HONDA marine BF135A Shop Manual
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HONDA marine BF135A Shop Manual

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BF135A•BF150A

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Summary of Contents for HONDA marine BF135A

  • Page 1 BF135A•BF150A...
  • Page 2 CONTENTS This supplement covers the use of the Dr. H to trou- SPECIFICATIONS bleshoot the BF135A • BF150A Outboard Motors. For service information which is not covered in this sup- SERVICE INFORMATION plement, please refer to the base shop manual (part number 66ZY600).

  • Page 3: Table Of Contents

    INDEX 5. PROGRAMMED-FUEL INJECTION ......5-1 1. TROUBLESHOOTING ..........5-1 2. TROUBLESHOOTING WITH Dr. H ......5-2 a. TROUBLESHOOTING GUIDE BY DTC....5-4 b. TROUBLESHOOTING ........5-7 MIL DOES NOT COME ON........ 5-7 MIL COMES ON BUT DTC CODE DOES NOT APPEAR.............

  • Page 4: Programmed-Fuel Injection

    5. PROGRAMMED FUEL INJECTION 1.TROUBLESHOOTING 2. TROUBLESHOOTING WITH Dr. H 1. TROUBLESHOOTING 3. Perform the troubleshooting by referring to the “Trou- bleshooting Guide by DTC” (P. 5-4). The ECM (Engine Control Module) has the self-diagno- Check each connector and wire harness for secure sis function which memorizes the failure code and turns connection and damage before troubleshooting.

  • Page 5: Troubleshooting With Dr. H

    2. TROUBLESHOOTING WITH • WHEN USING Dr. H DURING CRUISING Dr. H 1. Remove the engine cover and the electric part cover • DTC (DIAGNOSTIC TROUBLE (Section 4 of the base manual). CODE) CHECK 2. Remove the cap from the under cover front bracket. Route the extension wire through the front cover 1.
  • Page 6 5. Secure the extension wire as shown with the band. • TO CLEAR DTC EXTENSION WIRE 1. Remove the engine cover and the electric part cover. OF TESTER 2. Connect the Dr. H to the data link connector (DLC). 3. Turn the ignition switch ON. 4.

  • Page 7: Troubleshooting Guide By Dtc

    a. TROUBLESHOOTING GUIDE BY DTC PGM-FI MIL Detected unit Probable problem part Ref. page – MIL does not • Open circuit in MIL wire come ON/blinks • Blown MIL bulb 0-2, • Open circuit in ECM ground wire or 0-5, poor grounding •...
  • Page 8 PGM-FI MIL Detected unit Probable problem part Ref. page 10-1 MIL comes ON IAT sensor (Voltage too low) • Short circuit in IAT sensor wire 5-27 • Faulty IAT sensor • Faulty ECM 10-2 MIL comes ON IAT sensor (Voltage too high) •...
  • Page 9 PGM-FI MIL Detected unit Probable problem part Ref. page 140-1 MIL comes ON ECT sensor 2 (Voltage too low) • Short circuit in ECT sensor 2 wire 5-40 • Faulty ECT sensor 2 • Faulty ECM 140-2 MIL comes ON ECT sensor 2 (Voltage too high) •...

  • Page 10: Troubleshooting

    b. TROUBLESHOOTING 2. Main power line check -1. Disconnect the remote control harness 14P connector. • MIL Does Not Come ON -2. Measure the voltage between the No. 3 (White/Black) terminal of the main harness side 14P connector 1. Fuse check and the engine ground.
  • Page 11 3. IGP power line check 4. ECM power line check -1. Turn the ignition switch OFF. Disconnect the PGM-FI -1. Turn the ignition switch OFF and disconnect the fuse main relay 6P connector. box 3P connector. -2. Turn the ignition switch ON. Measure the voltage -2.
  • Page 12 5. MIL power line check 6. Alternator indicator light check -1. Turn the ignition switch OFF and disconnect the fuse -1. Turn the ignition switch ON and check the alternator box 3P connector. indicator light. -2. Turn the ignition switch ON. Measure the voltage between the No.

