Honda Marine BF135A Owner's Manual
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Honda Marine BF135A Owner's Manual

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  • 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 ........Top-Mount Type IMPORTANT SAFETY INFORMATION ....Ignition Switch ............24 SAFETY LABEL LOCATION ........Emergency Stop Switch Clip and Emergency Stop Switch ............24 CONTROLS AND FEATURES ........12 Gearshift/Throttle Control Lever ......
  • Page 6 CONTENTS INDICATORS ............33 OPERATION ..............39 Alternator (ACG) Indicator ........33 SAFE OPERATING PRECAUTIONS ..... 39 Malfunction Indicator ..........33 BREAK-IN PROCEDURE ........39 Oil Pressure Indicator ..........34 FUEL PRIMING ............
  • Page 7 CONTENTS SERVICING YOUR OUTBOARD MOTOR ....59 Spark Plug Service ............ . 72 THE IMPORTANCE OF MAINTENANCE ... . 59 REFUELING ............. . 75 MAINTENANCE SAFETY ........60 FUEL RECOMMENDATIONS ....... . 76 TOOL KIT and OWNER’S MANUAL ....
  • Page 8 . 91 Specifications ............109 ENGINE WILL NOT START ........92 CONSUMER INFORMATION ......111 HARD STARTING OR STALLS AFTER Honda Publications ..........111 STARTING ............94 Customer Service Information ......111 ENGINE OVERHEATS ...........

  • Page 9: Outboard Motor Safety

    Attach the emergency stop switch INFORMATION lanyard securely to the operator. It is the operator’s responsibility to The Honda BF135A/BF150A provide the necessary safeguards Always wear a PFD (Personal outboard motors are designed for use to protect people and property.
  • Page 10 OUTBOARD MOTOR SAFETY Refuel With Care Carbon Monoxide Hazard Gasoline is extremely flammable, Exhaust contains poisonous carbon and gasoline vapor can explode. monoxide, a colorless, odorless gas. Refuel outdoors, in a well- Breathing carbon monoxide can ventilated area, with the engine cause loss of consciousness and may stopped.

  • Page 11: Safety Label Location

    The label shown here contains important safety information. Please read it carefully. This label is considered a permanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized Honda Marine dealer for a replacement.
  • Page 12 The label shown here contains important safety information. Please read it carefully. This label is considered a permanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized Honda Marine dealer for a replacement.
  • Page 13 OUTBOARD MOTOR SAFETY Canadian Types Honda outboard motor is designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the outboard motor. Failure to do so could result in personal injury or equipment damage.

  • Page 14: Controls And Features

    CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES Model BF135A BF150A Type XCA XCC 20.0 in (508 mm) Transom Height 25.0 in (635 mm) Standard Rotating Propeller Shaft Counterrotating Propeller Shaft Power Trim/Tilt Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications. TYPE CODE (example) Destination A: American, C: Canadian...

  • Page 15: Component And Control Locations

    CONTROLS AND FEATURES COMPONENT AND CONTROL LOCATIONS OIL FILLER CAP ENGINE COVER SPARK PLUG JUNCTION BOX NMEA INTERFACE (under coil) (FUSES) COUPLER ENGINE COVER POWER TILT LATCH SWITCH OIL LEVEL DIPSTICK FLUSH PORT CONNECTOR TILT LOCK LEVER COOLING SYSTEM STERN INDICATOR BRACKET PRODUCT...
  • Page 16 CONTROLS AND FEATURES Remote Controls (optional equipment) Side-Mount Control Type Panel-Mount Control Type GEARSHIFT/THROTTLE GEARSHIFT/THROTTLE CONTROL LEVER CONTROL LEVER NEUTRAL RELEASE LEVER NEUTRAL RELEASE LEVER INDICATORS POWER TRIM/TILT (Oil pressure, Overheat, SWITCH Alternator, Malfunction) SPARE EMERGENCY POWER TRIM/TILT STOP SWITCH CLIP FAST IDLE SWITCH LEVER...
  • Page 17 CONTROLS AND FEATURES Top-Mount Type (Dual Outboard Motor Type) (Single Outboard Motor Type) GEARSHIFT/THROTTLE GEARSHIFT/THROTTLE CONTROL LEVER CONTROL LEVERS POWER TRIM/TILT SWITCH (LEFT) POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH (RIGHT) FAST IDLE BUTTON FAST IDLE BUTTON Control Panel (for Top-Mount Dual Type) (Top-Mount Single Type) INDICATORS BUZZER...
  • Page 18 CONTROLS AND FEATURES Instruments (optional equipment) Tachometer Digital Speedometer Trolling Control Switch Panel TRL (Trolling) CONTROL SWITCH Trim Meter Digital Tachometer...

