Honda BF75D Manual
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Honda BF75D Manual

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CONTENTS
IMPORTANT SAFETY PRECAUTIONS ................ 3
SET-UP RULES...................................................... 4
SYMBOLS USED IN THIS MANUAL.................... 4
1. UNPACKING...................................................... 5
2. LIFT UP THE OUTBOARD MOTOR .................. 7
3. PARTS PACKAGE INSPECTION....................... 8
4. TORQUE VALUES.............................................12
Motor Selection ................................................................... 13
and steering ..................................................................... 13
General Guidelines .............................................................. 15
Installation Height Check.................................................... 15
Boat Transom Height Adjustment..................................... 16
Removal of fixing stays....................................................... 17
Outboard Motor Installation .............................................. 18
6. LONG TILLER HANDLE.....................................19
Long tiller handle installation ............................................ 20
Steering Guide Cable Installation ...................................... 23
Control Cable Selection ...................................................... 24
Control Lever Directiosn Change ....................................... 25
CONTROL CABLE INSTALLATION ..................................... 27
CONTROL BOX SIDE ........................................................... 27
Control Box Installation ...................................................... 28
Control Lever Friction Adjustment .................................... 28
8. CONTROL CABLE INSTALLATION ..................29
OUTBOARD MOTOR SIDE .................................................. 29
Throttle control cable adjustment ..................................... 33
Shift control cable adjustment........................................... 36
9. INDICATOR PANEL ...........................................38
Indicator Panel Installation................................................. 38
10. WIRE HARNESS CONNECTION....................39
11. METERS..........................................................41
Meter Installation ................................................................ 41
Meter Wire Connection....................................................... 42
12. BATTERY ........................................................43
13. PROPELLER ....................................................44
Propeller Selection .............................................................. 44
Propeller Selection Chart.................................................... 45
Propeller type....................................................................... 46
Boat Type and Applicable Size........................................... 46
Propeller Installation ........................................................... 48
Trim Tab Adjustment .......................................................... 49
GPS MOUNTED ON THE BOAT....................52
17. BREAK-IN PROCEDURE ................................53
INDICATOR PANEL TEMPLATE
WIRING DIAGRAMS
• Long Tiller Handle Type
• Side Mount Remote Control Box Type
2

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Summary of Contents for Honda BF75D

  • Page 1: Table Of Contents

    CONTENTS 15. PRE-DELIVERY SERVICE CHECK LIST ..50 16. WHEN RADIO STATION/ THE IMPORTANCE OF PROPER SERVICING ..3 GPS MOUNTED ON THE BOAT....52 IMPORTANT SAFETY PRECAUTIONS ....3 17. BREAK-IN PROCEDURE ........53 SET-UP RULES............4 SYMBOLS USED IN THIS MANUAL....4 INDICATOR PANEL TEMPLATE 1.
  • Page 2 All information, illustrations, directions and specifications include in this publication are based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd. reserves the right to make changes without incurring any obligations whatever.

  • Page 3: The Importance Of Proper Servicing

    This manual describes the proper methods and procedures for performing service. Any person who intends to use service procedure, or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the outboard motor.

  • Page 4: Set-Up Rules

    SET-UP RULES 1) Use Honda-recommended lubricants or their equivalents. 2) When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless a particular sequence is specified. 3) Lubricate any sliding surfaces before reassembly.

  • Page 5: Unpacking

    1. UNPACKING 3) Remove the twelve 6 mm bolts from the upper frame. • Unpack the package with care not to drop the parts 4) Lift up the upper frame slowly and remove it with included in the crate. care not to damage the outboard motor. (Note this 1) Remove the tape from the two places on the operation must be made together with an assistant underside of the crate.
  • Page 6 5) Remove the corrugated board that contains the engine cover by sliding it straight to a side. Remove the engine cover from the corrugated board and remove the vinyl cover. PARTS CARTON (ENGINE COVER) 6) Remove the vinyl cover from the outboard motor. VINYL COVER 7) Check the parts list for the parts contained in the package (see P.

  • Page 7: Lift Up The Outboard Motor

    2. LIFT UP THE OUTBOARD 4) Remove the wire from the engine cover fixing lever. MOTOR • Use a hoist which allowable load is 250 kg or above and of the enough height to suspend the outboard motor. • Fix the hoist securely and support the outboard motor while lifting it up.

