Honda BF40A Owner's Manual
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Honda BF40A Owner's Manual

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2004
C 2003 Honda Motor Co., Ltd. -All Rights Reserved

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  • Page 1 2004 C 2003 Honda Motor Co., Ltd. -All Rights Reserved...
  • Page 2 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.
  • Page 3 INTRODUCTION Congratulations on your selection of We suggest you read the warranty a Honda outboard motor. We are policy to fully understand its certain you will be pleased with your coverage and your responsibilities of purchase of one of the finest ownership.
  • Page 4 INTRODUCTION A FEW WORDS ABOUT You will find important safety information in a variety of forms, including: SAFETY Safety Labels on the outboard motor. Your safety and the safety of others are very important. And using this Safety Messages preceded by a safety alert symbol and one of outboard motor safely is an important three signal words, DANGER, WARNING, or CAUTION.

  • Page 5: Table Of Contents

    CONTENTS OUTBOARD MOTOR SAFETY ........Common Controls IMPORTANT SAFETY INFORMATION ....Power Trim/Tilt Switch (LRT and XRT types) SAFETY LABEL LOCATIONS ........ (side-mount type) ..........23 Power Tilt Switch (LHT, LRT and XRT types) . 23 CONTROLS AND FEATURES ........
  • Page 6 CONTENTS OTHER FEATURES ..........29 STARTING THE ENGINE ........37 Overrev Limiter ............29 LH and LHT Types (long tiller handle) ....37 Anodes ..............29 LRT and XRT Types (remote control) ....39 Portable Fuel Tank (optional equipment) .....
  • Page 7 CONTENTS SERVICING YOUR OUTBOARD MOTOR ....56 STORAGE ..............77 THE IMPORTANCE OF MAINTENANCE ... . 56 STORAGE PREPARATION ........77 MAINTENANCE SAFETY ........57 Cleaning and Flushing .......... . 77 TOOL KIT (optional equipment) AND Fuel ................
  • Page 8 CONTENTS TECHNICAL AND CONSUMER INFORMATION . 94 TECHNICAL INFORMATION ....... . 94 Serial Number Locations ........94 Carburetor Modification for High Altitude Operation ............95 Battery ..............95 Oxygenated Fuels ........... 96 Emission Control System Information ....

  • Page 9: Outboard Motor Safety

    Attach the emergency stop switch INFORMATION lanyard securely to the operator. It is the operator’s responsibility to Honda BF40A and BF50A outboard provide the necessary safeguards Always wear a PFD (Personal motors are designed for use with to protect people and property.
  • Page 10 OUTBOARD MOTOR SAFETY Refuel With Care Carbon Monoxide Hazard Gasoline is extremely flammable, Exhaust gas contains poisonous and gasoline vapor can explode. carbon monoxide. Avoid inhalation Refuel outdoors, in a well- of exhaust gas. Never run the engine ventilated area, with the engine in a closed garage or confined area.

  • Page 11: Safety Label Locations

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

  • Page 12: Controls And Features

    CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES Model BF40A BF50A Type Shaft Length Long Tiller Handle Remote Control Gas Assisted Tilt Power Trim/Tilt Tachometer (optional equipment) Trim Meter (optional equipment) Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.

  • Page 13: Component And Control Locations

    CONTROLS AND FEATURES COMPONENT AND CONTROL LOCATIONS LH and LHT Types (long tiller handle) OIL FILLER CAP FUEL HOSE CONNECTOR OIL LEVEL LONG TILLER ENGINE COVER DIPSTICK HANDLE POWER TILT SWITCH (LHT type) COOLING SYSTEM INDICATOR TILT LOCK LEVER STERN ENGINE OIL BRACKET DRAIN PLUG...
  • Page 14 CONTROLS AND FEATURES SWITCH CLIP OIL PRESSURE INDICATOR LIGHT GEAR SHIFT OVERHEAT INDICATOR LIGHT EMERGENCY STOP SWITCH THROTTLE FRICTION ADJUSTER LANYARD POWER TRIM/TILT SWITCH STEERING FRICTION ADJUSTER (LHT type) THROTTLE GRIP IGNITION SWITCH IGNITION SWITCH KEY...

