Honda Power Equipment BF40A, BF50A User Manual

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Thank you for purchasing a Honda Outboard Motor.
This manuul describes the operation and maintenance of the Honda
BF3SA board Motors. All information in this publication is hased tion available at the time of printing. Honda Motor Co.. Ltd. reserves the right to make changes at any time without notice and without incurring any obligation.
and
BF4OA and BFWA Out-
on
the latest product informa-
No part of this publication may be reproduced without written permission.
This manual should be considered a permanent part of the Outboard Motor
and it must stay with the Outboard
Motor if resold.
READ THIS OWNER’S MANUAL CAREFULLY. Pay special attention to these symbols and any instructions that follow.
m
KILLED or SERIOUSLY HURT if you don’t follow instructions.
B You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
-
if you don’t follow instructions.
NOTICE 1 Your outboard motor or other property can be damaged if you don’t follow instructions.
You WILL be
You CAN be HURT
Honda Outboard Motors are designed to give safe and dependable service if operated according to instructions. Operating this Outboard Motor requires special effort on your part to ensure your-safety and the safety of others.
­or misuse may cause injury or property damage. Read and understand this owner’s manual before operating the Outboard Motor.
Careless operation
If a problem should arise, or if you have any questions about your
Outboard Motor, see an authorized
Honda Marine dealer.
HONDA MOTOR CO., LTD. 1994,
ALL RIGHTS RESERVED
1
TYPES OF HONDA BF35A/40A/5OA OUTBOARD MOTORS
It may hc necessary to rcfcr to this chart for reference purposes when reading this manual.
TYPE CODE (example)
L R T T = Power Trimmilt
TT-II
2
R = Remote Control H = Tiller Handle
X = Extra Long Shaft L = Long Shaft
IDENTIFICATION NUMBERS
RIGHT STERN BRACKET
PRODUCT IDEliTiFICATION NUMBER
Record the Product Identification Number (P.I.N.) Number for your reference. Refer to the Product Identification Number when
ordering parts, and when mak-
and the Engine Serial
, ,-in,
ing technical or warranty inquiries (see page 101).
STARTER MOTOR
- -\
The Product Identification Number is
stamped on a plate and attached to the right stern bracket. The Engine Serial Number is stamped on the cylinder block under the starter motor which is located in the front of the engine.
Product identification number:
Engine serial number:
3

