Honda Power Equipment BF45A, BF35A User Manual

Includes 31ZV360S supplement 
for the BF45A LHTA
Thank you for purchasing a Honda Outboard Motor.
This manual describes the operation and maintenance of the Honda BF35A/45A Outboard Motors.
All information in this publication is based on the latest product informa­tion 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.
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.
B injury or death WILL result if
instructions are not followed.
B Indicates a strong
possibility that serious injury or death may result if instructions are not followed.
w Indicates a possibil-
ity that minor injury could result if instructions are not followed.
[NOTICEI
or property damage could result if instructions are not followed.
Indicates serious
Indicates that equipment
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 iijury or property damage. Read and understand this owner’s manual before operating the Outboard Motor.
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. 1990, ALL RIGHTS RESERVED
Careless oneration
1
TYPES OF HONDA BF3§A/45A OUTBOARD MOTORS
It may be necessary to refer_tcthis chart for reference purposes when reading this manual
Model
BF35
BF45
S: Short Shaft The gas assisted tilt type motors use a gas damper to assist when manually tilting the motor.
The power trim/tilt type motors use an electric/hydraulic power cylinder to trim or tilt the motor.
L: Long Shaft X: Extra Long Shaft
H: Tiller Handle R: Remote Control T: Power Trim/Tilt
2
IDENTIFICATION NUMBERS
PRODUCT IDENTIFICATION NUMBER
Record the Product Identification Number (RLN.) 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 99).
STARTER MOTOR
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:
- -\
3

CONTENTS

1. SAFKI-Y
Safety labels Safety information
................................................................
......................................................
2. COMPONENT IDENTIFICATION ............................
.6
7 8
3. CONTROLS Tiller handle type
Engine start button
....................................................
Shift lever ..................................................................
Choke knob ...............................................................
Throttle grip ..............................................................
Throttle opening Throttle friction Engine stop switch Emergency stop
indicator ........................................
knob ................................................
....................................................
switch lanyard ................................
11 11 11 12 12 12 13
13
Oil pressure indicator light .......................................
Overheat indicator
light ............................................ :t
Remote control type
Remote control Neutral release Ignition switch Emergency stop Choke/fast idle Manual choke Oil pressure indicator
lever ................................................
lever .................................................
..........................................................
switch lanyard ................................
lever .................................................
knob ...................................................
light/buzzer ............................
Overheat indicator light/buzzer
................................
15
16 16 17 18 I8
.19
19
Remote control & power trim/tilt type
Power trim/tilt switch (remote control lever) Power tilt switch
(motor pan) ...................................
Trim meter ................................................................
Tachometer ...............................................................
Manual relief valve
...................................................
........... 20
21 21 21
22
Gas assisted tilt type
lever ....................................................................
Tilt
Controls & instruments (common)
lock lever ............................................................
Tilt
tab .....................................................................
Trim Anode Cooling Water Transom Fuel Engine
metal ..............................................................
system indicator ..........................................
intakes ............................................................
angle adjusting rod .....................................
cap/gauge/vent knob .........................................
over-rev limiter .............................................
4. PRE-OPERATION CHECKS Engine cover removal/installation Engine Fuel Gasoline containing Propeller Steering Remote control
oil ..................................................................
level ..................................................................
alcohol .....................................
and cotter
pin .............................................
friction adjustment (common)
friction adjustment
............................ 28
.................... 32
.......................... 33
Other checks
l l
l
bracket ...........................................................
Stem
kit ...................................................................
Tool
Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. STARTING THE ENGINE
line connection ..................................................
Fuel Starting the engine (Tiller handle type)
.................... 36
Starting the engine (Remote control type) Emergencv Troubcieshooting
starting ...................................................
&rting
problems
. . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6. OPERATION Break-in
procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 23
23 24 24 25 26 27 27
29 30 3 1 32
33 33 33
34
................ 40
43
49
CONTENTS
Tiller handle type
Gearshifting
Steering ..................................................................
Cruising ..................................................................
Remote control type
Gear shifting
Cruising .................................................................
Tilting motor
Gas assisted Power trim/tilt type
Power trim/tilt type
Trim meter .............................................................
Power tilt switch
Manual relief valve ................................................
Tilt lock lever Trim tab adjustment Motor protection system
Engine oil pressure and
Overheat warning
Over-rev limiter
Power trim warning system
Anodes ...................................................................
Shallow water High altitude operation
7. STOPPING THE ENGINE Tiller handle type Remote control
8. TRANSPORTING
9. CLEANING AND FLUSHING
10 MAINTENANCE
Tool kit and spare
...........................................................
..........................................................
tilt type ..............................................
.................................................
(motor pan)
........................................................
..................................................
system ......................................
.....................................................
operation ............................................
..............................................
......................................................
type ..................................................
.......................................................
..................................................... 74
parts .............................................
................................
...................................
..................................
50 51 5 1
52 53
54 57
58 59
2: 61
62 64
El 66 67
68
70 ;: 74
Maintenance schedule Engine Gear Spark plugs Battery Lubrication Engine Fuel Fuse replacement Propeller Submerged
11. STORAGE
12. TROUBLESHOOTING
13. SPECIFICATIONS
14. WARRANTY
15. WIRING DIAGRAM
16. INDEX
oil ..................................................................
oil .....................................................................
...............................................................
(not included) ...............................................
................................................................ 85
fuel filter .......................................................
tank and filter ....................................................
....................................................................
motor ......................................................
.................................................................
SERVICE ..........................................
.....................................................................
...............................................
......................................................
...................................................
.............................................. 100
76 78 80 82 83
86 88 89 90 9 1
93
............................................
95 97
.99 103
5
1. SAFETY
Frn~4.~~~~~MI-~ICan~INLWunr~-

