Honda BF4A, BF5D, BF6A Owner's Manual

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Owner`s Manual

BF4A

Includes US and Canadian Models

•

BF5D • BF6A

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 whatsoever. No part of this publication may be reproduced without written permission.

INTRODUCTION

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 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.

We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership (see page 112).

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.

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.

CONTENTS

OUTBOARD MOTOR SAFETY ................................... 6

IMPORTANT SAFETY INFORMATION .............. 6

SAFETY LABEL LOCATIONS .............................. 8

CONTROLS AND FEATURES ................................... 14

CONTROL AND FEATURE

IDENTIFICATION CODES ............................... 14

COMPONENT AND CONTROL LOCATIONS ... 15

CONTROLS ............................................................ 17

Emergency Stop Switch Clip and Emergency

Stop Switch ..................................................... 17

Choke Knob ........................................................ 17

Throttle Grip ........................................................ 18

Throttle Friction Knob ........................................ 18

Gearshift Lever .................................................... 19

Fuel Valve Lever ................................................. 19

Fuel Filler Cap Vent Knob .................................. 21

Starter Grip .......................................................... 22

Engine Cover Latch .............................................22

Transom Angle Adjusting Rod ........................... 22

Steering Friction Bolt .......................................... 23

Tilt Lever ............................................................. 23

Handle Stopper .................................................... 23

INDICATORS .........................................................24

Oil Pressure Indicator ..........................................24

Cooling System Indicator .................................... 25

OTHER FEATURES ...............................................25

Rev Limiter ..........................................................25

Anode ................................................................... 25

Fuel Hose Connector Cap and Fuel Hose

Connector ........................................................26

Portable Fuel Tank ...............................................26

Fuel Filler Cap Vent Knob ..................................26

Fuel Priming Bulb ...............................................27

Battery Charge Cable ...........................................27

INSTALLATION ..........................................................30

POWER REQUIREMENTS ...................................30

INSTALLATION POSITION .................................30

ATTACHMENT ......................................................31

TRANSOM ANGLE ADJUSTMENT ....................31

BATTERY CONNECTIONS ..................................32

Battery .................................................................32

Battery Terminals ................................................33

BEFORE OPERATION .................................................34

ARE YOU READY TO GET UNDERWAY? ........ 34

IS YOUR OUTBOARD MOTOR

READY TO GO? .................................................34

CONTENTS

OPERATION ................................................................ 36

SAFE OPERATING PRECAUTIONS ................... 36

BREAK-IN PROCEDURE ..................................... 36

TRANSOM ANGLE ADJUSTMENT .................... 37

PRIMING THE CARBURETOR WITH

GASOLINE ......................................................... 37

PORTABLE FUEL TANK ..................................... 39

FUEL HOSE CONNECTIONS .............................. 40

FUEL PRIMING ..................................................... 40

INFREQUENT OR OCCASIONAL USE .............. 41

STARTING THE ENGINE .................................... 41

EMERGENCY STARTING ................................... 45

STOPPING THE ENGINE ..................................... 51

Emergency Engine Stopping ............................... 51

Normal Engine Stopping ..................................... 51

GEARSHIFTING AND THROTTLE

OPERATION ......................................................53

STEERING .............................................................. 54

CRUISING .............................................................. 55

SHALLOW WATER OPERATION ...................... 56

MOORING, BEACHING, LAUNCHING ............. 57

SERVICING YOUR OUTBOARD MOTOR ............... 58

THE IMPORTANCE OF MAINTENANCE .......... 58

MAINTENANCE SAFETY ................................... 59

TOOL KIT AND EMERGENCY STARTER

ROPE ...................................................................60

MAINTENANCE SCHEDULE ..............................61

ENGINE COVER REMOVAL AND

INSTALLATION ................................................63

Engine Oil Level Check ...................................... 64

Engine Oil Change ...............................................65

Engine Oil Recommendations .............................67

Gear Case Oil Change .........................................67

Lubrication Points ................................................69

Spark Plug Service ...............................................70

REFUELING ...........................................................71

FUEL RECOMMENDATIONS .............................. 74

Fuel Filter Inspection and Replacement ..............75

Portable Fuel Tank and Tank Filter Cleaning .....77

Recoil Starter Rope Inspection ............................78

Anode Replacement .............................................78

Propeller and Shear Pin Replacement .................79

CONTENTS

CLEANING AND FLUSHING .................................... 81

Cleaning and Flushing ......................................... 81

STORAGE ..................................................................... 84

Fuel ...................................................................... 84

Engine Oil ........................................................... 86

Engine Cylinder .................................................. 86

STORAGE PRECAUTIONS .................................. 87

REMOVAL FROM STORAGE ............................. 88

TRANSPORTING ......................................................... 89

WITH OUTBOARD MOTOR INSTALLED ON

BOAT .................................................................. 89

WITH OUTBOARD MOTOR REMOVED FROM

BOAT .................................................................. 90

TAKING CARE OF UNEXPECTED PROBLEMS ..... 91

ENGINE WILL NOT START ................................ 91

HARD STARTING OR STALLS AFTER

STARTING ......................................................... 93

ENGINE OVERHEATS ......................................... 94

ENGINE WILL NOT DRIVE THE

PROPELLER BATTERY WILL NOT CHARGE

(Equipped type) ................................................... 96

Fuse Replacement ...............................................96

....................................................... 95

OIL PRESSURE INDICATOR GOES OFF AND

ENGINE SPEED IS LIMITED ........................... 97

SUBMERGED OUTBOARD MOTOR .................. 98

TECHNICAL INFORMATION ..................................100

Serial Number Locations .......................................100

Carburetor Modification for High Altitude

Operation ........................................................... 101

Battery .................................................................... 101

Emission Control System Information ..................102

Star Label ...............................................................104

Specifications .........................................................106

Specifications .........................................................107

Specifications .........................................................108

CONSUMER INFORMATION ..................................109

Dealer Locator Information ...............................109

Honda Publications ............................................109

Customer Service Information ...........................110

Warranty Statements ..............................................112

Distributor’s Limited Warranty ............................. 112

Emission Control System Warranty ...................... 117

Distributor’s Warranty ...........................................122

INDEX .........................................................................125

OUTBOARD MOTOR SAFETY

IMPORTANT SAFETY INFORMATION

The Honda BF4A, BF5D and BF6A 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 injuries or property damage can be prevented if you follow all instructions in this manual and on the outboard motor. The most common hazards are discussed in this chapter, along with the best way to protect yourself and others.

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.

OUTBOARD MOTOR SAFETY

Refuel With Care

• Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a well-ventilated 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 contains poisonous carbon monoxide, a colorless, odorless gas. Breathing carbon monoxide can cause loss of consciousness and may lead to death.

If you run the engine in an area that is confined, or even partly enclosed, the air you breathe could contain a dangerous amount of exhaust gas.

Never run your outboard inside a garage or other enclosure.

Running the engine of your outboard while in an enclosed or partially enclosed area can cause a rapid build-up of toxic carbon monoxide gas.

Breathing this colorless, odorless gas can quickly cause unconsciousness and lead to death.

Only run your outboard engine when it is located in a well ventilated area outdoors.

OUTBOARD MOTOR SAFETY

SAFETY LABEL LOCATIONS

US, Puerto Rico, and US Virgin Islands Types

OUTBOARD MOTOR SAFETY

FUEL CAUTION

PORTABLE FUEL TANK

FUEL CAUTION

CAUTION

KEEP TOTALLY CLOSED WHEN NOT IN USE. KEEP AWAY FROM HEAT, SPARKS, AND OPEN FLAME. SECURE ABOVE DECK IN WELL VENTILATED AREA. DO NOT USE FOR LONG TERM FUEL STORAGE.

DO NOT USE FUEL/OIL MIXTURE.

GASOLINE FLAMMABLE DANGER

DANGER

HARMFUL OR FATAL IF SWALLOWED.

KEEP OUT OF REACH OF CHILDREN.

IF SWALLOWED, DO NOT INDUCE

VOMITING. CALL A PHYSICIAN

IMMEDIATELY.

GASOLINE FLAMMABLE DANGER

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 Marine dealer for a replacement.

OUTBOARD MOTOR SAFETY

Canadian Types

OUTBOARD MOTOR SAFETY

FUEL CAUTION

PORTABLE FUEL TANK

GASOLINE FLAMMABLE DANGER GAZOLINE INFLAMMABLE DANGEREUX

DANGER

HARMFUL OR FATAL IF SWALLOWED.

KEEP OUT OF REACH OF CHILDREN.

IF SWALLOWED, DO NOT INDUCE

VOMITING. CALL A PHYSICIAN

IMMEDIATELY.

CAUTION

KEEP TOTALLY CLOSED WHEN NOT IN USE. KEEP AWAY FROM HEAT, SPARKS, AND OPEN FLAME. SECURE ABOVE DECK IN WELL VENTILATED AREA. DO NOT USE FOR LONG TERM FUEL STORAGE.

DO NOT USE FUEL/OIL MIXTURE.

GASOLINE FLAMMABLE DANGER GAZOLINE INFLAMMABLE DANGEREUX GASOLINA PELIGRO FLAMABLE

FUEL CAUTION

OUTBOARD MOTOR SAFETY

• Gasoline is harmful or fatal if swallowed. Keep the fuel tank out of reach of children.

• Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped.

• Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stored.

• Do not overfill the fuel tank. After refueling make sure that the fuel filler cap is closed properly and securely.

• Be careful not to spill any fuel while refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure that the area is dry before starting the engine.

US, Puerto Rico, and US Virgin Islands Types

Canadian Types

• Honda outboard motor is designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the outboard motor. Failure to do so could result in personal injury or equipment damage.

• Gasoline is harmful or fatal if swallowed. Keep the fuel tank out of reach of children.

• Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped.

• Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stored.

• Do not overfill the fuel tank. After refueling make sure that the fuel filler cap is closed properly and securely.

• Be careful not to spill any fuel while refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure that the area is dry before starting the engine.

OUTBOARD MOTOR SAFETY

CONTROLS AND FEATURES

(Example)

Destination

Charging System N=Without System

(Optional Equipment)

N□

Throttle Type H=Tiller Handle Type Shaft Length S=Short Shaft

L=Long Shaft

CONTROL AND FEATURE IDENTIFICATION CODES

Model BF4A BF5D BF6A

Type SHN□ LHN□ SHN□ SH□ LHN□ LH□ SHN□ SH□ LHN□ LH□

Shaft Length

Fuel Tank (Internal fuel tank)

Charging System

Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications. For the detailed equipment conditions of optional components, consult your Honda dealer.

S●●● ●●

L●●●●●

●●●●●●●●●●

●●●●

BF4A/BF5D/BF6A are provided with the following types according to the shaft length and charging system.