CONTENTS

1. SAFETY SAFETY LABELS.. SAFETY INFORMATION
2. COMPONENT IDENTIFICATION
................................................... 6
........................................ 7
............................
3. CONTROLS TILLER HANDLE TYPE
Engine Start Button Shift Lever..
.................................................... 1 I
................................................................
Choke Knob.. ..............................................................
Throttle Grip.. .............................................................
Throttle Opening Indicator Throttle Friction Knob Engine Stop Switch Emergency Stop Switch Oil Pressure Indicator Light Overheat Indicator Light
.........................................
...............................................
....................................................
Lanyard
...............................
.......................................
............................................ 14
REMOTE CONTROL TYPE
Remote Control Lever Neutral Release Lever Ignition Switch Emergency Stop Switch Choke/Fast Idle Lever
Manual Choke Knob Oil Pressure Indicator Light/Buzzer.. Overheat Indicator Light/Buzzer
................................................ 15
................................................
........................................................... I6
Lanyard
............................... I7
................................................
......... .........................................
.........................
................................ I9
REMOTE CONTROL & PQWER TRIM/TILT TYPE
Power Trim/Tilt Switch (remote control lever)
Power Tilt Switch (motor pan)
...................................
4
8
II 1 I
12 12 12
13 13 I4
I6
18 18
19
.......... 20
2 I
Trim Meter Tachometer Manual Relief Valve
.................................................................
.................................................................
..................................................
GAS ASSISTED TILT TYPE
Tilt Lever
.................................................................... 22
CONTROLS & INSTRUMENTS (common)
Tilt Lock Trim Tab.. Anode Metal Cooling Water Transom Angle Adjusting Rod
Fuel Cap/Gauge/Vent Over-Rev Limiter
Lever.. .........................................................
...................................................................
...............................................................
System
Intakes..
Indicator..
............................................................
.........................................
..................................
.......................................
Knob
.......................................................
4. PRE-OPERATION CHECKS Engine Cover Removal/Installation
..................................................................
Engine Fuel Level.. Fuel Recommendations Oxygenated Fuels Propeller and Cotter pin
Oil
.................................................................
..............................................
.......................................................
.............................................
...........................
Steering Friction Adjustment (common).
Remote Control
Friction
Adjustment
.........................
Other Checks
l
Stern
l
Tool Kit
l
Anodes
bracket
............................................................
....................................................................
.....................................................................
5. STARTING THE ENGINE Fuel Tank and Vent Knob
..........................................
21 2 I 22
23 23 24 24 25
26 27 27
28 29
30 3 1 32
33
................... 33
34 34
34 34
35
CONTENTS
Fuel Line Connection STARTING THE ENGINE (TILLER HANDLE TYPE).
STARTING THE ENGINE (REMOTE CONTROL TYPE). ...
Emergency Starting ....................................................
Troubleshooting Starting Problems.. ..........................
6. OPERATION
Break-in Procedure.. ...................................................
TILLER HANDLE TYPE
Gear Shifting
Steering ..................................................................
Cruising .................................................................
REMOTE CONTROL TYPE
Gear Shifting
Cruising .................................................................
Tilting motor
GAS ASSISTED TILT TYPE.. POWER TRIM/TILT TYPE
POWER TRIM/TILT TYPE
Trim Meter .............................................................
Power Tilt Switch (Motor Pan) Manual Relief Valve..
Tilt Lock Lever Trim Tab Adjustment MOTOR PROTECTION SYSTEM
Engine Oil Pressure and
Overheat Warning
Over-Rev Limiter
Power Trim Wgning System
................................................. 35
......................................................... 5 1
......................................................... 53
............................. 55
................................. 58
............................. 60
............................................ 60
...................................................... 6 1
................................................. 62
System.. ................................... 63
.................................................. 65
................................ 65
... 37
41 44 49
50
52 52
54
59
Anodes ................................................................... 66
Shallow Water Operation ...................................... 67
High Altitude Operation ........................................ 68
7. STOPPING THE ENGINE
TILLER HANDLE TYPE ..................................... 69
REMOTE CONTROL TYPE ................................ 7 1
8. TRANSPORTING
9. CLEANING AND FLUSHING
10. MAINTENANCE..
Tool Kit and Spare Parts.. ...................................... 76
MAINTENANCE SCHEDULE ............................ 77
Engine Oil .............................................................. 79
Gear Oil ................................................................. 8 I
Spark Plugs ............................................................ 83
Battery (not included). ........................................... 84
Lubrication ............................................................ 86
Engine Fuel Filter .................................................. 87
Fuel Tank and Filter .............................................. 89
Fuse Replacement.. ................................................ 90
Propeller ................................................................ 9 1
Submerged Motor .................................................. 92
I 1. STORAGE
12. TROUBLESHOOTING
13. SPECIFICATIONS
14. WARRANTY
15. WIRING
. 16. INDEX
................................................................. 94
DIAGRAM ................................................. 102
....................................................................... I05
.....................................................
..................................................... 75
............................................. 96
.................................................... 98
SERVICE ........................................... 101
72
................................. 73
5
1. SAFETY
SAFETYLABELS
These labels are in the locations show& They warn you of potential
hazards that could seriously injure you. Read these labels carefully.
EXTREMELY
FUI USE As A lwu1 FIEI. ma.” -#+A” omT,IN EM UlTl twa coparm
FLAMMABLE
6

