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.
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 -1
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. The
warranty policy is a separate document
that should have been given to you by
your dealer.
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.
0 1999 Honda Motor Co., Ltd.
All Right Reserved
1
INTRODUCTION
A FEW WORDS ABOUT
SAFETY
Your safety and the safety of others are
very important. And using this outboard
motor safely is an important responsibil-
ity.
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.
2
You will find important safety information a variety of forms, including:
l Safety Labels
l Safety Meswges
- on the outboard motor.
- preceded by a safety alert symbol &J and one of three signal
words, DANGER, WARNING, or CAUTION.
These signal word’s mean:
You WILL be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY
HURT if you don’t follow instructions.
l Safety Headings
l Safety Section
l Instructions
- such as IMPORTANT SAFETY INFORMATION.
- such as OUTBOARD MOTOR SAFETY.
- how to use this outboard motor correctly and safely.
This entire book is filled with important safety information -please read it carefully.
TYPES OF HONDA BF40AhOA OUTBOARD MOTORS
i
It may be necessary to refer to this chart for reference purposes when reading this manual.
Model
BWOA
BFSOA
TYPE CODE (example)
L R T
T = Power Trim/l%t R = Remote Control H = Tiller Handle X = Extra Long Shaft L = Long Shaft
TTT
3
IDENTIFICATION NUMBERS
RIGHT STERN BRACKET
PRODUCT IDEilTIFICATION
Record the Product Identification
Number (P.I.N.) and the Engine Serial
Number for your reference. Refer to the
Product Identification Number when
ordering parts, and when making
technical or warranty inquiries (see page
107).
, /---A
NUMBER
4
ENGINE SERIAL NUMBER
‘The Product
Identification Number is
stamped on a plate and attached to the
right stem 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:
CONTENTS
1. OUTBOARD MOTOR SAFETY
IMPORTANT SAFETY INFORMATION..
SAFETY LABEL LOCATIONS
2. COMPONENT
IDENTIFICATION
.......................... 9
............................ 10
3. CONTROLS
TILLER HANDLE TYPE
Engine Start
Button
...............................................
Shift Lever .............................................................
SERVICE ...........................................
. ........................... 103
73
74
76
77
78
80
...... 80
80
... 81
84
87
89
9 1
92
93
94
96
97
98
99
101
105
107
108
11 1
IMPORTANT SAFETY
INFORMATION
Honda BF4OA and BFSOA outboard
motors are designed for use with boats
that have a suitable manufacturer’s
power recommendation, and 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
l
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.
l
Stop the engine immediately if
anyone falls overboard, and do not
run the engine while the boat is near
anyone in the water.
l
Always stop the engine if you must
leave the controls for any reason.
l
Attach the emergency stop switch
lanyard securely to the operator.
1. OUTBOARD M;OTOR SAFETY
l
Always wear a PFD (Personal
Flotation Device) while on the boat.
l
Familiarize yourself with all laws and
regulations relating to boating and the
use of outboard motors.
l
Be sure that anyone who operates the
outboard motor receives proper
instruction.
l
Be sure the outboard motor is
properly mounted on the boat.
l
Do not remove the engine cover
while the engine is running.
l
Do not attempt to modify the
outboard motor.
l
Do not remove any labels, covers, or
safety devices; they are installed for
your safety.
7
1. OUTBOARD MOTOR SAFETY
Refuel With Care
l
Gasoline is extremely flammable, and
gasoline vapor can explode. Refuel
outdoors, in a well-ventilated area,
with the engine stopped. Never
smoke near gasoline, and keep other
flames and sparks away.
l
Remove any portable fuel tank from
the boat for refueling. Keep the
portable fuel tank away from the
battery or other potential spark
sources.
l
Refuel carefully to avoid spilling
fuel. Avoid overfilling the fuel tank.
l
After refueling, tighten the filler cap
securely. If any fuel is spilled, make
sure the area is dry before starting the
engine.
Carbon Monoxide Hazard
Exhaust gas contains poisonous carbon
monoxide. Avoid inhalation
gas. Never run the engine in a closed
garage or confined area.
.
of
exhaust
SAFETY LABEL LOCATIONS
These labels are in the locations shown.
They warn you of potential hazards that
could seriously injure you. Read these
labels carefully.
