California Proposition 65 Warning WARNING: Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Keep this owner’s manual handy, so you can refer to it at any time.
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.
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.
CONTENTS SERVICING YOUR HONDA OUTBOARD MOTOR (continued) TOOL KIT AND SPARE PARTS ............SCHEDULE ............. MAINTENANCE REFUELING ..................FUEL RECOMMENDATIONS............. COOLING SYSTEM CLEANING AND FLUSHING......43 Cleaning and Flushing With the Flush Kit ........Cleaning and Flushing Without the Flush Kit........ENGINE OIL LEVEL CHECK ...............
CONTENTS ......... TECHNICAL & CONSUMER INFORMATION ............TECHNICAL INFORMATION.. Serial Number Locations ..............Carburetor Modification for High Altitude Operation ......64 Fuels................Oxygenated Emission Control System Information..........Star Label ..................................Specifications.. WIRING DIAGRAM ................INFORMATION ............. CONSUMER Honda Publications .................
OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION Honda BF5A outboard motor is 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.
OUTBOARD MOTOR SAFETY Refuel With Care Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a well-ventilaed 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.
OUTBOARD MOTOR SAFETY SAFETY LABEL LOCATIONS The labels shown here contain important safety information. Please read them carefully. These labels are considered permanent parts of your out- board motor. If a label comes off or becomes hard to read, contact an authorized Honda servicing dealer for a replacement.
CONTROLS & FEATURES CONTROLS Engine Stop Switch ENGINE STOP SWITCH The engine stop switch has controls for normal engine stopping emergency engine stopping. In normal operation, press the en- gine stop button to stop the engine. A clip and lanyard system stops the engine automatically if the operator falls away from the controls.
CONTROLS & FEATURES Throttle Grip The throttle grip controls engine INDEX MARK speed. An index mark on the tiller arm indicates throttle position. The gearshift mechanism limits throttle grip movement when the gearshift lever (p. 14) is in the R TliROlTLE GRIP (reverse) or N (neutral) position.
CONTROLS & FEATURES Gearshift Lever The gearshift lever is used to select F (forward), N (neutral), or R (re- verse) 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, GEARSHIFT LEVER...
CONTROLS & FEATURES Steering Friction Bolt srEEnrNo FnrcrroN eoLr The steering friction bolt adjusts steering resistance. Turn the bolt clockwise to increase ’ friction for holding a steady course while cruising or to prevent the out- board motor from swinging while trailering the boat.
CONTROLS & FEATURES Transom Angle Adjusting Rod The transom angle adjusting rod is used to adjust the angle of the out- board motor in the normal operating position (see page 21). To adjust, first tilt the outboard mo- tor, so it is not resting on the rod. Push the rod in, and turn the end of TRANSdhl ANGLE...
CONTROLS & FEATURES Fuel Priming Bulb A priming bulb is built into the fuel hose that connects the portable fuel tank to the outboard motor. PRIMING BULB Before operating the outboard mo- tor, squeeze the priming bulb until it feels firm. This will ensure that fuel is supplied to the engine (see page 24).
INSTALLATION It is your responsibility to choose a boat suitable for the outboard motor. Exceeding the boat manufacturer’s power recommendation could cause an accident resulting in serious injury. Be sure to match the boat manufacturer’s power recommendation with the outboard power output. STERNCENTER INSTALLATION POSITION Install at the stern, at the center line...
INSTALLATION OUTBOARD MDTOR ATTACHMENT Attach the stern bracketJo the Van- som and tighten the clamp screws. Before operating the bdat, check the tightness of the clamp screws. Tie a rope through the hole in the stern bracketandsecure the other CLAMP SCREW end of the rope to the boat.
INSTALLATION MOTOR ANGLE ADJUSTMENT If the propeller shaft is not parallel with the water surface, adjust by changing the transom angle adjust- ing rod position. There are four adjustment positions. Push in (A) the adjusting rod, twist upwards (B) and pull out to remove.
BEFORE OPERATION ARE YOU READY TO GET UNDERWAY? 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.