SAFETY INFORMATION

For your safety and the safety of oth­ers, pay special attention to these pre­cautions.
Operator Responsibility
-Know how to stop the engine quickly in case of emergency. Understand the use of all controls. Do not exceed the boat manufactur­er’s power recommendation, and be sure that the outboard motor is properly mounted. Never permit anyone to operate the outboard motor without proper instruction. Stop the engine immediately if any one falls overboard. Do not run the motor while the boat is near anyone in the water. Attach the emergency stop switch lanyard securely to the operator.
Do
not remove the engine cover
while the engine is running.
l
Before operating the outboard
.motor, familiarize yourself with all
laws and regulations relating to boating and the use of outboard motors.
l
Do not attempt to modify the out­board motor.
l
Always wear PERSONAL FLOTATION DEVICE (PFD) when on board.
l
Do not remove any guards, labels,
shields, covers or safety devices;
they are installed for your safety.
Fire and Burn Hazards
Gasoline is extremely flammable, and gasoline vapor can explode. Use
extreme care when handling gasoline.
l
Remove the fuel tank from the boat for refueling.
l
Refuel in a well-ventilated area with the engine stopped. Keep flames and sparks away, and do not smoke in the area.
1. SAFETY
l
Refuel carefully to avoid spilling fuel. Avoid overfilling the fuel tank (there should be no fuel in the filler neck). After refueling, tighten the filler cap securely. If any fuel is spilled, make sure the area is dry before starting the engine.
7
2. COMPONENT IDENTIFICATION (TILLER HANDLE TYPE)
THROTTLE GRIP
FUEL LINE CONNECTOR
\
ENGINE COVER
I
OIL FILLER CAP
OIL LEVEL
GEAR SHIFT LEVER
PRESSURE INDICATOR LIGHT
OIL
\
OVERHEAT
INDICATOR
LIGHT
LEVER
STERN
TRANSOM ANGLE
GEAR OIL LEVEL PLUG
GEAR OIL DRAIN PLUG
I IP
IV,
ENGINE OIL
[ ANTI-VENTILATION
(ANODE METAL)
PROPELLER
U.-I
THROTTLE
FRICTION K
\
ENGINE START BUTTON
\
TILT LEVER
WATER INTAKE
.NOB
.---
a
/
CHOKE KNOB
EMERGENCY STOP SWITCH
CLIP
/ I
SPARE EMERGENCY
STOP SWITCH CLIP
\
EMERGENCY
STOP SWITCH
LANYARD
FUEL LINE CONNECTOR
\
2. COMPONENT IDENTIFICATION (REMOTE CONTROL TYPE)
ENGINE COVER
POWER TILT SWITCH
I
OIL LEVEL DIPSTIC
COOLING
SYSTEM INDICATOR
OIL FI$LER CAP
Fgi;fzL~gi;g
LEVEK
POWER TRIM/TILT
SWITCH
NEUTRAL
OVERHEAT
/
“DICATOR In LIGHT
CHOKE/FAST IDLE LEVER
M ANUA< RELIEF VALV
GEAR OIL
LEVEL PL
GEAR OIL DRAIN PLUG
\
PROPELLER
\ WASH PLUG (Flush plug)
ENGINE OIL DRAIN BOLT ACCESS COVER
EXHAUST PORT
/
ETAL)
STOP SWITCH CL1
\
WATER INTAKE
EMERGENCY STOP SWITCH LANYARD
EMERGENCY STOP SWITCH CLIP
ENGINE STOP
9
2. COMPONENT IDENTIFICATION
FUEL GAUGE
POWER TRIM/TILT TYPES
VENT KNOB
FUEL T
FUEi
10
I
PRIMER BULB
FUEL HOSE CONNECTOR
(FEMALE)
FUEL CAP
TACHOMETER
TRIM METER
3. CONTROLS (TILLER HANDLE TYPE)

Engine Start Button

R
(reverse) N
ENdINE START BUTTON
Move the gearshift lever to the N
(neutral) position before starting. The
engine will not start unless the gearshift lever is in the N (neutral) position.

Shift Lever

(reveZse)
SHIti LEVER
There are three gearshift lever posi­tions.
F (forward): The boat moves forward. N (neutral): The transmission gears
are disengaged from the engine.
R (reverse): The boat reverses.
N

Choke Knob

CHOti KNOB
When the engine is cold, pull the choke knob. A rich fuel mixture is provided to the engine by pulling the choke knob.
11
3. CONTROLS (TILLER HANIDLE TYPE)

Throttle Grip

THRO’ITLE GRIP
Turn the grip clockwise or counter­clocktiise to adjust the engine speed. Turning the grip in the direction shown by the arrow increases engine speed.

Throttle Opening Indicator

THROTTLE OPENING INDICATOR
The curve on the &tip indicates throttle opening.

Throttle Friction Knob

THROTI’LE FRICTION KNO
RELEASE
Use the throttle friction knob to set the throttle grip at a certain position while
cruising. Turning the friction knob clockwise sets the throttle grip, and it is released by turning the friction knob counterclockwise.
12
3. CONTROLS (TILLER HANDLE TYPE)

Engine Stop Switch

ENGINE STOP SWITCH
Push the engine stop switch to stop the engine.

