Honda Marine BF25D Owner's Manual
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Honda Marine BF25D Owner's Manual

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

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  • Page 1 2004 ©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 ........Gearshift/Throttle Control Lever IMPORTANT SAFETY INFORMATION ....(side-mount type) ..........22 SAFETY LABEL LOCATIONS ........ Common Controls Power Trim/Tilt Switch CONTROLS AND FEATURES ........10 (SRT and LRT types) (side-mount type) ... 23 CONTROL AND FEATURE (LHT type) ............
  • Page 6 CONTENTS OTHER FEATURES ..........29 STARTING THE ENGINE ........43 Overrev Limiter ............29 SH, LH, SHG and LHT Types Anodes ..............29 (long tiller handle) ..........43 Portable Fuel Tank ..........30 SRG, LRG, SRT and LRT Types Fuel Cap Vent Knob ..........
  • Page 7 CONTENTS SERVICING YOUR OUTBOARD MOTOR ....64 STORAGE ..............84 THE IMPORTANCE OF MAINTENANCE ... . 64 STORAGE PREPARATION ........84 MAINTENANCE SAFETY ........65 Cleaning and Flushing .......... . 84 TOOL KIT AND Fuel ................ .
  • Page 8 Emission Control System Information ....107 Star Label ............. 109 Specifications ............111 CONSUMER INFORMATION ......115 Honda Publications ..........115 Warranty Service Information ......115 INDEX ................116 WIRING DIAGRAMS ......Inside Back Cover...

  • Page 9: Outboard Motor Safety

    Attach the emergency stop switch INFORMATION lanyard securely to the operator. It is the operator’s responsibility to Honda BF25D and BF30D 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 BF25D BF30D Type Shaft Length Long Tiller Handle Remote Control Recoil Starter Electric Starter Mechanical Tilt Gas-assisted Tilt Power Trim/Tilt Tachometer (optional equipment) Trim Meter (optional equipment) Battery charging DC receptacle 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 SH, LH, SHG and LHT Types (long tiller handle) FUEL HOSE CONNECTOR OIL FILLER CAP ENGINE COVER LONG TILLER HANDLE POWER TILT OIL LEVEL SWITCH DIPSTICK (LHT type) TILT LEVER CLAMP (SH and LH types) SCREW COOLING SYSTEM INDICATOR...
  • Page 14 CONTROLS AND FEATURES GEARSHIFT LEVER SWITCH CLIP OIL PRESSURE INDICATOR LIGHT THROTTLE FRICTION (SHG and LHT types) ADJUSTER EMERGENCY STOP OVERHEAT SWITCH INDICATOR LIGHT (SHG and LHT types) OIL PRESSURE INDICATOR LIGHT (SH and LH types) POWER TRIM/TILT SWITCH (LHT type) THROTTLE GRIP RECOIL STARTER GRIP (Recoil starter type/SH and...

  • Page 15: Srg, Lrg, Srt And Lrt Types (Remote Control)

    CONTROLS AND FEATURES SRG, LRG, SRT and LRT Types (remote control) ENGINE COVER POWER TILT SWITCH OIL FILLER CAP (SRT and LRT types) FUEL HOSE TILT LOCK LEVER CONNECTOR OIL LEVEL DIPSTICK STEERING PLATE STERN BRACKET COOLING SYSTEM TILT LEVER INDICATOR (SRG and LRG types) ANODE...
  • Page 16 CONTROLS AND FEATURES Remote Control box (side-mount type) GEARSHIFT/THROTTLE CONTROL LEVER POWER TRIM/TILT SWITCH (SRT and LRT types) 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...
  • Page 17 CONTROLS AND FEATURES Fuel Tank 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 Ignition Switch Turning the ignition switch key to the (SHG and LHT types) START position operates the starter SH, LH, SHG and LHT Types motor. The key automatically returns (long tiller handle) to the ON position when released START from the START position.

