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TOHATSU BFT 200D Rigging Manual

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R I G G I N G  
M A N U A L
Models
OB No.92ZVL10-0AK1｜9-19

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  • Page 1 R I G G I N G   M A N U A L Models OB No.92ZVL10-0AK1｜9-19...
  • Page 2 Introduction Before reading this manual This rigging manual provides information that is needed for initial set-up and rigging of applicable outboard motors. For our customers' safe and comfortable use of the products for long term, it is essential to maintain the performance and quality of the outboard motors.

  • Page 3: Table Of Contents

    dummytext BF175D/BF200D/BF225D/BF250D INTRODUCTION···············································2 ELECTRICAL CONNECTIONS (hull side) (DBW model) ················································· 26 REVISION HISTORY ········································2 BATTERY (not included) ······························ 28 THE IMPORTANCE OF PROPER SERVICING ······················································3 PROPELLER·················································· 29 IMPORTANT SAFETY PRECAUTIONS ··········3 ADJUSTMENT AFTER INSTALLATION ······· 33 SERVICE RULES ·············································4 BREAK-IN PROCEDURE ······························ 35 SYMBOLS ························································4 WHEN RADIO SYSTEM/GPS MOUNTED ON THE BOAT ·····················································...

  • Page 4: Introduction

    dummyhead BF175D/BF200D/BF225D/BF250D INTRODUCTION BF175D/BF200D/BF225D/BF250D This manual covers setup, installation and pre-delivery service for the Honda BF175D/BF200D/BF225D/BF250D Outboard Motors. Setup, installation and pre-delivery service must be performed by authorized Honda Marine Dealer. These instructions are provided for dealer use only. Proper setup, installation and pre-delivery service are essential for safe, reliable operation. Your customer expects the Outboard Motor to be correctly set up, installed, adjusted, and ready for use;...

  • Page 5: Servicing

    dummyhead BF175D/BF200D/BF225D/BF250D THE IMPORTANCE OF PROPER SERVICING The service information contained in this manual is intended for use by qualified, professional technicians. Attempting service without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage the Outboard Motor or create an unsafe condition.

  • Page 6: Service Rules

    dummyhead BF175D/BF200D/BF225D/BF250D SERVICE RULES • Use Honda-recommended lubricants or their equivalents. • 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. • Lubricate any sliding surfaces before reassembly. •...

  • Page 7: Torque Values

    dummyhead BF175D/BF200D/BF225D/BF250D TORQUE VALUES TORQUE VALUES FASTENER APPLICATIONS DESCRIPTION N•m kgf•m lbf•ft Propeller lock nut Minimum torque (18 mm castle nut) Maximum torque 44.1 Steering link arm bolt 3/8-24 UNF Steering link arm lock nut 3/8-24 UNF Steering plate nut 10 mm Stern bracket mount bolt 12 x 119 mm...

  • Page 8: Dimensional Drawings

    dummyhead BF175D/BF200D/BF225D/BF250D DIMENSIONAL DRAWINGS Unit: mm (in) At 68° tilt up 582.7 (22.94) 30° 75.8 (2.98) 30° 30° 768 (30.2) 1,030 (340.6) 68° 12° 658.5 (25.93) Shaft length type 939.5 mm (36.99 in) 1,062 mm (41.8 in) 1,066.5 mm (41.99 in) 1,173.5 mm (46.20 in) 1,193.5 mm (46.99 in) 1,287.5 mm (50.69 in)

  • Page 9: Unpacking

    dummyhead BF175D/BF200D/BF225D/BF250D UNPACKING The steel crate frame may have sharp edges or burrs. You can be cut or injured if you come in contact with sharp metal. Always wear heavy gloves during unpacking to protect your hands from any sharp edges and burrs on the steel crate frame.
  • Page 10 dummyhead BF175D/BF200D/BF225D/BF250D Open the three lock levers [1] to unlock the engine cover [2] and remove it. Hook engine lifting sling chains [1] to the engine hangers, and lift up the outboard motor with a hoist. • To prevent damage the cooling fan cover [2], first hook the chains to the two engine hangers [3] on the cylinder head side, then hook the chain to the engine hanger [4] located near the alternator.
  • Page 11 dummyhead BF175D/BF200D/BF225D/BF250D With the lower crate frame set on the floor, remove the following: – Flange nut [1] and washer [2] – Flange bolt [3] and washer [4] – Two special bolts [5] – Four flange nuts [6], washers [7] and special washers [8] –...

