Honda Automobiles BFP20D User Manual

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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.

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.

Page 3

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 the information on how to do that; please read it carefully.

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

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

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

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

2004 Honda Motor Co., Ltd. All

Rights Reserved

Page 4

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 INFORMATION.

OUTBOARD MOTOR SAFETY.

−

Page 5

CONTROL AND FEATURE

..............................................................CONTROLS . 19

H Type (tiller handle)

..........................................................Throttle Grip . 20

.....................................................Gearshift Lever . 20

................................................Recoil Starter Grip . 21

Electric Starter Button

.........................................Steering Friction Lever . 21

................................................Tilt Lever (G type) . 22

R Type (remote control)

......................................................Ignition Switch . 23

.......................................................Fast Idle Lever . 24

...................................OUTBOARD MOTOR SAFETY . 7

................IMPORTANT SAFETY INFORMATION . 7

................................SAFETY LABEL LOCATIONS . 9

..................................CONTROLS AND FEATURES . 10

................................IDENTIFICATION CODES . 10

....COMPONENT AND CONTROL LOCATIONS . 14

....................Engine Stop Switch and Switch Clip . 19

....................Choke Knob (H type manual choke) . 19

.....................................Throttle Friction Adjuster . 20

.............(models equipped with electric starter) . 21

....................................Power Tilt Switch (T type) . 22

.............Switch Clip and Emergency Stop Switch . 23

..........................Gearshift/Throttle Control Lever . 25

....................................Power Tilt Switch (T type) . 26

...............................Manual Relief Valve (T type) . 26

...........................Tilt Lock Lever (G and T types) . 27

Common Controls

..............................................Engine Cover Latch . 27

.............................Transom Angle Adjusting Rod . 27

..................................Tilt Lever (manual tilt type) . 28

.......................................................INSTRUMENTS . 29

............................................................Fuel Gauge . 29

.........................Tachometer (optional equipment) . 29

...........................................................INDICATORS . 30

...............Oil Pressure Indicator (R type) (H type) . 30

..................................Overheat Indicator (R type) . 30

.....................................Cooling System Indicator . 31

................................................OTHER FEATURES . 31

.....................................................Overrev Limiter . 31

Automatic Choke

.............(models equipped with electric starter) . 31

...................................................................Anodes . 31

................................................Portable Fuel Tank . 32

.............................................Fuel Cap Vent Knob . 32

.................................................Fuel Priming Bulb . 32

Page 6

CONTENTS

..........................................................INSTALLATION . 33

.....................................POWER REQUIREMENTS . 33

..................................INSTALLATION POSITION . 33

.......................................................ATTACHMENT . 34

...................................BATTERY CONNECTIONS . 35

................................................BEFORE OPERATION . 38

IS YOUR OUTBOARD MOTOR

？

................................................READY TO GO . 38

................................................................OPERATION . 40

.......................................BREAK-IN PROCEDURE . 40

...................BOAT TRANSOM REQUIREMENTS . 33

.....................TRANSOM ANGLE ADJUSTMENT . 35

？

.....ARE YOU READY TO GET UNDER WAY . 38

....................SAFE OPERATING PRECAUTIONS . 40

.....................TRANSOM ANGLE ADJUSTMENT . 41

.......................................PORTABLE FUEL TANK . 43

................................FUEL HOSE CONNECTIONS . 43

.......................................................FUEL PRIMING . 44

......................................STARTING THE ENGINE . 44

............................................H Type (tiller handle) . 44

........................................R Type (remote control) . 47

.....................................EMERGENCY STARTING . 49

.......................................STOPPING THE ENGINE . 52

................................Emergency Engine Stopping . 52

.......................................Normal Engine Stopping . 52

GEARSHIFT AND

..............................THROTTLE OPERATION . 54

............................................H Type (tiller handle) . 54

........................................R Type (remote control) . 55

...............................................................STEERING . 56

............................................H Type (tiller handle) . 56

........................................R Type (remote control) . 56

................................................................CRUISING . 57

........................SHALLOW WATER OPERATION . 59

...............MOORING, BEACHING, LAUNCHING . 62

Page 7

CONTENTS

..............SERVICING YOUR OUTBOARD MOTOR . 64

.....................................MAINTENANCE SAFETY . 65

TOOL KIT AND EMERGENCY STARTER

.....................................................................ROPE . 66

...............................MAINTENANCE SCHEDULE . 67

......................MANUAL RELIEF VALVE (T type) . 69

ENGINE COVER REMOVAL AND

..................................................INSTALLATION . 69

............................................Engine Oil Level Check . 70

....................................................Engine Oil Change . 71

.......................................................Oil Filter Change . 72

..................................Engine Oil Recommendations . 73

................................................Gear Oil Level Check . 73

........................................................Gear Oil Change . 74

.....................................................Lubrication Points . 76

....................................................Spark Plug Service . 77

.............................................................REFUELING . 79

...............................FUEL RECOMMENDATIONS . 80

....................Portable Fuel Tank and Filter Cleaning . 82

.................................Recoil Starter Rope Inspection . 83

..................................................Anode Replacement . 83

..............................................Propeller Replacement . 84

...........THE IMPORTANCE OF MAINTENANCE . 64

.........Fuel Pump Filter Inspection and Replacement . 80

....................................................................STORAGE . 85

...................................STORAGE PREPARATION . 85

..........................................Cleaning and Flushing . 85

........................................................................Fuel . 87

.............................................................Engine Oil . 89

...................................STORAGE PRECAUTIONS . 89

...............................REMOVAL FROM STORAGE . 90

........................................................TRANSPORTING . 91

WITH OUTBOARD MOTOR INSTALLED

.............................................................ON BOAT . 91

WITH OUTBOARD MOTOR REMOVED

.......................................................FROM BOAT . 91

TAKING CARE OF UNEXPECTED

..........................................................PROBLEMS . 92

BATTERY WILL NOT CHARGE AND

.ELECTRIC STARTER WILL NOT OPERATE . 97

OIL PRESSURE INDICATOR LIGHT GOES OFF

...................AND ENGINE SPEED IS LIMITED . 98

OVERHEAT AND ENGINE SPEED IS

..............................................................LIMITED . 99

........................................SUBMERGED MOTOR . 101

Page 8

CONTENTS

TECHNICAL AND CONSUMER

.................................................INFORMATION . 103

.............................TECHNICAL INFORMATION . 103

......................................Serial Number locations . 103

Carburetor Modification for High Altitude

.........................................................Operation . 104

................................................Oxygenated Fuels . 105

............................................................Star Label . 108

......................................................Specifications . 110

.............................CONSUMER INFORMATION . 118

.............................................Honda Publications . 118

............................Customer Service Information . 118

.........................................................................INDEX . 123

.........................WIRING DIAGRAMS . Inside back cover

...............Emission Control System Information . 106

−

.............Distributors Limited Warranty 2005 . 119

...................Emission Control System Warranty . 121

This Owner’s Manual is using the following type names when it describes the operations special to a type.

Tiller handle type: Remote control type: Gas assist type: Power tilt type:

Check the type of your outboard motor and read this Owner’s Manual thoroughly before operation. Texts with no type indication are the information and/or procedures common to all types.

H type R type G type T type

Page 9

OUTBOARD MOTOR SAFETY

IMPORTANT SAFETY INFORMATION

Honda BF8D/BFP8D/BF9.9D/ BFP9.9D/BF15D/BFP15D/BF20D and BFP20D outboard motors are designed for use with boats that have a suitable manufacturer’s power recommendation. Other uses can result in injury to the operator or damage to the outboard motor and other property.