  • Page 15: Lrt And Xrt Types (Remote Control)

    CONTROLS AND FEATURES LRT and XRT Types (remote control) OIL FILLER CAP ENGINE COVER POWER TILT SWITCH FUEL HOSE TILT LOCK LEVER OIL LEVEL CONNECTOR DIPSTICK STEERING PLATE COOLING SYSTEM INDICATOR TRANSOM ANGLE ADJUSTING ROD STERN ENGINE OIL DRAIN BRACKET PLUG COVER MANUAL RELIEF TRIM TAB...
  • Page 16 CONTROLS AND FEATURES Remote Control box (side mount type/optional equipment) GEARSHIFT/THROTTLE CONTROL LEVER POWER TRIM/TILT SWITCH NEUTRAL RELEASE LEVER OIL PRESSURE INDICATOR LIGHT SPARE SWITCH CLIP OVERHEAT INDICATOR LIGHT BUZZER (inside of the box) FAST IDLE LEVER IGNITION SWITCH IGNITION SWITCH KEY LANYARD THROTTLE FRICTION ADJUSTER EMERGENCY STOP SWITCH...
  • Page 17 CONTROLS AND FEATURES Fuel Tank (optional equipment) Tachometer (optional equipment) FUEL GAUGE VENT KNOB FUEL TANK FUEL CAP Trim Meter (optional equipment) FUEL HOSE FUEL HOSE CONNECTOR (female) PRIMING BULB...

  • Page 18: Controls

    CONTROLS AND FEATURES CONTROLS Emergency Stop Switch and Turning the ignition switch key to the Switch Clip START position operates the starter LH and LHT Types motor. The key automatically returns EMERGENCY STOP SWITCH (long tiller handle) to the ON position when released from the START position.

  • Page 19: Throttle Grip

    CONTROLS AND FEATURES Throttle Grip The switch clip must be inserted in The throttle grip controls engine the engine stop switch in order for speed. the engine to start and run. The lanyard should be attached to the An index mark on the tiller arm operator’s PFD (Personal Flotation shows throttle position and is helpful Device) or worn around the wrist as...

  • Page 20: Throttle Friction Adjuster

    CONTROLS AND FEATURES Throttle Friction Adjuster Gearshif t Lever Steering Friction Adjuster STEERING FRICTION ADJUSTER THROTTLE FRICTION R (reverse) N (neutral) ADJUSTER (forward) GEARSHIFT RELEASE LEVER FREE LOCK THROTTLE GRIP The throttle friction adjuster adjusts The gearshift lever is used to select F The steering friction adjuster adjusts resistance to throttle grip rotation.

  • Page 21: Tilt Lever (Gas Assisted/Lh Type)

    CONTROLS AND FEATURES Tilt Lever LRT and XRT Types Moving the tilt lever to the FREE (gas assisted/LH type) (remote control/optional position allows the motor to be tilted equipment) and moving the tilt lever to the LOCK position locks the motor in the desired position.

  • Page 22: Switch Clip And Emergency Stop Switch (Side-Mount Type)

    CONTROLS AND FEATURES Switch Clip and Emergency Stop Turning the ignition switch key to the The switch clip must be inserted in Switch (side-mount type) START position operates the starter the emergency stop switch in order motor. The key automatically returns for the engine to start and run.

  • Page 23: Fast Idle Lever (Side-Mount Type)

    CONTROLS AND FEATURES Fast Idle Lever Gearshif t/Throttle Control (side-mount type) Lever (side-mount type) GEARSHIFT/THROTTLE N (neutral) CONTROL LEVER GEARSHIFT/THROTTLE FAST IDLE CONTROL LEVER START NEUTRAL RELEASE LEVER FAST IDLE LEVER The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the The fast idle lever is used to set idle...
  • Page 24 CONTROLS AND FEATURES The gearshift/throttle control lever controls engine speed and selects F (forward), N (neutral), or R (reverse) gears. GEARSHIFT/THROTTLE CONTROL LEVER Moving the control lever 30° from N (neutral) selects the gear, and further movement increases engine speed. N (neutral) F (forward) R (reverse)

  • Page 25: Common Controls Power Trim/Tilt Switch (Lrt And Xrt Types) (Side-Mount Type)

    CONTROLS AND FEATURES Common Controls Power Tilt Switch The power trim/tilt switch is located Power Trim/Tilt Switch (LHT, LRT and XRT types) on the control lever or the tiller [LRT and XRT types (side- handle. It is a rocker switch with UP mount type)] and DN (down) positions for changing the angle of the outboard...

