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Version: Jan. 27. 2022 BF115J / BF135D/ BF140A / BF150D New OBE Technical Training Confidentiality Category: Internal use only Honda Motor Co., Ltd. Life Creation Operations...
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Specifications: BF115J / BF135D Listed figures are accurate as of December 2021(Please be aware that there may be revisions) Basic Specification BF115J BF135D Type BBWJ BBVJ Engine type Water cooled, 4-Stroke DOHC 4 cylinder/16 Valves Total displacement 2,354 cm3 Bore x stroke 87.0 mm X 99.0 mm...
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Specifications: BF140A / BF150D Listed figures are accurate as of December 2021(Please be aware that there may be revisions) Basic Specification BF140A BF150D Type BBUJ BBTJ Engine type Water cooled, 4-Stroke DOHC 4 cylinder/16 Valves Total displacement 2,354 cm3 Bore x stroke 87.0 mm X 99.0 mm Compression ratio Valve train...
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Dimensional Drawing Listed figures are accurate as of December 2021(Please be aware that there may be revisions) 615.5 913.5 194.5 68° 50.5 76.2 4° 12° Transom L type 1688 1109 1033 XL type 1815 1068 1223 1100 1147...
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Dimensional Drawing Listed figures are accurate as of December 2021(Please be aware that there may be revisions) 163.5 203.2 251.5 13.5 83.7 125.4 251.5 250.8 203.2 177.6 63.5 31.75 14.5 34.3...
BF115J / BF135D/ BF140A / BF150D Description of Major Changes 【Frame】 【Engine】 Improved Appearance Improved Ease of Maintenance Improved Ease of Maintenance Non-resonant Knock Sensor Tilt Limit Switch (YOP) O2 Sensor Power Interface for 12V Accessories Smart Key System (DBW &...
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[Frame] Improved Appearance advanced design excellent waterproof performance. Adopts “Dynamic Motion Form” to achieve both To prevent the water from penetrating into the engine cover and rust from forming, the number of body panel sections (figures) is reduced. Previous model (7 sections) New model (5 sections) The simplified locking mechanism of the engine cover has been achieved by eliminating the cables, and a sealing function is improved by locking the cover at three points.
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[Frame] Improved Appearance Prevents moisture from entering the inside of the engine under case. Install the engine under cases while paying attention to the following in order to The mating part of the under cover seal A is positioned in the prevent moisture from entering.
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[Frame] Improved Ease of Maintenance PTT Assy. Improved maintainability of The structure of the lower cylinder shaft and the shape of the stern bracket have been changed. It is no longer necessary to loosen the stern brackets on both sides, and the PTT Assy. can be removed and installed by removing a bolt, lower cylinder shaft and nut.
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[Frame] Tilt Limit Switch (YOP) To prevent interference with the boat body, a tilt limit switch is made available as a YOP to allow for flexible tilt upper limit setting. To make the setting easier, the upper tilt limit position can be set by tightening at desired angle. Kit Components Angle cam Tilt limit switch...
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[Frame] Power Interface for 12V Accessories 12V power supply Provides to accessories. A dedicated accessory power supply is provided in the junction box of the outboard motor. The 12V power can be supplied from the wire terminals via the accessory relay (linked to the ignition switch) on the hull side. TRUNK Junction box DROP...
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BF115J / BF135D/ BF140A / BF150D Description of Major Changes 【Frame】 【Engine】 Improved Appearance Improved Ease of Maintenance Improved Ease of Maintenance Non-resonant Knock Sensor Tilt Limit Switch (YOP) O2 Sensor Power Interface for 12V Accessories Smart Key System (DBW &...
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[Engine] Improved Ease of Maintenance improved accessibility to various parts. Deeper engine cover and lowered engine under case for Previous model New model Examples of parts with improved accessibility Low pressure fuel High pressure fuel filter filter/Water separator Cylinder head cover Achieved easier detachability of each part.
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[Engine] Improved Ease of Maintenance improve workability Redesigned to of parts replacement Previous model (separate) Water separator Low pressure fuel filter Integration of low pressure fuel filter and water separator The low pressure fuel filter and water separator have been integrated and positioned in a location that affords good accessibility.
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[Engine] Improved Ease of Maintenance improve maintainability The structure around the level gauge pipe and oil filler cap has been modified to at sea. [Oil filler cap] The cap has been changed from a screw- [Level gauge pipe] on type to a 90-degree rotating type, making it easier to remove and install.