•Shaft Length S: Short Shaft L: Long Shaft

• Control System H: Tiller Handle Type

•Charging System N: Without System (Optional Equipment)

COMPONENT AND CONTROL LOCATIONS

GEARSHIFT LEVER

FUEL FILLER CAP

FUEL FILLER CAP VENT KNOB

TILLER HANDLE

FUEL VALVE LEVER

CLAMP SCREW

WATER INTAKE PORT (each side)

PROPELLER

ANTIVENTILATION PLATE

TRANSOM ANGLE ADJUSTING ROD

COOLING SYSTEM INDICATOR

ENGINE COVER

OIL FILLER CAP/DIPSTICK

SPARK PLUG

STARTER GRIP

THROTTLE GRIP

THROTTLE FRICTION KNOB

HANDLE STOPPER

STEERING FRICTION BOLT

STERN BRACKET

GEAR OIL LEVEL SCREW

GEAR OIL DRAIN/FILL SCREW

EXHAUST PORT

ANODE

WA SH S CR E W (FLUSH SCREW)

ENGINE OIL DRAIN BOLT

ENGINE COVER LATCH

TILT LEVER

CONTROLS AND FEATURES

OIL PRESSURE INDICATOR

FUEL HOSE CONNECTOR (MALE) (BF5D and BF6A only)

EMERGENCY STOP SWITCH

FUEL HOSE CONNECTOR CAP (BF5D and BF6A only)

CHOKE KNOB

EMERGENCY STOP SWITCH CLIP

EMERGENCY STOP SWITCH LANYARD

BATTERY CHARGE CABLE (equipped type)

VENT KNOB

FUEL FILLER CAP

PORTABLE FUEL TANK

FUEL PRIMING BULB

FUEL HOSE

FUEL HOSE CONNECTOR (FEMALE)

Portable Fuel Tank (standard or optionally applicable equipment)

CONTROLS AND FEATURES

EMERGENCY STOP SWITCH LANYARD

EMERGENCY STOP SWITCH CLIP

EMERGENCY STOP SWITCH

PUSH

EMERGENCY STOP SWITCH CLIP

EMERGENCY STOP SWITCH LANYARD

CHOKE KNOB

OFF

CONTROLS

Emergency Stop Switch Clip and Emergency Stop Switch

The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The emergency stop switch lanyard must be attached securely to the operator or to the PFD (Personal Flotation Device) equipped to an operator.

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

A spare emergency stop switch clip is supplied with the tool kit.

Choke Knob

The choke knob opens and closes the choke valve in the carburetor.

The ON position enriches the fuel mixture for starting a cold engine.

The OFF position provides the correct fuel mixture for operation after starting, and for restarting a warm engine.

The choke knob is also used to restart the engine after supplying fuel when the internal fuel tank is out of fuel. For more information, refer to page 44.

CONTROLS AND FEATURES

INDEX MARK

THROTTLE GRIP

SLOW

FAST

[USA model]

[Canadian model]

FAS T

FAST

SLOW

THROTTLE FRICTION KNOB

TO INCREASE FRICTION

TO DECREASE FRICTION

Throttle Grip

The throttle grip controls engine speed.

An index mark on the tiller handle shows throttle position and is helpful for setting the throttle correctly when starting (p. 44).

Throttle Friction Knob

The throttle friction knob adjusts resistance to throttle grip rotation.

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

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

CONTROLS AND FEATURES

GEARSHIFT LEVER

N (neutral)

R (reverse)

F (forward)

[USA model]

[Canadian model]

N (neutral)

R (reverse)

F (forward)

N (neutral)

R (reverse)

F (forward)

FUEL VALVE LEVER

ON (BF4A) or INTERNAL FUEL TANK POSITION (BF5D and BF6A)

OFF (BF4A) or PORTABLE FUEL TANK POSITION (BF5D and BF6A)

Gearshift Lever

Fuel Valve Lever

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

If the gearshift lever is in the F (forward) or R (reverse) position, the recoil starter will not operate.

CONTROLS AND FEATURES

[BF4A]

[BF5D and BF6A]

OFF

INTERNAL FUEL TANK POSITION

PORTABLE FUEL TANK POSITION

(BF4A)

The fuel valve opens and closes the passage between the internal fuel tank and the carburetor.

The fuel valve lever must be in the ON position for the engine to run.

When the engine is not in use, leave the fuel valve lever in the OFF position to prevent carburetor flooding and to reduce the possibility of fuel leakage.

(BF5D and BF6A)

The fuel valve lever has internal fuel tank position and portable fuel tank position.

When using the internal fuel tank, turn the fuel valve lever to the internal fuel tank position.

When not connecting the portable fuel tank, fuel is shut off at the portable fuel tank position.

When using the portable fuel tank, turn the fuel valve lever all the way to the portable fuel tank position.

CONTROLS AND FEATURES

VENT KNOB

OPEN

FUEL FILLER CAP

(BF4A)

(BF5D and BF6A)

LEVER POSITION FUNCTION

ON Fuel from the internal fuel tank is supplied.

OFF Fuel supply is shut off.

Set the fuel valve lever to the “OFF” position during transporting or storing the outboard motor.

LEVER POSITION FUNCTION

INTERNAL FUEL TANK

PORTABLE FUEL TANK

Fuel from the internal fuel tank is supplied.

• Fuel from the portable fuel tank is supplied.

• If the portable fuel tank is not connected, fuel supply is shut off. Set the fuel valve lever to the “PORTABLE FUEL TANK” position during transporting or storing the outboard motor.

Fuel Filler Cap Vent Knob (Internal Fuel Tank)

The fuel filler cap is provided with a vent knob to seal the fuel tank. Open the vent by turning the vent knob counterclockwise all the way before starting the engine. Close the vent by turning the vent knob clockwise all the way after stopping the engine.

CONTROLS AND FEATURES

Direction to pull

STARTER GRIP

ENGINE COVER LATCH

UNLOCK

TRANSOM ANGLE ADJUSTING ROD

Starter Grip

Pulling the starter grip operates the recoil starter to crank the engine for starting.

The “Neutral Starting System” prevents the starter rope from being pulled out for starting the engine unless the gearshift lever (P.19) is set in the N (neutral) position.

The engine will start only when the emergency stop switch clip is in the emergency stop switch.

Engine Cover Latch

The engine cover latch fastens the engine cover to the outboard motor.

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

Transom Angle Adjusting Rod

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

Proper adjustment prevents the outboard motor from being adjusted too low (p. 55).

CONTROLS AND FEATURES

STEERING FRICTION BOLT

TO DECREASE FRICTION

TO INCREASE FRICTION

ENGINE COVER GRIP

TILT LEVER

HANDLE STOPPER

TILLER HANDLE

Steering Friction Bolt

The steering friction bolt adjusts steering resistance.

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

Tilt Lever

The tilt lever enables the outboard motor to be raised for shallow water operation, beaching, launching, or mooring.

To tilt, raise the outboard motor by pulling on the engine cover grip until the tilt mechanism engages at 18°, 34°, or 58° (p. 56 and 57).

Handle Stopper

The tiller handle can be moved to the bottom direction by turning the handle stopper.

CONTROLS AND FEATURES

OIL PRESSURE INDICATOR

INDICATORS

Oil Pressure Indicator

When the oil pressure indicator is lit, oil pressure is OK.

If oil pressure becomes low, the oil pressure indicator will go off, and the engine protection system will limit engine speed. Refer to TAKING

CARE OF UNEXPECTED PROBLEMS, p. 97.

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

CONTROLS AND FEATURES

COOLING SYSTEM INDICATOR

ANODE

Cooling System Indicator

Water should flow from the cooling system indicator while the engine is running. This shows that water is circulating through the cooling system.

If water stops flowing while the engine is running, that indicates a cooling system problem, such as clogged water intakes, which will cause engine overheating.

OTHER FEATURES

Rev Limiter

The engine is equipped with a rev limiter to prevent the possibility of mechanical damage from excessive engine speed.

The rev limiter may be activated during operation, limiting engine speed, if the outboard motor is tilted excessively, or when propeller ventilation occurs during a sharp turn.

If the rev limiter is activated, check the tilt angle of the outboard motor.

Improper propeller selection may also cause the rev limiter to activate.

Check to see if the correct propeller is installed.

Anode

The anode is made of a sacrificial material that helps to protect the outboard motor from corrosion.

There is an anode on the antiventilation plate.

CONTROLS AND FEATURES

FUEL HOSE CONNECTOR (MALE)

FUEL HOSE CONNECTOR CAP

FUEL HOSE (standard equipment)

FUEL FILLER CAP

OPEN

VENT KNOB

Fuel Hose Connector Cap and Fuel Hose Connector (Male) (BF5D and BF6A only)

Use the fuel hose connector (male) to attach the portable fuel tank (standard or optionally applicable equipment).

Always install the fuel hose connector cap if the fuel hose connector (female) is not connected. Be sure the fuel hose connector cap is securely installed.

Portable Fuel Tank (standard or optionally applicable equipment)

The portable fuel tank has a capacity of 3.2 US gal (12 L, 2.6 Imp gal).

Fuel Filler Cap Vent Knob (standard or optionally applicable equipment)

The fuel filler cap is provided with a vent knob to seal the portable fuel tank for carrying it to and from the boat. Open the vent by turning the vent knob counterclockwise all the way before starting the engine. Close the vent by turning the vent knob clockwise all the way after stopping the engine.

CONTROLS AND FEATURES

INLET END (portable fuel tank side)

PRIMING BULB

OUTLET END (outboard motor side)

BATTERY CHARGE CABLE

Fuel Priming Bulb (standard or optionally applicable equipment)

A priming bulb is built into the fuel hose that connects the portable fuel tank to the outboard motor.

Before starting the engine, hold the priming bulb up in the direction of the arrow, then squeeze the priming bulb until it feels firm. This will ensure that fuel is supplied to the engine.

Battery Charge Cable

The battery charge cable is included in the battery charge cable kit (equipped type).

When removing the outboard motor or storing it for long periods, you can remove the battery charge cable from the outboard motor.

If the battery charge cable kit is attached, you must attach the battery. (page 32)

CONTROLS AND FEATURES

Battery Charge Cable Connection

1. Remove the covers off the charging connector and the battery charge cable connector, and save them in a secure place for later use if necessary.

2. Connect the battery charge cable connector to the charging receptacle connector.

3. Attach the wire band as shown in the figure.

Starting the engine with the battery charge cable not securely connected to a battery may cause a spark if the cable terminals touch one another or a metal surface. Do not start the engine if the battery charge cable is connected to the outboard, but not connected to a battery (p. 32).

WIRE BAND

CHARGING RECEPTACLE CONNECTOR

(1) PULL

WIRE BAND

COVER COVER

BATTERY CHARGE CABLE

BATTERY CHARGE CABLE CONNECTOR

CONTROLS AND FEATURES

TILLER HANDLE

Disconnecting Battery Charge Cable

1. Steer the tiller handle to the left with respect to the boat.

2. Remove the wire band by pulling the wire band tab in the direction shown and remove the wire band.

3. While pressing the lock on the connector, remove the battery charge cable connector from the charging receptacle connector.

4. Install the covers.

WIRE BAND TAB

(1) PULL

WIRE BAND

CHARGING RECEPTACLE CONNECTOR

(2) PULL

WIRE BAND

COVER

BATTERY CHARGE CABLE CONNECTOR

COVER

BATTERY CHARGE CABLE

(2) PULL

(1) PUSH

BATTERY CHARGE CABLE CONNECTOR

INSTALLATION

CENTER LINE

ANTIVENTILATION PLATE

0 – 2 in (0 – 50 mm)

IDLE PORT

OUTBOARD MOTOR TRANSOM HEIGHT

BOAT TRANSOM HEIGHT

Correct and secure installation is essential for safe boating and good performance. Follow the installation instructions provided in this manual.

