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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.
2006 Honda Motor Co., Ltd. All Rights Reserved
The information and specifications included in this publication were in effect at the
time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to
discontinue or change specifications or design at any time without notice and without
incurring any obligation whatever. No part of this publication may be reproduced
without written permission.
−
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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.
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.
Best Wishes,
Honda Motor Co., Ltd.
1
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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
Safety Messages
three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
Safety Headings
Safety Section
Instructions
This entire book is filled with important saf ety information please read it
carefully.
−
on the outboard motor.
−
preceded by a safety alert symbol and one of
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.
−
such as
−
such as
−
how to use this outboard motor correctly and safely.
IMPORTANT SAFETY INFORMAT ION.
OUTBOARD MOTOR SAFETY.
−
2
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CONTENTS
CONTROL AND FEATURE
..............................................................CONTROLS . 12
..........................................................Choke Knob . 12
..........................................................Throttle Grip . 13
..........................................Throttle Friction Knob . 13
.....................................................Gearshift Lever . 13
............................................................Starter Grip . 14
............................................Steering Friction Bolt . 15
...............................................................Tilt Lever . 15
.......................................................INSTRUMENTS . 15
............................................................Fuel Gauge . 15
...................................OUTBOARD MOTOR SAFETY . 6
................IMPORTANT SAFETY INFORMATION . 6
................................SAFETY LABEL LOCATIONS . 8
....................................CONTROLS AND FEATURES . 9
..................................IDENTIFICATION CODES . 9
....COMPONENT AND CONTROL LOCATIONS . 10
....................Switch Clip and Engine Stop Switch . 12
.....................................Engine Cover Lock Lever . 14
.............................Transom Angle Adjusting Rod . 14
...........................................................INDICATORS . 16
............................................Oil Pressure Indicator . 16
.....................................Cooling System Indicator . 16
................................................OTHER FEATURES . 16
.....................................................Overrev Limiter . 16
....................................................................Anode . 17
................................................Portable Fuel Tank . 17
....................................Fuel Filler Cap Vent Knob . 17
.................................................Fuel Priming Bulb . 18
..........................................................INSTALLATION . 19
.....................................POWER REQUIREMENTS . 19
..................................INSTALLATION POSITION . 19
.......................................................ATTACHMENT . 20
.....................TRANSOM ANGLE ADJUSTMENT . 20
................................................BEFORE OPERATION . 21
........ARE YOU READY TO GET UNDER WAY? . 21
IS YOUR OUTBOARD MOTOR
..................................................READY TO GO? . 21
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CONTENTS
................................................................OPERATION . 23
.......................................................FUEL PRIMING . 25
GEARSHIFTING AND
...............................................................STEERING . 32
................................................................CRUISING . 33
....................SAFE OPERATING PRECAUTIONS . 23
.......................................BREAK-IN PROCEDURE . 23
.....................TRANSOM ANGLE ADJUSTMENT . 23
.......................................PORTABLE FUEL TANK . 24
................................FUEL HOSE CONNECTIONS . 24
......................................STARTING THE ENGINE . 25
.....................................EMERGENCY STARTING . 27
.......................................STOPPING THE ENGINE . 30
................................Emergency Engine Stopping . 30
.......................................Normal Engine Stopping . 30
..................................THROTTLE OPERATION . 31
........................SHALLOW WATER OPERATION . 34
...............MOORING, BEACHING, LAUNCHING . 35
..............SERVICING YOUR OUTBOARD MOTOR . 36
...........THE IMPORTANCE OF MAINTENANCE . 36
.....................................MAINTENANCE SAFETY . 37
TOOL KIT AND EMERGENCY STARTER
.....................................................................ROPE . 38
...............................MAINTENANCE SCHEDULE . 39
ENGINE COVER REMOVAL AND
..................................................INSTALLATION . 41
........................................Engine Oil Level Check . 41
................................................Engine Oil Change . 42
..............................Engine Oil Recommendations . 43
...................................Gear Case Oil Level Check . 43
...........................................Gear Case Oil Change . 44
.................................................Lubrication Points . 46
................................................Spark Plug Service . 47
.............................................................REFUELING . 48
...............................FUEL RECOMMENDATIONS . 49
...............Fuel Filter Inspection and Replacement . 50
.......Portable Fuel Tank and Tank Filter Cleaning . 52
.............................Recoil Starter Rope Inspection . 53
..............................................Anode Replacement . 53
...................Propeller and Shear Pin Replacement . 54
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CONTENTS
....................................................................STORAGE . 56
...................................STORAGE PREPARATION . 56
..........................................Cleaning and Flushing . 56
........................................................................Fuel . 58
.............................................................Engine Oil . 60
...................................STORAGE PRECAUTIONS . 60
...............................REMOVAL FROM STORAGE . 61
........................................................TRANSPORTING . 62
WITH OUTBOARD MOTOR INSTALLED
.............................................................ON BOAT . 62
WITH OUTBOARD MOTOR REMOVED
.......................................................FROM BOAT . 62
TAKING CARE OF UNEXPECTED
..........................................................PROBLEMS . 63
..................................ENGINE WILL NOT START . 63
HARD STARTING OR STALLS AFTER
...........................................................STARTING . 65
...........................................ENGINE OVERHEATS . 66
OIL PRESSURE INDICATOR GOES OFF AND
............................ENGINE SPEED IS LIMITED . 68
..........................................SUBMERGED MOTOR . 69
..TECHNICAL AND CONSUMER INFORMATION . 71
...............................TECHNICAL INFORMATION . 71
........................................Serial Number locations . 71
Carburetor Modification for High Altitude
...........................................................Operation . 72
.................Emission Control System Information . 73
..............................................................Star Label . 75
........................................................Specifications . 77
...............................CONSUMER INFORMATION . 78
...............................................Honda Publications . 78
..............................Customer Service Information . 78
............................Distributor’s Limited Warranty . 81
.....................Emission Control System Warranty . 85
....................................................WIRING DIAGRAM . 89
...........................................................................INDEX . 90
..ENGINE WILL NOT DRIVE THE PROPELLER . 67
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OUTBOARD MOTOR SAFETY
IMPORTANT SAFETY INFORMATION
The Honda BF5A outboard motor is
designed for use with boats that have
a suitable manufacturer’s power
recommendation. Other uses can
result in injury to the operator or
damage to the outboard motor and
other property.
Most accidents can be prevented if
you follow all instructions in this
manual and on the outboard motor.
The most common hazards are
discussed 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.
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OUTBOARD MOTOR SAFETY
Carbon Monoxide HazardRefuel With Care
Gasoline is extremely flammable,
and gasoline vapor can explode.
Refuel outdoors, in a wellventilated area, with the engine
stopped. Never smoke near
gasoline, and keep other flames
and sparks away.
Remove any portable fuel tank
from the boat for refueling. Keep
the portable fuel tank away from
the battery or other potential spark
sources.
Refuel carefully to avoid spilling
fuel. Avoid overfilling the fuel
tank.
After refueling, tighten the filler
cap securely. If any fuel is spilled,
make sure the area is dry before
starting the engine.
Exhaust gas contains poisonous
carbon monoxide. Avoid inhalation
of exhaust gas. Never run the engine
in a closed garage or confined area.
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OUTBOARD MOTOR SAFETY
SAFETY LABEL LOCATIONS
FUEL TANK
The labels shown here contain important safety information. Please read them carefully. These labels are considered
permanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized Honda
marine dealer for a replacement.
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CONTROL AND FEATURE IDENTIFICATION CODES
CONTROLS AND FEATURES
Model
Type
Shaft Length
Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.
BF5A is provided with the following types
according to the shaf t length.
Shaft Length
S: Short Shaft
L: Long Shaft
SA
S
BF5A
LA
L
(Example)
LA
Destination
A=United States
S=Short Shaft
L=Long Shaft
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CONTROLS AND FEATURES
COMPONENT AND CONTROL LOCATIONS
GEARSHIFT LEVER
ENGINE COVER
TILT LEVER
TRANSOM ANGLE
ADJUSTING ROD
ANTIVENTILATION
PLATE
PROPELLER
CHOKE KNOB
ENGINE STOP
SWITCH
TILLER
HANDLE
THROTTLE
FRICTION KNOB
SWITCH
CLIP
LANYARD
FUEL HOSE
CONNECTOR
(MALE)
WATER INTAKE PORT
(each side)
OIL FILLER CAP/DIPSTICK
STARTER GRIP
THROTTLE GRIP
OIL PRESSURE
INDICATOR
CLAMP SCREW
STERN BRACKET
STEERING
FRICTION BOLT
GEAR OIL
LEVEL SCREW
GEAR OIL DRAIN/FILL SCREW
SPARK PLUG
ENGINE COVER
LOCK LEVER
COOLING SYSTEM
INDICATOR
ENGINE OIL
DRAIN BOLT
WASH SCREW
(FLUSH SCREW)
ANODE
EXHAUST PORT
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Portable Fuel Tank
CONTROLS AND FEATURES
FUEL GAUGE
FUEL FILLER CAP
PRIMING BULB
VENT KNOB
FUEL TANK
FUEL HOSE
FUEL HOSE CONNECTOR
(FEMALE)
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CONTROLS AND FEATURES
CONTROLS Choke Knob
The engine stop switch controls
normal engine stopping and
Switch Clip and Engine Stop
emergency engine stopping.
Switch
ENGINE STOP
SWITCH
PUSH
SWITCH
CLIP
LANYARD
SWITCH CLIP
LANYARD
The switch clip must be inserted in
the engine stop switch in order for
the engine to start and run. The
lanyard should be attached to the
operator’s PFD (Personal Flotation
Device) or worn around the wrist.
When used as described, the engine
stop switch and lanyard system stops
the engine if the operator falls away
from the controls.
A spare switch clip is supplied with
the tool kit.
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.
CHOKE KNOB
OOFFFF
OONN
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CONTROLS AND FEATURES
Throttle Grip Throttle Friction Knob Gearshift Lever
INDEX MARK
TTOO IINNCCRREEAASSEE
FFRRIICCTTIIOONN
TTOO DDEECCRREEAASSEE
FFRRIICCTTIIOONN
R (reverse)
N(neutral)
F(forward)
THROTTLE GRIP
The throttle grip controls engine
speed.