  • Page 19: Emergency Stop Switch And Switch Clip

    CONTROLS AND FEATURES Emergency Stop Switch and Throttle Grip The switch clip must be inserted in Switch Clip the engine stop switch in order for THROTTLE GRIP the engine to start and run. The EMERGENCY STOP lanyard should be attached to the SWITCH operator’s PFD (Personal Flotation Device) or worn around the wrist as...

  • Page 20: Throttle Friction Adjuster

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

  • Page 21: Tilt Lever

    CONTROLS AND FEATURES Tilt Lever (gas-assisted tilt/SHG, SRG and The steering friction adjuster adjusts (mechanical tilt/SH and LH steering resistance. LRG types) types) Less friction allows the outboard motor to turn more easily. More friction helps to hold steady course while cruising or to prevent the outboard motor from swinging while trailering the boat.

  • Page 22: Srg, Lrg, Srt And Lrt Types (Remote Control)

    CONTROLS AND FEATURES Switch Clip and Emergency Stop SRG, LRG, SRT and LRT Turning the ignition switch key to the Switch (side-mount type) Types (remote control) START position operates the starter motor. The key automatically returns For panel-mount or top-mount to the ON position when released EMERGENCY STOP SWITCH...

  • Page 23: Switch Clip And Emergency Stop Switch (Side-Mount Type)

    CONTROLS AND FEATURES Fast Idle Lever The switch clip must be inserted in (side-mount type) the emergency stop switch in order for the engine to start and run. The lanyard must be attached to the N (neutral) operator’s PFD (Personal Flotation GEARSHIFT/THROTTLE FAST IDLE Device) or worn around the wrist as...

  • Page 24: Gearshift/Throttle Control Lever (Side-Mount Type)

    CONTROLS AND FEATURES Gearshif t/Throttle Control GEARSHIFT/THROTTLE CONTROL LEVER Lever (side-mount type) GEARSHIFT/THROTTLE N (neutral) CONTROL LEVER F (forward) R (reverse) NEUTRAL RELEASE LEVER The control lever automatically locks HIGH itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle.

  • Page 25: Common Controls

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

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

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

  • Page 27: Transom Angle Adjusting Rod

    CONTROLS AND FEATURES Transom Angle Adjusting Rod Trim Tab The transom angle adjusting rod (SH and LH types) limits the tilt angle of the outboard TIGHTENING BOLT motor when fully lowered. Proper adjustment prevents the TRIM TAB outboard motor from being trimmed too low (p.

  • Page 28: Instruments

    CONTROLS AND FEATURES INSTRUMENTS Tachometer Fuel Gauge (optional equipment) Trim Meter [optional equipment (LHT, SRT and LRT Types)] FUEL GAUGE A fuel gauge is built into the cap of the portable fuel tank. TACHOMETER TRIM METER The trim meter has a range of 0° to The tachometer shows engine speed 16°...

  • Page 29: Indicators

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

  • Page 30: Overheating Indicator

    CONTROLS AND FEATURES Overheating Indicator SRT and LRT Types If the engine overheats, the red light (side-mount type) will come on, and the engine SHG 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 (time tab)

  • Page 32: Portable Fuel Tank

    CONTROLS AND FEATURES Portable Fuel Tank Fuel Cap Vent Knob The anodes are made of a sacrificial 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: Installation

    0 performance. Follow the installation inches below the bottom of the boat. instructions provided in this manual. Honda BF25D and BF30D outboard motors can be installed on a boat POWER REQUIREMENTS transom having a thickness range of 2.2 inches (35...

  • Page 35: Attachment

    INSTALLATION ATTACHMENT When the outboard motor is installed Attach the stern bracket to the boat extremely low, the idle port may be transom by tightening the clamp immersed and the engine may screws. become hard to start or may run poorly.