POWER REQUIREMENTS

Before installation, check to be sure that the outboard motor does not exceed the recommended maximum horsepower for the boat on which it is to be installed. Refer to the boat’s certification plate for recommended maximum horsepower. If the certification plate information is not available, contact the boat dealer or manufacturer.

For most applications, the outboard motor should have a horsepower rating which provides 80% of the maximum recommended horsepower for the boat.

INSTALLATION POSITION

Install the outboard motor on the center of the boat transom.

The antiventilation plate of the outboard motor should be 0 – 2 in (0 – 50 mm) below the bottom of the boat. The correct dimensions differ according to the type of boat and the configuration of the bottom of the boat. Follow the manufacturer’s recommended installation height.

Type: Outboard Motor

Transom Height S: 17.1 in (434 mm) L: 22.1 in (561 mm)

When the outboard motor is installed extremely low, the idle port may be immersed and the engine may become hard to start or may run poorly. Check that the idle port is high enough from the water level when the engine is stopped with the boat fully loaded.

INSTALLATION

SAFETY ROPE

CLAMP SCREWS

STERN BRACKET

If the outboard motor is installed too low, the boat will squat and be hard to plane, and the outboard motor will spray water that may enter the boat. It will tend to bounce, and high-speed stability will be reduced.

If the outboard motor is installed too high, that will cause propeller ventilation.

Optimum installation height varies with boat type and bottom shape. Contact the boat manufacturer for any special recommendations that are unique to a specific model of boat.

If the transom needs to be modified to accommodate the outboard motor, contact the boat manufacturer and follow their recommendations for corrective action.

ATTACHMENT

Attach the stern bracket to the boat transom by tightening the clamp screws.

Attach a rope from the boat to the hole in the stern bracket. This will help to prevent accidental loss of the outboard motor.

TRANSOM ANGLE ADJUSTMENT

Use the transom angle adjusting rod (p. 37) to adjust the angle of the outboard motor so the propeller is perpendicular to the surface of the water.

INSTALLATION

BATTERY

- TO ACCESSORIES

BATTERY CHARGE CABLE

BATTERY CONNECTIONS

The battery contains sulfuric acid (electrolyte), which is highly corrosive and poisonous.

Getting electrolyte in your eyes or on your skin can cause serious burns.

Wear protective clothing and eye protection when working near the battery.

KEEP CHILDREN AWAY FROM THE BATTERY.

An optional accessory charging kit is available for Honda BF4A, BF5D, and BF6A outboard motors and can produce a 12-volt, 6-ampere battery charging current to charge a 12-volt battery. The battery charging circuit is protected by a 15-ampere fuse.

The outboard motor's optional accessory 12-volt charge kit is designed to charge a ‘‘starting or cranking’’ type battery only. It is not intended to charge a ‘‘deep-cycle’’ type battery. Lights and electrical accessories for the boat should be connected to the battery.

The battery should be kept in a corrosion-resistant battery box that is securely mounted in a location away from the fuel tank and protected from water and direct sunlight.

Battery

For complete information, refer to the battery manufacturer's instructions.

Minimum Requirements

12V-28Ah/5HR (CCA 265)

INSTALLATION

RED TERMINAL COVER

(–) BATTERY TERMINAL

(+) BATTERY TERMINAL

BLACK TERMINAL COVER

Battery Terminals

WARNING: Battery posts,

terminals, and related accessories contain lead and lead compounds.

Wash hands after handling.

Connect the positive (+) battery cable (red terminal cover) to the positive (+) battery terminal, then connect the negative (-) battery cable (black terminal cover) to the negative (-) battery terminal.

The negative (-) battery cable should always be removed from the battery before connecting or disconnecting the positive (+) battery cable, so tools cannot cause a short circuit if they touch a grounded part while being used on the positive (+) battery terminal fitting.

• Be careful to avoid connecting the battery in reverse polarity, as this will damage the battery-charging system in the outboard motor.

• Do not disconnect the battery cables while the engine is running. Disconnecting the cables while the engine is running will damage the outboard motor's electrical system.

• Battery cable extension: Extending the original battery cable will cause the battery voltage to drop due to the increased length of the cable and number of connections. The outboard may not start if the battery voltage reaching the engine is too low.

BEFORE OPERATION

ARE YOU READY TO GET UNDERWAY?

Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury.

Knowledge

Read and understand this manual. Know what the controls do and how to operate them.

Familiarize yourself with the outboard motor and its operation before you get underway. Know what to do in case of an emergency.

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

Safety

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

Attach the emergency stop switch lanyard securely to the operator or to the PFD worn by the operator.

IS YOUR OUTBOARD MOTOR READY TO GO?

For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the outboard motor to check its condition. Be sure to take care of any problem you find, or have your authorized Marine dealer correct it, before you operate the outboard motor.

Failure to properly maintain this outboard motor, or failing to correct a problem before operation, could result in a significant malfunction.

Some malfunctions can cause serious injuries or death.

Always perform a pre-operation inspection before each operation and correct any problems.

Before beginning your pre-operation checks, be sure the emergency stop switch clip is removed from the emergency stop switch.

BEFORE OPERATION

Safety Inspection

• Before each use, look around and underneath the engine for signs of oil or gasoline leaks.

• If you are using the portable fuel tank, make sure it is in good condition and properly secured in the boat (p. 39).

• If you are using the portable fuel tank, check that the fuel hose is undamaged and properly connected (p. 39).

• Wipe up any spills before starting the engine.

• Check the stern bracket to be sure the outboard motor is securely installed.

• Check that all controls are operating properly.

• Check that all fasteners are in place and securely tightened.

• Check the emergency stop switch for proper operation (p. 17, 41). Start the engine (p. 41). Make sure the engine stops by pulling the emergency stop switch clip from the emergency stop switch (p. 51).

Maintenance Inspection

• Check the engine oil level (p. 64). Running the engine with a low oil level can cause engine damage.

• Check to be sure the propeller and shear pin are undamaged (p. 79).

• Check that the anode is securely attached to the antiventilation plate (p. 78) and is not excessively worn. The anode helps to protect the outboard motor from corrosion.

• Make sure the tool kit and emergency starter rope are onboard (p. 60). Replace any missing items.

• Check the fuel level in the fuel tank (p. 71).

• If you are using the battery, check that the battery fluid is between the upper and lower levels, and the battery leads are connected securely.

• Replace any damaged parts.

OPERATION

SAFE OPERATING PRECAUTIONS

To safely realize the full potential of this outboard motor, you need a complete understanding of its operation and a certain amount of practice with its controls.

Before operating the outboard motor for the first time, please review the

IMPORTANT SAFETY INFORMATION on page 6 and the

chapter titled BEFORE OPERATION.

For your safety, do not start or run the engine in a confined or partly enclosed area. Your engine’s exhaust contains poisonous carbon monoxide, a colorless, odorless gas that can collect rapidly. Breathing carbon monoxide can cause loss of consciousness and may lead to death.

Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas.

Breathing carbon monoxide can cause unconsciousness or death.

Never run this product's engine in a closed, or even partially closed area.

BREAK-IN PROCEDURE

Proper break-in procedure allows the moving parts to wear in smoothly for best performance and long service life.

• First 15 minutes: Run the outboard motor at trolling speed. Use the minimum amount of throttle opening necessary to operate the boat at a safe trolling speed.

• Next 45 minutes: Run the outboard motor up to a maximum of 10% to 30% throttle opening.

• Next 60 minutes: Run the outboard motor up to maximum of 50% to 80% throttle opening. Short bursts of full throttle are acceptable but do not operate the outboard motor continuously at full throttle.

• Next 8 hours: Avoid continuous full throttle operation (100% throttle opening). Do not run the outboard motor at full throttle for more than 5 minutes at a time.

OPERATION

TO LOCK

LOCKED POSITION

UNLOCKED POSITION

TRANSOM ANGLE ADJUSTING ROD

TO CHANGE

TRANSOM ANGLE ADJUSTMENT

The transom angle adjusting rod is used to adjust the angle of the outboard motor in the normal operating position (p. 55).

1. To adjust, first tilt the outboard motor so it is not resting on the rod.

2. Push the rod in and turn the end of the rod up, so the latch will fall into line with the rod.

3. Remove the rod and reinsert it in the desired position.

4. Push the rod in and turn the end of the rod down, so the latch will fall to the locked position. Then release the rod.

PRIMING THE CARBURETOR WITH GASOLINE (When using the internal fuel tank)

When starting the engine for the first time, or when starting the engine after the carburetor has been drained, the carburetor must be primed with gasoline before the engine will start. To prime the carburetor, remove the emergency stop switch clip from the outboard motor, and then pull the starter grip about 10 times.

If you do not fill fuel to the upper level of the internal fuel tank, fuel loading to the carburetor may be insufficient.

OPERATION

VENT KNOB

OPEN

ON (BF4A) or INTERNAL FUEL TANK POSITION (BF5D and BF6A)

FUEL VALVE LEVER

[BF4A]

[BF5D and BF6A]

INTERNAL FUEL TANK POSITION

N (neutral)

GEARSHIFT LEVER

[USA model]

[Canadian model]

N (neutral)

1. Fill the tank to the maximum fuel level (p.71).

2. Turn the internal fuel tank vent knob counterclockwise to the open position (p. 21).

3. Turn the fuel valve lever to the ON position (BF4A) or internal fuel tank position (BF5D and BF6A) (p. 19).

OPERATION

STARTER GRIP

Direction to pull

FUEL HOSE (standard equipment)

4. Check the position of the gearshift lever. It must be in the N (neutral) position for starting.

The recoil starter will not operate if the gearshift lever is in the F (forward) or R (reverse) position.

5. Pull the starter grip about 10 times.

Return the starter grip gently.

PORTABLE FUEL TANK (standard or optionally applicable equipment)

[When using the portable fuel tank]

Place the portable fuel tank in a well-ventilated location, away from direct sunlight, to reduce the possibility of a gasoline vapor explosion.

To ensure that the outboard motor will be able to draw fuel from the tank, place the tank within 6 feet (2 m) of the outboard motor and not more than 3 feet (1 m) below the fuel connector on the outboard motor.

Secure the portable fuel tank in the boat so that it won’t move around and become damaged.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Stop the engine and let it cool before handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.

• Keep away from your vehicle.

• Wipe up spills immediately.

OPERATION

FUEL HOSE CONNECTOR (FEMALE)

(OUTBOARD MOTOR SIDE)

(FUEL TANK SIDE)

OUTLET END (outboard motor side)

PRIMING BULB

INLET END (portable fuel tank side)

FUEL HOSE CONNECTIONS (standard or optionally applicable equipment)

[When using the portable fuel tank]

Turn the portable fuel tank vent knob counterclockwise to the open position (p. 26) and remove the fuel hose connector cap.

Connect the fuel hose to the portable fuel tank and the outboard motor, as shown. Be sure both connectors snap securely into place. Always disconnect the fuel hose and install fuel inlet cap when tilting up the outboard motor, storing or transporting the outboard motor.