An index mark on the tiller handle
shows throttle position and is helpf ul
for setting the throttle correctly when
starting (p. ).26
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.
GEARSHIFT LEVER
The gearshift lever is used to select F
(forward), N (neutral), or R (reverse)
gears.
The engine can be started with the
gearshift lever in the N (neutral)
position only.
If the gearshift lever is in the F
(forward) or R (reverse) position, the
recoil starter will not operate.
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CONTROLS AND FEATURES
Engine Cover Lock Lever Transom Angle Adjusting RodStarter Grip
STARTER GRIP
ENGINE COVER LOCK LEVER
UNLOCK
The transom angle adjusting rod
adjusts the transom angle of the
outboard motor when fully lowered.
Pulling the starter grip operates the
recoil starter to crank the engine for
starting.
The motor will start only when the
gearshift lever (p. ) is in the N
26
(neutral) position, and the clip is in
the engine stop switch.
14
The engine cover lock lever fastens
the engine cover to the outboard
motor.
TRANSOM ANGLE ADJUSTING ROD
Proper adjustment prevents the
outboard motor from being adjusted
too low (p. ).
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STEERING FRICTION BOLT
TTOO DDEECCRREEAASSEE
FFRRIICCTTIIOONN
TTOO IINNCCRREEAASSEE
FFRRIICCTTIIOONN
ENGINE COVER GRIP
TILT LEVER
CONTROLS AND FEATURES
INSTRUMENTSSteering Friction Bolt Tilt Lever
Fuel Gauge
FUEL FILLER CAP
FUEL GAUGE
The steering friction bolt adjusts
steering resistance.
Less friction allows the outboard
motor to turn more easily. More
friction helps to hold steady course
while cruising or to prevent the
outboard motor from swinging while
trailering the boat.
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 cover grip until the tilt
mechanism engages at 30°, 45°, or
70° (p. and ).34 35
A fuel gauge is built into the cap of
the portable fuel tank.
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CONTROLS AND FEATURES
INDICATORS
Oil Pressure Indicator
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
CARE OF UNEXPECTED
PROBLEMS
Low oil pressure indicates that the
engine oil level is low, or that there is
a problem with the engine lubrication
system.
,p. .68
TAKING
Cooling System Indicator OTHER FEATURES
Overrev Limiter
The engine is equipped with an
overrev limiter to prevent the
possibility of mechanical damage
from excessive engine speed.
The overrev limiter may be activated
during operation, limiting engine
speed, if the outboard motor is tilted
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.
excessively, or when propeller
ventilation occurs during a sharp turn.
If the overrev limiter is activated,
check the tilt angle of the outboard
motor.
Improper propeller selection may
also cause the overrev limiter to
activate.
Check to see if the correct propeller
is installed.
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CONTROLS AND FEATURES
Portable Fuel TankAnode Fuel Filler Cap Vent Knob
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.
The portable fuel tank has a capacity
of US gal ( ) and has a fuel
3.2 12
gauge built into the cap.
VENT KNOB
CLOSE
OOPPEENN
FUEL FILLER CAP
The cap is provided with a vent knob
to seal the portable fuel tank for
carrying it to and from the boat.
Open the vent knob 2 or 3 turns
before starting the engine.
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CONTROLS AND FEATURES
Fuel Priming Bulb
UP
OUTLET END
(MOTOR)
PRIMING BULB
INLET END
(TANK)
A priming bulb is built into the fuel
hose that connects the 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.
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INSTALLATION
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
CENTER LINE
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. When the outboard motor is
mounted on a sailboat, the
antiventilation plate should be 5.9 in
(150 mm) or more below the surface
of the water. For unusual situations,
see your Honda marine dealer for
advice.
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.
−
IDLE PORT
BBOOAATT
TTRRAANNSSOOMM
HHEEIIGGHHTT
02in
−
(0 50 mm)
−
ANTIVENTILATION PLATE
Type:
S:
L:
Motor Transom Height
17.1 in (434 mm)
22.1 in (561 mm)
MMOOTTOORR
TTRRAANNSSOOMM
HHEEIIGGHHTT
5.9 in
(150 mm)
WATER
SURFACE
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.
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INSTALLATION
If the outboard motor is installed too
low, the boat will squat and be hard
to plane, and the motor will spray
water that may enter the boat. It will
tend to porpoise, 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 TRANSOM ANGLE
ADJUSTMENT
Use the transom angle adjustment rod
(p. ) to adjust the angle of the
23
outboard motor so the propeller is
perpendicular to the surface of the
water.
STERN
BRACKET
SAFETY ROPE CLAMP SCREWS
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.
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BEFORE OPERATION
ARE YOU READY TO GET UNDER WAY?
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 under way. Know
what to do in case of emergencies.
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 your PFD or to
your wrist.
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
Honda marine dealer correct it,
before you operate the outboard
motor.
Improperly maintaining
this outboard motor, or
failing to correct a problem
before operation, can cause
a malfunction in which you
could be seriously hurt or
killed.
Always perform a preoperation inspection before
each operation, and correct
any problem.
Before beginning your pre-operation
checks, be sure the switch clip is
removed from the engine stop switch.
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BEFORE OPERATION
Safety Inspection Maintenance Inspection
Look around the outboard motor
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. ).
Check that the fuel hose is
undamaged and properly
connected (p. ).
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.
Replace any damaged parts.
Check that all fasteners are in
place and securely tightened.
24
24
Check the engine oil level (p. ).
Running the engine with a low oil
level can cause engine damage.
Check to be sure the propeller and
shear pin are undamaged (p. ).
Check that the anode is securely
attached to the antiventilation plate
(p. ) and is not excessively
53
worn. The anode helps to protect
the outboard motor from corrosion.
Make sure the tool kit and
emergency starter rope are
onboard (p. ). Replace any
missing items.
Check the fuel level in the fuel
tank (p. ).
38
48
41
54
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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
chapter titled
For your safety, avoid starting or
operating the engine in an enclosed
area. Your engine’s exhaust contains
poisonous carbon monoxide gas
which can collect rapidly in an
enclosed area and cause illness or
death.
on page and the
6
BEFORE OPERATION.
BREAK-IN PROCEDURE
Proper break-in procedure allows the
moving parts to wear in smoothly for
best performance and long service
life.
For the first 10 hours, run the
outboard motor at low speed, and
avoid full-throttle operation.
TRANSOM ANGLE ADJUSTMENT
TRANSOM ANGLE
ADJUSTING ROD
TO CHANGE
TO LOCK
LOCKED POSITION
UNLOCKED
POSITION
The transom angle adjusting rod is
used to adjust the angle of the
outboard motor in the normal
operating position (p. ).
To adjust, first tilt the outboard
1.
33
motor so it is not resting on the rod.
Push the rod in and turn the end of
2.
the rod up, so the latch will fall
into line with the rod.
Remove the rod and reinsert it in
3.
the desired position.
Push the rod in and turn the end of
4.
the rod down, so the latch will fall
to the locked position. Then
release the rod.
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OPERATION
PORTABLE FUEL TANK FUEL HOSE CONNECTIONS
Secure the portable fuel tank in the
boat, so it won’t move around and
become damaged.
FUEL HOSE CONNECTOR
Before use, open the fuel tank vent
by turning the vent knob at least 2 or
3 turns counterclockwise.
Gasoline is highly
flammable and explosive.
(FUEL TANK SIDE)
You can be burned or
Place the portable fuel tank in a wellventilated location, away from direct
seriously injured when
handling fuel.
sunlight, to reduce the possibility of a
gasoline vapor explosion.
Stop the engine and keep
heat, sparks, and flame
To ensure that the outboard motor
will be able to draw fuel from the
tank, place the tank within 6 feet of
the outboard motor and not more
than 3 feet below the fuel connector
on the outboard motor.
away.
Handle fuel only
outdoors.
Wipe up spills
immediately.
FUEL HOSE CONNECTOR
(OUTBOARD MOTOR SIDE)
Connect the fuel hose to the tank and
the outboard motor, as shown. Be
sure both connectors snap securely
into place.
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OPERATION
FUEL PRIMING STARTING THE ENGINE
SWITCH CLIP
UP
OUTLET END
(MOTOR)
PRIMING BULB
INLET END
(TANK)
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 engine.
Check to be sure there are no fuel
leaks before starting the engine.
Do not touch the priming bulb with
the engine running or when tilting up
the outboard motor. The carburetor
could overflow.
LANYARD
Put the emergency stop switch clip
1.
in the engine stop switch, and
attach the lanyard to your PFD
(Personal Flotation Device) or to
your wrist.
ENGINE STOP
SWITCH
The engine will not start or run
unless the clip is in the switch.
The emergency stop switch clip
and 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 lanyard to your
PFD, or to your wrist, before
starting the engine.
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OPERATION
N (neutral)
CHOKE KNOB
MARK
OOFFFF
GEARSHIFT LEVER
Check the position of the gearshif t
2. 3. 4.
lever. It must be in the N (neutral)
position for starting.
To start a cold engine, pull the
choke knob to the ON position. To
restart a warm engine, leave the
OONN
choke knob in the OFF position.
The engine will not start if the
gearshift lever is in the F (forward)
or R (reverse) position.
26
THROTTLE GRIP
Align the START position with
the mark for starting the engine.
Page 29
OPERATION
Direction to pull
STARTER GRIP
Pull the starter grip lightly until
5.
you feel resistance, then pull
briskly in the direction of the
arrow as shown above.
Return the starter grip gently.
If the choke knob was pulled to
6.
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.
Before getting under way, allow
7.
the engine to warm up sufficiently
to ensure good performance.
During the warm-up period, check
the oil pressure indicator (p. )
and cooling system indicator
(p. ).
16
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
p. and .
6866
16
on
EMERGENCY STARTING
If the recoil starter is inoperative, you
can start the engine manually using
the emergency starter rope supplied
with the tool kit.
ENGINE COVER LOCK LEVER
UNLOCK
Unlock and remove the engine
1.
cover.