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[Engine] Improved Ease of Maintenance Redesigned the oil drain area to improve maintainability and increase eco-friendliness Previous model New model To access the oil drain bolt, the maintenance cover must be The maintenance cover has been eliminated, and the oil drain bolts removed.
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[Engine] Non-resonant Knock Sensor Seeks to improve the accuracy of knocking detection Adopts non-resonant knock sensor different from conventional types. Improves engine output and fuel efficiency by improving knocking detection accuracy (detection of minute knocking). Output characteristics The conventional resonant type knock sensor generates an electric charge when the resonating body distorts. On the other hand, with a non-resonant type knock sensor, an electric charge is generated when an internal weight compresses a piezoelectric element.
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[Engine] O2 Sensor O2 sensor is adopted instead of the conventional LAF sensor. Block diagram of the control system Crank angle sensor Injector (Common) TDC sensor Ignition coil (Common) O2 sensor MAP sensor PGM-FI TP sensor EACV (Mechanical) EBT sensor Throttle motor (DBW) IAT sensor...
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[Engine] Smart Key System (DBW & Mechanical) Smart key system aimed at improving convenience theft prevention Smart key is a system designed to improve convenience as well as prevent theft. Communication devices Part name Function Smart key Battery-powered key. Setting an arbitrary communication ID (during user registration) allows linking to the smart key unit via UHF.* Smart key unit Smart key authentication unit that connects and communicates (H-CAN) with the FI-ECU.
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[Engine] Smart Key System (DBW & Mechanical) How it works (DBW) The smart key system of DBW control model works as follows. Effective range for smart key communication (authentication) is 80 cm or less Start/stop switch panel Remote control box assy. Key switch panel assy.
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[Engine] Smart Key System (DBW & Mechanical) How it works (Mechanical) The smart key system of mechanical control model works as follows. Effective range for smart key communication (authentication) is 80 cm or less Start/stop switch panel Key switch panel assy. Remote control box assy.
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[Engine] Smart Key System (DBW & Mechanical) cancel smart key usage when selling the boat, initialize the FI-ECU Since the FI-ECU of the outboard motor equipped with the smart key system thinks that the smart key is active even when the smart key unit is absent, the engine cannot start unless the FI-ECU is initialized.
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[Engine] Smart Key System (DBW & Mechanical) cancel smart key usage when selling the boat, initialize the FI-ECU Since the FI-ECU of the outboard motor equipped with the smart key system thinks that the smart key is active even when the smart key unit is absent, the engine cannot start unless the FI-ECU is initialized.
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[Engine] Battery Switch OFF Notification Prevents the battery from running out due to forgetting to turn off the ignition switch. The FI-ECU monitors the starter voltage and detects the ON/OFF status of the battery switch. When the engine is stopped and the battery switch is OFF, the system notifies the user with a buzzer to prevent the battery from running out due to forgetting to turn off the ignition switch.
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[Engine] Improved Ease of Re-Powering change of the panel cable connectors To support reusing of existing cables due to of the mechanical control model The 20P panel cable, which integrates the conventional switch panel cable (14P) and PGM indicator cable (6P), is newly adopted. In response to the engine connector change, a conversion cable is made available so that the existing cable can be used when the outboard motor is replaced.
BF115J / BF135D/ BF140A / BF150D DBW System DBW System Overview Safety Network System Function Explanations...
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DBW System Overview Electric throttle and electric shifting systems based on DBW (Drive-by-Wire) The DBW control system mainly changes throttle control and shift control mechanisms from a mechanical to an electrical system. Resulting benefits include improved cable workability during rigging setup. Throttle opening control...
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DBW System Overview Electric throttle system Basic flow of electric throttle control At Station At Engine Lever operation (angle) information Throttle opening degree Transmission of lever operation Control data transmission (angle) information (H-CAN transmission/NMEA2000) Transmission Transmission Transmission Remote Control Control Unit Assy. FI ECU Box Assy.
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DBW System Overview Electric shifting system With this electric type shifting system, an engine speed of 1,500 rpm or less is preset* to allow forward/reverse shifting in order to reduce wear and damage to the clutch. At Station At Engine Transmission of Lever operation (angle) information Operation...
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DBW System Overview Electric shifting system With the electric shifting system, the operation of the link rod is electrically controlled by an actuator (motor) in response to lever operation. All operations from the shift arm to the clutch are the same as conventional systems. Electrical operation DBW remote control...