FUEL PRIMING (standard or optionally applicable equipment)

[When using the portable fuel tank]

Turn the portable fuel tank vent knob counterclockwise to the open position (p. 26) and turn the fuel valve lever to the portable fuel tank position (p. 19).

Hold the priming bulb up in the direction of the arrow; then squeeze the priming bulb several times until it feels firm, indicating that fuel has reached the carburetor.

Check to be sure there are no fuel leaks before starting the engine.

OPERATION

EMERGENCY STOP SWITCH

EMERGENCY STOP SWITCH CLIP

EMERGENCY STOP SWITCH LANYARD

Do not touch the priming bulb with the engine running or when tilting up the outboard motor. The carburetor could overflow.

INFREQUENT OR OCCASIONAL USE

If your outboard motor will be used on an infrequent or intermittent basis, please refer to the fuel section of the STORAGE chapter (p. 84) for additional information regarding fuel deterioration.

STARTING THE ENGINE

Prime the carburetor with gasoline.

(When using the internal fuel tank)

When starting the engine for the first time after purchasing an outboard motor, or when starting the engine after draining the gasoline (p. 37).

(When using the portable fuel tank)

Connect the fuel line (p. 40) and prime the engine using the priming bulb (p. 40).

1. Put the emergency stop switch clip in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or to the PFD (Personal Flotation Device) equipped to an operator.

The engine will not start or run unless the emergency stop switch clip is in the emergency stop switch.

The emergency stop switch clip and emergency stop switch lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat.

Always attach the emergency stop switch lanyard securely to the operator or to the PFD equipped to an operator before starting the engine.

2. Connect the battery charge cable (equipped type) (p. 28).

OPERATION

OPEN

VENT KNOB

FUEL VALVE LEVER

ON (BF4A) or INTERNAL FUEL TANK POSITION (BF5D and BF6A)

OFF (BF4A) or PORTABLE FUEL TANK POSITION (BF5D and BF6A)

[BF4A]

[BF5D and BF6A]

OFF

INTERNAL FUEL TANK POSITION

PORTABLE FUEL TANK POSITION

3. Turn the internal fuel tank vent knob counterclockwise to the open position (p. 21).

Always open the internal fuel filler cap vent knob when using the portable fuel tank.

OPERATION

N (neutral)

GEARSHIFT LEVER

[Canadian model]

N (neutral)

[USA model]

4. If you are using the internal fuel tank, turn the fuel valve lever to the ON position (BF4A) or internal fuel tank position (BF5D and BF6A) (p. 19). If you are using the portable fuel tank, turn the fuel valve lever to the portable fuel tank position (BF5D and BF6A) (p. 19).

5. Check the position of the gearshift lever. It must be in the N (neutral) position for starting.

The recoil starter will not operate if the gearshift lever is in the F (forward) or R (reverse) position.

OPERATION

CHOKE KNOB

OFF

INDEX MARK

THROTTLE GRIP

[Canadian model]

START POSITION

[USA model]

STARTER GRIP

Direction to pull

6. Pull the choke knob when the engine is in any of the following conditions:

• When the engine is cold or the

outside temperature is low.

• When restarting the engine after

supplying fuel due to the internal fuel tank running out of fuel. In this case, when the engine starts, immediately return the choke knob to its original position.

8. Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown above.

Return the starter grip gently.

7. Align the START position with the index mark for starting the engine.

OPERATION

FUEL VALVE LEVER

ON (BF4A) or INTERNAL FUEL TANK POSITION (BF5D and BF6A)

OFF (BF4A) or PORTABLE FUEL TANK POSITION (BF5D and BF6A)

9. If the choke knob was pulled to the ON position to start the engine, gradually push it to the OFF position as the engine warms up.

Also, as the engine warms up, the throttle grip can be turned to the SLOW position without stalling.

10.Before getting underway, allow

the engine to warm-up sufficiently to ensure good performance.

During the warm-up period, check the oil pressure indicator (p. 24) and cooling system indicator (p. 25).

If the indicators show any abnormal condition, immediately stop the engine and determine the cause of the problem. Refer to

TAKING CARE OF UNEXPECTED PROBLEMS on

p. 94 and 97.

EMERGENCY STARTING

If the recoil starter is inoperative, you can start the engine using the emergency starter rope that came with your outboard motor.

1. Connect the battery charge cable (equipped type) (p. 28).

2. Turn the internal fuel tank vent knob counterclockwise to the open position (p. 21).

Always open the internal fuel filler cap vent knob when using the portable fuel tank.

OPERATION

[BF4A]

[BF5D and BF6A]

OFF

INTERNAL FUEL TANK POSITION

PORTABLE FUEL TANK POSITION

N (neutral)

GEARSHIFT LEVER

3. If you are using the internal fuel tank, turn the fuel valve lever to the ON position (BF4A) or internal fuel tank position (BF5D and BF6A) (p. 19). If you are using the portable fuel tank, turn the fuel valve lever to the portable fuel tank position (BF5D and BF6A) (p. 19).

[Canadian model]

N (neutral)

[USA model]

THROTTLE CABLES

COVER HOOK

NEUTRAL START CABLE

RECOIL CASE

6. Release the throttle cables from the cover hook.

OPERATION

7. Release the neutral start cable from the cover hook.

4. Move the shift lever to the N

5. Unlock and remove the engine

(neutral) position.

cover (p. 63).

8. Disconnect the neutral start cable from recoil case.

OPERATION

6 mm FLANGE BOLTS AND WA SH E R S

WA S HE R

6 mm FLANGE BOLT

WA S HE R

6 mm CAP NUT

RECOIL CASE

6 mm CAP NUTS AND WA S HE R S

6 mm FLANGE BOLT (tighten by hand)

THROTTLE CABLES

CORD HOOK

6 mm FLANGE BOLT (tighten by hand)

NEUTRAL START CABLE

9. Remove the two 6 mm cap nuts, two washers, two 6 mm flange bolts and two washers, and remove the recoil case.

Take care not to lose the bolts, nuts and washers.

10.Install and tighten the 6 mm flange bolts by hand.

11.Hook the throttle cables to the

cord hook.

12.Hook the neutral start cable to the under case.

13.Make sure the shift lever in the N (neutral) position.

The ‘‘Neutral Starting System’’ will not work in emergency starting. Be sure to set the shift lever into N (neutral) position to prevent start-in-gear when starting the engine in emergency. Sudden unexpected acceleration could result in serious injury or death.

14.Put the emergency stop switch clip

EMERGENCY STOP SWITCH

EMERGENCY STOP SWITCH CLIP

EMERGENCY STOP SWITCH LANYARD

CHOKE KNOB

OFF

INDEX MARK

THROTTLE GRIP

[Canadian model]

START POSITION

[USA model]

in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or to the PFD (Personal Flotation Device) worn by the operator.

OPERATION

15.To start a cold engine, pull the choke knob to the ON position. To restart a warm engine, leave the choke knob in the OFF position.

16.Align the START position with the index mark for starting the engine.

OPERATION

NOTCH

STARTER PULLEY

STARTER ROPE

KNOTTED END

17.Set the knotted end of the emergency starter rope (provided with the engine) in the notch in the starter pulley. Wind the rope clockwise around the starter pulley.

18.Pull the emergency starter rope slowly until resistance is felt, then pull briskly.

Keep away from moving parts while pulling the rope.

If necessary, rewind the rope and pull again. If the engine does not start after several attempts, refer to

TAKING CARE OF UNEXPECTED PROBLEMS,

p. 91.

Exposed moving parts can cause injury.

• Do not operate the outboard motor without the engine cover.

• Use extreme care when installing the engine cover.

19.If the choke control was used to start the engine, return the control to the normal operating position as the engine warms up.

During the warm-up period, check the oil pressure indicator (p. 24), and cooling system indicator (p. 25).

20.Install the engine cover (p. 63), and lock it in place by locking the engine cover lock lever.

21.If it was necessary to remove the emergency stop switch lanyard from you to perform the emergency starting procedure, be sure the lanyard is attached securely to the operator before operating the outboard motor.

22.Have your closest authorized Marine dealer check your system and correct the problem, so you can use the recoil starter.

OPERATION

EMERGENCY STOP SWITCH

EMERGENCY STOP SWITCH LANYARD

PULL

EMERGENCY STOP SWITCH CLIP

THROTTLE GRIP

SLOW

[Canadian model]

SLOW

[USA model]

SLOW

STOPPING THE ENGINE

Emergency Engine Stopping

To stop the engine in an emergency, pull the emergency stop switch clip out of the emergency stop switch by pulling the emergency stop switch lanyard.

If the emergency stop switch is activated while the engine is running, the engine will shut down abruptly and the boat will quickly decelerate, potentially causing occupants and objects to be thrown forward and/or overboard. If the emergency stop switch is activated, the emergency stop switch clip must be reinserted before the engine can be restarted.

We suggest that you stop the engine this way occasionally to verify that the engine and emergency stop switch are operating properly.

Normal Engine Stopping

OPERATION

N (neutral)

GEARSHIFT LEVER

[Canadian model]

N (neutral)

[USA model]

EMERGENCY STOP SWITCH

PUSH

1. Move the throttle grip to the slowest speed and gearshift lever to the N (neutral) position.

After cruising at full throttle, cool down the engine by idling for a few minutes before stopping the engine.

2. Press the emergency stop switch once to stop the engine.

3. Disconnect the battery charge cable (equipped type) (p. 29).

4. When the boat is not in use, remove and store the emergency stop switch clip and lanyard. If you are using the internal fuel tank, turn the fuel valve lever to the OFF position (BF4A) or portable fuel tank

position (BF5D and BF6A) (p.

) and close the internal fuel tank vent by turning the vent knob clockwise

all the way (p.

). If you are using a portable fuel tank, close the internal fuel tank vent by turning the vent knob clockwise all

the way (p.

) and close the portable

fuel tank vent by turning the vent

knob clockwise all the way (p.

). If you will be tilting up the outboard motor, storing or transporting the outboard motor, disconnect the fuel hose connectors from the outboard

motor and portable fuel tank (p.

), install fuel hose connector cap, close the internal fuel tank vent by turning the vent knob clockwise all the way

) and close the portable fuel

(p. tank vent by turning the vent knob

clockwise all the way (p.

OPERATION

THROTTLE GRIP

SLOW

[Canadian model]

SLOW

[USA model]

SLOW

R (reverse)

N (neutral)

F (forward)

GEARSHIFT LEVER

[USA model]

[Canadian model]

N (neutral)

R (reverse)

F (forward)

N (neutral)

R (reverse)

F (forward)

GEARSHIFTING AND THROTTLE OPERATION

To shift gears, turn the throttle grip to the SLOW position; then move the gearshift lever to select the F (forward), N (neutral), or R (reverse) gears.

Do not turn the throttle grip in the FAST direction in R (reverse) and N (neutral) gears.

The recoil starter can be operated with the gearshift lever in the N (neutral) position only.

OPERATION

THROTTLE FRICTION KNOB

TO DECREASE FRICTION

TO INCREASE FRICTION

RIGHT TURN

LEFT TURN

STEERING FRICTION BOLT

TO DECREASE FRICTION

TO INCREASE FRICTION

Use the throttle friction knob to help hold a constant throttle setting while cruising.

Turn the knob clockwise to increase throttle grip friction for holding a constant speed.