27
Page 30
OPERATION
6 mm CAP NUTS
6 mm FLANGE
BOLTS
Set the controls the same as for
3.
normal starting (see pages
). Use the choke control if
26
25
needed.
Set the knotted end of the
4.
emergency starter rope in the notch
in the flywheel. Wind the rope
clockwise around the flywheel.
−
STARTER ROPE
FLYWHEEL COVER
Remove the two 6 mm cap nuts
2.
and 6 mm flange bolts, and
remove the flywheel cover.
28
Pull the emergency starter rope
5.
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. .
63
Page 31
OPERATION
If the choke control was used to
5.
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. ),
and cooling system indicator
(p. ).
16
Install the engine cover (p. ),
6.
andlockitinplacebylockingthe
engine cover lock lever.
41
16
Exposed moving parts can
cause injury.
Do not operate the
outboard motor without
the engine cover.
Use extreme care when
installing the engine
cover.
If it was necessary to remove the
7.
emergency stop switch lanyard
from your wrist to perform the
emergency starting procedure, be
sure the lanyard is attached to your
wrist before operating the
outboard motor.
Have your closest authorized
8.
Honda marine dealer check your
system and correct the problem, so
you can use the recoil starter.
29
Page 32
OPERATION
STOPPING THE ENGINE
Emergency Engine Stopping
ENGINE STOP SWITCH
LANYARD
PULL
SWITCH CLIP
To stop the engine in an emergency,
pull the clip out of the engine stop
switch by pulling the lanyard.
We suggest that you stop the engine
this way occasionally to verify that
the engine or emergency stop switch
is operating properly.
Normal Engine Stopping
THROTTLE GRIP
N (neutral)
GEARSHIFT LEVER
Move the throttle grip to the
1.
slowest speed and gearshift lever
to the N (neutral) position.
ENGINE STOP SWITCH
PUSH
Press the engine stop switch until
2.
the engine stops.
When the boat is not in use,
3.
remove and store the emergency
stop switch clip and lanyard.
30
Page 33
OPERATION
GEARSHIFTING AND THROTTLE OPERATION
THROTTLE GRIP
R (reverse)
GEARSHIFT LEVER
N (neutral)
F(forward)
To shift gears, turn the throttle grip to
the SLOW position, then move the
gearshift lever to select F (forward),
N (neutral) or R (reverse) gears.
The engine can be started with the
gearshift lever in the N (neutral)
position only.
The throttle grip can be turned to the
FAST position only when the
gearshift lever is in the F (forward)
position.
TTOO DDEECCRREEAASSEE
FFRRIICCTTIIOONN
TTOO IINNCCRREEAASSEE
FFRRIICCTTIIOONN
THROTTLE
FRICTION KNOB
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.
31
Page 34
OPERATION
STEERING
STEERING FRICTION BOLT
TTOO DDEECCRREEAASSEE
FFRRIICCTTIIOONN
TTOO IINNCCRREEAASSEE
FFRRIICCTTIIOONN
Steer by moving the tiller handle
opposite the direction you want the
boat to turn.
32
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.
Page 35
OPERATION
CRUISING
Engine Speed
For best fuel economy, limit the
throttle opening to 80%. Use the
throttle friction control (p. ) 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.
31
Transom Angle
Install the outboard motor at the best
transom angle for stable cruising and
maximum power.
Transom angle too large: Incorrect
causes boat to ‘‘squat.’’
Transom angle too small: Incorrect
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. ).
23
Excessive transom angle during
operation can cause propeller
ventilation, overheating, and water
pump damage. This type of damage
is not covered by the
Limited Warranty
Transom Angle (Cruising)
MOTOR ANGLE
ADJUSTED TOO
LOW
ROUGH
WAVES
CORRECT
GIVES MAXIMUM PERFORMANCE
Distributor’s
81
(p. ).
MOTOR ANGLE
ADJUSTED TOO
HIGH
MOTOR ANGLE
ADJUSTED
CORRECTLY
33
Page 36
OPERATION
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.
ENGINE COVER GRIP
30°
To tilt the outboard motor, raise the
outboard motor to the 30° position by
pulling on the engine cover grip.
Do not use the tiller handle as a
lever to raise the outboard motor.
Applying excessive f orce 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. ) to be sure
the outboard motor is not tilted so
high that the water intakes are out of
the water.
16
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
Distributor’s
81
(p. ).
34
Page 37
OPERATION
TILT LEVER
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, then
slowly lower the outboard motor.
MOORING, BEACHING, LAUNCHING
ENGINE COVER GRIP
45°, 70° (when mooring)
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 45° or 70°
position.
Stop the engine before tilting the
outboard motor. The 45° or 70°
position is not an operating position.
Raise and lower the outboard motor
as described on p. .
34
35
Page 38
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.
Improperly maintaining
this outboard motor, or
failure to correct a problem
before operation, can cause
a malfunction in which you
could be seriously hurt or
killed.
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 f ully
equipped to maintain and repair it.
To ensure the best quality and
reliability, use only new, genuine
Honda 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.
36
Page 39
SERVICING YOUR OUTBOARD MOTOR
MAINTENANCE SAFETY Safety Precautions
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.
Failure to properly follow
maintenance instructions
and precautions can cause
you to be seriously hurt or
killed.
Always follow the
procedures and
precautions in the owner’s
manual.
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.
Be sure there is adequate
ventilation whenever you
operate the engine.
−
Burns from hot parts.
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.Let the engine and exhaust
37
Page 40
SERVICING YOUR OUTBOARD MOTOR
TOOL KIT AND EMERGENCY STARTER ROPE
×
10 12 mm WRENCH
FLAT SCREWDRIVER
PLIERS
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 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.
38
SPARK PLUG
WRENCH
COTTER PINS
PHILIPS SCREWDRIVER
8 mm WRENCH
SHEAR PINS
TOOL BAG
SPARE SWITCH CLIP
SPARE SPARK PLUG
FLUSH KIT
WATER MOUTH
SEAT
WATER HOSE
CONNECTOR
WATER MOUTH NUT
Page 41
SERVICING YOUR OUTBOARD MOTOR
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 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
REGULAR SERVICE PERIOD
Perform at every indicated month or
operating hour interval, whichever
comes first.
ITEM
Engine oil
Gear case oil
Starter rope
Carburetor linkage
Valve clearance
Spark plug
Propeller and cotter pin
Anode
Idle speed
Lubrication
Lubricate more frequently when used in salt water.
(1)
These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and are mechanically proficient.
(2)
(3)
Check level
Change
Change
Check
Check-adjust
Check-adjust
Check-adjust
Replace
Check
Check
Check-adjust
Grease
Each use After use
○
○
○
First month
or
20 hrs.
○
○
○
(2)
○
(2)
○
(1)
Every 6 months
or
100 hrs.
○
○
○
○
(2)
○
○
(2)
○
(1)
Refer to the Honda shop manual for service procedures.
For professional commercial use, log hours of operation to determine proper maintenance intervals.
(3)
Every year
or
200 hrs.
○
(2)
○
39
Page 42
SERVICING YOUR OUTBOARD MOTOR
REGULAR SERVICE PERIOD
Perform at every indicated month or
operating hour interval, whichever
comes first.
ITEM
Fuel tank and tank filter
Thermostat
Fuel filter
Fuel line
Bolts and nuts
Crankcase breather tube
Cooling water passages
Water pump
(3)
Clean
Check
Check
Replace
Check
Replace
Check-tightness
Check
Clean
Check
Each use After use
○
(4)
○
First month
or
20 hrs.
Every 2 years (If necessary) (2)
(2)
○
Every 6 months
or
100 hrs.
○
(2)
○
Lubricate more frequently when used in salt water.(1)
These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and are mechanically proficient.
(2)
Refer to the Honda shop manual for service procedures.
For professional commercial use, log hours of operation to determine proper maintenance intervals.
(3)
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.
(4)
Every year
or
200 hrs.
○
(2)
○
○
(2)
○
(2)
○
40
Page 43
SERVICING YOUR OUTBOARD MOTOR
ENGINE COVER REMOVAL AND INSTALLATION
ENGINE COVER LOCK LEVER
UNLOCK
The engine cover lock lever fastens
the engine cover to the outboard
motor.
To remove the engine cover, turn the
lock lever to the unlocked position,
then lift the engine cover off the
outboard motor.
To install the engine cover, place the
cover on the outboard motor, then
turn the lock lever to the locked
position.
Engine Oil Level Check
Check the engine oil level with the
engine stopped and the outboard
motor in the vertical position.
Unlock and remove the engine
1.
cover.
Remove the oil filler cap/dipstick
2.
and wipe it clean.
OIL FILLER CAP/DIPSTICK
Insert the dipstick without
3.
screwing it in, then remove it and
check the oil level shown on the
dipstick.
OIL FILLER CAP/DIPSTICK
UPPER
LIMIT
LOWER
LIMIT
If the oil level is low, add oil to
4.
reach the upper limit mark shown
on the dipstick. Use the oil
recommendedonp. .
43
Running the engine with a low oil
level can cause engine damage.
Install the oil filler cap/dipstick
5.
and tighten it securely.
Install and lock the engine cover.
6.
41
Page 44
SERVICING YOUR OUTBOARD MOTOR
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.
cover (p. ).
41
DRAIN BOLT
Remove the oil filler cap, and
2.
remove the engine oil drain plug
and washer.
Allow the used oil to drain
3.
completely, then reinstall the
engine oil drain plug and a new
washer, and tighten it securely.
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.Unlock and remove the engine
With the outboard motor in a
4.
vertical position, fill to the upper
limit mark on the dipstick (p. )
with the recommended oil.
Install the oil filler cap and tighten
5.
it securely.
Install and lock the engine cover.
6.
41
42
Page 45
SERVICING YOUR OUTBOARD MOTOR
Engine Oil Recommendations Gear Case Oil Level Check
The SAE oil viscosity and service
category are in the API label on the
Oil is a major factor affecting
performance and service life. Use
4-stroke automotive detergent oil.
oil container. Honda recommends
that you use API SERVICE category
SJ or later oil with the ‘‘starburst’’
Check the gear case oil level with the
engine stopped and the outboard
motor in the vertical position.
certification mark displayed on the
SAE Viscosity Grade
AMBIENT TEMPERATURE
container.
