Switch and Switch Clip..............	16
Throttle Grip...........................................................	17
Throttle Friction Adjuster ......................................	18
Gearshift Lever ......................................................	18
Steering Friction Adjuster......................................	18
Tilt Lever (gas assist/LH type) ..............................	19
LRT and XRT Types (remote control)
Ignition Switch (side-mount type) .........................	19
Switch Clip and Emergency Stop Switch
(side-mount type) ...............................................	20
Fast Idle Lever (side-mount type)..........................	21
Gearshift/Throttle Control Lever
(side-mount type) ...............................................	21

CONTENTS
Common Controls
Power Trim/Tilt Switch (LRT and XRT types)
(side-mount type) ...............................................	23
Power Tilt Switch (LHT, LRT and XRT types)....	23
Manual Relief Valve
(LHT, LRT and XRT types) ..............................	24
Tilt Lock Lever ......................................................	24
Engine Cover Latches ............................................	24
Transom Angle Adjusting Rod ..............................	25
Trim Tab.................................................................	25
INSTRUMENTS........................................................	26
Trim Meter (optional equipment) ..........................	26
Tachometer (optional equipment)..........................	26
Fuel Gauge (optional equipment) ..........................	26
INDICATORS............................................................	27
Oil Pressure Indicator.............................................	27
Overheat Indicator..................................................	28
Cooling System Indicator ......................................	29

3

CONTENTS

OTHER FEATURES .................................................	29
Overrev Limiter......................................................	29
Anodes....................................................................	29
Portable Fuel Tank (optional equipment) ..............	30
Fuel Cap Vent Knob (optional equipment) ...........	30
Fuel Priming Bulb..................................................	31
BEFORE OPERATION.................................................	32
ARE YOU READY TO GET UNDER WAY ......	32
IS YOUR OUTBOARD MOTOR
READY TO GO .................................................	32
OPERATION .................................................................	34
SAFE OPERATING PRECAUTIONS .....................	34
BREAK-IN PROCEDURE........................................	34
TRANSOM ANGLE ADJUSTMENT ......................	35
PORTABLE FUEL TANK (optional equipment).....	36
FUEL HOSE CONNECTIONS.................................	36
FUEL PRIMING........................................................	37

STARTING THE ENGINE .......................................	37
LH and LHT Types (long tiller handle).................	37
LRT and XRT Types (remote control) ..................	39
EMERGENCY STARTING......................................	42
STOPPING THE ENGINE........................................	45
Emergency Engine Stopping .................................	45
Normal Engine Stopping........................................	45
GEARSHIFTING AND
THROTTLE OPERATION ...............................	47
LH and LHT Types (long tiller handle).................	47
LRT and XRT Types (remote control) ..................	48
STEERING ................................................................	49
LH and LHT Types (long tiller handle).................	49
LRT and XRT Types (remote control) ..................	49
CRUISING .................................................................	50
TRIM TAB.................................................................	52
SHALLOW WATER OPERATIONS.......................	52
MOORING, BEACHING, LAUNCHING................	54

4

CONTENTS

SERVICING YOUR OUTBOARD MOTOR ...............	56
THE IMPORTANCE OF MAINTENANCE ............	56
MAINTENANCE SAFETY ......................................	57
TOOL KIT (optional equipment) AND
EMERGENCY STARTER ROPE ........................	58
MAINTENANCE SCHEDULE ................................	59
TRIM TAB ADJUSTMENT .....................................	61
MANUAL RELIEF VALVE.....................................	62
ENGINE COVER REMOVAL AND
INSTALLATION ..............................................	62
Engine Oil Level Check.........................................	63
Engine Oil Change .................................................	64
Engine Oil Recommendations ...............................	66
Lubrication Points ..................................................	67
Spark Plug Service .................................................	68
REFUELING..............................................................	70
FUEL RECOMMENDATIONS................................	71
Fuel Pump Filter Inspection and Replacement......	72
Portable Fuel Tank and Filter Cleaning
(optional equipment) ..........................................	74
Anode Replacement ...............................................	75
Propeller Replacement ...........................................	76