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

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.

Page 10

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.

Page 11

SAFETY LABEL LOCATIONS

OUTBOARD MOTOR SAFETY

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

Page 12

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES

Model

Type

Shaft Length Tiller Handle Remote Control Electric Starter Gas Assist Tilt Power Tilt Power Thrust Propeller Battery Charging DC Receptacle Tachometer

SHA

LHA

BF8D

SHSA

S H

LHSA

L H

BFP8D

LRA

LHA

XHA

XHSA

LHTA

H R S

＊＊

XRTA

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

BF8D/BFP8D are provided with the following types according to the shaft length, control system, tilt system, and start system.

Tilt system

Gas assist Tilt (with gas damper

assist function) Power Tilt (with hydraulic assist

(Example)

LHSA

function) Shaft Length S: Short Shaft L: Long Shaft X: Extra Long Shaft Control System H: Tiller Handle Control R: Remote Control

Optional Equipment

＊

Standard Equipment

Destination A=United States S=Electric Starter G=Gas assist Tilt T=Power Tilt None=Manual Tilt R=Remote Control H=Tiller Handle S=Short Shaft L=Long Shaft X=Extra Long Shaft

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Model

BFP9.9DBF9.9D

Type

Shaft Length Tiller Handle Remote Control Electric Starter Gas Assist Tilt Power Tilt Power Thrust Propeller Battery Charging DC Receptacle Tachometer

SHA

LHA

SHSA

S H

LHSA

L H

LRA

R S

LHA

L H

XHA

X H

XHSA

X H

LRA

R S

LHTA

L H

LRTA

R S

T P

XRTA

T P

＊＊＊＊

XHTA

X H

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

BF9.9D/BFP9.9D are provided with the following types according to the shaft length, control system, tilt system, and start system.

Tilt system

Gas assist Tilt (with gas damper

assist function)

Power Tilt (with hydraulic assist

(Example)

LHSA

function) Shaft Length S: Short Shaft L: Long Shaft X: Extra Long Shaft Control System H: Tiller Handle Control R: Remote Control

Optional Equipment

＊

Standard Equipment

Destination A=United States S=Electric Starter G=Gas assist Tilt T=Power Tilt None=Manual Tilt R=Remote Control H=Tiller Handle S=Short Shaft L=Long Shaft X=Extra Long Shaft

Page 14

Model BFP15D

LHSA

Type LGA

SHA

LHA

XHA

SHSA

LRA

BF15D

SHGA

LHGA

XHGA

LHTA

SRTA

SHTA

LRTA

XHTA

LRTA

XRTA

Shaft Length Tiller Handle Remote Control Electric Starter Gas Assist Tilt Power Tilt Power Thrust Propeller Battery Charging DC Receptacle Tachometer

S H

＊＊＊＊＊

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

BF20D/BFP20D are provided with the following types according to the shaft length, control system, tilt system, and start system.

Tilt system

Gas assist Tilt (with gas damper

assist function)

Power Tilt (with hydraulic assist

(Example)

LHSA

function) Shaft Length S: Short Shaft L: Long Shaft X: Extra Long Shaft Control System H: Tiller Handle Control R: Remote Control

Optional Equipment

＊

Standard Equipment

L H

R S

X H

Destination A=United States S=Electric Starter G=Gas assist Tilt T=Power Tilt None=Manual Tilt R=Remote Control H=Tiller Handle S=Short Shaft L=Long Shaft X=Extra Long Shaft

Page 15

Model

BF20D

BFP20D

Type SHSA

Shaft Length Tiller Handle Remote Control Electric Starter Gas Assist Tilt Power Tilt Power Thrust Propeller Battery Charging DC Receptacle Tachometer

SHA

LHA

LHSA

XHSA

SRA

LRA

LGA

＊＊＊＊＊

L H

SHGA

S H

S G

LHGA

L H

XHGA

X H

SHTA

LHTA

L H

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

BF20D/BFP20D are provided with the following types according to the shaft length, control system, tilt system, and start system.

Tilt system

Gas assist Tilt (with gas damper

assist function)

Power Tilt (with hydraulic assist

(Example)

LHSA

function) Shaft Length S: Short Shaft L: Long Shaft X: Extra Long Shaft Control System H: Tiller Handle Control R: Remote Control

Optional Equipment

＊

Standard Equipment

XHTA

SRTA

LRTA

Destination A=United States S=Electric Starter G=Gas assist Tilt T=Power Tilt None=Manual Tilt R=Remote Control H=Tiller Handle S=Short Shaft L=Long Shaft X=Extra Long Shaft

LRTA

Page 16

CONTROLS AND FEATURES

COMPONENT AND CONTROL LOCATIONS H Type (tiller handle)

RECOIL STARTER GRIP

OIL FILLER CAP

OIL LEVEL DIPSTICK

COOLING SYSTEM INDICATOR

ENGINE OIL DRAIN SCREW

ANODES

SHIFT LEVER

TILLER HANDLE

TILT LEVER (manual tilt type only)

MANUAL RELIEF VALUE (T type only)

TILT LEVER (G type only)

ELECTRIC STARTER BUTTON (electric starter type only)

STERN BRACKET

CLAMP SCREW

TRANSOM ANGLE ADJUSTING ROD

GEAR OIL LEVEL PLUG

COOLING WATER INTAKE PORT

GEAR OIL DRAIN/FILL PLUG

ENGINE COVER

FLUSH PORT HOLE (inside engine cover)

ANTIVENTILATION PLATE

EXHAUST PORT

PROPELLER

Page 17

CHOKE KNOB (equipped type only)

CONTROLS AND FEATURES

OIL PRESSURE INDICATOR LIGHT

SWITCH CLIP

FUEL HOSE CONNECTOR

STEERING FRICTION LEVER

POWER TILT SWITCH (T type only)

THROTTLE FRICTION ADJUSTER

THROTTLE GRIP

LANYARD

ENGINE STOP SWITCH

Page 18

CONTROLS AND FEATURES

R Type (remote control)

OIL FILLER CAP

OIL LEVEL DIPSTICK

COOLING SYSTEM INDICATOR

ENGINE OIL DRAIN SCREW

RECOIL STARTER GRIP

TILT LEVER (manual tilt type only)

MANUAL RELIEF VALVE (T type only)

ENGINE COVER

STERN BRACKET

CLAMP SCREW (applicable types)

TRANSOM ANGLE ADJUSTING ROD

GEAR OIL LEVEL PLUG

COOLING WATER INTAKE PORT

GEAR OIL DRAIN/FILL PLUG

FLUSH PORT HOLE (inside engine cover)

ANODES

ANTIVENTILATION PLATE

EXHAUST PORT

PROPELLER

Page 19

GEARSHIFT/THROTTLE CONTROL LEVER

NEUTRAL RELEASE LEVER

CONTROLS AND FEATURES

POWER TILT SWITCH (T type only)

SPARE SWITCH CLIP

REMOTE CONTROL FRICTION ADJUSTER

OIL PRESSURE INDICATOR LIGHT

OVERHEATING INDICATOR LIGHT

FAST IDLE LEVER

BUZZER (inside box)

IGNITION SWITCH

EMERGENCY STOP SWITCH

LANYARD

SWITCH CLIP

Page 20

CONTROLS AND FEATURES

FUEL GAUGE VENT KNOB

TACHOMETER

(optional equipment)

(R type)

PRIMING BULB

FUEL TANK

FUEL CAP

FUEL HOSE

FUEL HOSE CONNECTOR (FEMALE)

Page 21

CONTROLS AND FEATURES

CONTROLS

H Type (tiller handle)

Engine Stop Switch and Switch Clip

ENGINE STOP SWITCH

LANYARD

SWITCH CLIP

The engine stop switch has controls for normal engine stopping and emergency engine stopping.