Emergency Stop Switch Lanyard

EMERGENCY STOP SWITCH CLIP
The emergency stop switch lanyard is provided to stop the engine immedi-
ately in the event the operator should fall overboard or away from the con-
trols.
The emergency stop switch clip must be engaged with the engine stop
switch or the engine will not start. When the emergency stop switch clip becomes disengaged with the engine stop switch the engine will stop imme­diately.
ENGINE STOP
SWITCH
EMERGENCY STOP SWITCH LANYARD
Attach the emergency stop switch lan­yard securely to the operator when operating the outboard motor.
13
3. CONTROLS (TILLER HANDLE TYPE)
SPARE EMERGENCY
,STOP SWITCH CLIP
A spare emergency stop switch clip is provided near the engine stop switch.
Oil Pressure Indicator Light
f-

OIL PRESSURE INDICATOR LIGHT

The green oil pressure indicator light is normally ON when the outboard motor is running. When the engine oil level is low or the engine lubrication system is faulty, the
green oil pressure indicator light turns
OFF and the engine speed decreases
gradually.
Overheat Indicator Light

OVERHEAT INDICATOR LIGHT

When the engine cooling system is
faulty, the red overheat indicator light turns ON and the engine speed decreases gradually.
14
3. CONTROLS (REMOTE CONTROL TYPE)

Remote Control Lever

The remote control lever controls gear
selection and throttle opening posi-
tions. It is necessary to pull up the neutral release lever to operate the remote
control lever.
D
THROm
REMOTE CONTROL LEVER
F (forward):
Moving the lever to the F position
(approximately 30’ from the N
position) will engage the forward
gear. Moving the lever further from the F position will increase the throttle opening and the boat for­ward speed.
N (neutral):
The engine idles and the transmis­sion gears are disengaged.
(NEUiRAL, R
R (reverse):
Moving the lever to the R position (approximately 30” from the N position) will engage the reverse gear. Moving the lever furthen into the R position will increase the throttle opening and the boat reverse speed.
15
3. CONTROLS (REMOTE CONTROL TYPE)

Neutral Release Lever

The neutral release lever is on the remote control lever to prevent an accidental gear engagement.
The remote control lever will not engage forward or reverse gear unless the neutral release lever is pulled up.

Ignition Switch

+ ON
The remote control box is equipped with a key type ignition switch. Key positions:
START
To activate the starter motor and start the engine.
must be in the neutral position)
(the remote control lever
START
ON
To run the engine after starting (the battery will discharge if the key is left in this positidn with the engine not running).
OFF
To stop the engine (IGNITION OFF). To prevent the battery from dis­charging, keep the key in the OFF position when the engine is not run-
ning.
16
3. CONTROLS (REMOTE CONTROL TYPE)

Emergency Stop Switch Lanyard

The emergency stop switch lanyard is provided to stop the engine immedi-
ately in the event the operator should fall overboard or away from the con­trols.
The emergency stop switch clip must be engaged with the emergency engine stop switch or the engine will not start. When the emergency stop switch clip becomes disengaged from the emer­gency engine stop switch the engine will stop immediately.
4
The emergency engine stop switch should not he used to normally stop the engine. Use the ignition switch to normally stop the engine.
Attach the emergency stop switch lan­yard securely to the operator when operating the outboard motor.
SPA’RE EMERGENCY STOP SWITCH CLIP
A spare emergency stop switch clip is
provided on the remote control box.
17
3. CONTROLS (REMOTE CONTROL TYPE)
Choke/Fast Idle
Lever
f’-J CHOKE
The choke/fast idle lever provides two functions:
1. Electric choke solenoid activation for easy engine start up.
2. Engine fast idle.
The choke/fast idle lever will not move unless the remote control lever
is in the N (neutral) position.
Conversely, the remote control lever
will not move unless the choke/fast idle lever is in the lowest position.
XIMUM FAST IDLE
OWEST POSITION
&AST
IDLE LEVER
Lift and hold the choke/fast idle lever up fully, this will provide a rich fuel mixture and the correct fast idle.
Gradually lower the choke/fast idle lever to the lowest position to decrease the choke and fast idle.