  • Page 19: Controls

    CONTROLS AND FEATURES CONTROLS Emergency Stop Switch Clip and Turning the ignition switch key to the Emergency Stop Switch START position operates the starter Side-Mount Type motor. The key automatically returns to the ON position when released EMERGENCY STOP SWITCH Ignition Switch from the START position.

  • Page 20: Gearshift/Throttle Control Lever

    CONTROLS AND FEATURES Gearshif t/Throttle Control The emergency stop switch clip must A spare switch clip is stored in a slot Lever be inserted in the emergency stop in the control housing (optional switch in order for the engine to start equipment).

  • Page 21: Fast Idle Lever

    CONTROLS AND FEATURES Fast Idle Lever N (NEUTRAL) 30° 30° F (FORWARD) R (REVERSE) FAST IDLE LEVER SHIFT SHIFT MAXIMUM MAXIMUM GEARSHIFT/THROTTLE CONTROL LEVER Moving the control lever 30° from N A friction adjuster near the base of Use the fast idle lever to accelerate (neutral) selects the gear, and further the control lever adjusts the operating engine warm-up after starting the...

  • Page 22: Panel-Mount Type Ignition Switch

    CONTROLS AND FEATURES Panel-Mount Type Turning the ignition switch key to the START position operates the starter N (neutral) Ignition Switch motor. The key automatically returns MAXIMUM FAST IDLE to the ON position when released START from the START position. The engine will not start unless the LOWEST POSITION...

  • Page 23: Emergency Stop Switch Clip And Emergency Stop Switch

    CONTROLS AND FEATURES Emergency Stop Switch Clip and The emergency stop switch clip must A spare switch clip (optional Emergency Stop Switch be inserted in the emergency stop equipment) can be stored in the tool switch in order for the engine to start bag.

  • Page 24: Gearshift/Throttle Control Lever

    CONTROLS AND FEATURES Gearshif t/Throttle Control N (NEUTRAL) Lever 35° 35° F (FORWARD) R (REVERSE) GEARSHIFT/THROTTLE SHIFT SHIFT CONTROL LEVER MAXIMUM NEUTRAL RELEASE LEVER MAXIMUM GEARSHIFT/THROTTLE CONTROL LEVER The gearshift/throttle control lever Moving the control lever 35° from N A friction adjuster near the base of controls engine speed and selects F (neutral) selects the gear, and further the control lever adjusts the operating...

  • Page 25: Fast Idle Button

    CONTROLS AND FEATURES Fast Idle Button N (neutral) It is necessary to position the control F (forward) lever in the N (neutral) position to R (reverse) push in the fast idle button. Return the control lever to N (neutral) position to cancel the fast idle operation.

  • Page 26: Top-Mount Type Ignition Switch

    CONTROLS AND FEATURES Top-Mount Type Emergency Stop Switch Clip and Turning the ignition switch key to the Emergency Stop Switch START position operates the starter Ignition Switch motor. The key automatically returns to the ON position when released EMERGENCY STOP SWITCH from the START position.

  • Page 27: Gearshift/Throttle Control Lever

    CONTROLS AND FEATURES Gearshif t/Throttle Control The emergency stop switch clip must The gearshift/throttle control lever(s) Lever be inserted in the emergency stop controls engine speed and selects F switch in order for the engine to start (forward), N (neutral), or R (reverse) and run.
  • Page 28 CONTROLS AND FEATURES Moving the control lever 35° from N (neutral) selects the gear, and further N (NEUTRAL) movement increases engine speed. 35° 35° F (FORWARD) R (REVERSE) A friction adjuster inside the control box adjusts the operating resistance SHIFT SHIFT of the control lever(s).