  • Page 26: Manual Relief Valve (Lht, Lrt And Xrt Types)

    CONTROLS AND FEATURES Manual Relief Valve Tilt Lock Lever Engine Cover Latches (LHT, LRT and XRT types) FRONT RIGHT STERN BRACKET UNLATCH POWER MANUAL ENGINE COVER LATCH (To fix) (To release) REAR The tilt lock lever is used to support the outboard motor in the fully-raised position.

  • Page 27: Transom Angle Adjusting Rod

    CONTROLS AND FEATURES Transom Angle Adjusting Rod Trim Tab The transom angle adjusting rod limits the tilt angle of the outboard TIGHTENING BOLT motor when fully lowered. STERN BRACKET Proper adjustment prevents the outboard motor from being trimmed too low (p. TRIM TAB PROPELLER The trim tab compensates for...

  • Page 28: Instruments

    CONTROLS AND FEATURES INSTRUMENTS Tachometer Fuel Gauge (optional equipment) (optional equipment) Trim Meter [optional equipment (LHT, LRT and XRT Types)] FUEL GAUGE A fuel gauge is built into the cap of the portable fuel tank (optional TACHOMETER equipment). TRIM METER The trim meter has a range of 0°...

  • Page 29: Indicators

    CONTROLS AND FEATURES INDICATORS LRT and XRT Types When the green light is lit, oil (side-mount type) pressure is OK. Oil Pressure Indicator If oil pressure becomes low, the LH and LHT Types green light will go off, and the engine protection system will limit engine speed.

  • Page 30: Overheating Indicator

    CONTROLS AND FEATURES Overheating Indicator LRT and XRT Types If the engine overheats, the red light (side-mount type) will come on, and the engine LH and LHT Types protection system will limit engine speed. Remote controls are also equipped with a buzzer that sounds when the (RED) red light comes on.

  • Page 31: Cooling System Indicator

    CONTROLS AND FEATURES Cooling System Indicator OTHER FEATURES Anodes Overrev Limiter The engine is equipped with an overrev limiter to prevent the possibility of mechanical damage from excessive engine speed. The overrev limiter may be activated during operation, limiting engine ANODE speed, if the outboard motor is tilted (stern bracket)

  • Page 32: Portable Fuel Tank (Optional Equipment)

    CONTROLS AND FEATURES Portable Fuel Tank Fuel Cap Vent Knob The anodes are made of a sacrificial (optional equipment) (optional equipment) material that helps to protect the outboard motor from corrosion. VENT KNOB There are two anodes on the gear case, one on the stern bracket, and another is the trim tab.

  • Page 33: Fuel Priming Bulb

    CONTROLS AND FEATURES Fuel Priming Bulb OUTLET END (MOTOR) PRIMING BULB INLET END (TANK) A priming bulb is built into the fuel hose that connects the fuel tank to the outboard motor. Before starting the engine, hold the priming bulb up in the direction of the arrow, then squeeze the priming bulb until it feels firm.

  • Page 34: Before Operation

    OFF position. Familiarize yourself with all laws Honda Marine dealer correct it, and regulations relating to boating before you operate the outboard and the use of outboard motors.
  • Page 35 BEFORE OPERATION Safety Inspection Maintenance Inspection Check that all fasteners are in place and securely tightened. Look around the outboard motor Check the engine oil level (p. for signs of oil or gasoline leaks. Running the engine with a low oil level can cause engine damage.

  • Page 36: Operation

    OPERATION SAFE OPERATING BREAK-IN PROCEDURE Next 60 minutes: PRECAUTIONS Run the engine up to a maximum of Break-in period: 10 hours 4,000 to 5,000 rpm, which is about To safely realize the full potential of 50% to 80% of maximum throttle this outboard motor, you need a Proper break-in operation allows the opening.

  • Page 37: Transom Angle Adjustment

    OPERATION TRANSOM ANGLE The transom angle adjusting rod ADJUSTMENT limits the tilt angle of the outboard motor when fully lowered. Do not allow water to enter the idle STERN BRACKET exhaust port or the engine can be Proper adjustment prevents the damaged.

  • Page 38: Portable Fuel Tank (Optional Equipment)

    OPERATION PORTABLE FUEL TANK FUEL HOSE CONNECTIONS Secure the portable fuel tank in the (optional equipment) boat, so it won’t move around and become damaged. FUEL HOSE CONNECTOR Before use, open the fuel tank vent by turning the vent knob at least 2 or 3 turns counterclockwise.