1. OUTBOARD MOTOR SAFETY
GASOLINE&g:
FLAMMABLE DANGEROUS
GASOL I NE
RHINE fRou WI fOR fllllffi
IOlml~lb]
INFLAIAMABLE DANGEREUX
GAZOL I NE
SllllR al Miw fulRmIff lE RElWEIPhU
2. COMPONENT IDENTIFICATION (TILLER HANDLE TYPE)
THROTTLE GRIP
TILLER
HANDLE 1
\ x
I
FUEL LINE
CONNECT-C
I
/ ENGINE COVER I DIPSTICK
)R
OIL FILLER CAP
OIL LEVEL
GEAR SHIFT LEVER
I
OIL PRESSURE INDICATOR LIGHT
TRANSOM&
ADJUSTING /I
LEVEL PLUG/
WASH PLUG
(Flush
plug)
GEAR OIL DRAIN PLUG
10
A
NTICA- --- --
Y
(Al
\
EXHr.,,. . \
PROPELLER
VITATION
YODE METAL)
A 1 ICT DC,RT
(optional)
r
/
/
FRICTION KNOB
TiLT LEVER
W type)
WATER INTAKE
\ OVERHEAT
\ \ t---+1 / ENGINE
STOP SWITCH
CLIP
SPARE EMERGENCY
STOP SWITCH CLIP
\
INDICATOR
LIGHT
I \
-_ _-EMBR( ‘;ENCY
STOP S
LANYA
\
WITCH
.RD
ENGINE
COVER
FUEL LINE
CONNYCTOR
LEVEL PLUG
2. COMPONENT IDENTIFICATION (REMOTE CONTROL TYPE)
POWER TILT
SWITCH
(except LR type)
COOLING
SYSTEM
INDICATOR
ACCESS COVER
OIL FILLER CAP
a, (LR type)
KNOB
ra
POWER TRIWILT
SWITCH
TILT LEVER
SPARE EMERGENCY
STOP SWITCH CLIP
BUZZER
(inside of the box)
VITATION
\ /
NEUTRAL
RELEASE LEVER
OIL PRESSURE
INDICATOR
v VERHEAT
INDICATOR
HT
DRAIN PLUG
PROPELLER (optional)
\
WASH PLUG
(Flush plug)
\
\
WATER INTAKE
SWITCH LANYARD
EMERGENCY STOP igNG;kSTOp
SWITCH CLIP
EMERGENCY
I
11
2. COMPONENT IDENTIFICATION
FUEL GAUGE
FUEL
FUEL
POWER TRIM/TILT TYPES
VENT KNOB
/
TACHOMETER
I
PRIMER BULB
FtiEL HOSE CONNECTOR
(FEMALE)
TRIM METER
3. CONTROLS (TILLER HANDLE TYPE)
Engine Start Button
R
(reverse)
ENt-bF, START
BUTTON
Move the gearshift lever to the N
(neutra1) position before starting. The
engine will not start unless the
gearshift lever is in the N (neutral)
position.
N
Shift Lever
(revtse) N
SHIFI- LEVER
There are three gearshift lever posi-
tions.
F (forward): The boat moves forward.
N (neutral): The transmission gears
are disengaged from the
engine.
R (reverse): The boat reverses.
Choke Knob
CHOKiZ KNOB
When the engine is cold, pull the
choke knob. A rich fuel mixture is
provided to the engine by pulling the
choke knob.
13
,3. CONTROLS (TILLER HANDLE TYPE)
Throttle Grip
THROTTLE GRIP
‘lItm the grip clockwise or counterclockwise to adjust the engine speed.
Turning the grip in the direction
shown by the arrow increases engine
speed.
14
Throttle Opening Indicator
THRO’ITLE OPENING INDICATOR
The label on the grip indicates throttle
opening.
Throttle Friction Knob
THROTI’LE FRICTION KN
RELEASE
Use the throttle fiction knob to set the
throttle grip at a certain position while
cruising. Turning the friction knob
clockwise sets the throttle grip, and it
is reieased by turning the friction
counterclockwise.
knob
3. CONTROLS (TILLER HANDLE TYPE)
Engine Stop Switch
ENGINE STOP SVi’ITCH
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 from 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.
15
3. CONTROLS (TILLER HANDLE TYPE)
SPARE EMERGENCY
,STOP SWITCH CLIP
A spare emergency stop switch clip is
provided near the engine stop switch.
16
Oil Pressure Indicator Light
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.
I
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.
Remote Control Lever
NEUTRAL RELEASE
3. CONTROLS (REMOTE CONTROL TYPE)
a-”
IEVERSE)
THROTTLE 0 THROTTLE 0
The remote control lever controls gear
selection and throttle opening positions.
It is necessary to pull up the neutral
release lever to operate the 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 beyond
the F position will increase the
throttle opening and the boat forward speed.
N (neutral):
The transmission gears are disengaged.
REMOTE CONTROL LEVER
‘ER
R (reverse):
Moving the lever to the R position
(approximately 30’ from the N
position) will engage the reverse
gear. Moving the lever beyond the R
position will increase the throttle
opening and the boat reverse speed.