  • Page 29: Fast Idle Button

    CONTROLS AND FEATURES Fast Idle Button It is necessary to position the control N (neutral) lever in the N (neutral) position to F (forward) push in the fast idle button. R (reverse) Return the control lever to N (neutral) position to cancel the fast idle operation.

  • Page 30: Common Controls

    CONTROLS AND FEATURES Common Controls The power trim/tilt switch is located on the control lever. It is a rocker Power Trim/Tilt Switch switch with UP and DN (down) positions for changing the angle of (Side-Mount Type) (Top-Mount Type) the outboard motor. SINGLE TYPE You can use the power trim/tilt switch anytime whether the boat is...

  • Page 31: Power Tilt Switch

    CONTROLS AND FEATURES Power Tilt Switch Manual Relief Valve Tilt Lock Lever POWER TILT SWITCH TILT LOCK LEVER The power tilt switch is located on The tilt lock lever is used to support the engine pan. It is a rocker switch The outboard motor can be tilted the outboard motor in the fully-raised with UP and DN (down) positions...

  • Page 32: Trl (Trolling) Control Switch (Optional Equipment)

    CONTROLS AND FEATURES TRL (Trolling) Control Switch Engine Cover Latch Trim Tab (optional equipment) TRIM TAB BOLT SWITCH PANEL UNLOCK TRIM TAB TRL (Trolling) CONTROL SWITCH ENGINE COVER LATCH The Trolling Control Switch is a The engine cover latch fastens the The trim tab compensates for rocker switch with UP and DN engine cover to the outboard motor.

  • Page 33: Instruments

    CONTROLS AND FEATURES INSTRUMENTS Tachometer Digital Tachometer (optional equipment) (optional equipment) Trim Meter (optional equipment) The trim meter indicates the relative The tachometer shows engine speed Digital Tachometer includes the trim angle of the outboard motor. in revolutions per minute. following functions.

  • Page 34: Digital Speedometer (Optional Equipment)

    CONTROLS AND FEATURES Digital Speedometer NMEA Interface Coupler (optional equipment) NMEA2000 based information on engine speed, fuel consumption, and various warnings can be read by connecting to the motor with the interface cable (optional equipment). Contact your dealer for more information.

  • Page 35: Indicators

    (RED) (RED) develops a problem. Have your Honda Marine dealer check for burned-out bulbs or other problems. BUZZER Under normal conditions, the BUZZER following occur when the ignition...

  • Page 36: Oil Pressure Indicator

    CONTROLS AND FEATURES Oil Pressure Indicator Overheat Indicator When the oil pressure indicator is lit, oil pressure is OK. (Side-Mount Type) (Side-Mount Type) OVERHEAT OIL PRESSURE If oil pressure becomes low, the INDICATOR INDICATOR indicator will go off, and the engine protection system will limit engine speed.

  • Page 37: Cooling System Indicator

    CONTROLS AND FEATURES Cooling System Indicator OTHER FEATURES When the alert triggers, the overheat indicator comes on and the buzzer COOLING SYSTEM INDICATOR Water Separator Buzzer sounds a steady tone as the engine speed is reduced to 1,800 rpm. If the condition persists for another 20 The water separator buzzer sounds a seconds, the engine shuts off.

  • Page 38: Rev Limiter

    CONTROLS AND FEATURES Rev Limiter Anodes Fuel Priming Bulb The engine is equipped with a rev limiter to prevent the possibility of mechanical damage from excessive OUTLET END engine speed. (outboard motor side) The rev limiter may be activated during operation, limiting engine speed, if the outboard motor is trimmed or tilted up excessively, or PRIMING BULB...

  • 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 the emergency stop switch clip between the upper and lower levels, from the emergency stop switch. and the battery leads are connected Look around the outboard motor securely. Maintenance Inspection for signs of oil or gasoline leaks. Check the water separator for Check that the fuel hose is Check the engine oil level (p.

  • 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: Fuel Priming

    OPERATION FUEL PRIMING Gasoline is highly flammable and explosive. OUTLET END (outboard motor side) You can be burned or seriously injured when handling fuel. PRIMING BULB Stop the engine and keep heat, sparks, and flame away. INLET END Handle fuel only (tank side) outdoors.