  • Page 36: Transom Angle Adjustment

    The negative (-) cable has BLACK a black band at the battery connector. Honda BF25D and BF30D outboard motors produce a 12-volt, 4 or 10- For electric starter operation, use a ampere battery-charging current and...
  • Page 37 INSTALLATION Plug and Receptacle Battery Terminals (types with recoil starter) DC RECEPTACLE ) TERMINAL ) TERMINAL BLACK BATTERY Battery To prepare the outboard motor for Connect the positive (+) battery cable connection to a battery, pull the cover to the positive (+) battery terminal, out of the DC receptacle, connect For complete information, refer to then connect the negative (-) battery...
  • Page 38 INSTALLATION Be caref ul to avoid connecting the battery in reverse polarity, as that will damage the battery-charging system in the outboard motor.

  • Page 39: 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 40 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 41: 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 42: 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 exhaust port or the engine can be Proper adjustment prevents the damaged. outboard motor from being trimmed too low (p.
  • Page 43 OPERATION Motor Angle Inspection (Cruising) INCORRECT INCORRECT CAUSES BOAT TO ‘‘PLOW’’ CAUSES BOAT TO ‘‘SQUAT’’ O. K CORRECT GIVES MAXIMUM PERFORMANCE Install the outboard motor at the best The trim angle differs according to trim angle for stable cruising and the combination of the boat, outboard maximum power.

  • Page 44: Portable Fuel Tank

    OPERATION PORTABLE FUEL TANK FUEL HOSE CONNECTIONS Secure the portable fuel tank in the 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 45: Fuel Priming

    OPERATION FUEL PRIMING STARTING THE ENGINE The engine will not start or run, unless the clip is in the switch. SH, LH, SHG 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 46 OPERATION RECOIL STARTER GRIP N (neutral) START POSITION POINTER THROTTLE GRIP SHIFT LEVER Check the position of the gearshift Align the engine start symbol lever. It must be in the N (neutral) ‘‘ ’’ on the tiller handle with the position for starting.
  • Page 47 OPERATION Recoil starter type: During the warm-up period, check Pull the recoil starter grip slowly the oil pressure indicator (p. until you feel resistance, then pull Using the electric starter f or more overheating indicator (p. ) and briskly. than 5 seconds at a time will cooling system indicator (p.

  • Page 48: Srg, Lrg, Srt And Lrt Types (Remote Control)

    OPERATION SRG, LRG, SRT and LRT Types The engine will not start or run, N (neutral) (remote control) unless the clip is in the switch. For panel-mount or top-mount The emergency stop switch clip remote control information, refer to and lanyard system is a safety the instructions provided with the device that will stop the engine if remote control equipment.
  • Page 49 OPERATION FAST IDLE START Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can damage it. START Turning the ignition switch key to the START position while the engine is running can damage the starter motor and f lywheel.

  • Page 50: Emergency Starting

    OPERATION EMERGENCY STARTING Before getting under way, allow FAST IDLE LEVER the engine to warm up sufficiently 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 51 OPERATION 22 mm BOLT RECOIL STARTER 22 mm KNOT ASSEMBLY BOLT FLYWHEEL NEUTRAL START CABLE EMERGENCY STARTER ROPE FLYWHEEL COVER (Recoil starter type) (Electric starter type) Recoil starter type: Electric starter type: Set the knotted end of the Loosen the neutral start cable lock Remove the flywheel cover by emergency starter rope in the notch nut and disconnect the neutral start...
  • Page 52 (p. ), and cooling system indicator (p. Have your closest authorized Honda marine dealer check your Leave the recoil starter assembly electrical system and correct the off, but install the engine cover (p. problem, so you can use the ), and lock it in place by electric starter.