Turn the knob counterclockwise to decrease friction for easy grip rotation.

STEERING

Steer by moving the tiller handle opposite the direction you want the boat to turn.

Use the steering friction bolt to help hold a steady course while cruising.

Turn the bolt clockwise to increase steering friction for holding a steady course.

Turn the bolt counterclockwise to decrease friction for easy turning.

OPERATION

OUTBOARD MOTOR ANGLE ADJUSTED TOO LOW

Transom Angle (Cruising)

OUTBOARD MOTOR ANGLE ADJUSTED TOO HIGH

OUTBOARD MOTOR ANGLE ADJUSTED CORRECTLY

CORRECT GIVES MAXIMUM PERFORMANCE

ROUGH WAV ES

CRUISING

Engine Speed

For best fuel economy, limit the throttle opening to 80%. Use the throttle friction control (p. 53) to help you hold a steady speed.

For rough water conditions or large waves, slow down to prevent the propeller from rising out of the water.

Transom Angle

Install the outboard motor at the best transom angle for stable cruising and maximum power.

Transom angle too large: Causes boat to ‘‘squat.’’

Transom angle too small: Causes boat to ‘‘bow steer.’’

It is necessary to adjust the transom angle of the outboard motor to compensate for changes in boat load, weight distribution, water conditions, or propeller selection.

Under normal running conditions, the boat will perform best when the antiventilation plate is level with the water surface.

When cruising into a high wind, adjust the outboard motor down slightly to level the boat and improve stability. With a tail wind, adjust the outboard motor up slightly (p. 37).

Excessive transom angle during operation can cause propeller ventilation, overheating, and water pump damage. This type of damage is not covered by the Distributor’s Limited Warranty (U.S.) / Distributor’s Warranty (CA.) (p. 112).

OPERATION

ENGINE COVER GRIP

18°

SHALLOW WATER OPERATION

When operating in shallow water, tilt the outboard motor, using the tilt lever, so the propeller and gear case won’t hit the bottom.

To tilt the outboard motor, raise the outboard motor to the 18° position by pulling on the engine cover grip.

Do not use the tiller handle as a lever to raise the outboard motor. Applying excessive force to the tiller handle can damage it.

While the outboard motor is tilted, proceed at a low speed, and do not operate the outboard motor in reverse. The outboard motor will rise suddenly if operated in reverse.

Monitor water flow from the cooling system indicator (p. 25) to be sure the outboard motor is not tilted so high that the water intakes are out of the water.

An excessive tilt angle during operation can cause propeller ventilation, overheating, and water pump damage. This type of damage is not covered by the Limited Warranty (U.S.) / Distributor’s Warranty (CA.) (p. 112).

Distributor’s

MOORING, BEACHING,

TILT LEVER

ENGINE COVER GRIP

34°, 58° (when mooring)

LAUNCHING

Before tilting up, leave the outboard motor in the running position for one minute after stopping the engine to drain the water from inside the engine.

1. Move the shift lever to the N (neutral) position and stop the engine.

OPERATION

To return the outboard motor to the normal operating position, raise the outboard slightly by pulling on the engine cover grip, then pull the tilt lever to release the outboard, and then slowly lower the outboard motor.

2. Turn the fuel valve lever to the OFF position (BF4A) or portable fuel tank

position (BF5D and BF6A) (p.

3. When using the portable fuel tank (BF5D and BF6A), disconnect the fuel hose connectors from the outboard motor and portable fuel tank (p. 40), install fuel hose connector cap and close the portable fuel tank vent by turning the vent knob clockwise all the way (p. 26).

4. Close the internal fuel tank vent by turning the vent knob clockwise all the way (p. 21).

To raise the outboard motor out of the water while the boat is moored, or for maximum clearance when beaching or launching, tilt the outboard motor to the 34° or 58° position.

Stop the engine before tilting the outboard motor. The 34° or 58° position is not an operating position.

Raise and lower the outboard motor as described on p. 56.

SERVICING YOUR OUTBOARD MOTOR

THE IMPORTANCE OF MAINTENANCE

Proper maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution.

Failure to properly maintain this outboard motor, or failing to correct a problem before operation, could result in a significant malfunction.

Some malfunctions can cause serious injuries or death.

Always follow the inspection and maintenance recommendations and schedules in this owner's manual.

To help you properly care for your outboard motor, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions. If you operate your outboard motor under unusual conditions, consult an authorized Honda Marine dealer for recommendations applicable to your individual needs and use.

Remember that your authorized Honda Marine dealer knows your outboard motor best and is fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new, Honda Genuine parts or their equivalents for repair and replacement.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual, using parts that are ‘‘certified’’ to EPA standards.

SERVICING YOUR OUTBOARD MOTOR

MAINTENANCE SAFETY

Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

Improper maintenance can cause an unsafe condition.

Failure to properly follow maintenance instructions and precautions can cause serious injuries or death.

Always follow the procedures and precautions in this owner’s manual.

Safety Precautions

• Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:

─ Carbon monoxide poisoning

from engine exhaust.

Do not start or run the engine in a confined or partly enclosed area.

─ Burns from hot parts.

Let the engine and exhaust system cool before touching.

─ Injury from moving parts.

Do not run the engine unless instructed to do so.

• Read the instructions before you begin, and make sure you have the tools and skills required.

• To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related parts.

• Wear gloves when handling the propeller to protect your hands from sharp edges.

SERVICING YOUR OUTBOARD MOTOR

EMERGENCY STARTER ROPE

10 × 12 mm WRENCH

SHEAR PIN

SPARK PLUG WRENCH

COTTER PIN

SPARE EMERGENCY STOP SWITCH CLIP

GRIP

FLAT SCREWDRIVER

PLIERS

TOOL BAG

TOOL KIT AND EMERGENCY STARTER ROPE

The following tools are supplied with the outboard motor for simple maintenance procedures and emergency repairs. An emergency starter rope is also supplied. Keep these items on the boat so that they will always be available if you need them. If your tool kit needs replacement, it is not available as a kit and each item must be ordered individually.

SERVICING YOUR OUTBOARD MOTOR

REGULAR SERVICE PERIOD (3) Perform at every indicated month or operating hour interval, whichever comes first.

ITEM

MAINTENANCE SCHEDULE

Follow the MAINTENANCE SCHEDULE table and service your outboard motor accordingly. Please note, a claim for warranty coverage will not be denied simply because the maintenance schedule for your outboard motor was not followed. However, any part(s) that fails specifically due to lack of maintenance, or improperly performed maintenance, would not be covered under the Distributor’s Limited Warranty (U.S.) / Distributor’s Warranty (CA.).

Engine oil Check level o 64

Gear case oil Change o o 67 Starter rope Check o78 Carburetor linkage Check-adjust o (2) o (2) Valve clearance Check-adjust o (2) o (2) Spark plug Check-adjust o

Propeller and cotter pin Check o 79 Anode Check o (8) 35 Idling speed Check-adjust o (2) o (2) Lubrication Grease o (1) o (1) 69

(1) Lubricate more frequently when used in salt water.

(2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the

Honda shop manual for service procedures. See “Honda Publications” on page 109 for ordering information.

(3) For professional commercial use, log hours of operation to determine proper maintenance intervals.

(8) When there is 1/3 or more consumption, please exchange.

Each use After use

Change o o 65

Replace o

First month

20 hrs.

Every

6 months

100 hrs.

Every year

200 hrs.

Refer to

page

SERVICING YOUR OUTBOARD MOTOR

REGULAR SERVICE PERIOD (3) Perform at every indicated month or operating hour interval, whichever comes first.

ITEM

Fuel tank and tank filter (Internal) Clean o (2) Fuel tank and tank filter (Portable) Clean o77 Thermostat Check o (2) Fuel filter Check o

Fuel line Check o (5) 35

Bolts and nuts Check-tightness o (2) o (2) 35 Breather tube Check o (2) Cooling water passages Clean o (4) 81 Water pump Check o (2) Emergency stop switch Check o 35 Engine oil leak Check o Each operation part Check o Engine condition (7) Check o -

(2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the

Honda shop manual for service procedures. See “Honda Publications” on page 109 for ordering information.

(3) For professional commercial use, log hours of operation to determine proper maintenance intervals.

(4) When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

(5) Check the fuel line for leaks, cracks or damage. If it is leaking, cracked or damaged, take it to your servicing dealer for replacement before

using your outboard motor.

(6) Check the fuel line for leaks, cracks or damage. Replace the fuel line if there are signs of leaks, cracks or damage.

(7) Upon starting, check for unusual engine sounds and cooling water flowing freely from the check hole.

First month

Each use After use

Replace o

Replace Every 2 years (If necessary) (2) (6) -

20 hrs.

Every

6 months

100 hrs.

Every year

200 hrs.

Refer to

page

ENGINE COVER REMOVAL

ENGINE COVER LATCH

UNLOCK

ENGINE COVER

STARTER GRIP

ENGINE UNDER COVER

ENGINE COVER HOOK

ENGINE COVER

STARTER GRIP

ENGINE COVER HOOK

ENGINE UNDER COVER

AND INSTALLATION

SERVICING YOUR OUTBOARD MOTOR

To remove, unlatch the engine cover latch and slide the engine cover forward. Unhook the engine cover hook as shown. Remove the engine cover while turning a starter grip to the upward.

To install, lower the engine cover while turning a starter grip to the upward. Hook the engine cover hook as shown, and latch the engine cover latch.

SERVICING YOUR OUTBOARD MOTOR

OIL FILLER CAP/ DIPSTICK

UPPER LIMIT

LOWER LIMIT

Engine Oil Level Check

Check the engine oil level with the engine stopped and the outboard motor in the vertical position.

To avoid incorrect gauging of the engine oil level, inspect the oil level when the engine has cooled.

1. Unlock and remove the engine cover (p. 63).

2. Remove the oil filler cap/dipstick and wipe it clean.

3. Insert the dipstick and screw it in, then remove it and check the oil level shown on the dipstick.

4. If the oil level is low, add oil to reach the upper limit mark shown on the dipstick. Use the oil recommended on p. 67.

Running the engine with a low oil level can cause engine damage.

5. Install the oil filler cap/dipstick and tighten it securely.

6. Install the engine cover (p. 63), and lock it in place by locking the engine cover latch.

SERVICING YOUR OUTBOARD MOTOR

When you check the oil level with the dipstick, you might notice the engine oil appears milky or the oil level has increased. If you notice either condition, change the engine oil. See the following table for an explanation of these conditions

Operating Method Result Effect

Running the engine below 3,000 rpm for more than 30% of the time so the engine does not warm up.

Frequent starting and stopping without allowing the engine to warm up.

• Water condenses in the engine and mixes with the oil, resulting in a milky appearance.

• Unburned fuel mixes with the oil, increasing the volume of oil.

The engine oil deteriorates, becomes less efficient as a lubricant, and causes an engine malfunction.

Engine Oil Change

An engine oil evacuation device may be used to remove the engine oil.

Drain the used oil into a suitable container while the engine is warm. Warm oil drains quickly and completely.

1. Unlock and remove the engine cover (p. 63).

SERVICING YOUR OUTBOARD MOTOR

DRAIN BOLT

DIPSTICK

UPPER LIMIT

LOWER LIMIT

Improper disposal of engine oil can be harmful to the environment. If you change your own oil, please dispose of the used oil properly. Put it in a sealed container, and take it to a recycling center. Do not discard it in a trash bin, dump it on the ground, or pour it down a drain.