  • Page 43: Starting The Engine

    OPERATION STARTING THE ENGINE to the operator’s PFD (Personal Flotation Device). Control Side-Mount Type ...... . p. 41 The engine will not start or run, N (neutral) Panel-Mount Type ..... p. 44 unless the emergency stop switch Top-Mount Type ......
  • Page 44 OPERATION If the engine fails to start within 5 seconds, release the key and wait START at least 10 seconds before operating the starter again. LOWEST Using the electric starter f or more POSITION than 5 seconds at a time will overheat the starter motor and can damage it.
  • Page 45 OPERATION During the warm-up period, check the oil pressure indicator (p. MAXIMUM FAST IDLE If the engine is not properly overheat indicator (p. ), and warmed up bef ore raising the cooling system indicator (p. FAST IDLE engine speed, the buzzer and RANGE overheat indicator may activate If the indicators show any...

  • Page 46: Panel-Mount Type

    OPERATION Panel-Mount Type The engine will not start or run, unless the emergency stop switch N (neutral) EMERGENCY STOP clip is in the emergency stop SWITCH switch. The emergency stop switch clip and emergency stop switch lanyard system is a safety device that will CONTROL stop the engine if you fall away LEVER...
  • Page 47 OPERATION If the engine fails to start within 5 START N (neutral) seconds, release the key and wait at least 10 seconds before operating the starter again. Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can CONTROL damage it.

  • Page 48: Top-Mount Type

    OPERATION Top-Mount Type During the warm-up period, check the oil pressure indicator (p. EMERGENCY STOP If the engine is not properly overheat indicator (p. ), and SWITCH warmed up bef ore raising the cooling system indicator (p. engine speed, the buzzer and overheat indicator may activate If the indicators show any and the engine speed will be...
  • Page 49 OPERATION The engine will not start or run, START unless the emergency stop switch clip N (neutral) is in the emergency stop switch. The emergency stop switch clip and emergency stop switch lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat.
  • Page 50 OPERATION If the engine fails to start within 5 N (neutral) seconds, release the key and wait at least 10 seconds before If the engine is not properly operating the starter again. warmed up bef ore raising the engine speed, the buzzer and overheat indicator may activate CONTROL Using the electric starter f or more...

  • Page 51: Stopping The Engine

    OPERATION STOPPING THE ENGINE During the warm-up period, check To stop the engine in an emergency, the oil pressure indicator (p. pull the emergency stop switch clip Emergency Engine Stopping overheat indicator (p. ), and out of the emergency stop switch by cooling system indicator (p.

  • Page 52: Normal Engine Stopping

    OPERATION Normal Engine Stopping Top-Mount Type Panel-Mount/Top-Mount Types N (neutral) Side-Mount Type N (neutral) CONTROL IGNITION CONTROL LEVER SWITCH KEY LEVER Move the control lever(s) to the N Turn the ignition switch key to the (neutral) position. OFF position to stop the engine. In the event that the engine does Panel-Mount Type After cruising at full throttle, cool...

  • Page 53: Gearshift And Throttle Operation

    OPERATION GEARSHIFT AND Panel-Mount Type To shift gears, move the control lever THROTTLE OPERATION to select the F (forward), N (neutral), N (neutral) or R (reverse) gear. F (forward) Side-Mount Type R (reverse) The control lever cannot be moved CONTROL LEVER from the N (neutral) position unless the neutral release lever is squeezed (side-mount/panel-mount types).

  • Page 54: Steering

    OPERATION Side-Mount Type Top-Mount Type STEERING Steer the boat in the same manner as an automobile. TO INCREASE FRICTION TO INCREASE FRICTION TO DECREASE FRICTION CONTROL LEVER TO DECREASE FRICTION ADJUSTER FRICTION Panel-Mount Type CONTROL LEVER CONTROL LEVER FRICTION ADJUSTER FRICTION ADJUSTER Adjust the control lever friction adjuster so the control lever will hold...