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

When used as described, the 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 motor.

Choke Knob (H type manual choke)

CHOKE KNOB

OOPPEENN

CCLLOOSSEEDD

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

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

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

LANYARD

Page 22

CONTROLS AND FEATURES

Throttle Grip Gearshif t LeverThrottle Friction Adjuster

THROTTLE INDEX MARK

THROTTLE GRIP

The throttle grip controls engine speed.

An index mark on the tiller arm shows throttle position and is helpf ul for setting the throttle correctly when starting (p. ).

FIX

THROTTLE FRICTION ADJUSTER

RELEASE

THROTTLE GRIP

The throttle friction adjuster adjusts resistance to throttle grip rotation.

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

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

R (reverse)

N (neutral)

F(forward)

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, and the electric starter button (applicable models) will not operate the starter motor.

Page 23

CONTROLS AND FEATURES

Recoil Starter Grip Electric Starter Button (models

equipped with electric starter)

STARTER GRIP

SWITCH

Pull the starter grip to operate the recoil starter for starting the engine manually.

The engine will not start unless the gearshift lever (p. ) is in the N

20 20 (neutral) position, and the clip is in the engine stop switch.

CLIP

Press the starter button to operate the electric starter for starting the engine.

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

ELECTRIC STARTER BUTTON

Steering Friction Lever

LLOOCCKK

STEERING FRICTION LEVER

The steering friction lever 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.

FFRREEEE

Page 24

CONTROLS AND FEATURES

Power Tilt Switch (T type) Tilt Lever (G type)

Press UP to tilt the motor up.

Press DN to tilt the motor down.

POWER TILT SWITCH

The rocker type power tilt switch has UP and DN (down) positions for

During shallow water operation, beaching, launching, or mooring, proceed at low speed with a small throttle opening and tilt the motor up as necessary (p. ).59

(gas assist tilt type)

TTIILLTT

RRUUNN ((LLOOCCKK))

changing the angle of the outboard motor.

Moving the tilt lever to the TILT position allows the outboard motor to

Power tilt is a convenience for tilting the motor, shallow water operation, and trailering only. It is not designed to be used as a trim function to adjust the trim angle of the boat.

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

TILT LEVER

Page 25

CONTROLS AND FEATURES

R Type (remote control)

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

Ignition Switch (side-mount type)

OONN

OOFFFF

IGNITION SWITCH

EMERGENCY STOP SWITCH

SWITCH CLIP

The ignition switch controls the ignition system and starter motor.

SSTTAARRTT

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

The ignition switch can be used to start the engine only when the gearshift lever (p. ) is in the N

20 (neutral) position, and the switch clip is in the emergency stop switch.

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

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

EMERGENCY STOP SWITCH

LANYARD

SWITCH CLIP

LANYARD

SWITCH CLIP

Page 26

CONTROLS AND FEATURES

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

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

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

SPARE SWITCH CLIP

Fast Idle Lever

(side-mount type)

MAXIMUM FAST IDLE

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

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

LOWEST POSITION

FAST IDLE LEVER

Leave the fast idle lever in the lowest position to provide a rich f uel mixture for starting a cold engine.

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

Page 27

CONTROLS AND FEATURES

Gearshift/Throttle Control Lever (side-mount type)

GEARSHIFT/THROTTLE CONTROL LEVER

NEUTRAL RELEASE LEVER

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

GEARSHIFT/THROTTLE CONTROL LEVER

N (neutral)

EENNGGIINNEE SSPPEEEEDD

HIGH

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

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

R (reverse)F(forward)

EENNGGIINNEE SSPPEEEEDD

HIGH

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

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

Page 28

CONTROLS AND FEATURES

Power Tilt Switch (T type) Manual Relief Valve (T type) (side-mount type)

CONTROL LEVER

Press UP to tilt the motor up.

Power tilt is a convenience for tilting the motor, shallow water operation, and trailering only. It is not designed to be used as a trim function to adjust the trim angle of the boat.

RIGHT STERN BRACKET

MANUAL (Valve closed to fix)

During shallow water operation, beaching, launching, or mooring,

Press DN to tilt the motor down.

POWER TILT SWITCH

The rocker type power tilt switch is located on the control lever and has UP and DN (down) positions for changing the angle of the outboard motor.

proceed at low speed with a small throttle opening and tilt the motor up as necessary (p. ).59

POWER (Valve open to release)

※

MANUAL RELIEF VALVE

Do not turn this screw. If this

screw is turned hydraulic oil will bleed out of the power tilt system. Should this happen it will be necessary to consult your authorized Honda Marine dealer and have the system refilled.

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

Page 29

CONTROLS AND FEATURES

Tilt Lock Lever (G and T types)

FFRREEEE

TTIILLTT LLOOCCKK LLEEVVEERR

LLOOCCKK

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

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

Common Controls

Engine Cover Latch

EENNGGIINNEE CCOOVVEERR LLAATTCCHH

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

Transom Angle Adjusting Rod

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

(manual tilt SH type/LH type)

ADJUSTING ROD

Page 30

CONTROLS AND FEATURES

ADJUSTING ROD

(G and T type)(manual tilt XH type/R type)

ADJUSTING ROD (storage location)

There are four transom angle adjustment positions. Three are controlled by the adjusting rod and the fourth is controlled by the stern bracket. In order to use the fourth position, remove the adjusting rod and store it in the storage location, then lower the motor down to the stern bracket stop position.

Tilt Lever (manual tilt type)

TILT LEVER

TTIILLTT

RRUUNN ((LLOOCCKK))

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

To tilt, move the lever to the TILT position, then raise the outboard motor until the tilt mechanism engages at 30°, 45°, 71° or 72° (p. ).

Page 31

CONTROLS AND FEATURES

BF8D/BFP8D/BF9.9D/BFP9.9D 71° : Tiller handle S and L types. 72° : Tiller handle X type and

Remote control type.

BF15D/BFP15D/BF20D/BFP20D 71° : Tiller handle S type. 72° : Tiller handle L and X types and

Remote control type.

INSTRUMENTS

Fuel Gauge

FUEL GAUGE

A fuel gauge is built into the cap of the portable fuel tank.

Tachometer (optional equipment) (R Type)

TACHOMETER

The tachometer shows engine speed in revolutions per minute.

A tachometer will help to select the correct propeller.

Page 32

CONTROLS AND FEATURES

INDICATORS

Oil Pressure Indicator (R type)

(GREEN)

(H type)

OIL PRESSURE INDICATOR LIGHT

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

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

TAKING

CARE OF UNEXPECTED

,p. .

PROBLEMS

Remote controls are also equipped with a buzzer that sounds when the green light goes off. The buzzer sound stops below an engine speed of 1,400 rpm.

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

Overheat Indicator (R type only)

(RED)

(R type)

When the overheat protection system is activated, the red overheat light will come on, a buzzer will sound and the engine speed will be reduced to 1,800 rpm. If the condition persists for another 20 seconds, the engine will shut off. Refer to

TAKING CARE OF UNEXPECTED PROBLEMS

(H type)

When the overheat protection system is activated, the engine speed will be reduced to 1,800 rpm. If the condition persists for another 20 seconds, the engine will shut off. Refer to

UNEXPECTED PROBLEMS

Engine overheating may be the result of clogged water intakes.

,p. .

TAKING CARE OF

,p. .9999

Page 33

CONTROLS AND FEATURES

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.

excessively, or when propeller ventilation occurs during a sharp turn.