STORAGE .....................................................................	77
STORAGE PREPARATION ....................................	77
Cleaning and Flushing ...........................................	77
Fuel.........................................................................	80
Engine Oil ..............................................................	81
STORAGE PRECAUTIONS ....................................	82
REMOVAL FROM STORAGE................................	82
TRANSPORTING .........................................................	83
WITH OUTBOARD MOTOR INSTALLED
ON BOAT ..............................................................	83
WITH OUTBOARD MOTOR REMOVED
FROM BOAT ........................................................	83
TAKING CARE OF UNEXPECTED
PROBLEMS...........................................................	84
BATTERY WILL NOT CHARGE AND
ELECTRIC STARTER WILL NOT OPERATE..	89
OIL PRESSURE INDICATOR LIGHT GOES OFF
AND ENGINE SPEED IS LIMITED....................	90
OVERHEAT INDICATOR LIGHT COMES
ON AND ENGINE SPEED IS LIMITED.............	91
SUBMERGED MOTOR ...........................................	92

5

CONTENTS
TECHNICAL AND CONSUMER INFORMATION... 94
TECHNICAL INFORMATION...............................		. 94
Serial Number Locations ......................................		. 94
Carburetor Modification for High Altitude
Operation...........................................................		. 95
Battery ...................................................................		. 95
Oxygenated Fuels..................................................		. 96
Emission Control System Information .................		. 97
Star Label ..............................................................		. 99
Specifications......................................................	.	101
CONSUMER INFORMATION .............................	.	103
Customer Service Information............................	.	103
Distributors Limited Warranty 2005 ..............		104
Emission Control System Warranty ....................		106
INDEX.........................................................................	.	108
WIRING DIAGRAMS.........................	Inside Back Cover

6

IMPORTANT SAFETY INFORMATION

Honda BF40A and BF50A outboard motors are designed for use with boats that have a suitable manufacturer’s power recommendation. Other uses can result in injury to the operator or damage to the outboard motor and other property.

Most accidents can be prevented if you follow all instructions in this manual and on the outboard motor. The most common hazards are discussed below, along with the best way to protect yourself and others.

OUTBOARD MOTOR SAFETY

Operator Responsibility

It is the operator’s responsibility to provide the necessary safeguards to protect people and property. Know how to stop the engine quickly in case of emergency. Understand the use of all controls.

Stop the engine immediately if anyone falls overboard, and do not run the engine while the boat is near anyone in the water.

Always stop the engine if you must leave the controls for any reason.

Attach the emergency stop switch lanyard securely to the operator.

Always wear a PFD (Personal Flotation Device) while on the boat.

Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors.

Be sure that anyone who operates the outboard motor receives proper instruction.

Be sure the outboard motor is properly mounted on the boat.

Do not remove the engine cover while the engine is running.

7

OUTBOARD MOTOR SAFETY

Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a wellventilated area, with the engine stopped. Never smoke near gasoline, and keep other flames and sparks away.

Remove any portable fuel tank from the boat for refueling. Keep the portable fuel tank away from the battery or other potential spark sources.

Refuel carefully to avoid spilling fuel. Avoid overfilling the fuel tank.

After refueling, tighten the filler cap securely. If any fuel is spilled, make sure the area is dry before starting the engine.

Carbon Monoxide Hazard

Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run the engine in a closed garage or confined area.

8

OUTBOARD MOTOR SAFETY

SAFETY LABEL LOCATIONS

The labels shown here contain important safety information. Please read them carefully. These labels are considered permanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized Honda Marine servicing dealer for a replacement.

9

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

Model		BF40A			BF50A
Type	LH	LHT	LRT	LHT	LRT	XRT
	L
Shaft Length
	X
Long Tiller Handle
Remote Control
Gas Assist Tilt
Power Trim/Tilt
Tachometer (optional equipment)
Trim Meter (optional equipment)

Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.

TYPE CODE (Example)

L R T

T=Power Trim/Tilt

H=Long Tiller Handle

R=Remote Control

L=Long Shaft

X=Extra Long Shaft

10

CONTROLS AND FEATURES

COMPONENT AND CONTROL LOCATIONS LH and LHT Types

(long tiller handle)

FUEL HOSE CONNECTOR

OIL LEVEL LONG TILLER ENGINE COVER DIPSTICK HANDLE

POWER TILT SWITCH

(LHT type) COOLING

		SYSTEM
		INDICATOR
	STERN	ENGINE OIL
	BRACKET
		DRAIN PLUG
		COVER

TRANSOM ANGLE		ANTIVENTILATION
ADJUSTING ROD
		PLATE
		TRIM TAB (anode)
GEAR OIL LEVEL
CHECK PLUG		EXHAUST PORT
WASH PLUG	GEAR OIL	PROPELLER
(Flush plug)	DRAIN PLUG	(optional equipment)