  • Page 12: Parts Package Inspection

    dummyhead BF175D/BF200D/BF225D/BF250D PARTS PACKAGE INSPECTION The boat side parts are not listed. BF175D/BF200D/BF225D/BF250D Part name DBW model Mechanical model Remarks Fuel tank tube assembly Fuel tube joint – – – – Tube clip band (12.5 mm) Under case grommet (for DBW model) –...
  • Page 13 dummyhead BF175D/BF200D/BF225D/BF250D...

  • Page 14: Motor Installation

    dummyhead BF175D/BF200D/BF225D/BF250D MOTOR INSTALLATION MOTOR SELECTION Secure and correct installation is essential for safe boating and good performance. Follow the installation instructions provided in this manual. Improper set-up or pre-deliver service can cause an unsafe condition that can cause your customer to be seriously hurt or killed. Follow the procedures and precautions in this manual and shop manual carefully.
  • Page 15 dummyhead BF175D/BF200D/BF225D/BF250D As a general rule, the outboard motor should be installed so the anti-ventilation plate [1] is parallel to the boat bottom [2]. If the board transom angle [3] is less than 8°, the BF175D, BF200D, BF225D and BF250D anti-ventilation plate will not be parallel to the boat bottom when trimmed to the lowest hole.
  • Page 16 dummyhead BF175D/BF200D/BF225D/BF250D BOAT TRANSOM CENTER LINE Measure across the transom to determine the transom center line and draw a vertical line. On a "V" bottom boat, the vertical line should pass through the keel. Use a pencil and tape measure [1] to locate center line. Put one end of the tape measure on a chine [2] and place the other end on the upper edge of the transom, somewhere past the "visual"...
  • Page 17 dummyhead BF175D/BF200D/BF225D/BF250D INSTALLATION HEIGHT CHECK Optimum outboard motor installation height varies with boat type and bottom shape. Contact the boat manufacturer for any special recommendations that are unique to a specific model of boat. • If the outboard motor is installed too low –...
  • Page 18 dummyhead BF175D/BF200D/BF225D/BF250D When mounting dual outboard motors on "V" bottom boats, the outboard motor installation height range [1] is 0 – 25 mm (0 – 1 in). If the outboard motor installation height cannot be achieved, adjust boat transom height. BOAT TRANSOM HEIGHT ADJUSTMENT If the installation height is too low, or needs to be modified to a accommodate the width of the outboard motor(s), contact the boat’s...