17
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.
18
Ignition Switch
START
The remote control box is equipped
with a key type ignition switch.
Key positions:
START
To activate the starter motor and start
the
engine. (rhe remote
must be in the neutral position)
control lever
ON
H
ON
To run the engiie after starting (the
battery will discharge if the key is
left in this position 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 running.
Emergency Stop Switch Lanyard
3. CONTROLS (REMOTE CONTROL TYPE)
E
S
The emergency stop switch lanyard is
provided to stop the engine immediately 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.
SWITCH LANYARD
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.
SPAkE EMERGENCY
STOP SWITCH CLIP
A spare emergency stop switch clip is
provided on the remote control box.
19
3. CONTROLS (REMOTE CONTROL TYPE)
Choke/Fast Idle Lever
N
(neutral)
f-l 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.
20
XIMUM FAST
IDLE
EST IPOSWION
CHOKWFAST
IDLE LEVER
Lift and hold the choke/fast idle lever
up fully, this will provide a rich fuel
mixture.
Gradually lower the choke/fast idle
lever to the lowest position to disengage
the choke and lower the idle speed
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 dis-
charged. Pull the manual choke knob,
and a rich fuel mixture will be provid-
ed to the engine.
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.
. 21
3. CONTROLS (POWER TRIM/TILT TYPE)
Power Trim/Tilt Switch
Power Trim
Press the power hn/tilt switch on the
remote control lever (remote control type)
to adjust the motor trim angle of 00 to 20’
to maintain proper boat mm. The power
trim/tilt switch located on the remote
control lever (remote control type) 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 (remote control type)
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.
On the tiller handle type, the power
trim/tilt switch is the optional part. The
power trim/tilt switch is available on
your authorized Honda Marine dealer.
SWITCH
(remote control type)
-CONTROL
LEVER
-1 Excessive trim/tilt angle
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.
22
3. CONTROLS (POWER TRIM/TILT TYPE)
XRTA type outboard
Power Trim
Do not trim this engine when you are
using a large amount of throttle opening.
If you do try to tim the engine (for
example, wide open throttle), under
certain conditions, propeller thrust may
override the power trim hydraulics and
cause the engine to return to the transom
angle adjusting 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
operator can change the tilt angle of the
motor for shallow water operation,
beaching, launching from a trailer, or
mooring.
Power Tilt Switch (motor pan)
POWER TILT SWITCH
The power tilt switch located on the
motor pan is a convenience switch for
tilting the motor for trailering, or
preforming outboard maintenance. This
power tilt switch should only be operated with the boat is 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 him meter
when using the power trim/tilt switch to
achieve proper boat performance.
.
23
3. CONTROLS (POWER TRIM/TILT TYPE)
Tachometer
TACHOMETER
The tachometer shows the approximate
engine speed in revolutions per minute.
Refer to the tachometer when using the
power trim/tilt switch to achieve proper
boat and motor performance.
24
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-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.
(GAS ASSISTED TILT TYPE)
3. CONTROLS (COMMON)
Tilt Lever (GAS ASSISTED
LEVER
Moving the tilt lever to the FREE
position allows the motor to be tilted and
moving the tilt lever to the LOCK
position locks the motor in the desired
position. Use the tilt lever to temporarily
tilt the motor when the boat is operating
in shallow water, or mooring in shallow
water. The tilt lever’must be in the
LOCK position before operating the
motor or the motor could tilt up when
operating in reverse.
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.
25
3. CONTROLS (COMMON)
Distribute the load evenly in the boat
and run the boat in straight course at full
throttle. Slightly turn the steering wheel
?r 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.
26
Anode Metal
The anodes are made from a sacrificial
material which helps to protect the
outboard motor from corrosion.
ANODE
(stern bracket)
-1 Painting or coating the
anodes will lead to rust and corrosion
damage to the outboard motor.
3. CONTROLS (COMMON)
Cooling System Indicator
The cooling system is monitored here to
make sure cooling .water is circulating
through the engine.
Water Intakes
WATERINTAKES
The engine cooling water is drawn into
the water pump through these water
intakes.
27
3. CONTROLS (COMMON)
‘hansom Angle Adjusting Rod
TRANSOM
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.
PushQin 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 outward to be sure it is locked in place.
Start with the transom angle adjusting
rod in the hole closest to the boat tran-
ANGLEADJUSTINGROD
TOCHANGE ADJUSTINGROD
t
1’1
TRANSOM
ANGLE
UNLOCKED
POSITION
I I
i”
\
TOLOCK
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 water.. The transom angle adjtsting rod stops the motors forward
movement.
The motor should never be operated
with the transom angle adjusting rod
removed.
L~CKRD~~SITION
the
boat is parallel with
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