OIL FILLER CAP

TILT LOCK LEVER

TILT LEVER (LH type)

MANUAL RELIEF VALVE

(LHT Type)

WATER INTAKE

11

CONTROLS AND FEATURES

OIL PRESSURE	SWITCH CLIP
INDICATOR LIGHT
GEAR SHIFT
OVERHEAT
INDICATOR LIGHT	EMERGENCY STOP SWITCH
THROTTLE FRICTION ADJUSTER

	LANYARD
POWER TRIM/TILT SWITCH	STEERING FRICTION ADJUSTER
(LHT type)
	THROTTLE GRIP
	IGNITION SWITCH
	IGNITION SWITCH KEY

12

	CONTROLS AND FEATURES
LRT and XRT Types (remote control)
ENGINE COVER	OIL FILLER CAP
POWER TILT SWITCH
FUEL HOSE	TILT LOCK LEVER
CONNECTOR	OIL LEVEL
	DIPSTICK
STEERING
PLATE

TRANSOM ANGLE

ADJUSTING ROD

GEAR OIL LEVEL

CHECK PLUG

WASH PLUG (Flush plug)

COOLING SYSTEM

INDICATOR

ENGINE OIL DRAIN

PLUG COVER

TRIM TAB (anode)

EXHAUST PORT

PROPELLER

(optional equipment)

GEAR OIL DRAIN PLUG

STERN

BRACKET

MANUAL RELIEF

VALVE

ANTIVENTILATION

PLATE

WATER INTAKE

13

CONTROLS AND FEATURES

Remote Control box (side mount type/optional equipment)

	GEARSHIFT/THROTTLE
POWER TRIM/TILT SWITCH	CONTROL LEVER
	NEUTRAL RELEASE LEVER
	OIL PRESSURE INDICATOR LIGHT
SPARE SWITCH CLIP
	OVERHEAT INDICATOR LIGHT
BUZZER (inside of the box)	FAST IDLE LEVER
IGNITION SWITCH	IGNITION SWITCH KEY

LANYARD

THROTTLE FRICTION ADJUSTER

EMERGENCY STOP SWITCH

SWITCH CLIP

14

	CONTROLS AND FEATURES
Fuel Tank (optional equipment)	Tachometer
	(optional equipment)
	FUEL GAUGE
	VENT KNOB

FUEL TANK

FUEL CAP

Trim Meter (optional equipment)

FUEL HOSE

	FUEL HOSE CONNECTOR
PRIMING BULB	(female)

15

CONTROLS AND FEATURES

CONTROLS

LH and LHT Types (long tiller handle)

Ignition Switch

IGNITION SWITCH

ON

START

OFF

The ignition switch controls the ignition system and starter motor.

Turning the ignition switch key to the START position operates the starter motor. The key automatically returns to the ON position when released from the START position.

The ignition switch can be used to start the engine only when the gearshift lever (p. 18 ) is in the N (neutral) position, and the switch clip is in the emergency stop switch.

Turning the ignition switch to the OFF position stops the engine.

Emergency Stop Switch and

Switch Clip

EMERGENCY STOP SWITCH

LANYARD

SWITCH CLIP

SWITCH CLIP

LANYARD

16

CONTROLS AND FEATURES

The switch clip must be inserted in the engine stop switch in order for the engine to start and run. The lanyard should be attached to the operator’s PFD (Personal Flotation Device) or worn around the wrist as shown.

When used as described, the emergency stop switch and lanyard system stops the engine if the operator falls away from the controls.

A spare switch clip is supplied with the motor (LH and LHT types).

Throttle Grip	The throttle grip controls engine
	speed.
	An index mark on the tiller arm
	shows throttle position and is helpful
	for setting the throttle correctly when
	starting (p. 38 ).

INCREASE

THROTTLE GRIP

THROTTLE INDEX MARK

17

CONTROLS AND FEATURES

Throttle Friction Adjuster

THROTTLE FRICTION

ADJUSTER

FIX

RELEASE

THROTTLE GRIP

The throttle friction adjuster adjusts resistance to throttle grip rotation.