  • Page 19: Cable/Electrical Connections

    dummyhead BF175D/BF200D/BF225D/BF250D BOLTING MOTOR TO TRANSOM With the motor resting on the boat transom, verify correct motor Apply sealant. Apply sealant. height. Motor can be raised by using a lower set of mounting holes. Apply Marine silicone sealer or equivalent to the mounting bolt holes from both sides as shown.
  • Page 20 dummyhead BF175D/BF200D/BF225D/BF250D Connect the drop cable (DBW model) connector [1] or indicator DBW model shown: cable (Mechanical model) connector [1] to the main harness connector [2]. Install the connector onto the connector bracket [3]. Route the interface cable [1] in the engine under case. Remove the connector suspension [1] from the stays and remove the dummy connector [2] from the main harness connector [3].
  • Page 21 dummyhead BF175D/BF200D/BF225D/BF250D Install the interface cable [1] into the harness clip [2] and route it in the electric parts case [3]. Install the wire harness clip [1] onto the fuel tube stay. Secure the interface cable [2] and drop cable (DBW model) [3] or indicator cable (Mechanical model) [3] with the wire harness clip on the fuel tube stay.
  • Page 22 dummyhead BF175D/BF200D/BF225D/BF250D Mechanical model only: Set the lock plate [1] on the throttle pivot (White) [2] and install them onto the throttle control cable [3]. Install the shift pivot (Black) assembly [4] onto the shift control cable end [5]. Set the starter cables [1] and fuel tube A [2] into the under case grommet [3].
  • Page 23 dummyhead BF175D/BF200D/BF225D/BF250D Mechanical model only: Set the throttle control cable [1] and shift control cable [2] into the grooves in the remote control cable plate [3]. Mechanical model only: Install the remote control cable cover [1] onto the remote control plate [2] by inserting the cover end into the plate slot.
  • Page 24 dummyhead BF175D/BF200D/BF225D/BF250D SHIFT CONTROL CABLE CONNECTION (Mechanical model only) • Before connecting the shift control cable, check that the cable is connected to the remote control box side properly. 1. Move the remote control lever [1] fully to the "F" (Forward) side [2].
  • Page 25 dummyhead BF175D/BF200D/BF225D/BF250D 7. Push on the shift link end [1] lightly and check for play. If there is play in the shift link, set the link at the center [2] of the play. 8. With the shift control cable [1] set in step 7, loosen the lock nut [2] and turn the shift pivot (Black) [3] so that it can be connected to the link rod [4] smoothly.
  • Page 26 dummyhead BF175D/BF200D/BF225D/BF250D 10.After connecting the cable, move the remote control lever back and forth and check for proper shifting. ADJUSTMENT If it is hard to put the remote control lever in the "F" (Forward) or RANGE "R" (Reverse) position with the engine stopped, shift the gear while turning the propeller or propeller shaft.
  • Page 27 dummyhead BF175D/BF200D/BF225D/BF250D 2. Move the remote control lever [1] to the full throttle position [2]. "N" (NEUTRAL) 3. Make sure that the throttle arm [1] contacts the throttle arm stopper [2]. Adjust by turning the cable pivot if necessary. 4. After adjustment, recheck and tighten the lock nut [3].

  • Page 28: Electrical Connections (Hull Side)

    dummyhead BF175D/BF200D/BF225D/BF250D ELECTRICAL CONNECTIONS (hull side) (DBW model) OUTBOARD MOTOR-TO-HULL 4 Outboard motors mounted 1 Outboard motor mounted No.1 Outboard motor [10] To main station To main station No.2 Outboard motor No.3 Outboard motor To main station [10] No.4 Outboard motor To main station [1] Terminator (installed at factory) [5] Engine drop cable (Single)
  • Page 29 dummyhead BF175D/BF200D/BF225D/BF250D MAIN STATION (For Honda smart key applicable model) To second station [12] [13] [13] [14] [15] [15] [10] [11] [10] [18] [16] [11] From outboard motor [17] [10] From outboard motor [1] Dummy connector* [7] Function switch connector [13] Start/stop switch panel [2] Remote control ECU [8] DBW trunk cable...

  • Page 30: Battery (Not Included)

    dummyhead BF175D/BF200D/BF225D/BF250D BATTERY (not included) Recommended battery: 12 V – 92 Ah/5HR (CCA 800) or more capacity battery If boat is equipped with dual outboard motors, two batteries must be installed, one for each motor. • Install the battery [1] in the correct size corrosion-resistant battery box, in a dry, well-ventilated location protected from water and direct sunlight.