  • Page 13: Mil Comes On But Dtc Code Does Not Appear

    8. Function test • MIL Comes ON but DTC Code -1. Turn the ignition switch OFF and connect the Dr. H. Does Not Appear -2. Turn the ignition switch ON and perform the function 1. ECM power line check test. (See the Dr. H's operation manual for the test procedure.) -1.
  • Page 14 -3. Turn the ignition switch OFF and disconnect the Is there the continuity? ECM connector B. YES – Perform “3. DTC recheck”. -4. Check for the continuity between the No. 3 (Light NO – Repair open in the main harness. green/White) terminal of the data link connector and the engine ground.

  • Page 15: Alert System Initial Operation Is Faulty

    • Alert System Initial Operation Is 2. Buzzer line check -1. Turn the ignition switch OFF and disconnect the Faulty Yellow/Green terminal from the buzzer. 1. Function test -2. Connect the Yellow/Green terminal of the buzzer to the Black terminal with a jumper wire to short. -1.
  • Page 16 3. MIL line check -5. Check for continuity between the No. 4 (Yellow/ Black) terminal and the No. 6 (Red/Blue) terminal of -1. Turn the ignition switch OFF and disconnect the MIL the MIL 6P connector. 6P connector. -2. Turn the ignition switch ON. Measure the voltage between the No.
  • Page 17 4. Overheat indicator line check -3. Turn the ignition switch OFF and connect the indica- tor light Yellow terminal. -1. Turn the ignition switch OFF. Disconnect the Red -4. Disconnect the remote control harness 14P connector. terminal of the indicator light and connect the Black -5.

  • Page 18: Neutral Switch Malfunction

    • Neutral Switch Malfunction -4. Disconnect the ECM connector B. -5. Check for the continuity between the No. 13 • Before following test, perform the neutral position check. (Black/Blue) terminal of the ECM harness side con- Engine speed does not increase in gears (BF150A only). nector B and the No.

  • Page 19: Tachometer Malfunction

    • Tachometer Malfunction -4. Check for the continuity between the No. 12 (Gray) terminal of the main harness side 14P connector 1. Engine speed check using the Dr. H. and the No. 33 (Gray) terminal of the ECM harness -1. Turn the ignition switch OFF and connect the Dr. H. side connector B.

  • Page 20: Ecm Troubleshooting

    • ECM Troubleshooting • MAP Sensor Troubleshooting DTC 0-2, 0-5, 0-8: Inside of ECM is faulty DTC 3-1: MAP sensor voltage is low 1. Symptom reproduction test 1. Symptom reproduction test -1. Connect the Dr. H. -1. Connect the Dr. H and clear the DTC once. If the -2.
  • Page 21 DTC 3-2: MAP sensor voltage is high Is there the continuity? YES – Perform “4. MAP sensor ground line open 1. Symptom reproduction test circuit check”. -1. Connect the Dr. H and clear the DTC once. If the NO – Repair open in the wire between the MAP DTC can not be cleared, go on the troubleshooting.

  • Page 22: Ckp Sensor Troubleshooting

    6. MAP sensor signal line open circuit check • CKP Sensor Troubleshooting -1. Turn the ignition switch OFF and disconnect the DTC 4-1: No CKP pulse ECM connector B. 1. Symptom reproduction test -2. Check for the continuity between the No. 2 -1.
  • Page 23 3. CKP sensor power line open circuit check 5. CKP sensor signal line short circuit check -1. Turn the ignition switch ON and measure the voltage -1. Turn the ignition switch OFF. Check for continuity between the No. 1 (Yellow/Black) terminal of the CKP between the No.
  • Page 24 7. CKP sensor check DTC 4-2: CKP pulse is abnormal -1. Connect the Dr. H and clear the DTC once. 1. Symptom reproduction test -2. Start the engine and let it run at idling under no load. -1. Connect the Dr. H and clear the DTC once. If the Check the DTC with the Dr.

  • Page 25: Ect Sensor 1 Troubleshooting

    • ECT Sensor 1 Troubleshooting DTC 6-2: ECT sensor 1 voltage is high 1. Symptom reproduction test DTC 6-1: ECT sensor 1 voltage is low -1. Connect the Dr. H and clear the DTC once. If the 1. Symptom reproduction test DTC can not be cleared, go on the troubleshooting.