  • Page 39: Fuel Priming

    OPERATION FUEL PRIMING STARTING THE ENGINE The engine will not start or run, unless the clip is in the switch. LH and LHT Types (long tiller handle) The emergency stop switch clip OUTLET END and lanyard system is a safety (MOTOR) device that will stop the engine if EMERGENCY STOP SWITCH...
  • Page 40 OPERATION N (neutral) START START POSITION POINTER THROTTLE GRIP IGNITION SWITCH KEY SHIFT LEVER Check the position of the gearshift Align the engine start symbol Turn the ignition switch key to the lever. It must be in the N (neutral) ‘‘...

  • Page 41: Lrt And Xrt Types (Remote Control)

    OPERATION LRT and XRT Types During the warm-up period, check (remote control) the oil pressure indicator (p. Using the electric starter f or more overheating indicator (p. ) and than 5 seconds at a time will cooling system indicator (p. For panel-mount or top-mount overheat the starter motor and can remote control information, refer to...
  • Page 42 OPERATION The engine will not start or run, N (neutral) unless the clip is in the switch. FAST IDLE The emergency stop switch clip and lanyard system is a safety device that will stop the engine if START you fall away from the controls CONTROL while operating the boat.
  • Page 43 OPERATION FAST IDLE LEVER START Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can damage it. Turning the ignition switch key to the START position while the engine is running can damage the starter motor and f lywheel.

  • Page 44: Emergency Starting

    OPERATION EMERGENCY STARTING Before getting under way, allow 25 mm the engine to warm up sufficiently BOLTS to ensure good performance. If the battery is discharged, the starter motor is inoperative, you can start the Above 41°F (5°C), warm up the engine manually using the engine for 2 or 3 minutes.
  • Page 45 OPERATION If the fast idle control(s) was used FLYWHEEL to start the engine, return the control(s) to the normal operating EMERGENCY position as the engine warms up. STARTER ROPE During the warm-up period, check the oil pressure indicator (p. overheating indicator (p. ), and cooling system indicator (p.
  • Page 46 Have your closest authorized Honda marine dealer check your electrical system and correct the problem, so you can use the electric starter.

  • Page 47: Stopping The Engine

    OPERATION STOPPING THE ENGINE Normal Engine Stopping To stop the engine in an emergency, pull the clip out of the emergency Emergency Engine Stopping LH and LHT Types stop switch by pulling the lanyard. (long tiller handle) LH and LHT Types We suggest that you stop the engine (long tiller handle) this way occasionally to verify that...
  • Page 48 OPERATION LRT and XRT Types LH and LHT Types When the boat is not in use, (remote control) (long tiller handle) remove and store the ignition key and the emergency stop switch clip N (neutral) and lanyard. CONTROL LEVER IGNITION SWITCH KEY LRT and XRT Types (remote control) Move the throttle grip to the...

  • Page 49: Gearshifting And Throttle Operation

    OPERATION GEARSHIFTING AND To shift gears, turn the throttle grip to THROTTLE FRICTION ADJUSTER THROTTLE OPERATION the SLOW position, then move the gearshift lever to select F (forward), THROTTLE LH and LHT Types N (neutral) or R (reverse) gears. GRIP (long tiller handle) The engine can be started with the gearshift lever in the N (neutral)

  • Page 50: Lrt And Xrt Types (Remote Control)

    OPERATION LRT and XRT Types To shift gears, move the control lever (remote control) to select F (forward), N (neutral) and R (reverse) gears. Side-Mount Type TO INCREASE The control lever cannot be moved FRICTION from the N (neutral) position unless CONTROL LEVER the neutral release lever is squeezed.

  • Page 51: Steering

    OPERATION STEERING Steering Friction Adjuster LRT and XRT Types (remote control) STEERING FRICTION ADJUSTER LH and LHT Types FRICTION (long tiller handle) PLATE Steer the boat in the same manner as an automobile. TO DECREASE FRICTION (FREE) Steer by moving the tiller handle Use the steering friction adjuster to opposite the direction you want the help hold a steady course while...