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

Automatic Choke (models

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.

The cooling system indicator port can also become plugged.

equipped with electric starter)

The engine is equipped with an automatic choke so that the choke system operation is not needed when starting the engine.

Anodes

ANODE (G and T types only)

ANODES (each side)

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

There are two anodes on the gear case, one on the stern bracket.

Page 34

CONTROLS AND FEATURES

Portable Fuel Tank Fuel Cap Vent Knob Fuel Priming Bulb

The portable fuel tank has a capacity of US gal ( ) and has a fuel

123.2

gauge built into the cap.

VENT KNOB

OOPPEENN

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 (p. ).

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, squeeze the priming bulb until it feels firm. This will ensure that fuel is supplied to the engine (p. ).

Page 35

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.

BOAT TRANSOM REQUIREMENTS

Honda BF8D/BFP8D/BF9.9D/ BFP9.9D/BF15D/BFP15D/BF20D and BFP20D outboard motors can be installed on a boat transom having a thickness range of 1.3 2.2 inches

−

(35 57 mm).

−

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 2.0

−

inches below the bottom of the boat.

IIDDLLEE PPOORRTT

TTRRAANNSSOOMM HHEEIIGGHHTT

−

02.0in

−

(0 50 mm)

Transom HeightType: S: L:

17.0 in (433 mm)

22.2 in (563 mm)

27.7 in (703 mm)

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

Page 36

INSTALLATION

If the outboard motor is installed too low, the boat will squat and be hard to plane, it will tend to porpoise, and high-speed stability will be reduced.

If the outboard motor is installed too high, that will cause 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 (models with clamp screws)

ROPE

WASHER

BOLT

CLAMP SCREW

LOCK NUT

WASHER

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.

You may further secure the outboard motor by bolting the stern bracket to the boat transom. Use the optional mounting bolt and nut kit or other good quality stainless steel bolts, nuts, and washers. Apply silicone sealant to the bolt holes.

MOUNTING HOLE

TRANSOM BOARD

Page 37

INSTALLATION

(models without clamp screws)

WASHER

BOLT

WASHER

TRANSOM BOARD

Attach the stern bracket to the boat transom with good quality stainless steel bolts, nuts, and washers. Apply silicone sealant to the bolt holes.

LOCK NUT

WASHER

LOCK NUT

MOUNTING HOLE

ADJUSTMENT

Use the transom angle adjustment rod (p. ) to adjust the angle of the

41 outboard motor so the propeller is perpendicular to the surface of the water.

BATTERY CONNECTIONSTRANSOM ANGLE

−

TO ACCESSORIES

BATTERY

Honda BF8D/BFP8D/BF9.9D/ BFP9.9D/BF15D/BFP15D/BF20D and BFP20D outboard motors produce a 12-volt, 6 or 12-ampere battery-charging current and are equipped for connection to a 12-volt battery. The battery-charging circuit is protected by a 20-ampere fuse located in the engine compartment.

The outboard motor’s 12-volt output is intended for battery charging only. Lights and electrical accessories for the boat should be connected to the battery.

Page 38

INSTALLATION

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

Types With Electric Starter

These types are equipped with battery cables. The positive (+) cable has a red band at the battery connector. The negative (-) cable has a black band at the battery connector.

For electric starter operation, use a 12-volt battery with an ampere-hour rating of at least 35 Ah (CCA 270).

Types With Manual Start

These types are equipped with a 12volt DC battery-charging receptacle which can be wired to a 12-volt battery to power lights and electrical accessories for the boat.

Plug and Receptacle (models without electric starter)

BATTERY

−

TO ACCESSORIES

To prepare the outboard motor for connection to a battery, pull the cover out of the DC receptacle, connect your battery charging wires to the receptacle. Attach the connected DC receptacle on the holder on the tiller arm.

The receptacle is provided with a cover, which should be attached when the plug is removed, in order to keep the receptacle clean and dry.

−−

TTOO BBAATTTTEERRYY

DC RECEPTACLE

COVER

Battery

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

Minimum Requirements

12V-35Ah (CCA 270)

Page 39

Battery Terminals

＋

( ) TERMINAL

−

( ) TERMINAL

RED

BLACK or GREEN

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

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

INSTALLATION

Be caref ul to avoid connecting the battery in reverse polarity, as that will damage the battery-charging system in the outboard motor.

Page 40

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 preoperation checks, be sure the ignition switch is in the OFF position.

Page 41

Safety Inspection Maintenance Inspection

BEFORE OPERATION

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.

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

Check to be sure the propeller is undamaged, and the castle nut is secured with the cotter pin (p. ).

Check that the anodes are securely attached to the gear case (p. ) and are not excessively worn. The anodes help 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. ).

Check that the battery fluid is between the upper and lower levels, and the battery leads are connected securely (electric starter type).

Page 42

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

BEFORE OPERATION.

BREAK-IN PROCEDURE

Break-in period: 10 hours

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

First 15 minutes:

Run the engine at trolling speed. Use the minimum throttle opening necessary to operate the boat at a safe trolling speed.

Next 45 minutes:

Run the engine up to a maximum of 2,000 to 3,000 rpm, which is about 10% to 30% of maximum throttle opening.

Next 60 minutes:

Run the engine up to a maximum of 4,000 to 5,000 rpm, which is about 50% to 80% of maximum throttle opening.

Short full-throttle bursts are OK, but do not operate the engine continuously at full throttle.

For boats that plane easily, bring the boat up on plane, and then reduce the throttle opening to the recommended rpm range.

Next 8 hours:

Do not run the engine at full throttle for more than 5 minutes at a time.

Page 43

OPERATION

TRANSOM ANGLE ADJUSTMENT

(manual tilt SH type/LH type)

ADJUSTING ROD

LOCKED POSITION

(manual tilt XH type/R type)

ADJUSTING ROD

PINCH

TURN UP

PUSH

(G type/T type)

TTUURRNN UUPP

PPUUSSHH

ADJUSTING ROD

(XH type/R type/ G type/T type)

UNLOCKED POSITION

LOCKED POSITION

ADJUSTING ROD

TO CHANGE

TO LOCK

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

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

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

(manual tilt SH type/LH type)

Pinch the end of the rod.

Remove the rod and reinsert it in the desired position.

Push the rod in and hook the end of the rod. Then release the rod.

(XH type/R type/ G type/T type)

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

Page 44

OPERATION

Do not allow water to enter the idle exhaust port or the engine can be damaged.

IDLE EXHAUST PORT

Page 45

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)

FUEL HOSE CONNECTOR

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.

(OUTBOARD MOTOR SIDE)

Connect the fuel hose to the tank and the outboard motor, as shown. Be sure both connectors snap securely into place.

Page 46

OPERATION

FUEL PRIMING STARTING THE ENGINE

H Type (tiller handle)

OUTLET END (MOTOR)

PRIMING BULB

INLET END (TANK)

Hold the priming bulb with the outlet end higher than the inlet end. Squeeze the priming bulb several times, until it feels firm, indicating that fuel has reached the carburetor.

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

Do not squeeze the priming bulb when the engine is running because that could flood the carburetor.

SWITCH CLIP

ENGINE STOP SWITCH

LANYARD

Put the emergency stop switch clip in the engine stop switch, and attach the lanyard to your PFD (Personal Flotation Device) or to your wrist, as shown.

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

Page 47

OPERATION

N (neutral)

GEARSHIFT LEVER

2. lever. It must be in the N (neutral) position for starting.

The engine will not start if the gearshift lever is in the F (forward) or R (reverse) position.