SAFETY LABELS

These labels are in the locations shown. They warn you of potentia1 hazards that could seriously injure
you. Read these labels carefully.
EXTREMELY
DANGER
FLAMMABLE
SAFETY INFORMATION For your safety and the safety of oth­ers, pay special attention to these pre­cautions.
Operator Responsibility
l
Know how to stop the engine quickly in case of emergency. Understand the use of all controls.
l
Do not exceed the boat manufactur­er’s power recommendation, and be sure that the outboard motor is properly mounted.
l
Never permit anyone to operate the outboard motor without proper instruction.
l
Stop the engine immediately if any one falls overboard.
l
Do not run the motor while the boat is near anyone in the water.
l
Attach the emergency stop switch lanyard securely to the operator.
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.
I. 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
HANDLE
ldiir-7
o
Mi
w v
0
THdT
1
LOCK
STERN BRACKET
WASH PLUG (Flush plug)
GEAR OIL DRAIN PLUG
8
I
&l l/l
I
COOLING
ACCESS COVER
ANTI-VENTILATION c D, ATE-
‘RIM TAB
Y...-.-..YL . u
I
PROPEL1 --
XR
LEVER
=r
THROTTLE
_____- ~~~
FRICTION KNOB
ENGINE START
WATER INTAKE
on, PReS\SURE INDICATOR LIGHT
OVERHEAT
\
INDICATOR LIGHT
M
CHOKE KNOB
EMERGENCY STOP SWITCH CLIP
/ I
SPARE EMERGENCY STOP SWITCH CLIP
EMERGENCY STOP SWITCH LANYARD
ENGINE STOP
“.l”-..CH
\
\
ENGINE COVER
FUEL LINE
CONNECTOR
\ SWI;rCH
STEERING
2. COMPONENT IDENTIFICATION (REMOTE CONTROL TYPE)
POWER TILT
I I
OIL FILLER CAP
CHOKE KNOB
I
POWER TRIM/TILT SWITCH
\
\ - /
NEUTRAL RELEASE LEVER
V
OIL PRESSURE INDICATOR
TRANSOM ANGLE
MANUA< RELIEF VALVE
GEAR OIL LEVEL PLUG
/
GEAR DRAIN PLUG
\
PROPELLER
\
COOLING
INDICATOR
ENGINE OIL ’ ACCESS COVER
ETAL)
HAUST PORT
/e-r In!
- \
- STERN BRACKET
SPARE EMERGENCY
~BNTHATION
__ .-- r
hAIN
WA”“” .rwn. .,m
/
EMERGENCY STOP SWITCH LANYARD
CHOKE/FAST
/
/
IDLE LEVER
-/ EMERGENCY ENGINE SWITCH
STOP
I
EMERGENCY STOP SWITCH CLIP
9
2. COMPONENT IDENTIFICATION
FUEL GAUGE
POWER TRIM/TILT TYPES
VENT KNOB
/
10
I
PRIMER BULB
HOSE CONNECTOR
FiJEL
(FEMALE)
FUEL CAP
TACHOMETER
TRIM METER
3. CONTROLS (TILLER HANDLE TYPE)

Engine Start Button

R
(reverse)
EN&NE START BUTTON
N
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

R
(reverse)
SHIti LEVER
N
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.