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DBW System Overview Each throttle body/shift actuator is equipped with two sensors Each throttle body/shift actuator has two sensor circuits (main and sub). Even if the main or sub sensor malfunctions, the motor keeps running based on the unaffected sensor, enabling uninterrupted cruising even during a malfunction.* Throttle body Shift actuator...
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Safety Network System Safety network system (2 lines of communication) Robust system incorporates two lines: H-CAN (Honda CAN) and NMEA2000. Normally, system control is performed through the H-CAN line. Even if there is a problem* with the H-CAN line, system control can be done via the NMEA2000 line, so the vessel can continue to cruise. Dual lines with H-CAN and NMEA2000 Main Station TRUNK cable...
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Function Explanations PTT (Power Trim & Tilt) unified control system When running on multiple engines, pressing the PPT ALL SW on the remote control lever enables unified PTT control of all engines. PTT control equivalent to current models is still possible with the ignition switch in the OFF position (IG/SW-OFF). Flow of control When the switch is pressed/released, the control unit Assy.
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Function Explanations One-push Start/Stop unified system A push button type Start/Stop switch has been adopted. It is possible to start and stop up to 4 engines in unison by pressing the ALL Start/Stop button in a multi-engine mounted rig. Single-mounted: Engine on/off (w/o smart key) Standard Smart key Switch name...
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Function Explanations One-push Start/Stop unified system Use the ALL Start/Stop switch to start/stop the engine as described below. To avoid excessive battery load, cranking is done within 3 seconds, with 1-second intervals between successive engines. Normal: Start Normal: Stop Push Engines start from No.
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Function Explanations System overview of control devices for DBW control Based on the state of each switch and the sensor voltage of the remote control lever, information such as the shift position and lever degree is transmitted to the PGM-FI ECU via H-CAN by the remote control ECU. PTT SW ALL LED lighting indication...
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Function Explanations Functions list Various modes can be engaged by switching the DBW control box Assy. Function Purpose Control Adjust settings within the range of 650 rpm to 1,000 rpm Trolling control Each press changes the number of revolutions in increments Stable running in low speed range of ±50 rpm.
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Function Explanations Mode switching Switching to various modes is possible by operating the button on the remote control box assy. or the function panel. Lever position Switch operation Mode switch display Mode disengage ・Right SW: increase revs Shift-in for Long press TROLL SW Blue all levers 20°...
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Function Explanations Fast idle mode Engine speed can be increased or decreased while in Neutral, such as during maintenance. (1) Lever (3) Mode switch (2) Switch operation position display One of either Long press Blinks lever is Neutral FAST IDLE SW 20°...
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Function Explanations One-lever Mode Mode that allows 2 or more outboard motors to be controlled using one remote control lever. Up to 4 engines can be controlled. When this mode is engaged, the speed of all engines are synchronized with that of engine No.0. (1) Lever Left lever operation (2) Switch operation...
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Function Explanations Synchro mode Synchro mode is engaged only when all necessary conditions are met during One-lever mode operation. Synchro mode synchronizes the revs for all connected outboard motors to reduce the whirring noise caused by the difference in speed of multiple engines for quieter running. Flow until Synchro mode is engaged (image) Disengage Synchro (image) Synchro mode disengages if even one engine’s status becomes as follows.
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Function Explanations Conditions for Synchro mode engagement/disengagement Synchro mode disengages Conditions Synchro mode engages (Exits from Synchro mode) Remote control lever While lever position is fixed While lever is being operated operation (Not being operated) Engine speed ± 300 rpm range for 3 sec. Engine speed ±...
BF115J / BF135D/ BF140A / BF150D Rigging Rigging Overview Battery’s Power and Ground Connections Rigging Components (DBW) Terminating Resistor in System Circuit Rigging Components (Mechanical) Starter Kit...
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Rigging Overview DBW control type and mechanical control type selectable according to the user’s needs The customer can choose DBW control type or mechanical control (conventional) type. Different types are comprised of different devices. DBW type (150/140/135/115) Mechanical type (150/140/135/115) PGM-FI ECU FI-ECU FI-ECU...
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Rigging Overview Control Station There are two control stations for DBW control, the Main Station and 2nd Station. One station can control up to four mounted engines. If more than four engines, it is necessary to add both a “Main” and “2nd” station. Normally only the Main Station is used, but if the vessel has a 2nd floor deck, it is possible to install a 2nd Station separate from the 1st floor steering room and configure the systems separately.