Manual Choke Knob

CHOKE KNOB
A manual choke knob is provided on the right side of the motor which can be used in the event the battery is dis­charged. Pull the manual choke knob, and a rich fuel mixture will be provid­ed to the engine.
18
3. CONTROLS (REMOTE CONTROL TYPE)

Oil Pressure Indicator Light/Buzzer

The green oil pressure indicator light turns OFF and the buzzer sounds when the oil level is low and/or the engine lubrication system is faulty. The engine speed slows down gradual-
ly-

Overheat Indicator Light/Buzzer

The red overheat indicator light turns ON and the buzzer sounds when the engine cooling system is faulty. The engine speed Slows down gradually.
19
3. CONTROLS (REMOTE CONTROL & POWER TRIM/TILT TYPE)
Power ‘l’kim/Tilt Switch (remote
control lever) Power Tkim
Press the power trim/tilt switch on the remote control lever to adjust the motor trim angle of 0” to 20” to main­tain proper boat trim. The power trim/tilt switch located on the remote control lever can be operated while the boat is under way or while stopped.
By
using the power trim/tilt switch the operator can change the trim angle of the motor to achieve maximum boat acceleration, speed, stability and maintain optimum fuel consumption.
Power Tilt
Press the power trim/tilt switch on the
remote control lever to adjust the motor tilt angle of 20” to 60’.
By
using the power trim/tilt switch the operator can change the tilt angle of the motor for shallow water operation, beaching, launching from a trailer, or mooring.
pi6Tzq
during operation can cause the pro­peller to raise out of the water and cause propeller ventilation and engine over-revving. Excessive trim/tilt angle can also damage the water pump.
Excessive trim/tilt angle
XRTA type outboard
Power Trim
Do not trim
using a large amount of throttle opening. If you do try to trim the en­gine, under certain conditions, pro­peller thrust may override the power
trim hydraulics and cause the engine
to return to the transom angle adjust-
ing rod. (Full “in” position)
Power Tilt
Press the power tilt switch on the
remote control lever to adjust the
motor tilt angle of 20” to 60”.
By using the power tilt switch the op-
erator can change the tilt angle of the
motor for shallow water operation,
beaching, launching from a trailer, or
mooring.
this engine when you are
20
3. CONTROLS (REMOTE CONTROL & POWER TRIM/TILT TYPE)

Power Tilt Switch (motor pan)

POWER TILT SWITCH
The power tilt switch located on the motor pan is a conveyance switch for tilting the motor for trailering, or pre­forming outboard maintenance. This power tilt switch should only be oper­ated with the boat being stopped and
motor off.

Trim Meter

TRIM METER
The trim meter has a range of 0’ to 20” and indicates the trim angle of the out­board motor. Refer to the trim ‘meter when using the power trim/tilt switch to achieve proper boat performance.

Tachometer

TACHOMETER
The tachometer shows the approxi-
mate engine speed in revolutions per minute. Refer to the tachometer when using the power trim/tilt switch to
achieve proper boat and motor perfor­mance.
t
21
3. CONTROLS (REMOTE CONTROL & POWER TRIM/TILT TYPE)

Manual Relief Valve

If the power trim/tilt switch will not tilt the outboard motor, the motor can
be manually tilted up or down by opening the manual relief valve. To tilt the outboard motor manually, turn the manual valve under the left stem bracket no more than 1 or 2 turns counterclockwise using a screw driver. After tilting the motor, turn the manual relief valve clockwise securely. The manual relief valve must be tight­ened securely before operating the motor or the motor could tilt up when operating in reverse.
LEFT STERN BRACKET
MANUAL
WER (To WI-)
Rx)
MANUAL-RELIEF VALVE
Do not turn this -screw. If this screw is turned hydraulic oil will bleed out of the power trim/tilt system. Should this happen it will be necessary to consult your authorized Honda Marine dealer and have the system refilled.
Tilt Lever (GAS ASSISTED TYPE)
Moving the tilt lever to the FREE position allows the motor to be tilt-
ed and moving the tilt lever to the
LOCK
desired position.
temporarily tilt the motor when the boat is operating in shallow water, or mooring in shallow water. The tilt
lever must be in the LOCK position
before operating the motor or the
motor could tilt up when operating in reverse.
position
locks the
Use
the tilt
motor in the
lever to
22
3. CONTROLS & INSTRUMENTS (common)

Tilt Lock Lever

Use the tilt lock lever to hold the motor in the highest tilt position when the boat is moored for a long time. Tilt the motor up as far as it will go then move the tilt lock lever into the lock position and gently lower the motor.