  • Page 8: Parts Package Inspection

    3. PARTS PACKAGE INSPECTION BF75D LRTL LRTU LRTC LRTD LRTW LHTD LHTW XRTL XRTU XRTW Part name BF90D LRTL LRTU LRTC LRTD LRTW LHTC LHTD LHTW XRTL XRTU XRTC XRTD XRTW Indicator cord assembly Indicator panel assembly 5 x 40 mm pan-head screw...
  • Page 9 BF75D LRTL LRTU LRTC LRTD LRTW LHTD LHTW XRTL XRTU XRTW Part name BF90D LRTL LRTU LRTC LRTD LRTW LHTC LHTD LHTW XRTL XRTU XRTC XRTD XRTW Fuel tank assembly (25L) Fuel tank tube assembly 12.5 mm tube clip band...
  • Page 11 %0 - 2 %0 - 5 %0 - 6 %0 - 1 %0 - 3 %0 - 4 %0 - 9 %0 - 10 %0 - 8 %0 - 7 %0 - 13 %0 - 11 %0 - 12...

  • Page 12: Torque Values

    4. TORQUE VALUES FASTENER APPLICATION DESCRIPTION TORQUE VALUES N·m kgf·m lbf·ft Propeller lock nut (18 mm castle nut) Minimum torque Maximum torque Front separate cover bolt 6 x 17 mm special bolt 6 x 20 mm flange bolt 6 x 37 mm special bolt Steering link rod bolt 3/8-24 UNF Steering link rod lock nut...

  • Page 13: Outboard Motor Installation

    Never install an outboard motor which exceeds the recommended maximum horsepower of the boat. MAXIMUM HORSEPOWER: BF75D: 55.2 kW (75 PS) BF90D: 66.2 kW (90 PS) • Install the outboard motor in an adequate place where it does not hinder your operating the outboard motor during tilt-up and steering.
  • Page 14 [Remote Control Type] Unit: mm (in) AT 68˚ TILT UP: (Boat transom angle: 12˚) AT 30˚ STEERING: 76.2 454.8 (3.0) (17.9) 621.4 (24.5) 12˚ L type: 979 (38.5) X type: 1,097 (43.2) (20.9)

  • Page 15: General Guidelines

    — It reduces operating stability. — It reduces high speed sailing performance. If the boat transom angle is less than 8˚, the BF75D or — Water splashed over the wash board can be jetted BF90D anti-cavitation plate will not be parallel to the out and fan out the stern of the board.

  • Page 16: Boat Transom Height Adjustment

    • If the outboard motor installation height is too low, outboard motor transom length. attach wood block(s) to the top of the transom and • BF75D·BF90D Transom Length (Boat transom increase the installation height by the amount it is angle: 12˚) required.

  • Page 17: Removal Of Fixing Stays

    Removal of fixing stays After installing the outboard motor on the hull, remove the two hex. washer-bolts and the two hex. bolts. Then, remove the fixing stays from the swivel case and the mount frame. MOUNT FRAME FIXING STAYS SWIVEL CASE HEX.

  • Page 18: Outboard Motor Installation

    Outboard Motor Installation 4) Apply sealing agent to the outboard motor installation holes. Set the outboard motor on the hull and tighten it • When necessary connect the STEERING FRICTION using the bolts and nuts securely. SHAFT (equipped type) or STEERING GUIDE CABLE Insert the bolts into the holes from the outer side (equipped type) to the outboard motor before (i.e.

  • Page 19: Long Tiller Handle

    6. LONG TILLER HANDLE (equipped type) COMPONENT IDENTIFICATION and CONTROLS SHIFT/THROTTLE CONTROL CABLE EMERGENCY STOP SWITCH INDICATOR LIGHTS SHIFT LEVER IGNITION SWITCH CONNECTOR THROTTLE FRICTION FIXING DIAL CONNECTOR HEIGHT ADJUSTMENT (REMOTE CONTROL BLOCK CABLE ASSEMBLY) POWER TRIM/TILT SWITCH THROTTLE GRIP SHIFT/THROTTLE CONTROL CABLE ..