  • Page 26: Tp Sensor Troubleshooting

    • TP Sensor Troubleshooting Is the measurement 4.30 – 5.25V? YES – Repair open in the sensor ground line. DTC 7-1: TP sensor voltage is low NO – Repair open in the wire between the ECM 1. Symptom reproduction test and the ECT sensor 1.
  • Page 27 DTC 7-2: TP sensor voltage is high 3. TP sensor power line open circuit check -1. Turn the ignition switch ON. Measure the voltage 1. Symptom reproduction test between the No. 3 (Brown/White) terminal of the TP -1. Connect the Dr. H and clear the DTC once. If the sensor harness side 3P connector and the engine DTC can not be cleared, go on the troubleshooting.

  • Page 28: Cmp Sensor Troubleshooting

    5. TP sensor check • CMP Sensor Troubleshooting -1. Turn the ignition switch OFF and connect the TP DTC 8-1: No CMP sensor pulse sensor 3P connector. 1. Symptom reproduction test -2. Measure the TP sensor voltage using the Dr. H. -1.
  • Page 29 3. CMP sensor power line open circuit check DTC 8-2: CMP sensor pulse is abnormal -1. Turn the ignition switch ON. Measure the voltage 1. Symptom reproduction test between the No. 1 (Yellow/Black) terminal of the -1. Connect the Dr. H and clear the DTC once. If the CMP sensor harness side 3P connector and the DTC can not be cleared, go on the troubleshooting.

  • Page 30: Iat Sensor Troubleshooting

    • IAT Sensor Troubleshooting DTC 10-2: IAT sensor voltage is high 1. Symptom reproduction test DTC 10-1: IAT sensor voltage is low -1. Connect the Dr. H and clear the DTC once. If the 1. Symptom reproduction test DTC can not be cleared, go on the troubleshooting. -1.

  • Page 31: Baro Sensor Troubleshooting

    • BARO Sensor Troubleshooting Is there the continuity? YES – Perform “4. IAT sensor check”. DTC 13-1: BARO sensor voltage is low NO – Repair open in the wire between the IAT 1. Symptom reproduction test sensor and the engine ground. -1.
  • Page 32 DTC 13-2: BARO sensor voltage is high Is the measured voltage 4.75 – 5.25V? YES – Repair open in the wire between the BARO 1. Symptom reproduction test sensor and the engine ground. -1. Connect the Dr. H and clear the DTC once. If the NO –...

  • Page 33: Iac Valve Troubleshooting

    • IAC Valve Troubleshooting -2. Check for the continuity between the IAC valve No. 2 terminal and the body ground. DTC 14-1: IAC valve current is abnormal IAC VALVE SIDE 2P 1. Symptom reproduction test CONNECTOR -1. Connect the Dr. H and clear the DTC once. If the DTC can not be cleared, go on the troubleshooting.

  • Page 34: Vtec Solenoid Valve Troubleshooting

    5. IAC valve line short circuit check • VTEC Solenoid Valve Troubleshooting -1. Check for the continuity between the No. 26 DTC 21-1: VTEC solenoid valve output is abnormal (Green/White) terminal of the ECM connector B and 1. Symptom reproduction test the engine ground, and between the No.

  • Page 35: Knock Sensor Troubleshooting

    3. VTEC signal line short circuit check • Knock Sensor Troubleshooting -1. Disconnect the ECM connector A. DTC 23-1: Knock sensor detects failure -2. Check for the continuity between the No. 20 1. Symptom reproduction test (Green/Yellow) terminal of the ECM connector A and -1.