  • Page 52: Cruising

    OPERATION CRUISING If engine speed becomes unstable at antiventilation plate is level with the high speed due to activation of the water. Engine Speed overrev limiter, reduce speed and check the trim angle of the outboard When cruising into a high wind, trim For best fuel economy, limit the motor.
  • Page 53 OPERATION LH and LHT Types It is necessary to trim the angle of the MOTOR MOTOR TRIMMED TOO TRIMMED TOO (long tiller handle) outboard motor to compensate for HIGH changes in boat load, weight POWER TRIM/TILT SWITCH distribution, water conditions, or propeller selection.

  • Page 54: Trim Tab

    OPERATION TRIM TAB SHALLOW WATER LH Type OPERATION If steering effort is not equal in both When operating in shallow water, tilt LHT, LRT and XRT Types directions, adjust the trim tab to the outboard motor, using the tilt compensate for ‘‘torque steer,’’ lever, so the propeller and gear case which is the reaction of the outboard When operating in shallow water, use...
  • Page 55 OPERATION To tilt the outboard motor, move the Monitor water flow from the cooling ENGINE COVER GRIP tilt lever to the FREE position, then system indicator (p. ) to be sure raise the outboard motor to the the outboard motor is not tilted so desired position by pulling on the high the water intake is out of the engine cover grip.

  • Page 56: Mooring, Beaching, Launching

    OPERATION MOORING, BEACHING, If more clearance is needed to swing LAUNCHING the tilt lock lever into the LOCK TILT LOCK LEVER (lock position) position, rock the outboard motor LH Type back slightly by pulling on the engine Use the tilt lever to raise and lower cover grip.
  • Page 57 OPERATION Be sure the valve is closed before RIGHT STERN BRACKET operating the outboard motor. If the valve is not closed, the outboard MANUAL RELIEF motor will tilt up when operated in VALVE reverse. The outboard motor can also be tilted manually after opening the manual relief valve.

  • Page 58: Servicing Your Outboard Motor

    To ensure the best quality and pollution. that are more difficult, or require reliability, use only new, genuine special tools, are best handled by Honda parts or their equivalents for professionals and are normally repair and replacement. performed by a Honda technician or Improperly maintaining other qualified mechanic.

  • Page 59: Maintenance Safety

    SERVICING YOUR OUTBOARD MOTOR MAINTENANCE SAFETY Safety Precautions Read the instructions before you begin, and make sure you have the Some of the most important safety Make sure the engine is off before tools and skills required. precautions follow. However, we you begin any maintenance or cannot warn you of every repairs.

  • Page 60: Emergency Starter Rope

    SCREWDRIVER HANDLE EMERGENCY STARTER ROPE Always carry the spare emergency The above tool kit can be purchased from an authorized Honda marine dealer stop switch clip and the emergency and may be used for simple maintenance procedures and/or emergency starter rope onboard. The spare clip repairs.

  • Page 61: Maintenance Schedule

    Emission related items. Lubricate more frequently when used in salt water. These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures.
  • Page 62 Emission related items. Lubricate more frequently when used in salt water. These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures.

  • Page 63: Trim Tab Adjustment

    SERVICING YOUR OUTBOARD MOTOR TRIM TAB ADJUSTMENT The trim tab compensates for ‘‘torque steer’’ which is a reaction of the outboard motor to propeller rotation. TRIM TAB TRIM TAB If uncompensated, torque steer would RIGHT LEFT make the outboard motor tend to turn to one side.

  • Page 64: Manual Relief Valve

    SERVICING YOUR OUTBOARD MOTOR MANUAL RELIEF VALVE For manual tilting, use a flat (REAR) screwdriver to turn the valve LHT, LRT and XRT Types counterclockwise 2 and a half turns. Close the valve firmly after positioning the outboard motor. RIGHT STERN BRACKET MANUAL Be sure the valve is closed before RELIEF VALVE...

  • Page 65: Engine Oil Level Check

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Level Check OIL FILLER CAP Check the engine oil level with the Running the engine with a low oil engine stopped and the outboard level can cause engine damage. motor in the vertical position. Install the oil filler cap and tighten Unlatch and remove the engine it securely.

  • Page 66: Engine Oil Change

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Change DRAIN PLUG COVER An engine oil evacuation device may be used to remove the engine oil. Drain the used oil while the engine is warm. Warm oil drains quickly and completely. Unlatch and remove the engine cover (p.
  • Page 67 SERVICING YOUR OUTBOARD MOTOR With the outboard motor in a SEALING WASHER vertical position, fill to the upper Improper disposal of engine oil limit mark on the dipstick (p. can be harmf ul to the environment. with the recommended oil. If you change your own oil, please dispose of the used oil properly.