GEAR OIL
LEVEL SCREW
GEAR OIL
DRAIN/FILL
SCREW
Remove the oil level screw and see
SAE 10W-30 is recommended for
general use.
whether oil flows from the oil level
hole.
If oil flows from the oil level hole,
the oil level is OK. Reinstall the
screw and tighten it securely.
OIL LEVEL SCREW TORQUE:
4.8 lbf·ft (6.5 N·m , 0.66 kgf·m)
43
Page 46
SERVICING YOUR OUTBOARD MOTOR
If no oil flows from the oil level hole,
add the recommended oil (p. )
following the procedure described in
Gear Case Oil Change.
45
Gear Case Oil Change
Change the gear case oil with the
engine stopped and the outboard
motor in the vertical position.
Place a suitable container below
1.
the oil drain hole to catch the used
oil, then remove the oil level screw
and oil drain screw.
Allow the used oil to drain
2.
completely, then install an oil
pump adapter in the oil drain hole.
If water or contaminated (milkycolored) oil flows out the drain
hole when the screw is removed,
have the outboard motor checked
by an authorized Honda marine
dealer.
44
Page 47
GEAR OIL BOTTLE
Add oil through the oil drain hole
3.
until it flows out the oil level hole,
then install the oil level screw.
Remove the pump adapter and
install the oil drain screw.
GEAR OIL CAPACITY:
0.1 US qt (0.1 )
SERVICING YOUR OUTBOARD MOTOR
OIL LEVEL SCREW TORQUE:
4.8 lbf·ft (6.5 N·m, 0.66 kgf·m)
Avoid losing more than 1 fl oz (30
3
cm ) while reinstalling the drain
screw.
OIL DRAIN SCREW TORQUE:
4.8 lbf·ft (6.5 N·m, 0.66 kgf·m)
Outboard motor SAE 90 hypoid
gear oil API Service classification
(GL-4)
45
Page 48
SERVICING YOUR OUTBOARD MOTOR
Lubrication Points
Apply marine waterproof grease to the following parts:
Lubrication interval:
20 operating hours or one month after the date of
purchase or the initial use, then every 100 hours or 6
months (refer to the maintenance schedule on page ).39
To prevent corrosion, apply anticorrosion oil to pivot
surf aces where grease cannot penetrate.
THROTTLE
CABLE AND
PIVOT
SHIFT SHAFT
AND PIVOT
TILLER
HANDLE PIVOT
ENGINE COVER
LOCK LEVER
SWIVEL CASE
TRANSOM ANGLE
ADJUSTING ROD
CLAMP SCREWS
TILT RELEASE LEVER
AND REVERSE LOCK
ROD
PROPELLER SHAFT
Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover and any exposed metal
surfaces.
46
Page 49
SERVICING YOUR OUTBOARD MOTOR
Spark Plug Service
RECOMMENDED SPARK PLUGS:
BPR5ES (NGK)
W16EPR-U (DENSO)
Incorrect spark plug can cause
engine damage.
Unlock and remove the engine
1.
cover (p. ).
Disconnect the spark plug cap
2.
from the spark plug.
Remove the spark plug with a
3.
spark plug wrench and screwdriver
supplied in the tool kit.
41
SPARK PLUG WRENCH
Inspect the spark plug. Replace it
4. 5.
if the electrode is worn, or if the
insulator is cracked or chipped.
SIDE ELECTRODE
−
0.028 0.031 in
−
(0.70 0.80 mm)
SEALING WASHER
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:
0.028 0.031 in
−
(0.70 0.80 mm)
−
47
Page 50
SERVICING YOUR OUTBOARD MOTOR
Install the spark plug carefully, by
6.
hand, to avoid cross-threading.
After the spark plug seats, tighten
7.
with a spark plug wrench supplied
in the tool kit to compress the
sealing washer.
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.
Attach the spark plug cap.
8.
Install and lock the engine cover.
9.
REFUELING
Portable Fuel Tank
FUEL TANK CAPACITY:
3.2 US gal (12
Check the fuel gauge and refill the
tank when necessary.
Remove the fuel tank from the boat
for refueling.
VENT KNOB
FUEL FILLER
CAP
To refuel, turn the vent knob
counterclockwise to the OPEN
position, and unscrew the fuel tank
cap.
)
CLOSE
OOPPEENN
FUEL GAUGE
SAFE FILL LEVEL
Refuel in a well-ventilated area. Fill
the tank to the SAFE FILL LEVEL
line.
After ref ueling, install the cap and
tighten it securely. Turn the vent
knob clockwise to the CLOSED
position, and return the fuel tank to
the boat.
48
Page 51
SERVICING YOUR OUTBOARD MOTOR
Gasoline is highly
flammable and explosive.
You can be burned or
seriously injured when
handling fuel.
Stop the engine and keep
heat, sparks, and flame
away.
Handle fuel only
outdoors.
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.
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 stale or contaminated
gasoline or an oil/gasoline mixture.
Avoid getting dirt or water in the fuel
tank.
You may use regular 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 will be used on an
infrequent or intermittent basis,
please refer to the fuel section of the
STORAGE chapter (p. ) for
additional information regarding fuel
deterioration.
Occasionally you may hear a light
‘‘spark knock’’ or ‘‘pinging’’
(metallic rapping noise) while
operating under heavy loads. This is
no cause for concern.
58
49
Page 52
SERVICING YOUR OUTBOARD MOTOR
If spark knock or pinging occurs at a
steady engine speed, under normal
load, change brands of gasoline. If
spark knock or pinging persists, see
an authorized Honda marine dealer.
Running the engine with persistent
spark knock or pinging can cause
engine damage.
Running the engine with persistent
spark knock or pinging is misuse,
and the
Warranty Unlock and remove the engine
parts damaged by misuse.
Distributor’s Limited
82
(p. ) does not cover
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 keep
heat, sparks, and flame
away.
Handle fuel only
outdoors.
Wipe up spills
immediately.
ENGINE COVER LOCK LEVER
UNLOCK
1.
cover for access to the fuel pump
filter.
Inspect the filter for water and/or
2.
sediment accumulation.
If the filter is OK, reinstall it. If
water and/or sediment are present,
replace the filter as described in
the following steps. Always
replace the filter at the scheduled
replacement interval (p. ).
40
50
Page 53
Disconnect the fuel hose connector
3.
from the outboard motor, and
place commercially available hose
clips on the fuel hoses on each side
of the filter to prevent fuel leakage
when the fuel hoses are
disconnected.
FUEL HOSE
SERVICING YOUR OUTBOARD MOTOR
FUEL FILTER
ARROW
(Fuel Flow Direction)
FUEL FILTER
HOSE CLAMPS
Remove the fuel hoses from the
4.
FUEL HOSE
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.
HOSE CLAMPS
Install the new filter on the fuel
5.
hoses, with the fuel flow arrow
pointing toward the fuel pump as
shown. Fuel flow will be impeded
if the filter is installed backward.
Connect the fuel hoses to the fuel
6.
filter securely with the hose
clamps. Remove the fuel hose
clips used to close the fuel hoses.
51
Page 54
SERVICING YOUR OUTBOARD MOTOR
7.
Securely connect the fuel hose
connector to the outboard motor
(refer to page ).
8.
Prime the engine using the priming
bulb (p. ). Check for fuel leaks.
Repair any fuel leaks if necessary.
Install and lock the engine cover.
9.
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.
24
25
Portable Fuel Tank and Tank Filter Cleaning
Gasoline is highly
flammable and explosive.
You can be burned or
seriously injured when
handling fuel.
Stop the engine and keep
heat, sparks, and flame
away.
Handle fuel only
outdoors.
Wipe up spills
immediately.
Fuel Tank
FUEL HOSE
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.
52
Page 55
SERVICING YOUR OUTBOARD MOTOR
Fuel Tank Filter
TANK FILTER JOINT
(Fuel Hose Connector)
O-RING
FILTER
Unscrew the fuel hose connector
1.
by turning it counterclockwise,
then remove the fuel hose
connector and fuel tank filter from
the tank.
Clean the filter in nonflammable
2.
solvent. Inspect the fuel tank filter
and the connector O-ring. Replace
them if damaged.
Reinstall the filter and hose
3.
connector in the fuel tank. Tighten
the hose connector securely.
RECOIL STARTER ROPE
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 ReplacementRecoil Starter Rope Inspection
ANODE
BOLT
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 half its original size,
or if it is crumbling.
Painting or coating the anodes will
def eat their purpose and will lead to
rust and corrosion damage to the
outboard motor. The anodes must be
exposed to the water in order to
protect the outboard motor.
53
Page 56
SERVICING YOUR OUTBOARD MOTOR
Propeller and Shear Pin Replacement
Ashearpinisusedtoprotectthe
propeller and drive mechanism from
damage when the propeller strikes an
obstruction.
Before replacing the propeller or the
shear pin, remove the clip from the
engine 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
COTTER PIN
SHEAR PIN
PROPELLER CAP
Remove the cotter pin, the
1.
propeller cap, and the propeller.
Remove the broken shear pin and
2.
replace it with a new one.
54
Page 57
SERVICING YOUR OUTBOARD MOTOR
Installation
COTTER PIN
Install the shear pin and the
1.
propeller, then install the propeller
cap finger tight.
Be sure to replace the cotter pin
2.
with a new one.
Use a genuine Honda stainless
steel cotter pin or equivalent cotter
pin and bend the pin ends as
shown.
Spare shear pins and cotter pins are
provided in the engine compartment
(p. ).
38
55
Page 58
STORAGE
STORAGE PREPARATION
Proper storage preparation is
essential for keeping your outboard
motor trouble-free and looking good.
The following steps will help to keep
rust and corrosion from impairing
your outboard motor’s function and
appearance, and will make the engine
easier to start when you use the
outboard motor again.
Cleaning and Flushing
Thoroughly clean and flush the
outboard motor with f resh water after
operation in dirty water or salt water.
Cleaning
Wash the outside of the outboard
motor with clean, fresh water to
remove mud, salt, seaweed, etc.