  • Page 36: Shooting

    3. Knock sensor signal line short circuit test • A/F Heater Troubleshooting -1. Check for the continuity between the No. 15 DTC 41-3: A/F heater is abnormal (Red/Blue) terminal of the ECM connector A and the 1. Symptom reproduction test body ground.
  • Page 37 -9. Check for the continuity between the No. 3 (White) Is there the battery voltage? terminal of the A/F heater relay harness side 4P con- YES – Go to the step 5. nector and the No. 3 (White) terminal of the A/F sen- NO –...
  • Page 38 4. Heater line short circuit check DTC 41-4: A/F sensor heater is abnormal -1. Turn the ignition switch OFF and disconnect the 1. Symptom reproduction test ECM connector C. -1. Connect the Dr. H and clear the DTC once. If the -2.
  • Page 39 -9. Check for the continuity between the No. 3 (White) Is there the battery voltage? terminal of the A/F heater relay harness side 4P con- YES – Go to the step 5. nector and the No. 3 (White) terminal of the A/F sen- NO –...
  • Page 40 4. Heater line short circuit check -3. Check for the continuity between the No. 3 (Black/ White) terminal of the ECM connector C and the -1. Turn the ignition switch OFF and disconnect the respective terminals of the No. 1 (White/Black) and ECM connector C.

  • Page 41: A/F Sensor Troubleshooting

    • A/F Sensor Troubleshooting -3. Check for the continuity between the No. 2 (Black/Yellow) terminal of the A/F sensor harness DTC 48-5: A/F sensor current is abnormal side 4P connector and the No. 14 (Black/Yellow) ter- 1. Symptom reproduction test minal of the ECM connector A.
  • Page 42 DTC 48-6: A/F sensor V current is abnormal DTC 48-7: A/F sensor C current is abnormal 1. Symptom reproduction test 1. Symptom reproduction test -1. Connect the Dr. H and clear the DTC once. If the -1. Connect the Dr. H and clear the DTC once. If the DTC can not be cleared, go on the troubleshooting.

  • Page 43: Ect Sensor 2 Troubleshooting

    • ECT Sensor 2 Troubleshooting DTC 140-2: ECT sensor 2 voltage is high 1. Symptom reproduction test DTC 140-1: ECT sensor 2 voltage is low -1. Connect the Dr. H and clear the DTC once. If the 1. Symptom reproduction test DTC can not be cleared, go on the troubleshooting.

  • Page 44: Ect Sensor 3 Troubleshooting

    3. ECT sensor 2 ground line open circuit check • ECT Sensor 3 Troubleshooting -1. Connect the ECM connector B. DTC 141-1: ECT sensor 3 voltage is low -2. Check for the continuity between the No. 1 (Green/ 1. Symptom reproduction test Red) terminal of the ECT sensor 2 harness side 2P -1.
  • Page 45 DTC 141-2: ECT sensor 3 voltage is high 3. ECT sensor 3 ground line open circuit check -1. Connect the ECM connector B. 1. Symptom reproduction test -2. Check for continuity between the No. 1 (Green/Red) -1. Connect the Dr. H and clear the DTC once. If the terminal of the ECT sensor 3 harness side 2P con- DTC can not be cleared, go on the troubleshooting.

  • Page 46: Eop Switch (High Pressure Side) Troubleshooting

    • EOP switch (High pressure side) 3. EOP switch signal line short circuit check -1. Turn the ignition switch OFF. Disconnect the EOP Troubleshooting switch 2P connector and the ECM connector A. DTC 142-1: EOP switch signal is abnormal -2. Check for the continuity between the No. 1 (Yellow/Red) terminal of the EOP switch harness 1.

  • Page 47: Ect Sensor 4 Troubleshooting

    5. EOP switch check • ECT Sensor 4 Troubleshooting -1. Turn the ignition switch OFF and connect all the con- DTC 143-1: ECT sensor 4 voltage is low nectors. 1. Symptom reproduction test -2. Turn the ignition switch ON and check the EOP -1.
  • Page 48 DTC 143-2: ECT sensor 4 voltage is high 3. ECT sensor 4 ground line open circuit check -1. Connect the ECM connector B. 1. Symptom reproduction test -2. Check for the continuity between the No. 1 -1. Connect the Dr. H and clear the DTC once. If the (Green/Red) terminal of the ECT sensor 4 harness DTC can not be cleared, go on the troubleshooting.
  • Page 49 2008 66ZY600Z 2008.02...

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