  • Page 20: Long Tiller Handle Installation

    Long tiller handle installation 5) Align the 10 mm holes in the outboard motor mount frame with the holes in the tiller handle's 1) Remove the cap from the tilting shaft. steering handle bracket and install the steering handle bracket using the two 10 mm washers and the two 10 x 32 mm hex.

  • Page 21: Long Tiller Handle Height/Angle Adjustment

    Long tiller handle height/angle adjustment The long tiller handle height and angle can be adjusted in three positions by changing the installation direction of the height adjustment block. Select a suitable height and angle for the operator and secure the block. Reference point 1) Raise the long tiller handle and remove the 8 x 28 mm flange bolt and the height adjustment block.

  • Page 22: Side Mount Remote Control Box

    • The fast idle lever can be operated provided that the control lever is in the "N" (NEUTRAL) position. • The fast idle lever is only needed for starting carbureted outboard models. The BF75D and BF90D models use programmed fuel injection, so this lever will not be needed for starting.

  • Page 23: Steering Guide Cable Installation

    Steering Guide Cable Installation 3) Apply the marine grease to the collar and to the sliding surface of the steering link rod. • Attach the steering guide cable to the outboard motor 4) Attach the steering link rod to the hole in the first, then install the outboard motor on the boat.

  • Page 24: Control Cable Selection

    Control Cable Selection 2) Calculate the control cable length. Measure the distance of L1 and L2 and calculate the • The remote control cable must be of the correct required control cable length as follows. length. Sharp bend of the short cable causes “twist” in the cable.

  • Page 25: Control Lever Directiosn Change

    Control Lever Direction Change 4) Remove the control lever's 8 x 35 mm lock bolt using the 12 mm box wrench, and remove the Side mount remote control box: control lever. This surface-mounted remote control box can be mounted on the right or left side by reversing the CONTROL LEVER installation direction of the control lever.
  • Page 26 7) Assemble the neutral lock block with the control 12) Tighten the housing cover C with the two screws . housing B and tighten the two screws. Torque: 2 N·m (0.2 kgf·m, 1.4 lbf·ft) Torque: 2 N·m (0.2 kgf·m, 1.4 lbf·ft) •...

  • Page 27: Control Cable Installation

    CONTROL CABLE INSTALLATION • CONTROL BOX SIDE Side Mount Remote Control Box (equipped type): HOUSING COVER C 5 x 25 mm TAPPING SCREW (2) 6 mm LOCK PIN (2) THROTTLE CONTROL CABLE WASHER (2) EYE END (2) LOCK NUT (2) CABLE CLAMP SPACER SHIFT CONTROL CABLE 1) Remove the two 5 x 25 mm tapping screws and...

  • Page 28: Control Box Installation

    Control Box Installation Control Lever Friction Adjustment Side Mount Remote Control Box (equipped type) Adjust the friction by turning the control lever friction adjuster. This remote control box is designed to be mounted on the starboard side. When it is mounted on the port Side Mount Remote Control Box (Equipped type) side, reverse the control lever installation for the port mount type (see P.

  • Page 29: Control Cable Installation

    8. CONTROL CABLE INSTALLATION : Part in case the side mount remote control box assembly • OUTBOARD MOTOR SIDE is used. After installing the control cable to the remote control box, then install the control cable to the outboard motor. [Long Tiller Handle Type] PART NAME 6 x 17 mm SPECIAL BOLT...
  • Page 30 1) Set the starter cable on the front bracket. 3) Connect the 14P connector and the 6P connector to • Align the tape end on the starter cable with the the engine side harness and secure the connectors end of the front bracket. to the connector holders.
  • Page 31 6) Install the steerng handle cable grommet in the 8) Align the groove in the remote control cables (shift groove in the front bracket aligning the flat part of and throttle) with the groove in the remote control the front bracket with the flat part of the steerng cable plate.
  • Page 32 12) Set the front separate cover on the front bracket 13) Check that each cable and tube are set in the holes and tighten the 6 x 20 mm flange SH bolt, 6 x 17 in the steerng handle cable grommet securely. mm special bolt and the 6 x 37 mm special bolt to Secure the steerng handle cable grommet with the the specified torque.