Disengage the emergency engine
stop switch clip from the engine 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
Remove the flush screw from the
1.
WASH screw hole and install the
water hose connector.
Attach a hose from a fresh water
2.
faucet to the water hose connector
of the flush kit.
Remove the propeller (P. ).
3.
Turn on the fresh water supply to
4.
hose.
Start the engine and run in N
5.
(neutral) for 10 minutes.
54
WATER HOSE CONNECTOR
WATER HOSE
After flushing, stop the engine,
6.
remove the hose connector, and
reinstall the flush screw and the
propeller (p. ).
55
56
Page 59
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. ).
ANTIVENTILATION PLATE
Place a container under the
1.
outboard motor, and fill it with
clean, fresh water. The water level
must be at least 2 inches above the
antiventilation plate.
54
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
(p. ).
81
Start the engine and run in the N
2.
(neutral) position at low speed for
at least 10 minutes.
After flushing, stop the engine,
3.
remove the water container, and
reinstall the propeller (p. ).
55
STORAGE
57
Page 60
STORAGE
Fuel
Depending on the region where you
operate your outboard, fuel
f ormulations may deteriorate and
oxidize rapidly. Fuel deterioration
and oxidation can occur in as little
as 15 days and may cause damage to
the carburetors and fuel system.
Please check with your servicing
dealer f or local storage
recommendations.
Gasoline will oxidize and deteriorate
in storage. Old 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 30
days, if the gasoline was not fresh
when you filled the fuel tank. 2.
Adding a Fuel Stabilizer
When adding a fuel stabilizer, fill the
fuel tank with fresh gasoline. If only
partially filled, air in the 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.
3.
Add fuel stabilizer following the
manufacturer’s instructions.
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.
Turn the engine OFF.
58
Page 61
STORAGE
Distributor’s Limited Warranty After the fuel has drained from the
The
(p. ) does not cover fuel system
81
damage or engine performance
problems resulting from neglected
storage preparation.
Draining the Fuel System
You can avoid fuel deterioration
problems by draining the fuel tank
and carburetors.
Disconnect the fuel hose from the
1.
outboard motor.
Disconnect the drain tube from the
2.
air guide, then connect it to the
carburetor drain port as shown.
CARBURETOR
DRAIN PORT
AIR GUIDE
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.
Gasoline is highly
flammable and explosive.
You can be burned or
seriously injured when
handling fuel.
Stop the engine and keep
heat, sparks, and flame
4.3.
carburetor, tighten the drain screw
securely.
Reconnect the drain tube to the air
5.
guide.
Drain the portable fuel tank into an
6.
approved gasoline container, or 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 a fuel
stabilizer that is formulated for
that purpose. Firmly close the fuel
filler cap vent knob.
Store the portable fuel tank in a
cool place.
away.
Handle fuel only
outdoors.
Wipe up spills
immediately.
DRAIN
SCREW
DRAIN
TUBE
59
Page 62
STORAGE
Engine Oil STORAGE PRECAUTIONS
Change the engine oil (p. ).
1.
Remove the spark plug (p. ),
2.
42
47
and remove the clip from the
engine stop switch.
Pour a tablespoon (5 10 cm ) of
3.
−
clean engine oil into the cylinder.
Pull the starter grip several times
4.
to distribute the oil in the cylinder.
Reinstall the spark plug (p. ).
5.
48
3
Select a well-ventilated storage area.
If possible, avoid storage areas with
high humidity.
CARRYING HANDLE
To carry the outboard motor, hold it
by the carrying handle, or hold by the
carrying handle and the lug beneath
the engine cover lock lever, as shown.
Lif ting 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 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.
60
Page 63
STORAGE
Cover the outboard motor to keep out
dust. Do not use sheet plastic as a
dust cover. A nonporous cover will
trap moisture, promoting rust and
corrosion.
REMOVAL FROM STORAGE
Store the outboard motor either
vertically or horizontally with the
tiller handle side up.
CASE PROTECTORS
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.
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.
61
Page 64
TRANSPORTING
WITH OUTBOARD MOTOR INSTALLED ON BOAT
When trailering a boat with the
outboard motor attached, leave the
engine in the normal running position,
if possible, and tighten the steering
friction bolt securely (p. ).
If there is insufficient road clearance
in the normal running position, then
tilt the outboard motor and use a
motor support bar, or remove the
outboard motor from the boat. Refer
to the manufacturer’s instructions for
using a motor support bar.
MOTOR SUPPORT BAR
(commercially available)
32
WITH OUTBOARD MOTOR REMOVED FROM BOAT
Remove the outboard motor from the
boat and secure the outboard motor
in either the vertical or horizontal
position shown on p. .
61
CARRYING HANDLE
To carry, hold the outboard motor by
the carrying handle, or hold by the
carrying handle and the lug beneath
the engine cover lock latch, as shown.
Lif ting 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.
62
Page 65
TAKING CARE OF UNEXPECTED PROBLEMS
ENGINE WILL NOT START Possible Cause Correction
Check emergency stop switch
1.
clip.
Check control positions.
2. 26
Clip not inserted in stop switch. Insert clip in stop switch.
Gearshift lever not in neutral
position.
Choke OFF. Pull choke knob to ON position,
Throttle grip not in START
position.
Shift to neutral (p. ).
unless engine is warm (p. ).
Turn throttle grip to START
position (p. ).
26
26
63
Page 66
TAKING CARE OF UNEXPECTED PROBLEMS
(continued)
CorrectionPossible CauseENGINE WILL NOT START
Check fuel. Out of fuel.
3.
4.
Take outboard motor to an
5.
authorized Honda marine dealer,
or refer to the shop manual.
64
Fuel vent closed (portable fuel
tank).
Fuel hose not primed.
Fuel filter or fuel tank filter
restricted.
Bad fuel; boat 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).
Carburetor malfunction, fuel pump
failure, ignition malfunction, stuck
valves, etc.
Refuel (p. ).
Open fuel tank vent (p. ).
Squeeze priming bulb (p. ).
Replace restricted filters (p. or
).
53
Drain fuel tank and carburetor
59
(p. ). Refill with fresh
gasoline (p. ).
Gap or replace spark plug (p. ).Remove and inspect spark plug.
Dry and reinstall spark plug. Start
engine with choke and throttle open.
Replace or repair faulty
components as necessary.
48
24
25
50
48
47
Page 67
TAKING CARE OF UNEXPECTED PROBLEMS
CorrectionPossible CauseHARD STARTING OR STALLS
AFTER STARTING
Check control positions. Choke OFF. Pull choke knob to ON position,
1.
unless engine is warm (p. ).
26
Check fuel.
2.
Throttle grip not in START
position.
tank).
Fuel hose not primed. Squeeze priming bulb (p. ).
Fuel filter or fuel tank filter
restricted.
Bad fuel; boat stored without
treating or draining gasoline, or
refueled with bad fuel.
Turn throttle grip to START
(p. ).
26
Open fuel tank vent (p. ).Fuel vent closed (portable fuel
Replace restricted filters (p. or
).
53
Drain fuel tank and carburetor
(p. ). Refill with fresh
59
gasoline (p. ).
48
24
25
50
65
Page 68
TAKING CARE OF UNEXPECTED PROBLEMS
HARD STARTING OR STALLS
AFTER STARTING
(continued)
Possible Cause Correction
Remove and inspect spark plug. Gap or replace spark plug (p. ).
3.
Take outboard motor to an
4.
authorized Honda marine dealer,
or refer to the shop manual.
ENGINE OVERHEATS Possible Cause Correction
Check water intakes. Water intakes clogged. Clean water intakes.
1.
Take outboard motor to an
2.
authorized Honda marine dealer,
or refer to the shop manual.
Spark plug faulty, fouled or
improperly gapped.
Carburetor malfunction, fuel pump
failure, ignition malfunction, etc.
Faulty thermostat or water pump. Replace or repair faulty
Replace or repair faulty
components as necessary.
components as necessary.
66
47
Page 69
TAKING CARE OF UNEXPECTED PROBLEMS
ENGINE WILL NOT DRIVE
THE PROPELLER
Check shear pin.
1. 54
Take outboard motor to an
2.
authorized Honda marine dealer,
or refer to the shop manual.
Broken shear pin.
Damaged gearshift mechanism.
Possible Cause Correction
Replace shear pin (p. ).
Replace or repair faulty
components as necessary.
67
Page 70
TAKING CARE OF UNEXPECTED PROBLEMS
OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMITED
OIL PRESSURE INDICATOR
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. ), and add oil if needed.
41
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 Honda
marine dealer.
68
Page 71
TAKING CARE OF UNEXPECTED PROBLEMS
SUBMERGED 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 dealer
nearby, take the motor to the dealer
immediately. If you are far from a
dealer, proceed as follows:
Remove the engine cover, and
1.
rinse the outboard motor with
fresh water to remove salt water,
sand, mud, etc.
Drain the carburetor as described
2.
on p. .
59
Change the engine oil as described
3.
on p. . If there was water in the
42
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.
STARTER GRIP
Remove the spark plug (p. ),
4.
and remove the clip from the
engine 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.
47
69
Page 72
TAKING CARE OF UNEXPECTED PROBLEMS
Attempt to start the engine.
7.
When cranking the engine with
an open ignition circuit (spark
plug removed from the ignition
circuit), remove the clip from
the engine stop switch to
prevent possible damage to the
ignition system.
Pour a teaspoon of engine oil into
5.
the spark plug hole, then pull the
starter grip several times to
lubricate the inside of the cylinder.
Reinstall the spark plug, and put
6.
the emergency stop switch clip
into the switch.
If the engine fails to start, remove
the spark plug, clean and dry it,
then reinstall the spark plug and
attempt to start the engine again.
If the engine starts, and no
mechanical damage is evident,
continue to run the engine for a
half hour or longer. Be sure the
water level is at least two inches
above the antiventilation plate to
avoid overheating and water pump
damage.
As soon as possible, take the
8.
outboard motor to an authorized
Honda marine dealer for
inspection and service.
70
Page 73
TECHNICAL INFORMATION
Serial Number Locations
Record the product identification
number, the engine serial number and
the date of purchase in the space
provided on this page. You will need
these numbers when ordering parts,
and when making technical or
warranty inquiries (p. ).