CCLLOOSSEEDD

CHOKE KNOB

(manual choke type)Check the position of the gearshift

To start a cold engine, pull the

3. choke knob to the CLOSED position. To restart a warm engine, leave the choke knob in the OPEN position.

START POSITION

POINTER

THROTTLE GRIP

Do not turn the throttle grip before

4. starting and align the START position with the pointer for starting the engine.

Page 48

OPERATION

RECOIL STARTER GRIP

ELECTRIC STARTER BUTTON

Recoil starter

5. Pull the recoil starter grip slowly until you feel resistance, then pull briskly.

Return the starter grip gently.

Electric starter (electric starter model) Press the electric starter button and hold it there until the engine starts.

When the engine starts, release the button.

If the engine fails to start within 5 seconds, release the button, and wait at least 10 seconds before operating the starter again.

Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can damage it.

Pushing the electric starter button while the engine is running can damage the starter motor and f lywheel.

6.7.(Manual Start only) If the choke knob was pulled to the CLOSED position to start the engine, gradually push it to the OPEN 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 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. ).

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

from p. .

Page 49

OPERATION

R Type (remote control)

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

Side-Mount Type

SWITCH CLIP

Put the emergency stop switch clip

1. in the emergency stop switch, and attach the lanyard to your PFD (Personal Flotation Device) or to your wrist, as shown.

LANYARD

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

N(neutral)

CONTROL LEVER

Set the control lever in the N

2. (neutral) position.

The engine will not start if the F (forward) or R (reverse) gears are engaged.

Page 50

OPERATION

FAST IDLE

FAST IDLE LEVER

OFF

IGNITION SWITCH KEY

START

Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can damage it.

Turning the ignition switch key to the START position while the engine is running can damage the starter motor and f lywheel.

To start a cold engine, leave the

3. 4. fast idle lever in the OFF (fully lowered) position.

To restart a warm engine, raise the fast idle lever.

Fast idle lever cannot be raised unless the control lever is in the N (neutral) position.

The control lever cannot be moved away from the N (neutral) position unless the fast idle lever is lowered.

Turn the ignition switch key to the START position and hold it there until the engine starts.

When the engine starts, release the key, allowing it to return to the ON position.

If the engine fails to start within 5 seconds, release the key and wait at least 10 seconds before operating the starter again.

Page 51

OPERATION

FAST IDLE LEVER

If the fast idle lever was used to

5. start the engine, gradually lower the lever as the engine warms up.

When the fast idle lever is fully lowered, the control lever can be moved away from the N (neutral) position.

Before getting under way, allow

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

Above 41°F (5°C), warm up the engine for 2 or 3 minutes.

Below 41°F (5°C), warm up the engine for at least 10 minutes at 2,000 rpm.

During the warm-up period, check the oil pressure indicator (p. ), overheat indicator (p.

), and cooling system

indicator (p. ).

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

from p. .

EMERGENCY STARTING

If the battery is discharged, or the starter motor and the recoil starter are inoperative, you can start the engine manually using the emergency starter rope supplied with the motor.

UNLATCH

ENGINE COVER LATCH

Unlatch and remove the engine

1. cover (p. ).

6992

Page 52

OPERATION

NEUTRAL START CABLE

RECOIL STARTER ASSEMBLY

Move the shift lever to the F

2. 3. (forward) position. Loosen the neutral start cable lock nut and disconnect the neutral start cable.

FLANGE BOLT

RECOIL STARTER ASSEMBLY

Unscrew the three flange bolts and remove the recoil starter assembly.

Set the controls the same as for normal starting (see pages

). Use the choke and fast idle

−

controls if needed.

Turn the ignition switch key to the ON position.

emergency starter rope in the notch in the flywheel. Wind the rope clockwise around the flywheel, as shown.

FLYWHEEL (STARTER PULLEY)

STARTER ROPE

Pull the emergency starter rope

KNOT

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,Set the knotted end of the

p. .

Page 53

OPERATION

If the choke and fast idle control(s)

7. was used to start the engine, return the control(s) to the normal operating position as the engine warms up.

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

Leave the recoil starter assembly

8. off, but install the engine cover (p. ), and lock it in place by

latching the engine cover latch.

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

9. 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

10. Honda marine dealer check your electrical system and correct the problem, so you can use the electric starter.

The recoil starter assembly (p. ) should be reinstalled after the electric starter is working again. Install the recoil starter assembly with the engine stopped.

Page 54

OPERATION

Emergency Engine Stopping

LANYARD

PULL

SWITCH CLIP

LANYARD

PULL

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

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

Normal Engine StoppingSTOPPING THE ENGINE

SLOW

THROTTLE GRIP

N(neutral)

GEARSHIFT LEVER

SWITCH CLIP

Page 55

N (neutral)

CONTROL LEVER

Move the throttle grip to the

1. slowest position or the remote control lever to the N (neutral) position.

ENGINE STOP SWITCH

IGNITION SWTCH KEY

Turn the ignition switch key to the

2. OFF position or press the engine stop switch until the engine stops.

OPERATION

When the boat is not in use,

3. remove and store the ignition key and the emergency stop switch clip and lanyard.

Page 56

OPERATION

GEARSHIFT AND THROTTLE OPERATION

H Type (tiller handle)

THROTTLE GRIP

R (reverse)

N (neutral)

F(forward)

SLOW

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.

FIX

RREELLEEAASSEE

THROTTLE GRIP

THROTTLE FRICTION ADJUSTER

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

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

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

Page 57

OPERATION

R Type (remote control)

Side-Mount Type

CONTROL LEVER

NEUTRAL RELEASE LEVER

To shift gears, move the control lever to select F (forward), N (neutral) and R (reverse) gears.

The control lever cannot be moved from the N (neutral) position unless the neutral release lever is squeezed.

Moving the control lever beyond the gear selection range increases engine speed.

TO INCREASE FRICTION

THROTTLE FRICTION ADJUSTER

TO DECREASE FRICTION

Adjust the throttle friction adjuster so the control lever will hold a constant throttle setting while cruising.

Page 58

OPERATION

H Type (tiller handle)

R TypeSTEERING (remote control)

Steer the boat in the same manner as an automobile.

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

LLOOCCKK

STEERING FRICTION LEVER

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

Move the lever to the LOCK direction to increase steering friction for holding a steady course and for trailering.

Move the lever to the FREE direction to decrease friction for easy turning.

FFRREEEE

Page 59

OPERATION

CRUISING

Engine Speed

throttle opening to 80%. Use the throttle friction control (p. or 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.

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 conditions, the boat will perform best when the antiventilation plate is level with the water.

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. ).5541

Excessive transom angle during operation can cause propeller ventilation, overheating, and water pump damage.For best fuel economy, limit the

MOTOR ANGLE ADJUSTED TOO LOW

ROUGH WAVES

MOTOR ANGLE ADJUSTED TOO HIGH

MOTOR ANGLE ADJUSTED CORRECTLY

Page 60

OPERATION

BOW TOO LOW DUE TO

LOAD IN THE FRONT

1. MOTOR ANGLE ADJUSTED

2. TOO LOW

BOW TOO HIGH DUE TO

LOAD IN THE REAR

1. MOTOR ANGLE ADJUSTED

2. TOO HIGH

Motor Angle (Crusing)

O.K.

CORRECT GIVES MAXIMUM PERFORMANCE

Page 61

OPERATION

SHALLOW WATER OPERATION

Manual tilt Type

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, move the tilt lever to the TILT position, then raise the outboard motor to the 30° or 45° 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

31 the outboard motor is not tilted so high the water intake is out of the water.