Turn the adjuster clockwise to increase friction for holding a throttle setting while cruising.

Turn the adjuster counterclockwise to decrease friction for easy throttle grip rotation.

Gearshif t Lever

N (neutral) R (reverse)

F (forward)

GEARSHIFT

LEVER

The gearshift lever is used to select F (forward), N (neutral), or R (reverse) gears.

The engine can be started with the gearshift lever in the N (neutral) position only.

Steering Friction Adjuster

STEERING FRICTION ADJUSTER

LOCK

FREE

The steering friction adjuster adjusts steering resistance.

Less friction allows the outboard motor to turn more easily. More friction helps to hold steady course while cruising or to prevent the outboard motor from swinging while trailering the boat.

18

CONTROLS AND FEATURES

Tilt Lever

(gas assist/LH type)

FREE

LOCK

TILT LEVER

Moving the tilt lever to the FREE position allows the motor to be tilted and moving the tilt lever to the LOCK position locks the motor in the desired position. Use the tilt lever to temporarily tilt the motor when the boat is operating in shallow water, or mooring in shallow water. The tilt lever must be in the LOCK position before operating the motor or the motor could tilt up when operating in reverse.

LRT and XRT Types (remote control/optional equipment)

For panel mount or top mount remote control information, refer to the instructions provided with the remote control equipment.

Ignition Switch (side-mount type)

ON START

OFF

IGNITION

SWITCH

EMERGENCY STOP SWITCH

SWITCH CLIP

The ignition switch controls the ignition system and starter motor.

19

CONTROLS AND FEATURES

Turning the ignition switch key to the START position operates the starter motor. The key automatically returns to the ON position when released from the START position.

The ignition switch can be used to start the engine only when the gearshift lever (p. 18 ) is in the N (neutral) position, and the switch clip is in the emergency stop switch.

Turning the ignition switch to the OFF position stops the engine.

Switch Clip and Emergency Stop Switch (side-mount type)

EMERGENCY

STOP SWITCH

LANYARD

SWITCH CLIP

LANYARD SWITCH CLIP

The switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The lanyard must be attached to the operator’s PFD (Personal Flotation Device) or worn around the wrist as shown.

When used as described, the emergency stop switch and lanyard system stops the engine if the operator falls away from the controls.

A spare switch clip is stored in a slot in the control housing.

SPARE SWITCH CLIP

20

CONTROLS AND FEATURES

Fast Idle Lever (side-mount type)

	N (neutral)
	GEARSHIFT/THROTTLE	FAST IDLE
	CONTROL LEVER

START

FAST IDLE LEVER

The fast idle lever is used to set idle speed during warm-up.

The lever will not move unless the gearshift/throttle control lever is in the N (neutral) position. Conversely, the gearshift/throttle control lever will not move unless the fast idle lever is in the lowest position.

Leave the fast idle lever in the START position to provide a rich fuel mixture for starting a cold engine.

Lift the fast idle lever to warm up a cold engine after starting and to start a warm engine.

Gearshif t/Throttle Control Lever (side-mount type)

GEARSHIFT/THROTTLE

CONTROL LEVER

NEUTRAL

RELEASE

LEVER

The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle.

21

CONTROLS AND FEATURES

The gearshift/throttle control lever controls engine speed and selects F (forward), N (neutral), or R (reverse) gears.

Moving the control lever 30° from N (neutral) selects the gear, and further movement increases engine speed.

A friction adjuster near the base of the control lever adjusts the operating resistance of the control lever (p. 48 ).

Less friction allows easier control lever movement. More friction helps to hold a steady throttle setting while cruising.

GEARSHIFT/THROTTLE

CONTROL LEVER

N (neutral)

F (forward)

R (reverse)

ENGINE SPEED

ENGINE

SPEED

HIGH

HIGH

22

CONTROLS AND FEATURES

Common Controls

Power Trim/Tilt Switch [LRT and XRT types (sidemount type)]

CONTROL LEVER

Press UP to trim or tilt the motor up.

Press DN to trim or tilt the motor down.

POWER TRIM/TILT SWITCH

(LHT type)

POWER TRIM/TILT SWITCH

Press UP to trim or tilt the motor up.

Press DN to trim or tilt the motor down.