Trim Tab

PROPELLER
When making a turn, if an unequal amount of effort is required to turn the steering wheel or tiller handle right or left, adjust the trim tab so that an equal amount of effort is required.
TAB
I
Distribute the load evenly in the boat and run the boat in straight course at full throttle. Slightly turn the steering wheel or tiller handle for both right and left turns to determine if an equal amount of effort is required. If adjust­ment is necessary loosen the tighten­ing bolt and turn the trim tab right or left. Make small adjustments at a time and retest. Incorrect trim tab adjustment can cause adverse steering.
The trim tab also functions as an anode.
23
3. CONTROLS d!k INSTRUMENTS (common)

Anode Metal

Y----l
\
The anodes are made from a sacrificial material which helps to protect the outboard motor from corrosion.
ANODiX
(stem
bracket)
1
NOTICE]
anodes will lead to rust and corro­sion damage to the outboard motor.
Painting or coating the

Cooling System Indicator

C~~'LIN~ SYSTEM
INDICATOR
The cooling system is monitored here
to make sure cooling water is circulat­ing through the engine.
24

Water Intakes

The engine cooling water is drawn into the water pump through these water intakes.
3. CONTROLS & INSTRUMENTS (common)
WATER INTAKES
25
3. CONTROLS & INSTRUMENTS (common)

Transom Angle Adjusting Rod

TRANSOM ANGLE ADJUSTING ROD
The transom angle adjusting rod is used to adjust the motor angle to achieve the correct boat trim. There are 5 adjustment holes located in the stem bracket. Push in and turn the transom angle adjusting rod up to remove. To install insert into the proper hole and turn down to lock. After installation pull the transom angle adjusting rod out-
. ward to be sure it is locked in place.
Start with the transom angle adjusting
rod in the hole closest to the boat tran-
TRANSOM ANGLE
ADJUSTING ROD
UNLOCKED POSITION
‘ItI LOCK
LOCKED POSITION
som, lower the motor and operate the boat at full speed. If the bow is exces­sively low stop the boat. Tilt the motor up and raise the transom angle adjust­ing rod one more hole away from the transom and retest. The optimum boat trim is when the boat is parallel with the water.. The transom angle adjust-
ing rod stops the motors forward movement. The motor should never be operated with the transom angle adjusting rod removed.
26
3. CONTROLS & INSTRUMENTS (common)

Fuel Cap/Gauge/Vent Knob

VENT KNOB
GAUGk FUEL FiLLEIi CkP
The fuel gauge is part of the fuel cap.
The fuel cap vent knob controls air entering and leaving the fuel tank. When refilling the fuel tank, turn the vent knob counterclockwise to the open position and remove the fuel cap.
Before transporting, storing or refill­ing the fuel tank inspect the condition
of the fuel cap gasket and replace if necessary.
Before transporting or storing the fuel tank turn the vent knob fully clock­wise to the closed position. Anytime the fuel tank is in the boat with the vent knob closed, discon­nect the fuel hose connector from the outboard motor (refer to page
35).
extremely flammable, and gaso­line vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks
in your working area. KEEP
OUT OF REACH OF CHILDREN.

Over-Rev Limiter

This outboard motor is equipped with an engine over-rev limiter which limits the maximum engine rpm. This over­rev limiter protects the engine from mechanical damage.
The over-rev limiter may be activated by putting the propeller in a light load condition or propeller ventilation. When the over-rev limiter is activated the engine rpm will become unstable or erratic. Should this occur reduce the throttle opening and wait for the engine r-pm to stabilize then increase the throttle opening.
On the power trim/tilt type motors lower the trim angle on high speed turns to re­duce the possibility of propeller ventila­tion.
27
Engine Cover Removal/InstalIation
(FRONT) (WAR)
ENGINE COVER
LATCHES
To remove, release the front and rear engine cover latches and remove the engine cover.
To install, position the engine cover ovei the engine and hook and lpck the
front and rear latches.
28
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