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Rigging Components (DBW) One outboard motor, DBW control, Main Station only Setup: The following is a rigging example for a single engine in DBW control configuration using only a Main Station. FI-ECU TRUNK cable DROP cable Main Station H-CAN line Remote control box assy.
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Rigging Components (DBW) One outboard motor, DBW control, Smart key, Main Station only Setup: The following is a rigging example for a single engine in DBW control configuration with smart key, using only a Main Station. Smart Key Unit 80 cm or less Remote control box assy.
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Rigging Components (DBW) One outboard motor, DBW control, Main Station and 2nd Station Setup: The following is a rigging example for a single engine in DBW control configuration using a Main Station and 2nd Station. DROP cable FI-ECU TRUNK cable H-CAN line Main Station Remote control box assy.
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Rigging Components (DBW) One outboard motor, DBW control, Smart key, Main Station and 2nd Station Setup: The following is a rigging example for a single engine in DBW control configuration with smart key, using a Main Station and 2nd Station. Remote control Smart Key Unit box assy.
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Rigging Components (DBW) Four outboard motors, DBW control, Smart key, Main Station and 2nd Station Setup: The following is a rigging example for four engines in DBW control configuration with smart key, using a Main Station and 2nd Station. FI-ECU Smart Key Unit DROP cable Remote control...
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Rigging Components (Mechanical) One outboard motor, Mechanical control Setup: The following is a rigging example for a single engine in mechanical control configuration without trolling control. Remote control box assy. (PTT switch) Multi display Key switch NMEA2000 line Throttle cable panel assy.
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Rigging Components (Mechanical) One outboard motor, Mechanical control, Trolling control Setup: The following is a rigging example for a single engine in mechanical control configuration with trolling control. Remote control box assy. (PTT switch, trolling control) Multi display Key switch NMEA2000 line panel assy.
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Rigging Components (Mechanical) Two outboard motors, Mechanical control Setup: The following is a rigging example for two engines in mechanical control configuration without trolling control. Remote control box assy. (PTT switch) Panel indicator harness Multi display Throttle cable Shift cable NMEA2000 line Network cable FI-ECU...
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Rigging Components (Mechanical) Two outboard motors, Mechanical control, Trolling control Setup: The following is a rigging example for two engines in mechanical control configuration with trolling control. Remote control box assy. (PTT switch, trolling control) Panel indicator harness Throttle cable Multi display Shift cable NMEA2000 line...
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Rigging Components (Mechanical) One outboard motor, Mechanical control, Smart key Setup: The following is a rigging example for a single engine in mechanical control configuration with smart key. Remote control box assy. (PTT switch, trolling control) Key switch Smart Key Unit panel assy.
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Rigging Components (Mechanical) Two outboard motors, Mechanical control, Smart key Setup: The following is a rigging example for two engines in mechanical control configuration with smart key. Smart Key Unit 80 cm Remote control box assy. or less (PTT switch, trolling control) Smart key Throttle cable Shift cable...
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Battery temperature AWG4 AWG2 AWG1/0 AWG2/0 AWG4/0 20 ㎟ 30 ㎟ 50 ㎟ 60 ㎟ 100 ㎟ BF115J/ 130E41 5.5 m 8.3 m 13.8 m 16.6 m 26.0 m 0℃ or higher BF135D/ (JIS) (18 ft) (28 ft) (48 ft)
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Terminating Resistor in System Circuit terminating resistor is required for the H-CAN/NMEA2000 circuit The H-CAN/NMEA2000 lines need a terminating resistor. The system requires two terminating resistors; one on the engine side and one on the remote control side. The diagram below shows an example for four engines in DBW control configuration. Terminating resistor Terminating resistor 2nd Station...
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Starter Kit To facilitate the introduction NMEA2000 by providing a set of parts necessary for configuration To facilitate the introduction of NMEA2000, a kit that satisfies the minimum configuration is provided to achieve the improved availability of parts and convenience. The diagram below shows an example for single engine in mechanical control configuration.
BF115J / BF135D/ BF140A / BF150D Display Kit Multi Display Notification Functions of Multi Display Resetting the Maintenance Notification Indication...
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Multi Display Multi Display shows a wide range of information Multi display can be connected to the NMEA2000 line. The display shows various information, for example, mode transition indication such as trolling control mode, DTC display, in addition to engine speed. Battery charging Trim angle indicator indicator...