BEFORE OPERATION Safety Inspection Look around for signs of oil or gasoline leaks. Make sure the fuel tank is in good condition and properly secured in the boat (see page 24). Check that the fuel hose is undamaged and properly connected (see page 25). Wipe up any spills before starting the engine.
OPERATION SAFE OPERATING PRECAUTIONS To safely realize the full potential of this outboard motor, you need acomplete 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 lNFORMAT/ON on page 7 and the chapter titled BEFORE OPERATION.
OPERATION To ensure that the outboard motor VENT KNOB 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 FUEL TANK on the outboard motor.
OPERATION STARTING THE ENGINE 1. Put the emergency engine stop switch clip in the engine stop switch, and attach the lanyard to your wrist. The engine will not start or run, unless the clip is in the switch. The emergency engine 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.
OPERATION 3. Align the throttle grip START position with the mark on the tiller handle. MARK THROlTLE GRIP 4. To start a cold engine, pull out the choke knob. To restart a warm engine, leave the choke knob oushed in. CHOKE KNOB 5.
OPERATION 6. After starting, check the oil pressure indicator light. The light should be on while the engine is running. If the light is off, stop the engine immediately, check the engine oil level, and inspect the engine for oil leaks. OIL PRESSURE INDICATOR LIGHT...
OPERATION 7. After starting, be sure water is flowing out of the water check hole. If water does not flow out, or if steam comes out, stop the engine. check to see if the screen in the cooling water inlet is obstructed. Do not operate the engine until the problem has been corrected.
OPERATION EMERGENCY STARTING If the recoil starter is not working properly, the engine can be started with the spare starter rope in the tool kit. 1. Remove the engine cover. 2. Follow steps 1 through 4 of the normal engine starting procedure (see pages 26 and 27).
OPERATION STOPPING THE ENGINE Emergency Engine Stopping Disengage the emergency engine stop switch clip from the engine stop switch by pulling the lanyard. It is a good idea to stop the engine with the emergency engine stop switch lanyard from time to time to be sure that the switch is operating properly. ENGINE STOP SWITCH LANYARD EMERGENCY...
GEAR SHIFTING Put the tilt lever in the RUN position to prevent the outboard motor from tilting up when operating in reverse (refer to page 35). The gearshift lever has 3 positions : FORWARD, NEUTRAL, and REVERSE. An indicator at the base of the gearshift lever aligns with letters F, N, or R on the engine case to show the gear that has been selected.
OPERATION To turn to the right, swing the tiller handle to the left. To turn to the left, swing the tiller handle to the right. Boats equipped with a remove control steering wheel are controlled in the same way as a car. LEFT TURN RIGHT TURN Swing the tiller handle to the right.
CRUISING FORWARD With the gearshift lever in the for- ward position F, turn the throttle grip toward FAST to increase speed. For normal cruising, open the throttle about 3/4. To hold the throttle at a steady set- ting, turn the throttle friction knob clockwise.
TILTING THE OUTBOARD MOTOR Tilt the motor up to prevent the propeller and gear case from hitting the bottom when the boat is beached or stopped in shallow water. Always tilt the motor up out of the water when docked in salt water. 1.
SERVICING YOUR HONDA OUTBOARD MOTOR THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble-free opera- tion. 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 can be seriously hurt or killed.
SERVICING YOUR HONDA OUTBOARD MOTOR MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot arise in performing mainte- warn you of every conceivable hazard that can nance. 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.
SERVICING YOUR HONDA OUTBOARD MOTOR TOOL KIT AND SPARE PARTS The following tools and spare parts are supplied with the outboard motor for maintenance, adjustment, and emergency repairs. Spare shear pins and cotter pins are located near the oil filler cap inside the engine cover.
SERVICING YOUR HONDA OUTBOARD MOTOR MAINTENANCE SCHEDULE \REGULAR SERVICE PERIOD (3) First Everv Everv month ITEM Perform at every indicated Each 6 monihs yea; month or operating hour inter- 20 hrs. 200 hrs. 100 hrs. val, whichever comes first. 1 Enoine oil Check level Change Gear case oil...