The power trim/tilt switch is located on the control lever or the tiller handle. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.

You can use the power trim/tilt switch anytime without turning the ignition switch is ON, whether the boat is underway or stopped.

Trim the outboard motor to obtain the best performance and stability (p. 50 ).

Tilt the outboard motor for shallow water operation, beaching, launching, or mooring.

Power Tilt Switch

(LHT, LRT and XRT types)

POWER TILT SWITCH

The power tilt switch is located on the engine pan. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.

The power tilt switch will operate without turning the ignition switch ON.

This switch is used with the engine stopped to raise the outboard motor for mooring, trailering or maintenance.

23

CONTROLS AND FEATURES

Manual Relief Valve (LHT, LRT and XRT types)

RIGHT STERN BRACKET

POWER	MANUAL
(To fix)	(To release)

MANUAL RELIEF VALVE

The outboard motor can be tilted manually after opening the manual relief valve. This allows the outboard motor to be tilted when no battery is connected.

Tilt Lock Lever

TILT LOCK LEVER

FREE

LOCK

The tilt lock lever is used to support the outboard motor in the fully-raised position.

When the boat is to be moored for a long time, tilt the outboard motor as far as it will go. Then move the tilt lock lever to the LOCK position, and gently lower the outboard motor until the lever contacts the stern bracket.

Engine Cover Latches

FRONT

UNLATCH	FIX
ENGINE COVER LATCH
REAR

UNLATCH

FIX

ENGINE COVER LATCH

The engine cover latches fasten the engine cover to the outboard motor.

24

CONTROLS AND FEATURES

Transom Angle Adjusting Rod

STERN BRACKET

TURN UP

PUSH

TRANSOM ANGLE ADJUSTING ROD

TO CHANGE UNLOCKED POSITION

TO LOCK

LOCKED POSITION

TRANSOM ANGLE ADJUSTING ROD

The transom angle adjusting rod limits the tilt angle of the outboard motor when fully lowered.

Proper adjustment prevents the outboard motor from being trimmed too low (p. 50 ).

Trim Tab

TIGHTENING BOLT

TRIM TAB

PROPELLER

The trim tab compensates for ‘‘torque steer,’’ which is a reaction of the outboard motor to propeller rotation.

If uncompensated, torque steer would make the outboard motor tend to turn to one side.

When the trim tab is correctly adjusted (p. 61 ), steering effort is equal in either direction.

25

CONTROLS AND FEATURES

INSTRUMENTS

Trim Meter

[optional equipment (LHT, LRT and XRT Types)]

TRIM METER

The trim meter has a range of 0° to 16° and indicates the trim angle of the outboard motor.

Refer to the trim meter when using the power trim/tilt switch to achieve proper boat performance.

Tachometer (optional equipment)

TACHOMETER

The tachometer shows engine speed in revolutions per minute.

Refer to the tachometer when using the throttle and power trim/tilt controls to achieve the best performance from the boat.

Fuel Gauge

(optional equipment)

FUEL GAUGE

A fuel gauge is built into the cap of the portable fuel tank (optional equipment).

26

CONTROLS AND FEATURES

INDICATORS

Oil Pressure Indicator

LH and LHT Types

(GREEN)

LRT and XRT Types (side-mount type)

(GREEN)

BUZZER

When the green light is lit, oil pressure is OK.

If oil pressure becomes low, the green light will go off, and the engine protection system will limit engine speed. Refer to TAKING CARE OF UNEXPECTED PROBLEMS, p. 90 .

Remote controls are also equipped with a buzzer that sounds when the green light goes off.

The buzzer sound stops below an engine speed of 1,400 rpm.

Low oil pressure indicates that the engine oil level is low, or that there is a problem with the engine lubrication system.

27

CONTROLS AND FEATURES

Overheat Indicator

LH and LHT Types

(RED)

LRT and XRT Types (side-mount type)

(RED)

BUZZER

If the engine overheats, the red light will come on, and the engine protection system will limit engine speed.

If the condition persists for another 20 seconds, the engine will shut off. When normal engine temperature is restored, the engine speed will gradually rise to normal engine speed. Refer to TAKING CARE OF UNEXPECTED PROBLEMS, p. 91 .

Remote controls are also equipped with a buzzer that sounds when the red light comes on.

Engine overheating may be the result of clogged water intakes.

28