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Notification Functions of Multi Display DTC display on the Multi Display The current DTC can be indicated on the multi display screen. By connecting an SCS short connector to the DLC, it is also possible to display past DTC history. Example of DTC display SCS short connector FI system error...
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Resetting the Maintenance Notification Indication Reset notifications with display kit after periodic maintenance The engine ECU is programmed to notify the user that it is time for periodic maintenance every 20, 80, or 100 hours of operation. In order to correctly notify the next maintenance period, the notification needs to be reset after the maintenance is completed. 【Display when the notification appears】...
BF115J / BF135D/ BF140A / BF150D Changed Parts Table Changed Parts (Major Parts)
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Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) Parts BF150 (previous) BF115J-150D (new) CASE COMP, PISTON B CRANK 11100-ZY6-000 11100-ZVT-000 13101-ZY6-000 13102-ZY6-000 Old → New Old → New New → Old New → Old GAUGE BLOCK COMP, COMP, OIL...
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Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) Parts BF150 (previous) BF115J-150D (new) GUARD, VAPOR THROTTLE SEPARATOR BODY ASSY (DBW) 16406-ZVT-000 16730-ZY6-123 16730-ZVT-003 Old → New New → Old New → Old GUARD, STRAINER THROTTLE ASSY, FUEL BODY (MECH)
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Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) Parts BF150 (previous) BF115J-150D (new) GASKET, GROMMET, THROTTLE SILENCER BODY (DBW) (DBW) 16176-ZVT-003 17374-ZVT-000 New → Old New → Old SPACER COMP, GROMMET, THROTTLE SILENCER BODY (MECH) (DBW) 16404-ZVT-000 17374-ZY6-000 17374-ZVT-900 New →...
Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) Parts BF150 (previous) BF115J-150D (new) CASE COMP, BRACKET, MOUNT STERN R 23170-ZY6-000 23170-ZVT-000 50301-ZW1-070 50301-ZVT-000 Old → New Old → New New → Old New → Old CASE ASSY, BRACKET, ELEC PARTS...
Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) Parts BF150 (previous) BF115J-150D (new) SHAFT, LWR BRKT, SHIFT CYLN LINK (MECH) 56539-ZZ0-C00 56539-ZVL-000 24628-ZY6-000 24628-ZVT-600 Old → New Old → New New → Old New → Old SHAFT COMP PLATE,...
Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) Parts BF150 (previous) BF115J-150D (new) GUIDE, SHIFT LINK (SHAFT COMP B, SHIFT) (DBW) 24620-ZY6-000 24628-ZY6-000 24627-ZVT-000 Old → New Old → New New → Old SHAFT COMP, SHIFT (DBW) SHIFT- NEUTRAL...
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Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) Parts BF150 (previous) BF115J-150D (new) GROMMET, UNDER CASE COVER, (DBW) REAR 40105-ZVL-000 40116-ZY6-000 63721-ZVT-000 New → Old New → Old New → Old GROMMET, COVER, UNDER CASE SEPARATE (MECH) 40105-ZY6-020 40105-ZVT-600...
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Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) Parts BF150 (previous) BF115J-150D (new) DUCT ASSY, SEAL, ENGINE ENGINE COVER COVER 63144-ZY6-000 63140-ZVT-000 63102-ZY6-010 63102-ZVT-000 Old → New New → Old New → Old New → Old GUIDE, CASE, ENG...
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Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) Parts BF150 (previous) BF115J-150D (new) CASE, ENG CASE ASSY, UNDER L GEAR L 41100-ZY6-050 (STD) 41100-ZVT-600 (STD) 40106-ZVT-000 41100-ZY6-705 (C/R) 41100-ZVT-800 (C/R) New → Old New → Old New → Old...
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Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) Parts BF150 (previous) BF115J-150D (new) SENSOR, OXYGEN (LAF Sensor) (O2 Sensor) 35668-ZY6-003 35655-ZY9-H01 Old → New New → Old ECU ASSY 34750-ZVT-003 (BF150 DBW) 34750-ZVT-A01 (BF150 DBW) 34750-ZVT-901 (BF150 MECH) 34750-ZVT-A11 (BF150 MECH)
Changed Parts (Major Parts) Parts BF150 (previous) BF115J-150D (new) BOX ASSY, JUNCTION (DBW) 32370-ZVT-003 New → Old BOX ASSY, JUNCTION (MECH) 32370-ZY6 -004 32370-ZVT-900 Old → New New → Old RELAY ASSY, POWER TILT 38550-ZY6-003 38550-ZVT-003 Old → New New → Old...
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