SERVICING YOUR HONDA OUTBOARD MOTOR Fuel tank capacity 3.2 US gal (12.0 & 2.6 Imp gal) FilEL GAUGE Check the fuel gauge and refill the tank to the SAFE FILL LEVEL mark if necessary. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
SERVICING YOUR HONDA OUTBOARD MOTOR FUEL RECOMMENDATIONS Use unleaded gasoline with a pump octane rating of 86 or higher. This outboard motor is certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life.
SERVICING YOUR HONDA OUTBOARD MOTOR COOLING SYSTEM CLEANING AND FLUSHING After each use in salt water or dirty water, thoroughly clean and flush the outboard motor. For safety, the propeller must be removed. Be sure the outboard motor is securely mounted, and do not leave it unattended while running.
SERVICING YOUR HONDA OUTBOARD MOTOR Cleaning and Flushing Without the Flush Kit 1. Wash the outside of the outboard motor with clean, fresh water. 2. Remove the propeller. 3. Stand the motor in a suitable container of water. The water level must be at least 2 inches above the antiventilation plate.
SERVICING YOUR HONDA OUTBOARD MOTOR ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and the outboard motor in a vertical position. 1. Move the engine cover lock lever down to unlock the cover, and remove the cover.
SERVICING YOUR HONDA OUTBOARD MOTOR ENGINE OIL CHANGE Drain the used oil while the engine is warm. Warm oil drains quickly and completely. 1. Move the engine cover lock lever (p. 45) down to unlock the cover, and remove the cover. Place a suitable container below the engine oil drain location to catch the used oil, then remove the oil filler cap and the drain plug.
SERVICING YOUR HONDA OUTBOARD MOTOR ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. SAE 1 OW-30 is recommended for general use. SAE Viscosity Grades 100 ‘F 40 % AMBIENT TEMPERATURE The SAE oil viscosity and service classification are in the API label on the oil container.
SERVICING YOUR HONDA OUTBOARD MOTOR GEAR OIL LEVEL CHECK Check the oil level when the motor is in the vertical position. Remove the level plug and see if oil flows out. If no oil flows out, use a commercially available oil pump or squeeze tube to fill the gear case with gear oil recommended on page 49.
GEAR OIL CHANGE Marine SAESO hypoid gear oil Recommended oil : API Service Classification (GL-4 or GL-5) : O.lUS qt (0.1 e, 0.1 Imp qt) Oil Capacity Remove the level plug and drain plug and allow the gear oil to thoroughly drain into a suitable container.
SERVICING YOUR HONDA OUTBOARD MOTOR LUBRICATION Apply marine anticorrosion grease to the following areas: ENGINE COVER LOCK LEVER THROTTLE CABLE AND PIVOT SHIFT SHAFT AND PIVOT SWIVEL CASE TILLER HANDLE PIVOT TILT LINKAGE PROPELLER SHAFT TILT RELEASE LEVER AND CLAMP SCREWS REVERSE LOCK LEVER surfaces where grease cannot penetrate.
SERVICING YOUR HONDA OUTBOARD MOTOR SPARK PLUG SERVICE Recommended spark plug: BPRSES (NGK), Wl GEPR-U (DENSO) W14EPR-U (DENSO) Remove the engine cover. 2. Remove the spark plug cap. 3. Use the wrench supplied in the tool kit to remove the spark plug. 4.
SERVICING YOUR HONDA OUTBOARD MOTOR 6. Check that the spark plug washer are in good condition, and thread the spark plug in by hand to prevent cross-threading. 7. After the spark plug are seated, tighten with a spark plug wrench to compress the washer.
Disconnect the fuel tank line from the motor. Remove the engine cover, and remove the fuel filter. Before removing the filter, place clamps on the fuel tubes on each side of the filter to prevent fuel leakage. Install the new fuel filterwith the arrow mark pointing toward the carburetor. Fuel flow will be impeded if the filter is installed backward.
SERVICING YOUR HONDA OUTBOARD MOTOR RECOIL STARTER ROPE INSPECTION Inspect the recoil starter rope, and replace it if it becomes frayed. Always keep the tool kit’s emer- gency starter rope onboard in case the recoil starter rope fails. The anode is a sacrificial material ANODE which helps to protect the outboard motor from corrosion.