An excessive tilt angle during operation can cause propeller ventilation, overheating, and water pump damage.

45°

Page 62

OPERATION

ENGINE COVER GRIP

TILT LEVER

TTIILLTT

RRUUNN ((LLOOCCKK))

To return the outboard motor to the normal operating position, move the tilt lever to the RUN (LOCK) position, raise the outboard motor slightly to disengage the tilt mechanism, then slowly lower the outboard motor.

TType GType

When operating in shallow water, use the power tilt switch to tilt the outboard motor, so the propeller and gear case won’t hit the bottom.

Proceed at low speed, and monitor water flow from the cooling system indicator (p. ) to be sure the

31 outboard motor is not tilted so high that the water intakes are out of the water.

An excessive tilt angle during operation can cause propeller ventilation, overheating, and water pump damage.

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

Page 63

OPERATION

To tilt the outboard motor, move the tilt lever to the TILT position, then raise the outboard motor to the desired 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

31 the outboard motor is not tilted so high the water intake is out of the water.

An excessive tilt angle during operation can cause propeller ventilation, overheating, and water pump damage.

ENGINE COVER GRIP

TTIILLTT

RRUUNN ((LLOOCCKK))

TILT LEVER

To return the outboard motor to the normal operating position, move the tilt lever to the RUN (LOCK) position, you may need to raise the outboard motor slightly to disengage the tilt mechanism, then slowly lower the outboard motor.

Page 64

OPERATION

MOORING, BEACHING, LAUNCHING Manual tilt Type

71° or 72° (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 71° or 72° position.

Stop the engine before tilting the outboard motor. The 71° or 72° position is not an operating position.

GandTTypes

To raise the outboard motor out of the water while the engine is stopped and the boat is moored, or for maximum clearance when beaching or launching, use the power tilt switch to tilt the outboard motor as far as it will go, move the tilt lock lever to the LOCK position, then gently lower the outboard motor until the lever contacts the stern bracket.

If more clearance is needed to swing the tilt lock lever into the LOCK position, rock the outboard motor forward slightly by pulling on the engine cover grip.

To lower the outboard motor, tilt up, move the tilt lock lever to the FREE position, then lower the outboard motor to the desired position.

FFRREEEE

TILT LOCK LEVER (lock position)

LLOOCCKK

Do not attempt to use the power tilt switch to tilt the outboard motor down while the tilt lock lever is in the lock position. Damage to the power tilt system may occur.

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

Page 65

OPERATION

T Type

MANUAL RELIEF VALVE

POWER (Valve closed to fix)

MANUAL (Valve open to release)

※

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

RIGHT STERN BRACKET

Do not turn this screw. If this screw is turned hydraulic oil will bleed out of the power tilt system. Should this happen it will be necessary to contact your closest authorized Honda Marine dealer and have the system refilled.

For manual tilting, use a flat screwdriver to turn the valve counterclockwise 2 and a half turns. Close the valve firmly after positioning the engine.

Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.

Page 66

SERVICING YOUR OUTBOARD MOTOR

THE IMPORTANCE OF MAINTENANCE

Good 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.

Honda will not deny a claim for warranty coverage simply because you did not maintain your outboard. However, any part that fails due to lack of maintenance, or improper maintenance will not be covered under your product warranty.

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.

Page 67

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

Page 68

SERVICING YOUR OUTBOARD MOTOR

TOOL KIT AND EMERGENCY STARTER ROPE

8 mm WRENCH

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.

10 12 mm WRENCH

PHILIPS SCREWDRIVER

OIL CHECK SCREWDRIVER

FLAT SCREWDRIVER

SCREWDRIVER GRIP

PLIERS

SPARK PLUG WRENCH

10 mm SOCKET WRENCH

TOOL BAG

SPARE CLIP

Page 69

MAINTENANCE SCHEDULE

SERVICING YOUR OUTBOARD MOTOR

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

Engine oil

Gear case oil Engine oil filter Starter rope Carburetor linkage Idle speed Valve clearance Spark plugs

Propeller and cotter pin Lubrication Fuel tank and tank filter

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 Replace Check Check-adjust Check-adjust Check-adjust Check-adjust Replace Check Grease Clean

Each use After use

○

First month

20 hrs.

○ ○

(2)

○

(2)

○

(1)

○

Every 6 months

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)

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

(4)

Every year

200 hrs.

○

(2)

○

Page 70

SERVICING YOUR OUTBOARD MOTOR

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

Fuel filter

Thermostat Fuel line

Battery and cable connection Bolts and Nuts Crankcase breather tube Anode Cooling water passages Water pump

(3)

Check Replace Check Check Replace Check level-tightness Check-tightness Check Check Clean Check

Each use

○

After use

Every 2 years ( Replace if necessary) (2)

(4)

○

First month

20 hrs.

(2)

○

Every 6 months

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

200 hrs.

○

(2)

○

(2)

○

(2)

○

Page 71

SERVICING YOUR OUTBOARD MOTOR

MANUAL RELIEF VALVE ENGINE COVER REMOVAL

RIGHT STERN BRACKET

PPOOWWEERR ((VVaallvvee cclloosseedd ttoo ffiixx))

For manual tilting, use a flat screwdriver to turn the valve counterclockwise 2 and a half turns. Close the valve firmly after positioning the outboard motor.

AND INSTALLATION(T type)

(REAR)

Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.

ENGINE COVER LATCH

※

MANUAL RELIEF VALVE

※

Do not turn this screw. If this

MMAANNUUAALL ((VVaallvvee ooppeenn ttoo rreelleeaassee))

screw is turned hydraulic oil will bleed out of the power tilt system. Should this happen it

(FRONT)

will be necessary to contact your closest authorized Honda Marine dealer and have the system refilled.

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

Page 72

SERVICING YOUR OUTBOARD MOTOR

(INSTALLATION)

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

To remove the engine cover, unlatch the engine cover latch, then lift the engine cover off the outboard motor.

To install the engine cover, place the cover on the outboard motor, then latch the engine cover latch securely.

Engine Oil Level Check

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

Unlatch and remove the engine

cover.

Remove the dipstick and wipe it

clean.

OIL LEVEL DIPSTICK

UPPER LIMIT

LOWER LIMIT

Insert the dipstick all the way in,

then remove it and check the oil level shown on the dipstick.

OIL FILLER CAP

If the oil level is low, remove the

4. oil filler cap, and add oil to reach the upper limit mark shown on the dipstick. Use the oil recommended on p. .

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

Install the oil filler cap and tighten

5. it securely.

Install and lock the engine cover.

Page 73

Engine Oil Change

SERVICING YOUR OUTBOARD MOTOR

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

Drain the used oil while the engine is warm. Warm oil drains quickly and completely.

Unlatch and remove the engine

1. cover (p. ).

ENGINE OIL DRAIN SCREW

Remove the oil filler cap, and

2. remove the engine oil drain screw.

Allow the used oil to drain

3. completely, then reinstall the engine oil drain screw, and tighten it securely.

Inspect the sealing O-ring and replace if damaged or torn.

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.

With the outboard motor in a

4. vertical position, fill to the upper limit mark on the dipstick (p. ) with the recommended oil.

Engine oil refill capacity: Without oil filter change:

1.1 US qt (1.0

With oil filter change:

1.4 US qt (1.3 )

Install the oil filler cap and tighten

5. it securely.

Install and lock the engine cover.

)

Page 74

SERVICING YOUR OUTBOARD MOTOR

Oil Filter Change

Drain the engine oil, and reinstall

1. the drain screw (see Engine Oil Change on p. ).