  • Page 33: Throttle Control Cable Adjustment

    Align the tie wrap band on each of the 14P Throttle control cable adjustment connector cable and the 6P connector cable with 1) Set the throttle grip in the forward full open the end of the remote control cable grommet. position.
  • Page 34 2) With the throttle grip in the full open position, 4) Move the throttle grip to the full close position. check that the throttle arm is in contact with the full Check that the throttle cam of the throttle body is in open stopper of the shift link bracket.
  • Page 35 2) Screw in the shift pivot until the throttle arm comes <Throttle cam not in full open position> in contact with the full open stopper and loosely Adjust the throttle control cable with it connected to the install the shift pivot on the throttle arm. throttle arm.

  • Page 36: Shift Control Cable Adjustment

    Shift control cable adjustment 4) Move the gear shift lever to the “R” (Reverse) position and return it slowly to the “N” (Neutral) Check the following before connecting the shift control position. cable to the outboard motor. 5) While holding the gear shift lever in the position Shift control cable adjustment procedure is the same described in step 4, mark (B) at the end of the cable when the side remote control box assembly is used.
  • Page 37 8) Move the tip of the shift link pin lightly to the right 10) After connecting the shift control cable, move the and left. If there is a free play in the shift link pin, gear shift lever back and forth to check for gear set the shift link pin at the center of the free play.

  • Page 38: Indicator Panel

    9. INDICATOR PANEL Indicator Panel Installation 1) Determine the indicator panel installation position. 2) Attach the template shown at the end of this manual at the indicator panel installation position. 3) Drill the holes according to the indication on the template.

  • Page 39: Wire Harness Connection

    10. WIRE HARNESS CONNECTION Wire harness connection differs depending on a type of the remote control box. Connect the wires as per the wiring diagram. Use remote control cable assembly and indicator cord, and modify it if necessary. • Stake the lead wire against the terminal securely. •...
  • Page 40 Side Mount Remote Control Box (equipped type) SIDE MOUNT REMOTE CONTROL BOX To meter wire (equipped type) harness A EXTENSION HARNESS REMOTE CONTROL CABLE (P. 42) (optional equipment) ASSEMBLY (equipped type) TIE-WRAP BAND CORRUGATED TUBE Protect the connector with a corrugated tube.

  • Page 41: Meters

    11. METERS Meter Installation Meters and other instruments should be installed on the instrument/mounting panel. If any other location is selected, it will be necessary to use a mounting plate with a thickness of 2 – 11 mm (1/16 – 7/16 in). •...

  • Page 42: Meter Wire Connection

    Meter Wire Connection This is an independent engine-control system. Do not attempt to integrate it with the boat’s system or other accessories, except for the instrument light switch. Route and connect the wire harness properly, as There are three ways to illuminate the instrument shown in the wiring diagram.

  • Page 43: Battery

    12. BATTERY (commercially avaiable) WARNING • The battery contains sulfuric acid. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. • Antidote: EXTERNAL — Flush with water. INTERNAL — Drink large quantities of water or milk.

  • Page 44: Propeller

    PITCH PROPELLER DIMENSIONS (Diameter x Pitch) Recommended full throttle engine speed range: Select the correct propeller so that full throttle engine BF75D: 5,000 – 6,000 min –1 speed is within the recommended range. BF90D: 5,300 – 6,300 min –1 • If the engine min –1...

  • Page 45: Propeller Selection Chart

    Propeller Selection Chart • BF75D Propeller Size Speed within recommended engine speed (km/h) Speed [km/h] Propeller Dia. x pitch Type (in) 5,000 min 6,000 min 13.5 x 15 13.25 x 17 46.8 66.1 13.25 x 19 58.1 77.5 13.25 x 21 61.3...

  • Page 46: Propeller Type

    13.5 x 15 13.25 x 21 13.25 x 17 13 x 19 13 x 21 13.2 x 19 13.25 x 21 Boat Type and Applicable Size (Length and Weight) • BF75D Boat Type Hull Shape Overall Weight Example (Example) length (ft)
  • Page 47 • BF90D Boat Type Hull Shape Overall Weight Example (Example) length (ft) (kg) [lbs] Recommende Outboard Overall Weight d full throttle motor length [ft] [kg] speed [km/h] 16.7 64.8 Fishing boat 15.5–17.1 495 – 1,300 Single 15.6 63.2 (off shore) [1,091-2,866] 17.1 1,000...