  • Page 53: 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 SH, LH, SHG and LHT Types stop switch by pulling the lanyard. (long tiller handle) SH, LH, SHG and LHT Types We suggest that you stop the engine (long tiller handle) this way occasionally to verify that...
  • Page 54 OPERATION SRG, LRG, SRT and LRT Types SH and LH Types SRG, LRG, SRT and LRT Types (remote control) (long tiller handle) (remote control) N (neutral) EMERGENCY STOP SWITCH CONTROL LEVER IGNITION SWITCH KEY Move the throttle grip to the Turn the ignition switch key to the SHG and LHT Types slowest speed and control gears to...

  • Page 55: 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 SH, LH, SHG and LHT Types N (neutral) or R (reverse) gears. GRIP (long tiller handle) The engine can be started with the...

  • Page 56: Srg, Lrg, Srt And Lrt Types (Remote Control)

    OPERATION SRG, LRG, SRT and LRT 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 57: Steering

    OPERATION STEERING Steering Friction Adjuster Use the steering friction adjuster to help hold a steady course while SH, LH, SHG and LHT Types SH and LH Types cruising. (long tiller handle) STEERING Move the adjuster to the LOCK FRICTION direction to increase steering friction ADJUSTER BOLT for holding a steady course.

  • Page 58: Cruising

    OPERATION CRUISING If engine speed becomes unstable at will perform best when the high speed due to activation of the antiventilation plate is level with the Engine Speed overrev limiter, reduce speed and water. check the trim angle of the outboard For best fuel economy, limit the motor.
  • Page 59 OPERATION LHT Type 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. MOTOR Under normal conditions, the boat ROUGH...

  • Page 60: Trim Tab

    OPERATION TRIM TAB SHALLOW WATER BOW TOO LOW DUE TO OPERATION LOAD IN THE FRONT If steering effort is not equal in both MOTOR TRIMMED TOO LOW LHT, SRT and LRT Types directions, adjust the trim tab to compensate for ‘‘torque steer,’’ which is the reaction of the outboard When operating in shallow water, use motor to propeller rotation.
  • Page 61 OPERATION SHG, SRG and LRG Types While the outboard motor is tilted, ENGINE COVER GRIP proceed at a low speed, and do not When operating in shallow water, tilt operate the outboard motor in reverse. the outboard motor, using the tilt The outboard motor will rise lever, so the propeller and gear case suddenly if operated in reverse.
  • Page 62 OPERATION SH and LH Types To tilt the outboard motor, move the ENGINE COVER GRIP tilt lever to the TILT position, then When operating in shallow water, tilt raise the outboard motor to the 30° or the outboard motor, using the tilt 45°...

  • Page 63: Mooring, Beaching, Launching

    OPERATION MOORING, BEACHING, SHG, SRG and LRG Types LAUNCHING Use the tilt lever to raise and lower An excessive tilt angle during the outboard motor as described on SH and LH Types operation can cause propeller ventilation, overheating, and water LHT, SRT and LRT Types pump damage.
  • Page 64 OPERATION If more clearance is needed to swing RIGHT STERN BRACKET the tilt lock lever into the LOCK position, rock the outboard motor MANUAL RELIEF VALVE back slightly by pulling on the engine cover grip. POWER (To fix) To lower the outboard motor, tilt up, move the tilt lock lever to the FREE position, then lower the outboard motor to the desired position.
  • Page 65 OPERATION Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.

  • Page 66: 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 67: 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 68: Tool Kit And 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 69: 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 70 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 71: 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. If uncompensated, torque steer would make the outboard motor tend to turn to one side. When the trim tab is correctly adjusted, steering effort is equal in either direction.

  • Page 72: Manual Relief Valve

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

  • Page 73: 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 74: Engine Oil Change

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Change SEALING WASHER An engine oil evacuation device may Improper disposal of engine oil be used to remove the engine oil. can be harmf ul to the environment. If you change your own oil, please Drain the used oil while the engine is dispose of the used oil properly.

  • Page 75: Engine Oil Recommendations

    API label on limit mark on the dipstick (p. Oil is a major factor affecting the oil container. Honda recommends with the recommended oil. performance and service life. Use that you use API SERVICE category 4-stroke automotive detergent oil.