  • Page 31: Propeller

    dummyhead BF175D/BF200D/BF225D/BF250D PROPELLER Propeller Selection Pitch Advanced Distance During One Turn (Apparent Advanced Distance) Pitch Ratio P: Pitch (mm) D: Outer Diameter of Propeller PROPELLER Slip Ratio (A - B) x 100 / A PITCH DIMENSIONS A: Visual Advanced Distance (Diameter x Pitch) B: Measured Distance During running;...
  • Page 32 dummyhead BF175D/BF200D/BF225D/BF250D Propeller Selection Chart BF175D/BF200D/BF225D Speed [km/h] Speed within recommended engine speed (km/h) Propeller Size Dia. x pitch (in) 5,000 rpm 6,000 rpm 15-3/4 x 15 15-1/2 x 17 15-1/4 x 19 15 x 21 14-3/4 x 23 14-1/2 x 25 14-1/2 x 27 BF250D Speed [km/h]...
  • Page 33 dummyhead BF175D/BF200D/BF225D/BF250D Boat Type and Applicable Size (Length and Weight) Example Overall Weight Recommended full throttle Out- Overall Boat Type Hull Shape (Example) length (kg) Weight speed [km/h] board length (ft) [lbs] [kg] motor [ft] 175D 200D 225D 250D 1,170 545 –...
  • Page 34 dummyhead BF175D/BF200D/BF225D/BF250D Propeller Installation • Disconnect the battery cable terminal to prevent the engine from starting accidentally. The propeller blades may have sharp edges or burrs. You can be cut or injured if you come in contact with sharp metal. Always wear heavy gloves when handling propellers to protect your hands from any sharp edges.

  • Page 35: Adjustment After Installation

    dummyhead BF175D/BF200D/BF225D/BF250D ADJUSTMENT AFTER INSTALLATION Trim Tab Adjustment Single Motor After the engine break-in, run the boat at full speed and check to see if the boat pulls to the left or right. Adjust the trim tab as required to ensure good and straight running characteristics.
  • Page 36 dummyhead BF175D/BF200D/BF225D/BF250D Dual Motors Remove the trim tab lock bolt/washer [1] and trim tab [2] from the standard rotation outboard motor. Replace the trim tab with the gear case cover [3], install it with the trim tab lock bolt/washer (10 x 32 mm) and tighten the bolt/washer. [2] (Single motor use only) [3] (For dual motors)

  • Page 37: Break-In Procedure

    dummyhead BF175D/BF200D/BF225D/BF250D 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 38: The Boat

    dummyhead BF175D/BF200D/BF225D/BF250D WHEN RADIO SYSTEM/GPS MOUNTED ON THE BOAT The ECM and its wires are designed so that they are not affected by the external jamming, but the ECM can function erroneously when it receives the extremely strong electric wave. Check the ECM for erroneous operation whenever a radio system or a navigation system is mounted on the boat.

  • Page 39: Pre-Delivery Service Check List

    dummyhead BF175D/BF200D/BF225D/BF250D PRE-DELIVERY SERVICE CHECK LIST Check all items on the following list. Refer to the Owner’s Manual or Shop Manual for the specifications and the detailed procedures. Test every unit to be sure it is functioning properly. On land EXTERNAL APPEARANCE Check for paint scratches;...

  • Page 40: Operation Check List

    dummyhead BF175D/BF200D/BF225D/BF250D OPERATION CHECK LIST In the Water OUTBOARD MOTOR INSTALLATION Check that there are no water leaks from the motor mounting bolt holes. Check for the balanced weight distribution in the boat. OUTBOARD MOTOR OPERATION Check the neutral switch for proper operation. Turn the combination switch ON and check whether the buzzer sounds twice.

  • Page 41: Wiring Diagram (Dbw Model)