  • Page 68: Engine Oil Recommendations

    Engine Oil Recommendations The SAE oil viscosity and service classification are in the API label on Oil is a major factor affecting the oil container. Honda recommends performance and service life. Use that you use API SERVICE category 4-stroke automotive detergent oil.

  • Page 69: Lubrication Points

    6 months. (Refer to the maintenance schedule page To prevent corrosion, apply anticorrosion oil to pivot SWIVEL CASE surf aces where grease cannot penetrate. PROPELLER SHAFT SWIVEL CASE Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover except the belts.

  • Page 70: Spark Plug Service

    SERVICING YOUR OUTBOARD MOTOR Spark Plug Service 0.024 0.028 in RECOMMENDED SPARK PLUGS: (0.60 0.70 mm) DR7EA (NGK) X22ESR-U (DENSO) Incorrect spark plugs can cause SEALING WASHER engine damage. SPARK PLUG WRENCH Unlatch and remove the engine cover (p. SPARK PLUG CAPS Disconnect the spark plug caps from the spark plugs.
  • Page 71 SERVICING YOUR OUTBOARD MOTOR After each spark plug seats, tighten with a spark plug wrench to compress the sealing washer. If reinstalling used spark plugs, tighten 1/8 - 1/4 turn after the spark plugs seat. If installing new spark plugs, tighten 1/2 turn after the spark plugs seat.

  • Page 72: Refueling

    SERVICING YOUR OUTBOARD MOTOR REFUELING Portable Fuel Tank Gasoline is highly (optional equipment) flammable and explosive. You can be burned or FUEL TANK CAPACITY: 6.6 US gal (25 ) seriously injured when handling fuel. FUEL GAUGE Stop the engine and keep heat, sparks, and flame Check the fuel gauge and refill the SAFE FILL LEVEL...

  • Page 73: Fuel Recommendations

    This is no cause for concern. If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda marine dealer.

  • Page 74: Fuel Pump Filter Inspection And Replacement

    SERVICING YOUR OUTBOARD MOTOR Fuel Pump Filter Inspection and Replacement Gasoline is highly flammable and explosive. The fuel pump filter is located under the engine cover between the fuel coupling and the fuel pump. You can be burned or seriously injured when Water or sediment accumulated in handling fuel.
  • Page 75 SERVICING YOUR OUTBOARD MOTOR Place clamps on the fuel hoses on HOSE CLAMP GRIPPERS each side of the filter to prevent (commercially available) fuel leakage when the fuel hoses FUEL HOSE CLIPS are disconnected. FUEL FUEL PUMP HOSE CLIPS SPRING RETAINR FUEL FILTER FUEL HOSES...

  • Page 76: Portable Fuel Tank And Filter Cleaning (Optional Equipment)

    SERVICING YOUR OUTBOARD MOTOR Portable Fuel Tank and Filter Fuel Tank Filter Connect the fuel hoses to the fuel Cleaning filter securely with the hose clips. (optional equipment) Remove the fuel hose clamps used TANK FILTER JOINT to close the fuel hoses. (Fuel Connector) Fuel Tank Securely connect the fuel hose...

  • Page 77: Anode Replacement

    SERVICING YOUR OUTBOARD MOTOR Anode Replacement The anodes are located on the trim tab and the stern bracket. They are made of a sacrificial material that Painting or coating the anodes will helps to protect the outboard motor def eat their purpose and will lead to from corrosion.

  • Page 78: Propeller Replacement

    Install the thrust washer with the are working with the propeller. grooved side toward the gear case. The propeller blades may have sharp Use a genuine Honda stainless edges, so wear heavy gloves to cotter pin and bend the pin ends as protect your hands.

  • Page 79: Storage

    Be sure not to remove the oil level plug from the Touch up any damaged paint, and OIL LEVEL plug hole in the gear coat areas that may rust with Honda case. Corrosion Inhibitor, or equivalent. Lubricate controls with a silicone...
  • Page 80 STORAGE Move the gearshift lever or control GARDEN HOSE ADAPTER lever to the N (neutral) position. (FLUSH KIT COUPLER) Flush the outboard motor in the neutral position only. Turn on the fresh water supply to the flush kit coupler. Running the engine without good water circulation can cause overheating and water pump damage.
  • Page 81 STORAGE Allow the engine to run at idle for Remove the sealing washer from at least 5 minutes to clean the the garden hose adapter and install inside of the motor. the sealing washer on the wash plug. Stop the motor and remove the garden hose adapter.