Unscrew the six bolts and remove

2. the R. engine under cover.

Use a suitable tool to remove the

3. 4. oil filter, and throughly drain the filter into the used oil container.

USE A SUITABLE TOOL

OIL FILTER

RUBBER SEAL

and coat the rubber seal of the new oil filter with clean engine oil.

Use only a genuine Honda oil f ilter or a f ilter of equivalent quality specified f or your model. Using the wrong f ilter, or a nonHonda f ilter which is not of equivalent quality, may cause engine damage.

Screw on the new filter by hand until it contacts the engine, then use a suitable tool to tighten the filter an additional 7/8 turn.

OIL FILTER TIGHTENING TORQUE:

9 lbf·ft (12 N·m , 1.2 kgf·m)

Fill the crankcase with the

6. specified amount (p. ) of the

recommended oil.

Start the engine and check for

7. leaks.Clean the oil filter mounting base,

Running the engine without water can cause serious engine damage. If you are changing the oil filter while the outboard motor is out of the water, place unit in water or supply adequate water to the water intakes before running the engine. Do not run engine with flush attachment on power head.

Stop the engine, and check the oil

8. level as described on page . If

70 necessary, add oil to bring the oil level to the upper limit mark on the dipstick.

Page 75

SERVICING YOUR OUTBOARD MOTOR

Engine Oil Recommendations Gear Oil Level Check

The SAE oil viscosity and service

classification are in the API label on Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil.

the oil container. Honda recommends

that you use API SERVICE category

SG, SH or SJ oil with the ‘‘starburst’’

Check the gear 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.

DRAIN PLUG

LEVEL PLUG

SAE 10W-30 is recommended for general use.

Remove the oil level plug and see whether oil flows from the oil level hole.

If oil flows from the oil level hole, the oil level is OK. Reinstall the plug and tighten it securely.

OIL LEVEL PLUG TORQUE:

2.6 lbf·ft (3.5 N·m , 0.36 kgf·m)

Page 76

SERVICING YOUR OUTBOARD MOTOR

If no oil flows from the oil level hole, add the recommended oil following the procedure described in Gear Oil Change.

Gear Oil Change

Change the gear 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 plug and oil drain plug.

Remove any metal particles from

2. the magnetic end of the oil drain plug.

Allow the used oil to drain

3. 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 plug is removed, have the outboard motor checked by an authorized Honda Marine dealer.

Page 77

GEAR OIL BOTTLE

Add oil through the oil drain hole

4. until it flows out the oil level hole, then install the oil level plug and the oil drain plug.

GEAR OIL CAPACITY:

0.301 US qt (0.285 )

SERVICING YOUR OUTBOARD MOTOR

OIL LEVEL PLUG TORQUE:

2.6 lbf·ft (3.5 N·m , 0.36 kgf·m)

Avoid losing more than 1 fl oz (30

cm ) while reinstalling the drain plug.

OIL DRAIN PLUG TORQUE:

2.6 lbf·ft (3.5 N·m , 0.36 kgf·m)

Outboard motor SAE 90 hypoid gear oil API Service classification (GL-4 or GL-5)

Page 78

SERVICING YOUR OUTBOARD MOTOR

Lubrication Points

Apply marine waterproof grease to the following parts: Lubrication interval: 20 operating hours or a month after the date of purchase for initial, then every 100 operating hours or 6 months.

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

TILT SHAFT

TILLER HANDLE

CLAMP SCREWS

ADJUSTING ROD/

TILT STOPPER

THROTTLE REEL

MOUNT FRAME

SWIVEL CASE

PROPELLER SHAFT

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

Page 79

SERVICING YOUR OUTBOARD MOTOR

Spark Plug Service

RECOMMENDED SPARK PLUGS:

CR5EH-9 (NGK)

SPARK PLUG WRENCH

SPARK PLUG CAP

0.031 0.035 in

−

(0.80 0.90 mm)

−

U16FER9 (DENSO)

SEALING

Incorrect spark plugs can cause

WASHER

engine damage.

Unlatch and remove the engine

1. cover (p. ).

Disconnect the spark plug caps

2. from the spark plugs. Measure the spark plug electrode

Remove the spark plugs with a

3. sparkplugwrench.

Inspect the spark plugs. Replace

4. 5. them if the electrodes are worn, or if the insulators are cracked or chipped.

gap with a suitable gauge. The gap should be 0.031 0.035 inches

−

(0.80 0.90 mm).

−

Page 80

SERVICING YOUR OUTBOARD MOTOR

After each spark plug seats, tighten

7. with a spark plug wrench supplied in the tool kit to compress the sealing washer.

If reinstalling used spark plugs, tighten 1/8 - 1/4 turn after the spark plugs seat.

If installing new spark plugs, tighten 1/2 turn after the spark plugs seat.

Install the spark plugs carefully,

6. by hand, to avoid cross-threading.

Loose spark plugs can overheat and damage the engine. Overtightening the spark plugs can damage the threads in the cylinder head.

Attach the spark plug caps.

Install and lock the engine cover.

Page 81

REFUELING

SERVICING YOUR OUTBOARD MOTOR

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

OPEN

FUEL CAP

To refuel, turn the vent knob counterclockwise to the OPEN position, and unscrew the fuel tank cap.

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.

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.

Page 82

SERVICING YOUR OUTBOARD MOTOR

FUEL RECOMMENDATIONS

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

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

Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.

Occasionally you may hear a light ‘‘spark knock’’ or ‘‘pinging’’ (metallic rapping noise) while operating under heavy loads. This is no cause for concern.

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

damaged by misuse.

Distributor’s Limited

does not cover parts

Fuel Pump Filter Inspection and Replacement

The fuel pump filter is located under the engine cover, on the right side of the engine.

Water or sediment accumulated 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.

Page 83

UNLATCH

ENGINE COVER LATCH

SERVICING YOUR OUTBOARD MOTOR

FUEL PUMP FILTER

Disconnect the fuel hose from the

3. outboard motor, and place clamps on the fuel hoses on each side of the filter to prevent fuel leakage when the fuel hoses are disconnected.

Unlatch and remove the engine cover for access to the fuel pump filter.

Inspect the filter for water and/or

2.1. 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. ).

FUEL PUMP FILTER

FUEL HOSE

Remove the fuel hoses from the

4. used filter, and discard the filter.

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

Page 84

SERVICING YOUR OUTBOARD MOTOR

ARROW (Fuel Flow Direction)

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.

Remove the fuel hose clamps, and

6. connect the fuel hose to the outboard motor. Check for leaks.

Install and lock the engine cover.

Portable Fuel Tank and Filter Cleaning

Fuel Tank

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

Fuel Tank Filter

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 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.

Page 85

SERVICING YOUR OUTBOARD MOTOR

Recoil Starter Rope Inspection Anode Replacement

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.

ANODES

ANODE (G and T types only)

The anodes are located on each side of the gearcase and the stern bracket (G and T types only). They are made of a sacrificial material that helps to protect the outboard motor from corrosion.

Replace the anodes when they have been reduced to about half their original size, or if they are 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.

Page 86

SERVICING YOUR OUTBOARD MOTOR

Propeller Replacement

Before replacing the propeller, 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 Installation

COTTER PIN

TOWARD GEAR CASE

THRUST WASHER

Remove the cotter pin, unscrew the castle nut, remove the washer, then remove the propeller and thrust washer.

Install the propeller in the reverse order of removal.

Install the thrust washer with the grooved side toward the gear case.

Use a genuine Honda cotter pin.