  • Page 48: Propeller Installation

    Propeller Installation 4) Tighten the 18 mm castle nut and secure with the split pin. If the split pin does not align with the hole in the • Remove the switch clip of the emergency stop propeller shaft, adjust by turning the nut in the switch to prevent the engine from starting tightening direction.

  • Page 49: Adjustment After Installation

    14. ADJUSTMENT AFTER INSTALLATION • When the boat is drawn to the left: Loosen the 8 x 25 mm hex. bolt and turn the trim tab to Trim Tab Adjustment the left. Fix the trim tab in the position. After the engine break-in (see P. 53), run the boat at full speed and check to see if the boat is drawn to the left or right.

  • Page 50: Pre-Delivery Service Check List

    15. PRE-DELIVERY SERVICE CHECK • TILLER HANDLE CONTROL SYSTEM Check the tiller handle for proper operation. LIST Make sure that the gear shift operates properly with Check all items on the following list. Refer to Owner’s the shift lever. Manual or Shop Manual for the specifications and the Check that the throttle link operates correctly with detailed procedures.
  • Page 51 Check for the balanced weight distribution on the MAXIMUM RECOMMENDED ENGINE SPEED: boat. BF75D: 5,000 – 6,000 min –1 BF90D: 5,300 – 6,300 min –1 • OUTBOARD MOTOR OPERATION Make sure that there is no propeller cavitation in a Check the neutral switch for proper operation.

  • Page 52: When Radio Station/ Gps Mounted On The Boat

    16. WHEN RADIO STATION/ • Set the GPS antenna and navigation unit at least 3 m (9.8 ft) or more away from the ECM. GPS MOUNTED ON THE BOAT • Ground the GPS antenna ground securely. • After installing a radio station or GPS, the ECM must be inspected for erroneous operation.

  • Page 53: Break-In Procedure

    17. BREAK-IN PROCEDURE Break-in period: 10 hours Break-in operation allows the moving parts to wear-in evenly and thus ensures proper performance and longer outboard motor service life. First 15 minutes: Run the outboard motor at trolling speed. Use the minimum amount of throttle opening necessary to operate the boat at a safe trolling speed.
  • Page 54 INDICATOR PANEL TEMPLATE GABARIT DU PANNEAU DE TEMOINS ARMATURENTAFEL-SCHABLONE PLANTILLA DEL PANEL DE INDICADORES 63 mm (2.48 in) CUT OUT DECOUPER AUSSCHNEIDEN CORTE Ø5.50 mm (0.22 in)-4 50 mm (1.97 in) Outline of indicator panel Cut out shaded areas as indicated Esquisse du panneau de témoins Découper les zones rayées comme indiqué...
  • Page 55 Long Tiller Handle Type Type avec barre franche longue Ausführung mit verlängerter Ruderpinne Tipo de caña del timón larga...
  • Page 56 Side Mount Remote Control Box Type Type avec boîtier de télécommande à montage latéral Ausführung mit seitlich montiertem Fernbedienungsgehäuse Tipo de caja de control remoto de montaje lateral...
  • Page 57 WIRING DIAGRAMS Long Tiller Handle Type [48] To LIGHT SWITCH Bl Black Br Brown TACHOMETER Y Yellow O Orange TRIM METER Bu Blue Lb Light blue VOLTMETER G Green Lg Light green HOUR METER R Red P Pink OPTIONAL W White Gr Gray FUSE (10A) [49]...
  • Page 58 WIRING DIAGRAMS Side Mount Remote Control Box Type [48] To LIGHT SWITCH Bl Black Br Brown TACHOMETER Y Yellow O Orange TRIM METER Bu Blue Lb Light blue VOLTMETER G Green Lg Light green HOUR METER R Red P Pink OPTIONAL W White Gr Gray...
  • Page 59 BF75D•BF90D Set-up Instructions Instructions d'installation Vorauslieferungsanweisungen Instruccions de preparación...
  • Page 60 © Honda Motor Co., Ltd. 2006 Published by Honda Motor Co., Ltd. Printed in Japan 96ZY900...

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