  • Page 76: Lubrication Points

    MOUNT FRAME CLAMP SCREWS To prevent corrosion, apply anticorrosion oil to pivot 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 77: 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. Unlatch and remove the engine cover (p. SPARK PLUG SPARK PLUG CAPS WRENCH Disconnect the spark plug caps...
  • Page 78 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 79: Refueling

    SERVICING YOUR OUTBOARD MOTOR REFUELING Portable Fuel Tank Gasoline is highly flammable and explosive. FUEL TANK CAPACITY: 6.6 US gal (25 ) You can be burned or seriously injured when Check the fuel gauge and refill the handling fuel. FUEL GAUGE Stop the engine and keep tank when necessary.

  • Page 80: 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 81: Fuel Pump Filter Inspection And Replacement

    SERVICING YOUR OUTBOARD MOTOR Fuel Pump Filter Inspection and Replacement Gasoline is highly The fuel pump filter is located under flammable and explosive. the engine cover between the fuel coupling and the fuel pump. You can be burned or seriously injured when PUSH Water or sediment accumulated in handling fuel.
  • Page 82 SERVICING YOUR OUTBOARD MOTOR FUEL HOSE CLIPS Place clamps on the fuel hoses on each side of the filter to prevent fuel leakage when the fuel hoses are disconnected. FUEL HOSES HOSE CLAMP GRIPPER (commercially available) FUEL FILTER Raise the fuel filter, and remove it Inspect the filter for water and/or FUEL FILTER from the engine under case.

  • Page 83: Portable Fuel Tank And Filter Cleaning

    SERVICING YOUR OUTBOARD MOTOR Portable Fuel Tank and Filter Securely connect the fuel hose FUEL PUMP FUEL HOSE Cleaning connector to the outboard motor CLIPS (refer to page Fuel Tank Prime the engine using the priming bulb (p. ). Check for fuel leaks. FUEL HOSE Repair any fuel leaks if necessary.

  • Page 84: Anode Replacement

    SERVICING YOUR OUTBOARD MOTOR Fuel Tank Filter Anode Replacement The anodes are located on the trim tab and the stern bracket. They are TANK FILTER JOINT made of a sacrificial material that (Fuel Connector) helps to protect the outboard motor from corrosion.

  • Page 85: 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 86: 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 87 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 88 STORAGE Flushing Without the Honda Remove the sealing washer from WATER INTAKES Garden Hose Adapter the garden hose adapter and install the sealing washer on the wash plug. It is necessary to run the engine during the flushing procedure. For...

  • Page 89: Fuel

    STORAGE Fuel Adding a Fuel Stabilizer When adding a fuel stabilizer, fill the Running the engine without good Gasoline will oxidize and deteriorate fuel tank with fresh gasoline. If only water circulation can cause in storage. Old gasoline will cause partially filled, air in the tank will overheating and water pump hard starting, and it leaves gum...
  • Page 90 STORAGE Distributor’s Limited Warranty With the outboard motor in a does not cover fuel system damage vertical position, place an 1 CARBURETOR DRAIN SCREW or engine performance problems approved gasoline container below resulting from neglected storage the fuel drain outlet, and use a preparation.

  • Page 91: Engine Oil

    STORAGE Engine Oil STORAGE PRECAUTIONS Repeat this procedure to drain carburetor. Change the engine oil (p. Select a well-ventilated storage area. After all three carburetors are If possible, avoid storage areas with drained, reinstall the drain tube on Remove the spark plugs (p. high humidity.

  • Page 92: Removal From Storage

    STORAGE 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 we recommend storing it vertically dust cover. A nonporous cover will by mounting it on a stand. trap moisture, promoting rust and corrosion.