MARINE GREASE

PROPELLER

PLAIN WASHER

CASTLE NUT

COTTER PIN

Page 87

STORAGE

STORAGE PREPARATION

Proper storage preparation is essential for keeping your outboard motor troublefree 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.

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

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.

Flushing With the Honda Garden Hose Adapter (optional equipment)

Unlatch the engine cover latch and

1. remove the engine cover (p. ), and install the garden hose adapter.

Attach a garden hose from a fresh

2. water faucet to the garden hose adapter.

Turn on the fresh water supply,

3. and verify that there is good water pressure at the outboard motor.

Flush the engine with fresh water

4. for at least 10 minutes.

Do not run the engine.

GARDEN HOSE ADAPTER

After flushing, remove the garden hose adapter, reinstall the engine cover.

Page 88

STORAGE

Flushing Without the Honda Garden Hose Adapter

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.

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.

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. ).

Page 89

STORAGE

Fuel

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 within a few months, or even less if the gasoline was not fresh when you filled the fuel tank.

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

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.

Add fuel stabilizer following the

1. manufacturer’s instructions.

After adding a fuel stabilizer, run

2. 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.

Distributor’s Limited Warranty

The does not cover fuel system 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.

DRAIN SCREW

Page 90

STORAGE

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 away. Handle fuel only outdoors. Wipe up spills immediately.

After the fuel has drained from the

3.2. carburetor, tighten the drain screw securely.

Drain the portable fuel tank into an

4. 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 cap vent knob.

Store portable fuel tank in a cool place.

Page 91

STORAGE

Engine Oil STORAGE PRECAUTIONS

Change the engine oil and the oil

1. filter (p. ).

Remove the spark plugs (p. ),

−

71 72

77 and remove the clip from the emergency stop switch.

Pour a tablespoon (5 10 cm ) of

−

clean engine oil into each cylinder.

Pull the starter rope several times

4. to distribute the oil in the cylinders.

Reinstall the spark plugs (p. ).

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 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.

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.

LUG

Page 92

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.

PROTECTOR

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 or oil leakage.

CASE PROTECTOR

Check your outboard motor as described in the

OPERATION

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

BEFORE

chapter of this manual.

Page 93

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 lever 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)

WITH OUTBOARD MOTOR REMOVED FROM BOAT

Secure the outboard motor in either the vertical or horizontal position shownonp. .

LUG

CARRYING HANDLE

To carry, hold the outboard motor by the carrying handle, or hold by the carrying handle and the lug beneath 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.

Page 94

TAKING CARE OF UNEXPECTED PROBLEMS

ELECTRIC STARTER WILL

NOT OPERATE

Check battery.

Check fuse. Fuse burnt out. Replace fuse (p. ).

Use emergency starting

procedure (p. ), then take outboard motor to an authorized Honda Marine dealer, or refer to the shop manual.

Battery connections loose or corroded.

Starter malfunction, switch malfunction, or electrical problem in the starting circuit.

Possible Cause Correction

Clean and tighten battery connections.

Recharge battery.Battery discharged.

Replace or repair faulty components as necessary.

Page 95

TAKING CARE OF UNEXPECTED PROBLEMS

CorrectionPossible CauseENGINE WILL NOT START

Check emergency stop switch

clip.

Check control positions. Shift to neutral (p. or p. ).

2. 20 25

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

Gearshift lever or control lever not in neutral position.

Choke OPEN (tiller-handle and manual choke type).

Throttle grip not in START position (tiller-handle type).

Fast idle lever raised (side-mount type).

Pull choke knob to CLOSED position, unless engine is warm (p. ).

Turn throttle grip to START position (p. ).

Leave fast idle lever OFF, unless engine is warm (p. ).

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TAKING CARE OF UNEXPECTED PROBLEMS

(continued)

CorrectionPossible CauseENGINE WILL NOT START

Check fuel. Out of fuel.

Remove and inspect spark plugs.

Take outboard motor to an

authorized Honda marine dealer, or refer to the shop manual.

Fuel vent closed (portable fuel tank).

Fuel hose not primed.

Fuel pump filter or fuel tank filter clogged.

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

Spark plugs faulty, fouled or improperly gapped.

Spark plugs 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 fuel filters (p. ).

Drain fuel tank and carburetors (p. ). Refill with fresh gasoline

(p. ).

Gap or replace spark plugs (p. ).

Dry and reinstall spark plugs. Start engine with choke and throttle open.

Replace or repair faulty components as necessary.

Page 97

AFTER STARTING

TAKING CARE OF UNEXPECTED PROBLEMS

CorrectionPossible CauseHARD STARTING OR STALLS

Check control positions.

Check fuel.

Choke OPEN (tiller-handle and manual choke type).

Throttle grip not in START position (tiller-handle type).

Fast idle lever raised (side-mount type).

Fuel vent closed (portable fuel tank).

Fuel hose not primed. Fuel pump filter or fuel tank clogged.

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

Pull choke knob to CLOSED position, unless engine is warm (p. ).

Turn throttle grip to START position (p. ).

Leave fast idle lever OFF, unless engine is warm (p. ).

Open fuel tank vent (p. ).

Squeeze priming bulb (p. ). Replace fuel filters (p. ).

Drain fuel tank and carburetors (p. ). Refill with fresh gasoline

(p. ).

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TAKING CARE OF UNEXPECTED PROBLEMS

HARD STARTING OR STALLS

AFTER STARTING

(continued)

Possible Cause Correction

Remove and inspect spark plugs.

Take outboard motor to an

authorized Honda marine dealer, or refer to the shop manual.

ENGINE OVERHEATS Possible Cause Correction

Check water intake screens. Water intake screens clogged. Clean water intake screens.

Take outboard motor to an

authorized Honda marine dealer, or refer to the shop manual.

Spark plugs faulty, fouled or improperly gapped.

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

Faulty thermostat or water pump. Replace or repair faulty

Gap or replace spark plugs (p. ).

Replace or repair faulty components as necessary.

components as necessary.

Page 99

TAKING CARE OF UNEXPECTED PROBLEMS

BATTERY WILL NOT CHARGE AND ELECTRIC STARTER WILL NOT OPERATE

The battery-charging circuit and the electric starter relay circuit are protected by the 20-ampere fuse. If the fuse burns out, the engine will not charge the battery, and the electric starter will not operate. The engine can be started using the recoil starter or the emergency starter rope.

The ignition switch is also protected by the 20-ampere fuse. If the fuse burns out, the engine will not start or run, and the power tilt switch will not operate.

Fuse Replacement

With the engine stopped, remove

1. the engine cover.

Remove the fuse case lid.

Remove and inspect the fuse. If

3. burnt out, install a replacement fuse of the specified rating. The outboard motor only comes with one spare fuse in the fuse holder.

DESIGNATED FUSE:

Never use a f use with a rating greater than specif ied. Serious damage to the electrical system could result.

20A

SPARE 20A FUSE

FUSE CASE LID20A FUSE

BLOWN FUSE

Reinstall the fuse case lid and the

4. engine cover.

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

Page 100

TAKING CARE OF UNEXPECTED PROBLEMS

OIL PRESSURE INDICATOR LIGHT GOES OFF AND ENGINE SPEED IS LIMITED

OIL PRESSURE (GREEN)

(tiller handle type)

(GREEN)

(remote control type)

If oil pressure becomes low, the green indicator light will go off, and the engine protection system will limit engine speed. If you are at cruising speed, engine speed will decrease automatically.

When normal oil pressure is restored, the engine speed will gradually rise to normal engine speed.

Remote-control types are equipped with a buzzer that sounds when the green indicator light goes off. The buzzer sound stops below an engine speed of 1,400 rpm.

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.

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