  • Page 55: Cruising

    OPERATION CRUISING Trim Under normal conditions, the boat will perform best when the Engine Speed Use the power trim/tilt switch to trim antiventilation plate is level with the the outboard motor for the best water surface. For best fuel economy, limit the performance and stability.
  • Page 56 OPERATION Side-Mount Type Top-Mount Type OUTBOARD OUTBOARD MOTOR TRIMMED MOTOR TRIMMED (single type) TOO LOW TOO HIGH POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH OUTBOARD MOTOR TRIMMED CORRECTLY BOW TOO LOW DUE TO LOAD IN THE FRONT OUTBOARD MOTOR TRIMMED Panel-Mount Type (dual type) TOO LOW POWER TRIM/TILT SWITCH...

  • Page 57: Trolling Speed Control

    OPERATION Trolling Speed Control DN: Reduce engine speed when in the Trolling Speed Control (optional equipment) UP: Increase engine speed mode, but once the speed reaches 3,000 RPM, the Trolling Speed SWITCH PANEL The engine must be fully warmed up Control is deactivated.

  • Page 58: Trim Tab

    OPERATION TRIM TAB SHALLOW WATER OPERATION If steering effort is not equal in both directions, adjust the trim tab to When operating in shallow water, use compensate for ‘‘torque steer,’’ the power trim/tilt switch (p. ) to which is the reaction of the outboard tilt the outboard motor so that the motor to propeller rotation.

  • Page 59: Mooring, Beaching, Launching

    OPERATION MOORING, BEACHING, To lower the outboard motor, tilt up POWER TILT SWITCH LAUNCHING using the power tilt switch, then move the tilt lock lever to the FREE Before tilting up, leave the outboard position, and then lower the outboard motor in the running position for one motor to the desired position.
  • Page 60 OPERATION Be sure the valve is closed before MANUAL RELIEF VALVE operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse. Check that nobody is under the outboard motor before opening the manual relief valve.

  • Page 61: Servicing Your Outboard Motor

    Honda special tools are best handled by Genuine parts or their equivalents for professionals and are normally repair and replacement. performed by a Honda technician or Improperly maintaining other qualified mechanic. Maintenance, replacement, or this outboard motor or...

  • Page 62: 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 63: Tool Kit And Owner's Manual

    SERVICING YOUR OUTBOARD MOTOR TOOL KIT and OWNER’S MANUAL SPARE EMERGENCY STOP SWITCH CLIP (optional equipment) 17 mm WRENCH 19 mm EYE WRENCH 12 mm WRENCH SPARK PLUG WRENCH 8 mm WRENCH 17 mm BOX WRENCH OIL CHECK SCREWDRIVER PLIERS FLAT SCREWDRIVER TOOL BAG OWNER’S MANUAL...

  • Page 64: Maintenance Schedule

    Check 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. For professional commercial use, log hours of operation to determine proper maintenance intervals.
  • Page 65 Replace 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. For professional commercial use, log hours of operation to determine proper maintenance intervals.

  • Page 66: Trim Tab Adjustment

    SERVICING YOUR OUTBOARD MOTOR TRIM TAB ADJUSTMENT LEFT The trim tab compensates for ‘‘torque steer,’’ which is a reaction of RIGHT the outboard motor to propeller rotation. TRIM TAB BOLT TRIM TAB BOLT If uncompensated, torque steer would make the outboard motor tend to turn RIGHT to one side.

  • Page 67: Manual Relief Valve

    If the difficult to secure, an adjustment valve is not closed, the outboard may be necessary. Please see the motor will tilt up when operated in shop manual or your Honda Marine reverse. dealer for adjustment.

  • Page 68: Engine Oil Level Check

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Level Check Engine Oil Change OIL FILLER CAP Check the engine oil level with the An engine oil evacuation device may engine stopped and the outboard be used to remove the engine oil. motor in the vertical position. Drain the used oil while the engine is Unlock and remove the engine warm.
  • Page 69 SERVICING YOUR OUTBOARD MOTOR SEALING WASHER DRAIN BOLT COVER Improper disposal of engine oil can GUIDE be harmf ul to the environment. If you change your own oil, please dispose of the used oil properly. Put it in a sealed container, and take it to DRAIN a recycling center.