  • Page 93: Transporting

    TRANSPORTING WITH OUTBOARD MOTOR All Types STEERING FRICTION ADJUSTER INSTALLED ON BOAT If there is insufficient road clearance When trailering a boat with the in the normal running position, then outboard motor attached, leave the tilt the outboard motor and use a engine in the normal running position, motor support bar, or remove the if possible.

  • Page 94: With Outboard Motor Removed From Boat

    TRANSPORTING WITH OUTBOARD MOTOR To carry, hold the outboard motor by REMOVED FROM BOAT the carrying handle, or hold by the carrying handle and the lug beneath Secure the outboard motor in either engine cover lock lever, as shown. the vertical or horizontal position shown on p.
  • Page 95 TRANSPORTING HOIST HOOK LIFTING When transporting the outboard Secure the outboard motor with Reinstall the engine cover. motor on a vehicle, perform the the bolts and nuts. following. When trailing or transporting the boat with the motor attached, it is Remove the engine cover, lift the recommended that the motor outboard motor using the engine...

  • Page 96: 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 97 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 98 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 99 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). position (p. Fast idle lever not raised (side- Raise fast idle lever, unless engine mount type).
  • Page 100 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 101: 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 10A FUSE FUSE COVER 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 102: Oil Pressure Indicator Light Goes Off And Engine Speed Is Limited

    Low oil pressure may be the result of and have the outboard motor a low engine oil level, or there may inspected by an authorized Honda be a problem with the engine marine dealer. (long tiller handle/SHG and LHT types)

  • Page 103: 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 104: Submerged Motor

    If there is a Honda marine dealer for half an hour. indicator again. nearby, take the motor to the dealer immediately.
  • Page 105 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 106: Technical And Consumer Information

    TECHNICAL AND CONSUMER INFORMATION TECHNICAL INFORMATION PRODUCT IDENTIFICATION STARTER MOTOR NUMBER 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 SWIVEL CASE ENGINE SERIAL NUMBER...

  • Page 107: 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 108: 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 109: 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 110 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 111: 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 112 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 113: Specifications

    See shop manual Intake: 0.12 0.02 mm See shop Valve clearance (cold) Exhaust: 0.20 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 114 See shop manual Intake: 0.12 0.02 mm See shop Valve clearance (cold) Exhaust: 0.20 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 115 See shop manual Intake: 0.12 0.02 mm See shop Valve clearance (cold) Exhaust: 0.20 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 116 See shop manual Intake: 0.12 0.02 mm See shop Valve clearance (cold) Exhaust: 0.20 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 117: 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 118: Index

    INDEX Anodes ................29 EMERGENCY STARTING ......... . 48 Replacement .............. . 82 Emission Control System Information ......107 ARE YOU READY TO GET UNDER WAY ..37 Emergency Stop Switch and Switch Clip ..... . 17 ATTACHMENT ............
  • Page 119 Oil Pressue Indicator ............27 SRG, LRG, SRT and LRT Types (remote control) . 54 OIL PRESSURE INDICATOR LIGHT GOES OFF AND ENGINE SPEED IS LIMITED .... . 100 Honda Publications ............115 OPERATION ..............39 OTHER FEATURES ............

  • Page 120: Tool Kit And Emergency Starter Rope

    INDEX Recoil Starter Grip (SH and LH types) ......16 STORAGE ..............84 REFUELING ..............77 STORAGE PRECAUTIONS ......... 89 REMOVAL FROM STORAGE ........90 STORAGE PREPARATION ......... 84 Cleaning and Flushing ..........84 SAFE OPERATING PRECAUTIONS ......
  • Page 121 INDEX TRANSPORTING ............91 WITH OUTBOARD MOTOR INSTALLED ON BOAT ............. . 91 WITH OUTBOARD MOTOR REMOVED FROM BOAT ............92 Trim Meter (optional equipment) ........26 Trim Tab ..............25, 58 TRIM TAB ADJUSTMENT .........
  • Page 127 2eY1500.2003.07 31ZW2600 00X31-ZW2-6000 Printed in Japan...

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