79
TECHNICAL AND CONSUMER INFORMATION
PRODUCT IDENTIFICATION
NUMBER
The product identification number is
stamped on the swivel case.
Date of purchase:
ENGINE SERIAL NUMBER
The engine serial number is
stamped on the right side of the
motor.
Engine serial number:Product identification number:
71
Page 74
TECHNICAL AND CONSUMER INFORMATION
Carburetor Modification for High Altitude Operation
At high altitude, the standard
carburetor air-fuel mixture will be
too rich. Performance will decrease,
and fuel consumption will increase.
A very rich mixture will also foul the
spark plug and cause hard starting.
High altitude performance can be
improved by specific modifications
to the carburetor. If you always
operate your outboard motor at
altitudes above 5,000 feet (1,500
meters), have an authorized Honda
marine dealer perform this carburetor
modification.
Even with carburetor modification,
engine horsepower will decrease
about 3.5% for each 1,000-foot (300meter) increase in altitude. The effect
of altitude on horsepower will be
greater than this if no carburetor
modification is made.
When the carburetor has been
modif ied for high altitude operation,
the air-f uel mixture will be too lean
f or low altitude use. Operation at
altitudes below 5,000 feet (1,500
meters) with a modified carburetor
may cause the engine to overheat
and result in serious engine damage.
For use at low altitudes, have an
authorized Honda marine dealer
return the carburetor to original
f actory specif ications.
72
Page 75
TECHNICAL AND CONSUMER INFORMATION
Emission Control System Information
Source of Emissions
The combustion process produces
carbon monoxide, oxides of nitrogen,
and hydrocarbons. Control of
hydrocarbons and oxides of nitrogen
is very important because, under
certain conditions, they react to form
photochemical smog when subjected
to sunlight. Carbon monoxide does
not react in the same way, but it is
toxic.
Honda utilizes appropriate air/fuel
ratios and other emissions control
systems to reduce the emissions of
carbon monoxide, oxides of nitrogen,
and hydrocarbons.
Air Acts
EPA and California regulations
require all manufacturers to furnish
written instructions describing the
operation and maintenance of
emission control systems.
The following instructions and
procedures must be followed in order
to keep the emissions from your
Honda engine within the emission
standards.
Tampering and AlteringThe U.S. and Calif ornia Clean
Tampering with or altering the
emission control system may increase
emissions beyond the legal limit.
Among those acts that constitute
tampering are:
Removal or alteration of any part
of the intake, fuel, or exhaust
systems.
Alterations that would cause the
engine to operate outside its design
parameters.
73
Page 76
TECHNICAL AND CONSUMER INFORMATION
Emissions
If you are aware of any of the
following symptoms, have your
engine inspected and repaired by
your servicing dealer.
Hard starting or stalling after
starting.
Rough idle.
Misfiring or backfiring under load.
Afterburning (backfiring).
Black exhaust smoke or high fuel
consumption.
Replacement PartsProblems That May Af f ect
The emission control systems on
your Honda engine were designed,
built, and certified to conform with
EPA and California emission
regulations. We recommend the use
of genuine Honda parts whenever
you have maintenance done. These
original-design replacement parts are
manufactured to the same standards
as the original parts, so you can be
confident of their performance. The
use of replacement parts that are not
of the original design and quality
may impair the effectiveness of your
emission control system.
A manufacturer of an aftermarket
part assumes the responsibility that
the part will not adversely affect
emission performance. The
manufacturer or rebuilder of the part
must certify that use of the part will
not result in a failure of the engine to
comply with emission regulations.
Maintenance
Follow the maintenance schedule on
p. and . Remember that this
39 40
schedule is based on the assumption
that your machine will be used for its
designed purpose. Sustained highload operation, or use in unusual
conditions, will require more
frequent service.
74
Page 77
TECHNICAL AND CONSUMER INFORMATION
Star Label
A Star label was applied to this
outboard motor in accordance with
the requirements of the California
Air Resources Board.
The Star Label means Cleaner Marine Engine
This engine has been certified as a:
The Symbol for Cleaner Marine Engines:
Cleaner Air and Water -
Better Fuel Economy -
conventional carbureted two-stroke engines, saving money and resources.
Longer Emission Warranty -
for healthier lifestyle and environment.
burns up to 30 - 40 percent less gas and oil than
protects consumer for worry-free operation.
75
Page 78
TECHNICAL AND CONSUMER INFORMATION
The one-star label identifies engines that meet the Air Resources Board’s
One Star
Low
Emission
Two Stars
Very Low
Emission
Three Stars
Ultra Low
Emission
Four Stars
Super Ultra
Low Emission
Personal Watercraft and Outboard marine engine 2001 exhaust emission
standards. Engines meeting these standards have 75% lower emissions than
conventional carbureted two-stroke engines. These engines are equivalent to
the U.S. EPA’s 2006 standards for marine engines.
The two-star label identifies engines that meet the Air Resources Board’s
Personal Watercraft and Outboard marine engine 2004 exhaust emission
standards. Engines meeting these standards have 20% lower emissions than
One Star-Low Emission engines.
The three-star label identifies engines that meet the Air Resources Board’s
Personal Watercraft and Outboard marine engine 2008 exhaust emission
standards or the Sterndrive and Inboard marine engine 2003-2008 exhaust
emission standards. Engines meeting these standards have 65% lower
emissions than One Star-Low Emission engines.
The four-star label identifies engines that meet the Air Resources Board’s
Sterndrive and Inboard marine engine 2009 exhaust emission standards.
Personal Watercraft and Outboard marine engines may also comply with
these standards. Engines meeting these standards have 90% lower emissions
than One Star-Low Emission engines.
76
Cleaner Watercraft - Get the Facts
1-800-END-SMOG
www.arb.ca.gov
Page 79
Specifications
TECHNICAL AND CONSUMER INFORMATION
MODEL
Description Code
Type
Overall length
Overall width
Overall height
Transom height
Weight
Rated power
Full throttle range
Engine type
Displacement
Sparkpluggap
Starter system
Ignition system
Lubrication system
Specified oil
Oil capacity
CARB star label
Cooling system
Exhaust system
BF5A
BADS
20.7 in (525 mm)
39.6 in (1,005 mm) 44.7 in (1,135 mm)
17.1 in (434 mm) 22.1 in (561 mm)
59.5 lbs (27.0 kg) 60.6 lbs (27.5 kg)
4 stroke OHV 1 cylinder, water-cooled
Digital Ignition Control Module (ICM)
Trochoid pump pressure lubrication
Engine:
Gear case:
13.8 in (350 mm)
3.7 kW (5.0 HP)
−
4,500 5,000 rpm
7.7 cu-in (127 cm
−− ×
0.028 0.031 in (0.70 0.80 mm)
Water cooling with thermostat
Recoil starter
API standard (SJ or later oil)
SAE 10W-30
API standard (GL-4)
SAE 90 outboard motor gear oil
Engine:
Gear case:
0.58 US qt (0.55
0.1 US qt (0.1
ULTRA LOW EMISSION
Underwater exhaust
LASA
)
)
)
Spark plug
Fuel pump
Fuel
Tank capacity
Gear change
Steering angle
Transom angle
Tilt angle
(transom angle at 12°)
Standard propeller
(No. of bladesdiameter pitch)
Tuneup
Sparkpluggap
Idle speed
Valve clearance
(cold)
Other specifications
BPR5ES (NGK)
Diaphragm type fuel pump
Automotive unleaded gasoline
(86 pump octane or higher)
Forward-Neutral-Reverse (dog type)
3 stages adjustment (18°, 38° and 58°)
7-25/32 7-31/64 in (3-200 190 mm)
Intake:
Exhaust:
3.2 US gal (12
45° right and left
5 stages (4°,8°,12°,16°,20°)
××
0.028 0.031 in
−
(0.70 0.80 mm)
−
1,550 100 rpm
±
0.10 0.04 mm
±
0.15 0.04 mm
No other adjustment is needed
±
)
Seepage47
See shop
See shop
Honda outboards are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.
manual
manual
77
Page 80
TECHNICAL AND CONSUMER INFORMATION
CONSUMER INFORMATION
Honda Publications
These publications will give you
additional information for
maintaining and repairing your
outboard motor.
Shop Manual
This manual covers complete
maintenance and overhaul procedures.
It is intended to be used by a skilled
technician.
Available through your Honda
marine dealer or through Helm Inc. at
1 888-292-5395 or
visit www.Honda-marine.com
andclickonOWNERS.
Parts Catalog
This manual provides complete,
illustrated parts lists.
The catalog is available through your
Honda marine dealer.
Customer Service Information
Contacting Honda
Your owner’s manual was written to
cover most of the questions you
might ask about your Honda. Any
questions not answered in the owner’s
manual can be answered by your
Honda dealer. If your dealer doesn’t
have an immediate answer, they
should be able to get it for you.
If you have a difference of opinion
with your dealer, please remember
that each dealership is independently
owned and operated. That’s why it’s
important to work to resolve any
differences at the dealership level. If
the service personnel are unable to
assist you, please discuss your
concerns with the dealer management
such as the Service Manager or
Dealer Owner.
If you need to contact American
Honda regarding your experiences
with your Honda product or with
your dealer, please send your
comments to the following address:
American Honda Motor Co., Inc.
Marine Division
Customer Relations Office
4900 Marconi Drive
Alpharetta, GA 30005-8847
Telephone (770)497 6400
M-F 8:30am-8:00pm (Eastern Time
Zone)
−
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TECHNICAL AND CONSUMER INFORMATION
Please include the following
information in your communication:
Your name, address and telephone
number (complete with area code)
Model and complete serial number
Date of purchase
Name and location of selling
dealer
Name and location of servicing
dealer (if different)
A detailed description of your
concerns
Warranty Coverage
Your new Honda is covered by the
following warranties:
Distributor’s Limited Warranty
Emission Control Warranty
Please read the warranty statements
contained in this manual. There are
responsibilities, restrictions, and
exclusions that apply to these
warranties.