2. Remove the oil filler cap, and remove the engine oil drain bolt and washer.

3. Allow the used oil to drain completely, then reinstall the engine oil drain bolt and a new washer, and tighten it securely.

Insert the dipstick and screw it in, then remove it and check that oil level is shown on the dipstick upper limit mark. ENGINE OIL CAPACITY: 18 US oz (0.55 L, 0.48 Imp qt)

5. Install the oil filler cap and tighten it securely.

ENGINE OIL DRAIN BOLT TORQUE: 24 lbf·ft (33 N·m, 3.4 kgf·m)

4. With the outboard in a vertical position, using the recommended oil, fill to the upper limit mark on the dipstick.

6. Install the engine cover (p. 63), and lock it in place by locking the engine cover latch.

SERVICING YOUR OUTBOARD MOTOR

AMBIENT TEMPERATURE

OIL LEVEL SCREW

Engine Oil Recommendations

Oil is a major factor affecting performance and service life.

Honda recommends that you use API service category SG, SH or SJ oil. The SAE oil viscosity and service category are in the API label on the oil container.

Gear Case Oil Change

Change the gear case oil with the engine stopped and the outboard motor in the vertical position.

1. Place a suitable container below the oil drain hole to catch the used oil, then remove the oil level screw and oil drain/fill screw.

2. Allow the used oil to drain completely, then install an oil pump adapter in the oil drain hole.

If water or contaminated (milky-colored) oil flows out the drain hole when the screw is removed, have the outboard motor checked by an authorized Marine dealer.

SERVICING YOUR OUTBOARD MOTOR

GEAR OIL BOTTLE

OIL LEVEL SCREW

3. Add oil through the oil drain hole until it flows out the oil level hole, and then install the oil level screw. Remove the pump adapter and install the oil drain/fill screw.

GEAR OIL CAPACITY: 3 US oz (0.10 L, 0.09 Imp qt)

Outboard motor SAE 75W-90 or 90 hypoid gear oil API Service category (GL-4)

OIL LEVEL SCREW TORQUE:

2.6 lbf·ft (3.5 N·m, 0.36 kgf·m)

Avoid losing more than 1 fl oz

(30 cm

) while reinstalling the

drain/ fill screw.

OIL DRAIN SCREW TORQUE:

2.6 lbf·ft (3.5 N·m, 0.36 kgf·m)

Lubrication Points

Apply Honda Marine waterproof grease to the parts shown below: Lubrication interval: 20 operating hours or one month after the date of purchase or the initial use, then every 100 operating hours or 6 months (refer to the maintenance schedule on page 61).

To prevent corrosion, apply anticorrosion oil to pivot surfaces where grease cannot penetrate.

SHIFT SHAFT

TILLER HANDLE PIVOT

CLAMP SCREWS

TILT RELEASE LEVER AND REVERSE LOCK ROD

PROPELLER SHAFT

TRANSOM ANGLE ADJUSTING ROD

SWIVEL CASE

THROTTLE LINK

(LEFT AND RIGHT INSERTION SECTIONS OF THE TRANSOM ANGLE ADJUSTING ROD)

EXTENSION CASE

SERVICING YOUR OUTBOARD MOTOR

Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover and any exposed metal surfaces.

SERVICING YOUR OUTBOARD MOTOR

SPARK PLUG WRENCH

SPARK PLUG CAP

New plug Plug needing

replacement

SIDE ELECTRODE

SEALING WASHER

INSULATOR

0.024 - 0.028 in (0.6 - 0.7 mm)

Spark Plug Service

RECOMMENDED SPARK PLUG: BKR6E-E (NGK)

Incorrect spark plug can cause engine damage.

1. Unlock and remove the engine cover (p. 63).

2. Disconnect the spark plug cap from the spark plug.

3. Remove the spark plug with a spark plug wrench and screwdriver provided in the tool kit.

4. Inspect the spark plug. Replace it if the electrode is worn, or if the insulator is cracked or chipped.

5. Measure the spark plug electrode gap with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode.

The gap should be:

0.024 - 0.028 in (0.6 - 0.7 mm)

SERVICING YOUR OUTBOARD MOTOR

FUEL FILLER CAP

VENT KNOB

MAXIMUM FUEL LEVEL

FUEL TANK

6. Install the spark plug carefully, by hand, to avoid cross-threading.

7. After the spark plug seats, tighten with a spark plug wrench to compress the sealing washer.

SPARK PLUG TORQUE: 13 lbf·ft (18 N·m, 1.8 kgf·m)

If reinstalling the used spark plug, tighten 1/8 – 1/4 turn after the spark plug seats.

If installing new spark plug, tighten 1/2 turn after the spark plug seats.

A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head.

8. Attach the spark plug cap.

9. Install the engine cover (p. 63), and lock it in place by locking the engine cover latch.

REFUELING

If you do not anticipate using at least one complete tank of fuel within a 30 day period, we recommend adding Honda Marine Fuel Stabilizer or equivalent each time you refuel.

Internal Fuel Tank

FUEL TANK CAPACITY:

0.40 US gal (1.5 L, 0.33 Imp gal)

With the engine stopped, turn the internal fuel tank vent knob counterclockwise to the open position (p. 21), and then remove the fuel filler cap. Refill the fuel tank if the fuel level is low.

Refuel in a well-ventilated area. Fill the tank to the maximum fuel level.

After refueling, install the fuel filler cap and tighten it securely. Close the internal fuel tank vent by turning the vent knob clockwise all the way (p. 21).

Fuel can damage paint and plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under the Distributor’s Limited Warranty (U.S.) / Distributor’s Warranty (CA.).

SERVICING YOUR OUTBOARD MOTOR

VENT KNOB

OPEN

FUEL FILLER CAP

PRESSURE RELIEF TAB

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Stop the engine and let it cool before handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.

• Keep away from your vehicle.

• Wipe up spills immediately.

Never refill the fuel tank inside a building where gasoline fumes may reach flames or sparks. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc.

Spilled fuel is not only a fire hazard, it causes environmental damage. Wipe up spills immediately.

Portable Fuel Tank

FUEL TANK CAPACITY:

3.2 US gal (12 L, 2.6 Imp gal)

Check the fuel level. Refill the fuel tank if the fuel level is low.

Remove the fuel tank from the boat for refueling.

1. Turn the vent knob counterclockwise all the way to open the vent.

2. Turn the fuel filler cap counterclockwise so that it touches the pressure relief tab.

SERVICING YOUR OUTBOARD MOTOR

FUEL FILLER CAP

PRESSURE RELIEF TAB

PRESS

SAFE FILL LEVEL

FUEL FILLER CAP

VENT KNOB

3. Press down the pressure relief tab, and then turn the fuel filler cap 1/4 counterclockwise. Release the pressure relief tab. Wait to relieve pressure.

4. The fuel filler cap will lock again. Press down the pressure relief tab, and turn counterclockwise to remove the fuel filler cap.

Refuel in a well-ventilated area. Fill the tank to the SAFE FILL LEVEL line.

After refueling, install the cap and tighten it until you hear it click. Close the vent by turning the vent knob clockwise all the way, and return the fuel tank to the boat.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Stop the engine and let it cool before handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.

• Keep away from your vehicle.

• Wipe up spills immediately.

Never refill the fuel tank inside a building where gasoline fumes may reach flames or sparks. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc.

Spilled fuel is not only a fire hazard, it causes environmental damage. Wipe up spills immediately.

SERVICING YOUR OUTBOARD MOTOR

FUEL RECOMMENDATIONS

Use unleaded gasoline with a pump octane rating of 86 or higher.

Your outboard motor is certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life.

Never use gasoline that is stale, contaminated, or mixed with oil. Avoid getting dirt or water in the fuel tank.

You may use unleaded gasoline containing no more than 10% ethanol (E10) or 5% methanol by volume. In addition, methanol must contain cosolvents and corrosion inhibitors.

Use of fuels with content of ethanol or methanol greater than shown above may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system.

Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty.

If your outboard motor will be used on an infrequent or intermittent basis, please refer to the fuel section of the STORAGE chapter (p. 84) for additional information regarding fuel deterioration.

SERVICING YOUR OUTBOARD MOTOR

UNLOCK

ENGINE COVER LATCH

Fuel Filter Inspection and Replacement

The fuel filter is located under the engine cover, on the right side of the engine. Water or sediment accumulation in the filter can cause loss of power or hard starting. To prevent engine malfunction, inspect the filter and replace when necessary.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Stop the engine and let it cool before handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.

• Keep away from your vehicle.

• Wipe up spills immediately.

1. Unlock and remove the engine cover (p. 63).

2. Inspect the fuel filter for water and/ or sediment accumulation.

If the fuel filter is OK, reinstall it. If water and/or sediment are present, replace the fuel filter as described in the following steps. Always replace the fuel filter at the scheduled replacement interval (p.

62).

3. Turn the fuel valve lever to the OFF position (BF4A) or portable fuel tank position (BF5D and BF6A) (p. 19).

4. When using the portable fuel tank (BF5D and BF6A), turn the portable fuel tank vent knob counterclockwise to the open position (p. 26), disconnect the fuel hose connectors from the outboard motor and portable fuel tank (p.

40), install fuel hose connector cap and close the portable fuel tank vent by turning the vent knob clockwise all the way (p. 26).

5. Close the internal fuel tank vent by turning the vent knob clockwise all the way (p. 21).

SERVICING YOUR OUTBOARD MOTOR

FUEL FILTER

FUEL HOSE

HOSE CLAMPS

ARROW (Fuel Flow Direction)

FUEL HOSE CLIPS

FUEL PUMP

6. Place commercially available hose clips on the fuel hoses on each side of the fuel filter to prevent fuel leakage when the fuel hoses are disconnected.

7. Remove the fuel hoses from the used filter, and discard the filter.

To ease hose removal, release the hose clamps by squeezing the clamp ends together with pliers while pulling off the hoses.

8. Install the new fuel filter on the fuel hoses, with the fuel flow arrow pointing toward the fuel pump as shown. Fuel flow will be impeded if the fuel filter is installed backward.

9. Connect the fuel hoses to the fuel filter securely with the hose clamps.

10.Remove the fuel hose clips used to close the fuel hoses.

11.When using the internal fuel tank,

prime the carburetor with gasoline (p. 37). When using the portable fuel tank, connect the fuel line (p. 39) and prime the engine using the priming bulb (p. 40).

12.Check for fuel leaks. Repair any

fuel leaks if necessary.

13.Install the engine cover (p. 63),

and lock it in place by locking the engine cover latch.

If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fuel tank.

Clean the fuel tank and tank filter if necessary. It may be necessary to drain the fuel tank completely and refill with fresh gasoline.

SERVICING YOUR OUTBOARD MOTOR

FUEL HOSE (standard equipment)

CONNECTOR GASKET

FUEL TANK FILTER JOINT (Fuel Hose Connector)

FUEL TANK FILTER

Portable Fuel Tank and Tank Filter Cleaning

(standard or optionally applicable equipment)

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Stop the engine and let it cool before handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.