Choke Knob

CHOKk 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 HANDLE TYPE)

Throttle Grip

THROTTLE GRIP
Turn the grip clockwise or counter­clockwise to adjust the engine speed. Turning the grip in the direction
shown by the arrow increases engine
speed.

Throttle opening indicator

THROTTLE OIPENING INDICATOR
The curve on the grip indicates throttle opening.

Throttle Friction Knob

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 StiTCH
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 immedi­ately in the event the operator should fall overboard or away from the con­trols.
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 imme-
diately.
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 I’ndicator Light

OIL PRESSURE INDICATOR LIGHT

I I-
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

Remote Control Lever

3. CONTROLS (REMOTE CONTROL TYPE)
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.
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 for-
ward speed.
N (neutral):
The engine idles and the transmis­sion gears are disengaged.
R (reverse):
Moving the lever to the R position (approximately 30” from the N position) will engage the reverse gear. Moving the lever further from. 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

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
ON
To run the engine 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).
16

Emergency Stop Switch Lanyard

3. CONTROLS (REMOTE CONTROL TYPE)
SPAkE EMERGENCY
SWITCH LANYARD
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 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 emer-
gency engine stop switch the engine
will stop immediately.
The emergency engine stop switch should not be 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.
A spare emergency stop switch clip is
provided on the remote control box.
17
3. CONTROLS (REMOTE CCDNTROL TYPE)

Choke/Fast Idle Lever

n 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
CHOKE/FAST
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 tiOB
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)
03 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.CONTRBL & POWER TRIM/TILT TYPE)
Power ‘Ikim/Tilt Switch (remote
control lever) Power Ikim
Press the power him/tilt switch on the
remote control lever to adjust the
motor trim angle of 0” to 20” to main­tain proper boat trim. The power
him/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.
TRIM/TILT
SWITCH
picziq
\ !I I
Excessive trim/tilt angle
during operaUion 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.
XRTA
Power Trim Do not trim this engine when you are
type outboard
using a large amount of throttle
opening. If you do try lo trim the en­gine, 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.
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 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.
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
POWER
MANUAL-RELIEF VALVE
m rel=1
I
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 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.
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.
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 & INSTRUMENTS
(common)

Anode Metal

+I
The anodes are made from a sacrificial material which helps to protect the outboard motor from corrosion.
\
ANODi (stem bracket)
Painting or coating the 1 NoTlCq anodes will lead to rust and corro­sion damage to the outboard motor.

Cooling System Indicator

\
COOiING SYSTEM INDICATOR
The cooling system is monitored here to make sure cooling water is ing through the engine.
circulat-
24

Water Intakes

The engine cooling water is drawn
into the water pump through these water intakes.
3. CONTROLS & INSTRUMENTS (ctimmon)
WATiR 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 him. 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 out­ward to be sure it is locked in place. Start with the transom angle adjusting
rod in the hole closest to the boat tran-
TO CHANGE
TO LOCK
TRANSOM
ADJUSTING ROD
I
+=I
ANGLE
UNLOCKED POSITION
1
---
.
--/’
J
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 adjust­ing 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
I
GAUGE
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.
FUEL FILLER CAP
Before transporting or storing the fuel tank turn the vent knob fully clock­wise to the closed position.
B Gasoline is 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 r-pm. 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 rpm to stabilize then increase the throttle opening.
On the power
the trim angle
duce the possibility of propeller ventila-
tion.
trim/tilt type motors lower
on high speed turns to re-
27
4. PRE-OPERATION CHECKS

Engine Cover Removal/Installation

(FRONT)
ENGINE COVER
To remove, release the front and rear engine cover latches and remove the engine cover.
To install, position the engine cover over the engine and hook and lpck the front and rear latches.
(REAR)
28
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