  • Page 70: Oil Filter Change

    SERVICING YOUR OUTBOARD MOTOR Oil Filter Change Install the oil drain bolt cover. FILTER WRENCH, 65 mm Push the lever of the oil drain bolt OIL FILTER cover in the direction pointed by Drain the engine oil, and then the arrow mark of ‘‘LOCK’’, and reinstall the drain bolt and sealing install the oil drain bolt cover so washer.

  • Page 71: Engine Oil Recommendations

    Using the wrong f ilter, or a non- available ear muffs and water hose Honda f ilter which is not of to supply water. equivalent quality, may cause engine damage.

  • Page 72: Lubrication Points

    ENGINE COVER BRACKET TILT SHAFT PTT THRUST RECEIVER PROPELLER SWIVEL CASE SHAFT Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover and any exposed metal surfaces except the belts.
  • Page 73 SERVICING YOUR OUTBOARD MOTOR THROTTLE ARM/ SHIFT ARM/PIVOT ENGINE COVER PLATE/NEUTRAL LOCK CABLE SWITCH/CLICK ENGINE COVER ENGINE COVER LOCK COVER LOCK BOLTS (LEFT SIDE) ARM ROLLER CABLE (FRONT) LEVER/OPEN SHAFT TILT LOCK LEVER ENGINE COVER LOCK CABLE (RIGHT SIDE) TILT SHAFT THREAD SWIVEL SHAFT LOWER CYLINDER UPPER CYLINDER PIN/...

  • Page 74: Spark Plug Service

    SERVICING YOUR OUTBOARD MOTOR Spark Plug Service Remove the two clips from the Standard Spark Plug upper part of the under cover grommet. UNDER COVER RECOMMENDED SPARK PLUGS: To remove the clips, raise the inner GROMMET ZFR6K-11 (NGK) part of each clip with a CLIP KJ20DR-M11 (DENSO) screwdriver, then pull out the clips.
  • Page 75 SERVICING YOUR OUTBOARD MOTOR Remove the ignition coil by SPARK PLUG COVER IGNITION COIL pulling it up slightly. BOLT Do not strike or drop the ignition coil, or it may be damaged and require replacement. WIRE CONNECTOR BOLTS Remove the two bolts with the 6 Use a 6 mm hex.
  • Page 76 SERVICING YOUR OUTBOARD MOTOR SIDE ELECTRODE Install the spark plugs carefully, Install the ignition coil. Reinstall by hand, to avoid cross-threading. the bolt. 0.039 0.043 in (1.0 1.1 mm) After each spark plug seats, tighten Repeat this procedure for the other with the spark plug wrench three spark plugs.

  • Page 77: Refueling

    SERVICING YOUR OUTBOARD MOTOR Optional Parts : Iridium REFUELING Use only a ‘‘wire-type feeler Spark Plug gauge’’ to check the spark plug gap if necessary. To prevent Check the fuel level and refill if RECOMMENDED SPARK PLUGS: damaging the iridium coating of necessary.

  • Page 78: Fuel Recommendations

    SERVICING YOUR OUTBOARD MOTOR FUEL RECOMMENDATIONS Never refill the fuel tank inside a building where gasoline fumes may Gasoline is highly reach flames or sparks. Keep Use unleaded gasoline with a pump flammable and explosive. gasoline away from appliance pilot octane rating of 86 or higher.

  • Page 79: Fuel Filter Inspection And Replacement

    SERVICING YOUR OUTBOARD MOTOR Fuel Filter Inspection and Engine damage or performance Replacement problems that result from using a fuel with percentages of ethanol or Gasoline is highly methanol greater than shown above The fuel filter (inside the strainer flammable and explosive. are not covered under warranty.
  • Page 80 Honda Marine dealer. Remove the suspension strap from the fuel filter bracket, and then remove the strap from the fuel filter assembly.
  • Page 81 SERVICING YOUR OUTBOARD MOTOR Prime the engine using the priming STRAINER BODY FUEL STRAINER ASSEMBLY bulb (refer to page ). Check for STRAINER fuel leaks. BRACKET Repair any fuel leaks if necessary. If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fuel tank.