• Keep away from your vehicle.

• Wipe up spills immediately.

Fuel Tank

Empty the portable fuel tank into an approved gasoline container. Use a funnel to avoid spilling fuel. Rinse the fuel tank with nonflammable solvent to remove any accumulated sediment.

Fuel Tank Filter

1. Turn the fuel tank filter joint counterclockwise and remove the fuel tank filter.

2. Clean the fuel tank filter in nonflammable solvent. Inspect the fuel tank filter and the connector gasket. Replace them if damaged.

3. After cleaning, reinstall the fuel tank filter and fuel tank filter joint securely.

SERVICING YOUR OUTBOARD MOTOR

RECOIL STARTER ROPE

BOLT

ANODE

Recoil Starter Rope Inspection

Inspect the recoil starter rope, and replace it if it becomes frayed.

Always keep the emergency starter rope on the boat in case the recoil starter rope fails.

Anode Replacement

The anode is located on the antiventilation plate. It is made of a sacrificial material that helps to protect the outboard motor from corrosion.

Replace the anode when it has been reduced to about two-thirds of the original size, or if it is crumbling.

Painting or coating the anode will defeat its purpose and will lead to rust and corrosion damage to the outboard motor. The anode must be exposed to the water in order to protect the outboard motor.

SERVICING YOUR OUTBOARD MOTOR

PROPELLER CAP

COTTER PIN

SHEAR PIN

Propeller and Shear Pin Replacement

A shear pin is used to protect the propeller and drive mechanism from damage when the propeller strikes an obstruction.

If the propeller is damaged by striking a rock, or other obstacle, replace the propeller.

Before replacing the propeller or the shear pin, remove the emergency stop switch clip from the emergency stop switch to prevent any possibility of the engine being started while you are working with the propeller.

The propeller blades may have sharp edges, so wear heavy gloves to protect your hands.

Operating the outboard motor at higher altitudes will reduce available power. This may require decreasing the propeller pitch to maintain correct engine RPM.

Removal

1. Remove the cotter pin, the propeller cap, and the propeller.

2. Remove the broken shear pin and replace it with a new one.

SERVICING YOUR OUTBOARD MOTOR

COTTER PIN

Installation

1. Install the shear pin and the propeller, then install the propeller cap finger tight.

2. Be sure to replace the cotter pin with a new one.

• Use a Honda Genuine stainless steel cotter pin or equivalent cotter pin and bend the pin ends as shown.

Spare shear pin and cotter pin are provided in the engine compartment (p. 60).

CLEANING AND FLUSHING

FLUSH KIT (Optional Equipment)

WATER MOUTH NUT

WATER HOSE CONNECTOR

WATER MOUTH SEAT

Cleaning and Flushing

After each use in salt water or dirty water, thoroughly clean and flush the outboard motor with fresh water.

Cleaning

Wash the outside of the outboard motor with clean, fresh water to remove mud, salt, seaweed, etc.

Disengage the emergency stop switch clip from the emergency stop switch, and pull the recoil starter rope several times to expel any water remaining in the water pump.

Touch up any damaged paint, and coat areas that may rust with Honda Corrosion Inhibitor, or equivalent. Lubricate controls with a silicone spray lubricant.

Flushing With the Honda Water Hose Connector

1. Tilt down the outboard motor (p. 56).

2. Remove the flush screw from the WASH screw hole and install the water hose connector.

3. Attach a hose from a fresh water faucet to the water hose connector of the flush kit.

4. Remove the propeller (p. 79).

5. Turn on the fresh water supply to hose.

6. Start the engine and run in N (neutral) for 10 minutes.

CLEANING AND FLUSHING

WATER HOSE

WATER HOSE CONNECTOR

7. After flushing, when using the internal fuel tank, close the internal fuel tank vent by turning the vent knob clockwise all the way (p. 21), turn the fuel valve lever to the OFF position (BF4A) or portable fuel tank position (BF5D and BF6A) (p.

19) and leave the outboard motor in the running position for one minute to drain the water from inside the engine.

After flushing, when using the portable fuel tank (BF5D and BF6A), turn the portable fuel tank vent knob counterclockwise to the open position (p. 26), disconnect the fuel hose connectors from the outboard motor and portable fuel tank (p. 40), install fuel hose connector cap, close the internal fuel tank vent by turning the vent knob clockwise all the way (p. 21), close the portable fuel tank vent by turning the vent knob clockwise all the way (p. 26) and leave the outboard motor in the running position for one minute to drain the water from inside the engine.

8. Reinstall the flush screw and the propeller (p. 80).

9. Tilt up the outboard motor (p. 57).

CLEANING AND FLUSHING

ANTIVENTILATION PLATE

Flushing Without the Honda Water Hose Connector

It is necessary to run the engine during the flushing procedure. For safety, remove the propeller from the outboard motor (p. 79).

1. Tilt down the outboard motor (p. 56).

2. Place a container under the outboard motor, and fill it with clean, fresh water. The water level must be at least 2 inches (5 cm) above the antiventilation plate.

Running the engine without good water circulation can cause overheating and water pump damage.

Damage caused by running the outboard motor without sufficient cooling water is not covered by the

Distributor’s Limited Warranty (U.S.) / Distributor’s Warranty (CA.)

3. Start the engine and run in the N (neutral) position at low speed for at least 10 minutes.

4. After flushing, when using the internal fuel tank, close the internal fuel tank vent by turning the vent knob clockwise all the way (p. 21), turn the fuel valve lever to the OFF position (BF4A) or portable fuel tank position (BF5D and BF6A) (p.

19) and leave the outboard motor in the running position for one minute to drain the water from inside the engine.

(p. 112).

5. Reinstall the propeller (p. 80).

6. Tilt up the outboard motor (p. 57).

STORAGE

Fuel

Depending on the region where you operate your outboard, fuel formulations may deteriorate and oxidize rapidly. Fuel deterioration and oxidation can occur in as little as 15 days and may cause damage to the carburetor and fuel system. Please check with your servicing dealer for local storage recommendations.

Gasoline will oxidize and deteriorate in storage. Deteriorated gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your fuel tank and carburetor deteriorates during storage, you may need to have the carburetor and other fuel system components serviced or replaced.

The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled. The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel deterioration problems may occur in less than 15 days, if the gasoline was not fresh when you filled the fuel tank.

You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining all the fuel from the fuel tank and carburetor.

The

Distributor’s Limited Warranty (U.S.)

/ Distributor’s Warranty (CA.)

does not cover fuel system damage or engine performance problems resulting from neglected storage preparation.

(p. 112)

Adding a Fuel Stabilizer

When adding a fuel stabilizer, fill the internal fuel tank with fresh gasoline. If only partially filled, air in the internal fuel tank will promote fuel deterioration during storage. If you keep an additional container of gasoline for refueling, be sure that it contains only fresh gasoline.

1. Add Honda Marine fuel stabilizer or equivalent following the instructions on the label.

2. After adding a fuel stabilizer, run the engine in water for 10 minutes to be sure that the treated gasoline has replaced the untreated gasoline in the carburetor.

3. Stop the engine (p. 51).

STORAGE

CARBURETOR DRAIN PORT

AIR GUIDE

DRAIN SCREW

DRAIN TUBE

ENGINE UNDER COVER

Draining the Fuel System

You can avoid fuel deterioration problems by draining the fuel tank and carburetor.

1. When using the portable fuel tank (BF5D and BF6A), turn the portable fuel tank vent knob counterclockwise to the open position (p. 26), disconnect the fuel hose connectors from the outboard motor and portable fuel tank (p. 40), install fuel hose connector cap, remove the portable fuel filler cap, drain the gasoline from the portable fuel tank into a suitable container, install the portable fuel filler cap and close the portable fuel tank vent by turning the vent knob clockwise all the way (p. 26).

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

• Stop the engine and let it cool before handling fuel.

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.

• Keep away from your vehicle.

• Wipe up spills immediately.

2. Turn the internal fuel tank vent knob counterclockwise to the open

position (p.

), remove the fuel filler cap, and drain the gasoline from the internal fuel tank into a suitable container.

3. Install the fuel filler cap.

4. Turn the fuel valve lever to the OFF position (BF4A) or portable fuel tank position (BF5D and

BF6A) (p.

5. Unlock and remove the engine cover (p.

6. Disconnect the drain tube from the air guide, then connect it to the carburetor drain port as shown.

7. With the outboard motor in a vertical position, place an approved gasoline container below the fuel drain outlet, and use a funnel to avoid spilling fuel. Loosen the drain screw to drain fuel from the carburetor.

STORAGE

8. After the fuel has drained from the carburetor, tighten the drain screw securely.

9. Reconnect the drain tube to the air guide and the engine under cover.

10.Close the internal fuel tank vent

by turning the vent knob

clockwise all the way (p.

11.Turn the fuel valve lever to the

OFF position (BF4A) or portable fuel tank position (BF5D and

BF6A) (p.

12.If you need to store fuel in the fuel tank, you can extend fuel storage life by filling the fuel tank with fresh gasoline and adding Honda Marine fuel stabilizer or equivalent following the directions on the container (p.

Store the portable fuel tank in a cool dry place out of direct sunlight.

(When using the internal fuel tank)

When starting the engine after draining the gasoline, prime the

carburetor with gasoline (p.

Engine Oil

Change the engine oil (p. 65).

Engine Cylinder

1. Remove the spark plug (p. 70), and remove the emergency stop switch clip from the emergency stop switch.

2. Pour 1 – 2 teaspoons (5 – 10 cm3) of clean engine oil into the cylinder.

3. Pull the starter grip several times to distribute the oil in the cylinder.

When cranking the engine with an open ignition circuit (spark plug removed from the ignition circuit), remove the emergency stop switch clip from the emergency stop switch to prevent possible damage to the ignition system.

4. Reinstall the spark plug and connect the spark plug cap (p. 71).

5. Install the engine cover (p. 63), and lock it in place by locking the engine cover latch.

STORAGE

CARRYING HANDLE

STORAGE PRECAUTIONS

Select a well-ventilated storage area. If possible, avoid storage areas with high humidity.

Disconnect the battery charge cable (equipped type) (p. 29).

To carry the outboard motor, hold it by the carrying handle, or hold by the carrying handle and the lug beneath the engine under cover, as shown.

Lifting the outboard motor by the engine cover, or using the installed outboard motor as a handle or lever to move the boat, can damage the outboard motor.

If your internal fuel tank and portable fuel tank contains gasoline, store it away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a spark-producing electric motor, or where power tools are operated.

Store the outboard motor either vertically or horizontally with the tiller handle side up and move the shift lever to the R (reverse) position to lock the tilt system.

STORAGE

CASE PROTECTORS

REMOVAL FROM STORAGE

If storing horizontally, be sure to fold the tiller handle, and rest the outboard motor on its case protectors. Be sure all water has drained from the outboard motor before placing it on its side, so no residual water can enter the engine exhaust port.

• Any other horizontal storage position may cause damage to the outboard motor or oil leakage.

• Position the outboard motor so that the engine side is higher than the propeller side. Failure to do so may cause engine oil leakage.

Cover the outboard motor to keep out dust. Do not use a plastic sheet as a dust cover. A nonporous cover will trap moisture, promoting rust and corrosion.