To obtain warranty service you must
take your Honda outboard engine,
together with proof of original retail
purchase date, at your expense, to a
Honda engine dealer or distributor
authorized to sell that product in the
United States, Puerto Rico, or the
U.S. Virgin Islands.
It is important to realize that your
warranty applies to defects in
material or workmanship of your
Honda. Your warranty coverage does
not apply to normal wear or
deterioration associated with using
your Honda outboard.
Your warranty coverage will not be
voided if you choose to perform your
own maintenance. However, you
should have the proper tools and
service information and be
mechanically qualified. Failures that
occur due to modifications, improper
maintenance or service are not
covered.
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TECHNICAL AND CONSUMER INFORMATION
Warranty Service
Please remember that recommended
maintenance interval servicing is not
included in your warranty coverage.
Additionally, your warranty does not
apply to the normal wear of items
(such as spark plug(s), water pump,
etc.).
As the owner of a Honda product,
your servicing dealer may ask you to
authorize an inspection. If the
problem is covered under warranty,
your dealer will perform any
warranty repairs for you at no cost.
However, you may be responsible for
additional non-warranty charges.
If you have questions about warranty
coverage or the nature of the repair, it
is best to talk to the service manager
of your Honda dealer.
Sometimes, in spite of the best
intentions of all concerned, a
misunderstanding may occur. If you
aren’t satisfied with your dealer’s
handling of the situation, we suggest
you discuss your problem with the
appropriate member of the
dealership’s management team. If the
problem has already been reviewed
with the appropriate manager of the
Service, Parts, or Sales department,
contact the owner of the dealership or
their designated representative.
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TECHNICAL AND CONSUMER INFORMATION
Distributor’s Limited Warranty
This warranty is limited to Honda Outboard Motors distributed by American Honda Motor Co., Inc., Power Equipment
Division, 4900 Marconi Drive, Alpharetta, Georgia 30005-8847.
Products Covered by Warranty:
All Models: Model Year 2000 (Y)
and Newer
Models BF115/BF130: All Model
Years
Models BF2 BF90 Model
Year 1999 and Earlier
−−
NONCOMMERCIAL/
NONRENTAL
Length of Warranty: (from date of original retail purchase)
36 months
36 months
24 months 12 months
To Qualify for This Warranty:
The Honda Outboard Motor must be purchased from
American Honda or a dealer authorized by American
Honda to sell Honda Outboard Motors in the United
States, Puerto Rico, or the U.S. Virgin Islands. This
limited warranty applies to the f irst retail purchaser and
each subsequent owner during the applicable warranty
time period.
What American Honda Will Repair or Replace Under
Warranty:
American Honda will repair or replace, at its option, any
part that is proven to be defective in material or
workmanship under normal use during the applicable
COMMERCIAL/RENTAL STATE/LOCAL/FEDERAL
GOVERNMENT
12 months 24 months
12 months
24 months
24 months
warranty time period. Warranty repairs and replacements
will be made without charge for parts or labor. Anything
replaced under warranty becomes the property of
American Honda Motor Company, Inc. All parts replaced
under warranty will be considered as part of the original
product and any warranty on those parts will expire
coincidentally with the original product warranty.
To Obtain Warranty Service:
You must take your Honda Outboard Motor and proof of
the original purchase date, at your expense, to any dealer
who is authorized to service Honda Outboard Motors in
the United States, Puerto Rico, or the U.S. Virgin Islands,
during the dealer’s normal business hours.
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TECHNICAL AND CONSUMER INFORMATION
If you are unable to obtain warranty service, or are
dissatisfied with the warranty service you receive, take
the following steps: First, contact the owner of the
dealership involved; normally this should resolve the
problem. However, if you should require further
assistance, write or call the Honda Marine Customer
Relations. Please see page 79 .
Exclusions:
This warranty does not extend to the following:
Conditions caused by lack of routine maintenance (as
outlined in the owner’s manual)
Conditions caused by the use of propeller (s) that do
not allow the outboard motor to run in its
recommended full throttle rpm range
Operation inconsistent with the recommended
operation/duty cycle (as outlined in the owner’s
manual)
Parts aff ected or damaged by an accident, submersion
and/or collision
Normal wear and tear
Fuel contamination and water entering engine through
the fuel intake, air intake or exhaust system
Operation with fuels, oils, additives and lubricants
which are not suitable for use in the product
Use in an application for which the outboard motor
was not designed, such as racing or competitive use or
any other misuse or neglect
Contacting Honda
Incorporation of unsuitable attachments or parts
The unauthorized alteration, improper installation and/
or rigging, or any causes other than defects in material
or workmanship
Corrosion to steering system or electrical components,
corrosion due to electrolysis, water born foreign
chemicals, improper service or corrosion caused by
damage or abuse
Reimbursement for towing charges, in and out of
water charges, or technician travel time
Growth of marine organisms on motor surfaces,
external or internal
Disclaimer of consequential damage and limitation of
implied warranties:
American Honda disclaims any responsibility for loss of
time or use of the outboard, revenue, or the equipment in
which the outboard is installed,transportation,
commercial loss, or any other incidental or consequential
damage. Any implied warranties are limited to the
duration of this written limited warranty. Some states do
not allow limitations on how long an implied warranty
lasts and/or do not allow the exclusion or limitation of
incidental or consequential damages, so the above
exclusions and limitations may not apply to you. This
warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
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TECHNICAL AND CONSUMER INFORMATION
Accessories and Replacement Parts
This warranty is limited to Honda Power Equipment parts,accessories and apparel when distributed by American Honda
Motor Co., Inc., 1919 Torrance Blvd., Torrance, California 90501-2746.
Products Covered by Warranty:
Non Commercial Commercial/Rental Local/State/Federal
Accessories
Replacement Parts
Length of Warranty: (from date of original retail purchase)
Government
12 months 3 months 3 months
3 months3 months6 months
To Qualify for This Warranty: What American Honda Will Repair or Replace Under
The accessories or replacement parts must be
1.
purchased from American Honda, or a dealer,
distributor or distributor’s dealer authorized by
American Honda to sell those products in the United
States, Puerto Rico, and the U.S. Virgin Islands.
You must be the first retail purchaser. This warranty is
2.
not transferable to subsequent owners.
Warranty:
American Honda will repair or replace, at its option, any
marine product accessories or replacement parts that are
proven to be defective in material or workmanship under
normal use during the applicable warranty time period.
Anything replaced under warranty becomes the property
of American Honda Motor Company, Inc. All parts
replaced under warranty will be considered as part of the
original product and any warranty on those parts will
expire coincidentally with the original product warranty.
Accessories and replacement parts, installed by a dealer
who is authorized by American Honda to sell them, will
be repaired or replaced under warranty without charge for
parts or labor. If installed by anyone else, accessories and
replacement parts will be repaired or replaced under
warranty without charge for parts, but any labor charges
will be the responsibility of the purchaser.
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TECHNICAL AND CONSUMER INFORMATION
To Obtain Warranty Service:
You must take the Honda Outboard Motor product
accessory or replacement part or the outboard motor or
boat on which the accessory or replacement part is
installed, and proof of purchase, at your expense, to any
Honda Marine authorized service facility or dealer in the
United States, Puerto Rico, or the U.S. Virgin Islands,
during normal business hours.
Exclusions:
This warranty does not extend to accessories or parts
affected or damaged by accident and/or collision, normal
wear, use in an application for which the product was not
designed or any other misuse, neglect, incorporation or
use of unsuitable attachments or parts, unauthorized
alteration, improper installation, or any causes other than
defects in material or workmanship of the product.
Disclaimer of consequential damage and limitation of
implied warranties:
American Honda disclaims any responsibility for loss of
time or use of the outboard motor, or the boat on which
the product is installed, transportation, commercial loss,
or any other incidental or consequential damage. Any
implied warranties are limited to the duration of this
written warranty. Some states do not allow limitations on
how long an implied warranty lasts and/or do not allow
the exclusion or limitation of incidental or consequential
damages, so the above exclusions and limitations may not
apply to you. This warranty gives you specific legal
rights, and you may also have other rights which vary
from state to state.
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TECHNICAL AND CONSUMER INFORMATION
Emission Control System Warranty
Your new Honda outboard engine complies with both the
U.S. EPA and State of California emission regulations.
American Honda provides the same emission warranty
coverage for outboard engines sold in all 50 states.
YOUR WARRANTY RIGHTS AND OBLIGATION
California
The California Air Resources Board and American
Honda Motor Co., Inc. are pleased to explain the
emission control system warranty on your 2001 and later
Honda outboard engine. In California, new outboard
engines must be designed, built and equipped to meet
California’s stringent anti-smog emission standards in
addition to the U.S. EPA emissions standards.
Other States
In other areas of the United States your outboard engine
must be designed, built and equipped to meet the U.S.
EPA Emission Standard for spark ignited marine engines.
All States
American Honda Motor Co., Inc. must warranty the
emission control system on your outboard engine for the
period of time listed below provided there has been no
abuse, neglect or improper maintenance of your outboard
engine. Where a warranty condition exists, American
Honda Motor Co., Inc. will repair your outboard engine
at no cost to you including diagnosis, parts and labor.
Your emission control system may include such parts as
the carburetor or fuel injection system and catalytic
converter. Also included may be hoses, connectors and
other emission-related assemblies.
MANUFACTURER’S EMISSION CONTROL
SYSTEM WARRANTY COVERAGE:
The 2001 and later outboard engines are warranted for
four years or 250 hours of operation, whichever comes
first. However, warranty coverage based on the hourly
period is only permitted for outboard engines equipped
with appropriate hour meters. If any emission-related part
on your outboard engine is defective under warranty, the
part will be repaired or replaced by American Honda
Motor Co., Inc.