  • Page 82: Water Separator Inspection And Service

    Clean it or consult with it is difficult to remove the the wire harness with the separator an authorized Honda Marine dealer separator assembly by yourself, bracket. for cleaning. consult an authorized Honda Marine dealer.
  • Page 83 SERVICING YOUR OUTBOARD MOTOR Squeeze and release the priming WATER SEPARATOR BRACKET bulb to fill the vapor separator, and WATER SEPARATOR check for leaks. If the buzzer sounds or water or sediment accumulation are found to be caused by excessive water or sediment accumulation in the fuel O-RING filter, inspect the fuel tank.

  • Page 84: Anode Replacement

    SERVICING YOUR OUTBOARD MOTOR Anode Replacement Propeller Replacement Painting or coating the anodes will Before replacing the propeller, def eat their purpose and will lead to remove the emergency stop switch rust and corrosion damage to the clip from the emergency stop switch outboard motor.

  • Page 85: Installation

    Apply marine grade grease to the propeller shaft. TIGHTENING TORQUE LIMIT: Use a Honda Genuine stainless 33 lbf·ft (44 N·m , 4.5 kgf·m) steel cotter pin or equivalent Install the thrust washer with the Do not tighten the castle nut above cotter pin and bend the pin ends grooved side toward the gear case.

  • Page 86: Storage

    Flushing With a Garden Hose operation in dirty water or salt water. (commercially available) Touch up any damaged paint, and coat areas that may rust with Honda Corrosion Inhibitor, or equivalent. Do not run the engine when f lushing FLUSH PORT...

  • Page 87: Fuel

    STORAGE Fuel GARDEN HOSE FLUSH PORT Gasoline will oxidize and deteriorate CONNECTOR in storage. Old gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your fuel tank and vapor separator deteriorates during storage, you may need to have the vapor separator and other fuel system components serviced or replaced.
  • Page 88 STORAGE Adding a Fuel Stabilizer Draining the Fuel System You can extend fuel storage life by adding a gasoline stabilizer that is When adding a fuel stabilizer, fill the You can avoid fuel deterioration formulated for that purpose, or you fuel tank with fresh gasoline.

  • Page 89: Engine Oil

    STORAGE Engine Oil Unhook the drain hose from the Tilt the outboard motor up all the front bracket clamp. way. Leave the outboard motor tilted up until the gasoline stops Change the engine oil and the oil Set the end of the hose toward the flowing.

  • Page 90: Hoisting The Outboard Motor

    STORAGE HOISTING THE OUTBOARD STORAGE PRECAUTIONS HOIST MOTOR HOOKS Select a well-ventilated storage area. ENGINE COVER If possible, avoid storage areas with high humidity. LIFTING EYES If storing a container of gasoline, store it away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer.

  • Page 91: Removal From Storage

    STORAGE REMOVAL FROM STORAGE Check your outboard motor as described in the BEFORE OPERATION chapter of this manual. If the cylinders were coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal. PROTECTOR OUTBOARD MOTOR STAND If the outboard motor will be If it is necessary to store the outboard removed from the boat for storage,...

  • Page 92: Transporting

    TRANSPORTING WITH OUTBOARD MOTOR WITH OUTBOARD MOTOR INSTALLED ON BOAT REMOVED FROM BOAT When trailering a boat with the Secure the outboard motor in either outboard motor attached, leave the the vertical or horizontal position outboard motor in the normal shown on p.

  • Page 93: Taking Care Of Unexpected Problems

    ); if engine still will not pump failure, ignition malfunction, components as necessary. start, then take outboard motor stuck valves, starter malfunction, to an authorized Honda Marine switch malfunction, or electrical dealer, or refer to the shop problem in the starting circuit, etc. manual.

  • Page 94: Engine Will Not Start

    TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction Check emergency stop switch Clip not inserted in emergency Insert clip in emergency stop clip. stop switch. switch. Check control positions. Control lever not in neutral Shift to neutral. position.
  • Page 95 Dry and reinstall spark plugs. Start engine). engine with the throttle open. Take outboard motor to an Fuel system malfunction, fuel Replace or repair faulty authorized Honda Marine dealer, pump failure, ignition malfunction, components as necessary. or refer to the shop manual. etc.