  • Page 82: Fuel

    STORAGE Fuel Distributor’s Limited Warranty does not cover fuel system damage Gasoline is highly Gasoline will oxidize and deteriorate or engine performance problems in storage. Old gasoline will cause resulting from neglected storage flammable and explosive. hard starting, and it leaves gum preparation.

  • Page 83: Engine Oil

    STORAGE Engine Oil Repeat this procedure to drain 1 CARBURETOR carburetor. DRAIN SCREW Change the engine oil (p. 2 CARBURETOR After all three carburetors are DRAIN SCREW drained, reinstall the drain tube on Remove the spark plugs (p. 1 carburetor. and remove the clip from the emergency stop switch.

  • Page 84: Storage Precautions

    STORAGE STORAGE PRECAUTIONS If the outboard motor will be Cover the outboard motor to keep out removed from the boat for storage, dust. Do not use sheet plastic as a Select a well-ventilated storage area. we recommend storing it vertically dust cover.

  • Page 85: Transporting

    TRANSPORTING WITH OUTBOARD MOTOR LRT and XRT Types WITH OUTBOARD MOTOR INSTALLED ON BOAT (remote control) REMOVED FROM BOAT When trailering a boat with the Use a motor support bar to prevent Secure the outboard motor in either outboard motor attached, leave the the outboard motor from moving the vertical or horizontal position engine in the normal running position,...

  • Page 86: Taking Care Of Unexpected Problems

    Use emergency starting Starter malfunction, switch Replace or repair faulty procedure (p. ), then take malfunction, or electrical problem components as necessary. outboard motor to an authorized in the starting circuit. Honda Marine dealer, or refer to the shop manual.
  • Page 87 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction Check emergency stop switch Clip not inserted in stop switch. Insert clip in stop switch. clip. Check control positions. Gearshift lever or control lever not Shift to neutral (p. in neutral position.
  • Page 88 Dry and reinstall spark plugs. Start engine). engine with the throttle open. Take outboard motor to an Carburetor malfunction, fuel pump Replace or repair faulty authorized Honda Marine dealer, failure, ignition malfunction, stuck components as necessary. or refer to the shop manual. valves, etc.
  • Page 89 TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS Possible Cause Correction AFTER STARTING Check control positions. Throttle grip not in START Turn throttle grip to START position (long tiller-handle type). Fast idle lever not raised (side- Raise fast idle lever, unless engine mount type).
  • Page 90 Gap or replace spark plugs (p. improperly gapped. Take outboard motor to an Carburetor malfunction, fuel pump Replace or repair faulty authorized Honda Marine dealer, failure, ignition malfunction, etc. components as necessary. or refer to the shop manual. ENGINE OVERHEATS...

  • Page 91: Battery Will Not Charge And Electric Starter Will Not Operate

    TAKING CARE OF UNEXPECTED PROBLEMS BATTERY WILL NOT Remove and inspect the fuse. If a FUSE COVER 10A FUSE CHARGE AND ELECTRIC fuse is burnt out, install a STARTER WILL NOT replacement fuse of the specified OPERATE rating. The outboard motor is supplied with spare fuse in the The battery-charging circuit and the fuse holder.

  • Page 92: Oil Pressure Indicator Light Goes Off And Engine Speed Is Limited

    (GREEN) If the engine protection system remains activated after 30 seconds, return to the nearest boat landing, and have the outboard motor inspected by an authorized Honda BUZZER marine dealer. (remote control type)

  • Page 93: Overheating Indicator Light Comes On And Engine Speed Is Limited

    TAKING CARE OF UNEXPECTED PROBLEMS OVERHEATING INDICATOR If the engine overheats, the red LIGHT COMES ON AND indicator light will come on, and the ENGINE SPEED IS LIMITED engine protection system will limit engine speed. If you are at cruising speed, engine speed will decrease gradually.

  • Page 94: Submerged Motor

    If there is a Honda marine dealer for half an hour. indicator again. nearby, take the motor to the dealer immediately.
  • Page 95 As soon as possible, take the lubricate the inside of the cylinders. outboard motor to an authorized Honda Marine dealer for Reinstall the spark plugs, and put inspection and service. the emergency stop switch clip...