SERVICING YOUR HONDA OUTBOARD MOTOR SHEAR PIN REPLACEMENT A shear pin is used to protect the propeller and drive mechanism from damage when the propeller strikes an obstruction. 1. Remove the cotter pin, the propeller cap, and the propeller. 2. Remove the broken shear pin and replace it with a new one. 3.
HELPFUL TIPS & SUGGESTIONS STORING YOUR OUTBOARD MOTOR 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.
HELPFUL TIPS & SUGGESTIONS 1. Disconnect the fuel hose from the outboard motor. 2. 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.
HELPFULTIPS & SUGGESTIONS Storage Precautions Select a well-ventilated storage area. If possible, avoid storage areas with high humidity. 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.
HELPFUL TIPS & SUGGESTIONS Removal From Storage Check your outboard motor as described in the BEFORE OPERATlON chapter of this manual. If the cylinder was coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal. TRANSPORTING When trailering a boat with the outboard motor attached, leave the engine in the normal running position, if possible, and tighten the steering friction bolt...
TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START 1. Is the emergency stop switch clip in place? 2. Is the gearshift lever in neutral? 3. Is there fuel in the fuel tank? 4. Is the fuel cap vent knob turned to open? 5.
TAKING CARE OF UNEXPECTED PROBLEMS SUBMERGED MOTOR A submerged motor must be serviced immediately after it is recovered from the water in order to minimize corrosion. If there is a Honda marine dealership nearby, take the motor immediately to the dealer. If you are far from a dealership, proceed as follows: 1.
TAKING CARE OF UNEXPECTED PROBLEMS 5. Pour a teaspoon of engine oil into the spark plug hole, then pull the recoil starter several times to lubricate the inside of the cylinder. Reinstall the spark plug and engage the emergency engine stop switch clip with the engine stop switch.
TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Locations ENGINE SERIAL NUMBER V’ FRAME SERIAL NUMBER Record the engine and frame serial numbers in the space below. You will need these serial numbers when ordering parts, and when making technical or warranty inquiries (see page 74).
TECHNICAL & CONSUMER INFORMATION Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. High altitude performance can be improved by specific modifications to the...
TECHNICAL 81 CONSUMER INFORMATION Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions.
TECHNICAL 81 CONSUMER INFORMATION Emission Control System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen’is very impor- tant because, under certain conditions, they react to form photochemical smog when subjected to sunlight.
TECHNICAL & CONSUMER INFORMATION Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring).
TECHNICAL & CONSUMER INFORMATION Star Label A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board. The Star Label means Cleaner Marine Engines This engine has been certified as a: The Symbol for Cleaner Marine Engines: Cleaner Air and Water - for a healthier lifestyle and environment.
TECHNICAL & CONSUMER INFORMATION One Star - Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.
TECHNICAL & CONSUMER INFORMATION Tuneur, 0.028-0.031 in (0.70-0.80 mm) See page 51. Spark plug gap See shop manual. Idle speed 1 ,100 f 50 rpm Valve clearance Intake: 0.12 + 0.02 mm See shop manual. (cold) Exhaust: 0.20 -+ 0.02 mm Other specifications No other adjustments needed.
TECHNICAL & CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining repairing your outboard motor. You may order them from your Honda marine dealer. Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician.
TECHNICAL & CONSUMER INFORMATION Warranty Service Information Honda marine dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management.
INDEX SAFE OPERATING PRECAUTIONS ....................SAFETY, A FEW WORDS ABOUT....................... Safety Inspection ..........................MOTOR ......................SAFETY, OUTBOARD IMPORTANT SAFETY INFORMATION..................... Carbon Monoxide Hazard ......................Operating Responsibility ....................... Refuel With Care ........................... SAFETY LABEL LOCATIONS ......................SHEAR PIN REPLACEMENT ......................
QUICK REFERENCE INFORMATION Unleaded gasoline with a pump octane Type rating of 86 or higher (page 42) Fuel 3.2 US gal (12.0 J?) Capacity SAE 1 OW-30, API SF or SG, for general Type use (page 50) Engine Oil 0.58 US qt (0.55 1) Capacity Marine SAE 90 hypoid, API GL-4 or GL-5 Type...