Check your outboard motor as described in the

OPERATION

If the cylinder was coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal.

BEFORE

chapter of this manual.

TRANSPORTING

OUTBOARD MOTOR SUPPORT BAR (commercially available)

WITH OUTBOARD MOTOR INSTALLED ON BOAT

When using the portable fuel tank (BF5D and BF6A), turn the portable fuel tank vent knob counterclockwise to the open position (p. 26), disconnect the fuel hose connectors from the outboard motor and portable fuel tank (p. 40), install fuel hose connector cap and close the portable fuel tank vent by turning the vent knob clockwise all the way (p. 26).

Drain the internal fuel tank and carburetor as described on p. 85, turn the fuel valve lever to the OFF position (BF4A) or portable fuel tank position (BF5D and BF6A) (p. 19), close the internal fuel tank vent by turning the vent knob clockwise all the way (p. 21), move the shift lever to the R (reverse) position to lock the tilt system and tighten the steering friction bolt securely (p. 54).

The preferred method is to leave the engine in the normal running position, but if there is insufficient road clearance, you can tilt the outboard motor using a commercially available outboard motor support bar available through your dealer. Refer to the manufacturer’s instructions for using an outboard motor support bar.

TRANSPORTING

CARRYING HANDLE

WITH OUTBOARD MOTOR REMOVED FROM BOAT

Disconnect the battery charge cable (equipped type) (p. 29).

When using the portable fuel tank (BF5D and BF6A), turn the portable fuel tank vent knob counterclockwise to the open position (p. 26), disconnect the fuel hose connectors from the outboard motor and portable fuel tank (p. 40), install fuel hose connector cap and turn the portable fuel tank vent knob clockwise all the way (p. 26).

Remove the outboard motor from the boat and secure the outboard motor in either the vertical or horizontal position shown on p. 88.

To carry, hold the outboard motor by the carrying handle, or hold by the carrying handle and the lug beneath the engine under cover, as shown.

Lifting the outboard motor by the engine cover, or using the installed outboard motor as a handle or lever to move the boat, can damage the outboard motor.

TAKING CARE OF UNEXPECTED PROBLEMS

Starting After Starting

18°

ENGINE WILL NOT START

Possible Cause Correction

Clip not inserted in emergency stop switch. Insert clip in emergency stop switch.

Gearshift lever not in neutral position. Shift to neutral (p. 41).

Choke OFF. Pull choke knob to ON position, unless engine is warm

(p. 44).

Throttle grip not in START position. Turn throttle grip to START position (p. 44).

Engine ran out of fuel. Refill fuel tank (p. 71). Perform the priming procedure

after refilling the tank (p. 37). Pull choke knob (p. 44).

Engine is at negative trim angle. Tilt the engine up to the first shallow water drive position

(p. 56). Return engine to normal operating position after starting (p. 57).

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START

Possible Cause Correction

Out of fuel. Refuel (p. 71).

Fuel valve lever is not turned to the appropriate position.

Fuel vent closed (internal fuel tank).

When using the portable fuel tank (BF5D and BF6A), fuel vent closed (portable fuel tank).

When using the portable fuel tank (BF5D and BF6A), fuel hose not primed.

Fuel filter or fuel tank f ilter restricted. Replace restricted filters (p. 75 or 77).

Bad fuel; outboard motor stored without treating or draining gasoline, or refueled with bad gasoline.

Spark plug faulty, fouled, or improperly gapped.

Spark plug wet with fuel (flooded engine). Dry and reinstall spark plug. Start engine with choke and

Carburetor malfunction, fuel pump failure, ignition malfunction, stuck valves, etc.

Turn the fuel valve lever to the appropriate position (p. 19).

Turn the internal fuel tank vent knob counterclockwise to the open position (p. 21).

Turn the portable fuel tank vent knob counterclockwise to the open position (p. 26).

Squeeze priming bulb (p. 40).

Drain fuel tank and carburetor (p. 85). Refill with fresh gasoline (p. 71).

Adjust the spark plug electrode gap or replace spark plug (p. 70).

throttle open.

Take outboard motor to an authorized Marine dealer, or refer to the shop manual.

TAKING CARE OF UNEXPECTED PROBLEMS

HARD STARTING OR STALLS AFTER STARTING

Possible Cause Correction

Choke OFF. Pull choke knob to ON position, unless engine is warm

(p. 44).

Throttle grip not in START position. Turn throttle grip to START position (p. 44).

Fuel valve lever is not turned to the appropriate position.

Fuel vent closed (internal fuel tank).

When using the portable fuel tank (BF5D and BF6A), fuel vent closed (portable fuel tank).

When using the portable fuel tank (BF5D and BF6A), fuel hose not primed.

Fuel filter or fuel tank f ilter restricted. Replace restricted filters (p. 75 or 77).

Bad fuel; outboard motor stored without treating or draining gasoline, or refueled with bad fuel.

Turn the fuel valve lever to the appropriate position (p. 19).

Turn the internal fuel tank vent knob counterclockwise to the open position (p. 21).

Turn the portable fuel tank vent knob counterclockwise to the open position (p. 26).

Squeeze priming bulb (p. 40).

Drain fuel tank and carburetor (p. 85). Refill with fresh gasoline (p. 71).

TAKING CARE OF UNEXPECTED PROBLEMS

HARD STARTING OR STALLS AFTER STARTING

Possible Cause Correction

Spark plug faulty, fouled, or improperly gapped.

Carburetor malfunction, fuel pump failure, ignition malfunction, etc.

ENGINE OVERHEATS

Possible Cause Correction

Water intakes clogged. Clean water intakes.

Faulty thermostat or water pump. Take outboard motor to an authorized Marine dealer, or

Adjust the spark plug electrode gap or replace spark plug (p. 70).

Take outboard motor to an authorized Marine dealer, or refer to the shop manual.

refer to the shop manual.

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT DRIVE THE PROPELLER

Possible Cause Correction

Broken shear pin. Replace shear pin (p. 79).

Damaged gearshift mechanism. Take outboard motor to an authorized Marine dealer, or

refer to the shop manual.

TAKING CARE OF UNEXPECTED PROBLEMS

SPARE FUSE

FUSE HOLDER

FUSE

FUSE CASE LID

BLOWN FUSE

BATTERY WILL NOT CHARGE (Equipped type)

The battery-charging circuit is protected by the 15-ampere fuse.

Fuse Replacement

1. Stop the engine.

2. Remove and inspect the fuse. If a fuse is burnt out, install a replacement fuse of the specified rating. The outboard motor is supplied with a spare fuse in fuse holder.

DESIGNATED FUSE RATING: 15A

Never use a fuse with a rating greater than specified. Serious damage to the electrical system could result.

3. Reinstall the fuse case lid.

Before further operation, try to determine and correct the electrical problem that caused the fuse to burn out. An uncorrected electrical problem may cause the fuse to burn out again.

TAKING CARE OF UNEXPECTED PROBLEMS

OIL PRESSURE INDICATOR

OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMITED

If oil pressure becomes low, the green indicator will go off. If you are at cruising speed, engine speed will decrease gradually.

Low oil pressure may be the result of a low engine oil level, or there may be a problem with the engine lubrication system.

If the throttle is closed suddenly after full throttle operation, engine speed may drop below the specified idle rpm, and that could activate the engine protection system momentarily.

If low oil pressure activates the engine protection system, stop the engine, check the engine oil level (p. 64), and add oil if needed.

With the engine oil at the recommended level, restart the engine. If the lubrication system is OK, the green indicator should come on within 30 seconds, and the engine will respond normally to throttle grip operation.

If the engine protection system remains activated after 30 seconds, return to the nearest boat landing, and have the outboard motor inspected by an authorized Marine dealer.

TAKING CARE OF UNEXPECTED PROBLEMS

STARTER GRIP

SUBMERGED OUTBOARD MOTOR

A submerged outboard motor must be serviced immediately after it is recovered from the water in order to minimize corrosion.

If there is a Honda Marine dealership nearby, take the outboard motor to the dealer immediately. If you are far from a dealer, proceed as follows:

1. Unlock and remove the engine cover (p. 63), and rinse the outboard motor with fresh water to remove salt water, sand, mud, etc.

2. Drain the internal fuel tank and carburetor as described on p. 85.

3. Change the engine oil as described on p. 65. If there was water in the engine crankcase, or if the used engine oil showed signs of water contamination, then a second engine oil change should be performed after running the engine for half an hour.

4. Remove the spark plug (p. 70), and remove the emergency stop switch clip from the emergency stop switch. Pull the starter grip, rotate the flywheel a few revolutions to completely expel any water from the cylinder.

If the engine was running when it submerged, there may be mechanical damage, such as a bent connecting rod. If the engine binds when cranked, do not attempt to run the engine until it has been repaired.

Honda BF4A, BF5D, BF6A Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

OUTBOARD MOTOR SAFETY

IMPORTANT SAFETY INFORMATION

SAFETY LABEL LOCATIONS

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

COMPONENT AND CONTROL LOCATIONS

CHOKE KNOB

CONTROLS

Emergency Stop Switch Clip and Emergency Stop Switch

THROTTLE GRIP

THROTTLE FRICTION KNOB

GEARSHIFT LEVER

FUEL VALVE LEVER

STARTER GRIP

ENGINE COVER LATCH

TRANSOM ANGLE ADJUSTING ROD

STEERING FRICTION BOLT

TILT LEVER

HANDLE STOPPER

OIL PRESSURE INDICATOR

INDICATORS

COOLING SYSTEM INDICATOR

ANODE

OTHER FEATURES

Rev Limiter

BATTERY CHARGE CABLE

INSTALLATION

POWER REQUIREMENTS

INSTALLATION POSITION

ATTACHMENT

TRANSOM ANGLE ADJUSTMENT

BATTERY

BATTERY CONNECTIONS

Battery Terminals

BEFORE OPERATION

ARE YOU READY TO GET UNDERWAY?

IS YOUR OUTBOARD MOTOR READY TO GO?

OPERATION

SAFE OPERATING PRECAUTIONS

BREAK-IN PROCEDURE

TRANSOM ANGLE ADJUSTMENT

PRIMING THE CARBURETOR WITH GASOLINE (When using the internal fuel tank)

INFREQUENT OR OCCASIONAL USE

STARTING THE ENGINE

EMERGENCY STARTING

STOPPING THE ENGINE

Emergency Engine Stopping

Normal Engine Stopping

GEARSHIFTING AND THROTTLE OPERATION

STEERING

CRUISING

SHALLOW WATER OPERATION

SERVICING YOUR OUTBOARD MOTOR

THE IMPORTANCE OF MAINTENANCE

MAINTENANCE SAFETY

TOOL KIT AND EMERGENCY STARTER ROPE

MAINTENANCE SCHEDULE

Engine Oil Level Check

Engine Oil Change

Engine Oil Recommendations

Gear Case Oil Change

Lubrication Points

Spark Plug Service

REFUELING

FUEL RECOMMENDATIONS

Fuel Filter Inspection and Replacement

Portable Fuel Tank and Tank Filter Cleaning

Recoil Starter Rope Inspection

Anode Replacement

Propeller and Shear Pin Replacement

CLEANING AND FLUSHING

Cleaning and Flushing

STORAGE

Fuel

Engine Oil

Engine Cylinder