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TECHNICAL AND CONSUMER INFORMATION
OWNER’S WARRANTY RESPONSIBILITY: WARRANTY COVERAGE:
As the outboard engine owner, you are responsible for
the performance of the required maintenance listed in
your owner’s manual. American Honda Motor Co., Inc.
recommends that you retain all receipts covering
maintenance on your outboard engine, but American
Honda Motor Co., Inc. cannot deny warranty solely for
the lack of receipts or for your failure to ensure the
performance of all scheduled maintenance. As the
outboard engine owner, you should, however, be aware
that American Honda Motor Co., Inc. may deny you
warranty coverage if your outboard engine or a part has
failed due to abuse, neglect, improper maintenance, or
unapproved modifications. You are responsible for
presenting your outboard engine to a Honda Marine
dealer as soon as a problem exists. The warranty repair
should be completed in a reasonable amount of time, not
to exceed 30 days. If you have any questions regarding
your warranty rights and responsibilities, you should
contact American Honda Motor Co., Inc., Marine
Division Customer Relations Office. Please see
Contacting Honda
page 79.
Honda outboard engines manufactured after June 1, 2000
are covered by this warranty for a period of four years or
250 operating hours, whichever comes first, from the
date of delivery to the retail purchaser. This warranty is
transferred to each subsequent purchaser for the duration
of the warranty period. Warranty repairs will be made
without charge for diagnosis, parts and labor. All
defective parts replaced under this warranty become the
property of American Honda Motor Co., Inc. A list of
warranty parts is on page 89. Normal maintenance items,
such as spark plugs and filters, that are on the warranted
parts list are warranted up to their required replacement
interval only. American Honda Motor Co., Inc. is also
liable for damages to other engine components caused by
a failure of any warranted part during the warranty period.
Only Honda approved replacement parts will be used in
the performance of any warranty repairs and they will be
provided without charge to the owner. The use of
replacement parts not equivalent to the original parts may
impair the effectiveness of your engine’s emission
control system. If such a replacement part is used in the
repair or maintenance of your engine, and an authorized
Honda Marine dealer determines it is defective or causes
a failure of a warranted part, your claim for your engine
may be denied. If the part in question is not related to the
reason that your engine requires repair, your claim will
not be denied.
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TECHNICAL AND CONSUMER INFORMATION
TO OBTAIN WARRANTY SERVICE:
You must take your Honda outboard engine, along with
your sales registration card or other proof of original
purchase date, at your expense, to any Honda Marine
dealer who is authorized by American Honda Motor Co.,
Inc. to sell and service that Honda marine product during
his normal business hours. Claims for repair or
adjustment found to be caused solely by defects in
material or workmanship will not be denied because the
engine was not properly maintained and used. If you are
unable to obtain warranty service, or are dissatisfied with
the warranty service you received, contact the owner of
the dealership involved. Normally this should resolve
your problem. However, if you require further assistance,
write or call the Honda Marine Customer Relations
Office of American Honda Motor Co., Inc.
EXCLUSIONS:
Failures other than those resulting from defects in
material or workmanship are not covered by this warranty.
This warranty does not extend to emission control
systems or parts which are affected or damaged by owner
abuse, neglect, improper maintenance, misuse, misfueling,
improper storage, accident and/or collision.The
incorporation of, or use of, unsuitable attachments, or the
unauthorized alteration of any part. This warranty does
not cover replacement of expendable maintenance items
made in connection with required maintenance service
after the item’s first scheduled replacement as listed in
the maintenance section of the product ownwer’s manual,
such as: spark plugs and filters.
DISCLAIMER OF CONSEQUENTIAL DAMAGE
AND LIMITATION OF IMPLIED WARRANTIES:
American Honda Motor Co., Inc. disclaims any
responsibility for incidental or consequential damages
such as loss of time or the use of outboard engine, or any
commercial loss due to the failure of the equipment; and
any implied warranties are limited to the duration of this
written warranty. This warranty is applicable only where
the California or U.S. EPA emission control system
warrantyregulationisineffect.
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TECHNICAL AND CONSUMER INFORMATION
EMISSION CONTROL SYSTEM WARRANTY PARTS:
PARTS DESCRIPTIONSYSTEMS COVERED BY THIS
WARRANTY:
Fuel Metering
Air Induction
Ignition
Lubrication system
Crankcase Emission Control
Exhaust
Valve Control System
＊
Miscellaneous Parts
Covered up to the first required replacement only. See the Maintenance Schedule (p. 39)
Carburetor assembly, Throttle body, Fuel injector, Fuel pump, Fuel pressure
regulator, Throttle position sensor, Intake air temperature sensor, Engine temperature
sensor, Manifold absolute pressure sensor, Idle air control valve, Barometric pressure
sensor, Fuel line solenoid valve, Intake manifold, Intake valves, and Oxygen sensor
or Air fuel ratio sensor
Air intake duct, Crankcase breather tube, Positive crankcase ventilation valve, Vapor
separator, Intake manifold tuning valve (Intake air bypass control valve)
Flywheel magneto, Ignition pulse generator, Ignition coil assembly, Ignition control
module, Engine control module, Crankshaft position sensor, Spark plug cap,
Spark plug , Knock sensor, and Camshaft position sensor
＊
Oil pump and internal parts
Oil filler cap
Exhaust manifold and Exhaust valves
Rocker arm oil control valve
Tubing, fittings, seals, gaskets, and clamps associated with these listed systems.
88
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WIRING DIAGRAM
89
Page 92
INDEX
............................................................................Anode . 17
..............................................................Replacement . 53
............ARE YOU READY TO GET UNDER WAY? . 21
...........................................................ATTACHMENT . 20
................................................BEFORE OPERATION . 21
...........................................BREAK-IN PROCEDURE . 23
...................................................................Choke Knob . 12
........COMPONENT AND CONTROL LOCATIONS . 10
...................................CONSUMER INFORMATION . 79
..................................................................CONTROLS . 12
CONTROLS AND FEATURE IDENTIFICATION
........................................................................CODES . 9
....................................CONTROLS AND FEATURES . 9
..............................................Cooling System Indicator . 16
....................................................................CRUISING . 33
......................................Customer Service Information . 79
.....................................Distributor’s Limited Warranty . 82
.Carburetor Modification for High Altitude Operation . 72
.........................................EMERGENCY STARTING . 27
.........................Emission Control System Information . 74
..............................Emission Control System Warranty . 86
Engine
Cover
............................................................Lock Lever . 14
...................REMOVAL AND INSTALLATION . 41
Oil
...................................................................Change . 42
..........................................................Level Check . 41
.................................................Recommendations . 43
...............................................ENGINE OVERHEATS . 66
......ENGINE WILL NOT DRIVE THE PROPELLER . 67
......................................ENGINE WILL NOT START . 63
Fuel
................................................Filler Cap Vent Knob . 17
............................Filter Inspection and Replacement . 50
.........................................................................Gauge . 15
...........................................HOSE CONNECTIONS . 24
..................................................................PRIMING . 25
.............................................................Priming Bulb . 18
..........................................RECOMMENDATIONS . 49
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INDEX
Gear Case Oil
.......................................................................Change . 44
...............................................................Level Check . 43
..............................................................Gearshift Lever . 13
HARD STARTING OR STALLS AFTER
...............................................................STARTING . 65
.......................................................Honda Publications . 79
...............................................................INDICATORS . 16
..........................................................INSTALLATION . 19
......................................INSTALLATION POSITION . 19
...........................................................INSTRUMENTS . 15
IS YOUR OUTBOARD MOTOR
......................................................READY TO GO? . 21
.........................................................Lubrication Points . 46
.........................................MAINTENANCE SAFETY . 37
...................................MAINTENANCE SCHEDULE . 39
..GEARSHIFTING AND THROTTLE OPERATION . 31
....................IMPORTANT SAFETY INFORMATION . 6
...................MOORING, BEACHING, LAUNCHING . 35
....................................................Oil Pressure Indicator . 16
OIL PRESSURE INDICATOR GOES OFF AND
................................ENGINE SPEED IS LIMITED . 68
................................................................OPERATION . 23
....................................................OTHER FEATURES . 16
...................................OUTBOARD MOTOR SAFETY . 6
.............................................................Overrev Limiter . 16
..................................................Portable Fuel Tank . 17, 24
...............Portable Fuel Tank and Tank Filter Cleaning . 52
.........................................POWER REQUIREMENTS . 19
...........................Propeller and Shear Pin Replacement . 54
......................................Recoil Starter Rope Inspection . 53
.................................................................REFUELING . 48
...................................REMOVAL FROM STORAGE . 61
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INDEX
........................SAFE OPERATING PRECAUTIONS . 23
....................................SAFETY LABEL LOCATIONS . 8
...............................................Serial Number Locations . 71
..............SERVICING YOUR OUTBOARD MOTOR . 36
............................SHALLOW WATER OPERATION . 34
........................................................Spark Plug Service . 47
................................................................Specifications . 77
......................................................................Star Label . 75
....................................................................Starter Grip . 14
..........................................STARTING THE ENGINE . 25
....................................................................STEERING . 32
....................................................Steering Friction Bolt . 15
...........................................STOPPING THE ENGINE . 30
.....................................Emergency Engine Stopping . 30
...........................................Normal Engine Stopping . 30
....................................................................STORAGE . 56
........................................STORAGE PRECAUTIONS . 60
........................................STORAGE PREPARATION . 56
..............................................Cleaning and Flushing . 56
..................................................................Engine oil . 60
............................................................................Fuel . 58
...............................................SUBMERGED MOTOR . 69
............................Switch Clip and Engine Stop Switch . 12
....TAKING CARE OF UNEXPECTED PROBLEMS . 63
..TECHNICAL AND CONSUMER INFORMATION . 71
...................................TECHNICAL INFORMATION . 71
...............THE IMPORTANCE OF MAINTENANCE . 36
..................................................Throttle Friction Knob . 13
..................................................................Throttle Grip . 13
.......................................................................Tilt Lever . 15
..TOOL KIT AND EMERGENCY STARTER ROPE . 38
.....................................Transom Angle Adjusting Rod . 14
...................TRANSOM ANGLE ADJUSTMENT . 20, 23
........................................................TRANSPORTING . 62
WITH OUTBOARD MOTOR INSTALLED
.............................................................ON BOAT . 62
WITH OUTBOARD MOTOR REMOVED
.......................................................FROM BOAT . 62
....................................................WIRING DIAGRAM . 89
92
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31ZV1639
00X31-ZV1-6390
N
BF5AK0
2eY1400.2007.01
Printed in Japan
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