    dummytext BF175D/BF200D/BF225D/BF250D BF175D/BF200D/BF225D/BF250D WIRING DIAGRAM (DBW model) - OUTBOARD MOTOR No.2 FUEL No.4 FUEL No.6 FUEL No.3 INJECTOR INJECTOR INJECTOR TBW UNIT SHIFT ACTUATOR No.6 No.7 No.8 No.4 No.5 (20A) No.1 FUEL No.3 FUEL No.5 FUEL (30A) (15A) (10A) (30A) (7.5A) SPARE START...
  • Page 42 dummytext BF175D/BF200D/BF225D/BF250D WIRING DIAGRAM (DBW model) - OUTBOARD MOTOR-TO-HULL TERMINATOR CABLE ASSY, DBW TRUNK G/Bl G/Bl W/Bl W/Bl Bl/W Bl/W Bl/R Bl/R O/Bu Bl/W Bl/W Bl/Y Bl/Y TO MAIN STATION W/Bl W/Bl T-CONNECTOR G/Bl G/Bl ENGINE 4 W/Bl Bu/Bl Bu/Bl W/Bu W/Bl W/Bl...
  • Page 43 dummytext BF175D/BF200D/BF225D/BF250D WIRING DIAGRAM (DBW model) - MAIN STATION KEY SWITCH PANEL (Honda smart key applicable model only) WARNING COMBINATION BUZZER SMART SMART CONTROL UNIT SWITCH (SMART) JOINT CONNECTOR KEY 1 START/ RELAY(SMART) COMB SW RY BAT(REM+B) POWER TILT SWITCH START/STOP SWITCH STOP KEY SWITCH PANEL...
  • Page 44 dummytext BF175D/BF200D/BF225D/BF250D WIRING DIAGRAM (DBW model) - SECOND STATION START/STOP SWITCH EMERGENCY WARNING POWER TILT SWITCH ALL START/STOP STOP SWITCH ENGINE 1 ENGINE 2 ENGINE 3 ENGINE 4 BUZZER SWITCH REMOTE CONTROL BOX ENGINE 1 ENGINE 2 ENGINE 3 ENGINE 4 ONLY TWIN (TOP MOUNT) L.

  • Page 45: Wiring Diagram (Mechanical Model)

    dummytext BF175D/BF200D/BF225D/BF250D WIRING DIAGRAM (Mechanical model) - OUTBOARD MOTOR No.2 FUEL No.4 FUEL No.6 FUEL INJECTOR INJECTOR INJECTOR No.8 No.4 No.5 No.1 FUEL No.3 FUEL No.5 FUEL (10A) (30A) (10A) No.1 PTC No.2 PTC No.3 PTC No.4 PTC No.5 PTC No.6 PTC INJECTOR INJECTOR...
  • Page 46 dummytext BF175D/BF200D/BF225D/BF250D WIRING DIAGRAM (Mechanical model) - OUTBOARD MOTOR (Revision history No.1) No.2 FUEL No.4 FUEL No.6 FUEL INJECTOR INJECTOR INJECTOR No.8 No.4 No.5 No.1 FUEL No.3 FUEL No.5 FUEL (10A) (30A) (10A) No.1 PTC No.2 PTC No.3 PTC No.4 PTC No.5 PTC No.6 PTC INJECTOR...
  • Page 47 dummytext BF175D/BF200D/BF225D/BF250D WIRING DIAGRAM (Mechanical model) - REMOTE CONTROL TERMINATOR TERMINATOR TERMINATOR TERMINATOR DIODE SUB CABLE Bl/Y Bl/Y Bl/Bu Bl/G Bl/W NETWORK CABLE NETWORK CABLE NETWORK CABLE NETWORK CABLE NETWORK CABLE NETWORK CABLE NETWORK CABLE INTERFACE CABLE INTERFACE CABLE NETWORK CABLE INTERFACE CABLE INTERFACE CABLE Blue...
  • Page 48 © 2018 Honda Motor Co., Ltd. – All Rights Reserved PGM-FI is a trademark of Honda Motor Co., Ltd. registered in Japan and other countries.
  • Page 49 R I G G I N G   M A N U A L BFT  200D BFT  225D BFT  250D Models 5-4, Azusawa 3-Chome, Itabashi-Ku Tokyo 174-0051, Japan Tel: +81-3-3966-3117   F ax: +81-3-3966-0090 OB No.92ZVL10-0AK1                                  9-19 www.tohatsu.com Printed in Japan...

This manual is also suitable for:

Bft 225dBft 250d

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