  • Page 96: Technical And Consumer Information

    TECHNICAL AND CONSUMER INFORMATION TECHNICAL INFORMATION STARTER MOTOR SWIVEL CASE Serial Number Locations Record the product identification number and engine serial number in the space provided on this page. You will need these numbers when ordering parts, and when making technical or warranty inquiries PRODUCT IDENTIFICATION ENGINE SERIAL NUMBER...

  • Page 97: Carburetor Modification For High Altitude Operation

    5,000 f eet (1,500 altitudes above 5,000 feet (1,500 meters) with modif ied carburetors meters), have an authorized Honda may cause the engine to overheat marine dealer perform this carburetor and result in serious engine damage.

  • Page 98: Oxygenated Fuels

    TECHNICAL AND CONSUMER INFORMATION Oxygenated Fuels The following are the EPA-approved damage metal, rubber, and plastic percentages of oxygenates: parts of your fuel system. Some conventional gasolines are being blended with alcohol or an ETHANOL: ethyl or grain alcohol; If you notice any undesirable ether compound.

  • Page 99: Emission Control System Information

    Carbon monoxide does Honda engine within the emission Alterations that would cause the not react in the same way, but it is standards. engine to operate outside its design toxic.
  • Page 100 The emission control systems on the part will not adversely affect If you are aware of any of the your Honda engine were designed, emission performance. The following symptoms, have your built, and certified to conform with...

  • Page 101: Star Label

    TECHNICAL AND CONSUMER INFORMATION Star Label The Star Label means Cleaner Marine Engine A Star label was applied to this This engine has been certified as a: outboard motor in accordance with the requirements of the California Air Resources Board. The Symbol for Cleaner Marine Engines: Cleaner Air and Water - for healthier lifestyle and environment.
  • Page 102 TECHNICAL AND CONSUMER INFORMATION The one-star label identifies engines that meet the Air Resources Board’s One Star Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than Emission conventional carbureted two-stroke engines. These engines are equivalent to the U.S.EPA’s 2006 standards for marine engines.

  • Page 103: Specifications

    90 outboard motor gear oil manual Valve clearance Intake: 0.15 0.02 mm See shop (cold) Exhaust: 0.23 0.02 mm manual No other adjustment is needed Other specifications Honda outboards are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.
  • Page 104 90 outboard motor gear oil Valve clearance Intake: 0.15 0.02 mm See shop (cold) Exhaust: 0.23 0.02 mm manual No other adjustment is needed Other specifications Honda outboards are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.

  • Page 105: Consumer Information

    You may purchase does not solve to your satisfaction, Name of the dealer who sold the them from your Honda marine dealer. please discuss it with the dealership’s outboard motor to you management. The Service Manager Shop Manual or General Manager can help.

  • Page 106: Index

    INDEX Anodes ................29 EMERGENCY STARTING ......... . 42 Replacement .............. . 75 Emission Control System Information ......97 ARE YOU READY TO GET UNDER WAY ..32 Emergency Stop Switch and Switch Clip ..... . 16 Engine Battery ................
  • Page 107 INDEX Gearshift Lever .............. . 18 Oil Pressue Indicator ............27 Gearshift/Trottle Control Lever OIL PRESSURE INDICATOR LIGHT GOES LRT and XRT Types (remote control) OFF AND ENGINE SPEED IS LIMITED ....90 Side-Mount Type ........... 21 OPERATION ..............

  • Page 108: Tool Kit (Optional Equipment) And Emergency Starter Rope

    INDEX REFUELING ..............70 STORAGE ..............77 REMOVAL FROM STORAGE ........82 STORAGE PRECAUTIONS ......... 82 STORAGE PREPARATION ......... 77 SAFE OPERATING PRECAUTIONS ......34 Cleaning and Flushing ..........77 SAFETY LABEL LOCATIONS ........
  • Page 109 INDEX TRANSPORTING ............83 WITH OUTBOARD MOTOR INSTALLED ON BOAT ............. . 83 WITH OUTBOARD MOTOR REMOVED FROM BOAT ............83 Trim Meter (optional equipment) ........26 Trim Tab ..............25, 52 TRIM TAB ADJUSTMENT .........
  • Page 113 31ZW3601 N HC 1000.2003.07 00X31-ZW3-6010 Printed in Japan...

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Marine bf50aBf50aMarine bf40a

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