  • Page 96: Hard Starting Or Stalls After Starting

    TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS Possible Cause Correction AFTER STARTING Check control positions. Fast idle lever raised (side-mount Leave fast idle lever OFF (p. type). Check fuel. Fuel hose not primed. Squeeze priming bulb (p. Fuel filter or fuel tank filter clogged. Replace fuel filters (p.

  • Page 97: Engine Overheats

    Gap (non-iridium type) or replace improperly gapped. spark plugs (p. Take outboard motor to an Fuel system malfunction, fuel Replace or repair faulty authorized Honda Marine dealer, pump failure, ignition malfunction, components as necessary. or refer to the shop manual. etc. ENGINE OVERHEATS...

  • Page 98: Fuses

    TAKING CARE OF UNEXPECTED PROBLEMS FUSES Fuse Replacement Remove the junction box lid. Electric Starter Will Not Operate Disconnect the battery cable at the RELAYS (Do not remove the relays) battery negative ( ) terminal bef ore The 10A, 15A, and 30A main fuses replacing the f use.
  • Page 99 An uncorrected electrical problem may cause the fuse to blow again. If fuses continue to blow, take the outboard motor to an authorized Honda Marine dealer for inspection and service, or refer to the shop manual.

  • Page 100: Oil Pressure Indicator Goes Off And Engine Speed Is Limited

    TAKING CARE OF UNEXPECTED PROBLEMS ACG Fuse OIL PRESSURE INDICATOR Install a new fuse with the ‘‘100A.’’ GOES OFF AND ENGINE SPEED IS LIMITED ACG FUSE: 100 A Side-Mount Type Reinstall the junction box lid, and the engine cover. OIL PRESSURE INDICATOR Reconnect the battery.

  • Page 101: Overheat Indicator Comes On And Engine Speed Is Limited

    (RED) have the outboard motor inspected by Low oil pressure may be the result of an authorized Honda Marine dealer. a low engine oil level, or there may be a problem with the engine BUZZER...
  • Page 102 Engine overheating may be the result outboard motor inspected by an of restricted water intake screens, or authorized Honda Marine dealer. there may be a problem with the cooling system thermostat or water pump.

  • Page 103: Water Separator Buzzer Sounds

    Normal If there is a Honda Marine dealership Abnormal nearby, take the outboard motor to the dealer immediately. If you are far from a dealership, proceed as...
  • Page 104 2 inches As soon as possible, take the above the antiventilation plate). outboard motor to an authorized Honda Marine dealer for If you are changing the oil filter inspection and service. while the outboard motor is out of...

  • Page 105: Technical And Consumer Information

    TECHNICAL AND CONSUMER INFORMATION TECHNICAL INFORMATION PRODUCT IDENTIFICATION Serial Number Locations NUMBER Record the product identification number, the engine serial number, and the date of purchase in the space provided on this page. You will need these numbers when ordering parts, and when making technical or warranty inquiries (p.

  • Page 106: Battery

    Do not disconnect the battery Honda utilizes appropriate air/fuel cables while the engine is running. ratios and other emissions control Disconnecting the cables while the systems to reduce the emissions of...
  • Page 107 Ignition Timing Control System Honda engine within the emission Alterations that would cause the standards. engine to operate outside its design The system constantly adjusts the parameters.
  • Page 108 Emissions The emission control systems on Follow the maintenance schedule on If you are aware of any of the your Honda engine were designed, ). Remember that this following symptoms, have your built, and certified to conform with schedule is based on the assumption...

  • Page 109: Star Label

    TECHNICAL AND CONSUMER INFORMATION Star Label The Star Label means Cleaner Marine Engine US, Puerto Rico, and US Virgin This engine has been certified as a: Islands A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board.
  • Page 110 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.

  • Page 111: Specifications

    0.02 mm manual (cold) Gear case: 1.04 US qt (0.98 L) Other specifications No other adjustment is needed Without battery cable, with propeller Honda outboard motors are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.
  • Page 112 Other specifications No other adjustment is needed Gear case: 1.04 US qt (0.98 L) Without battery cable, with propeller Honda outboard motors are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.

  • Page 113: Consumer Information

    Honda regarding your experiences outboard motor. accessories. with your Honda product or with your dealer, please send your Shop Manual Customer Service Information comments to the following address: This manual covers complete Contacting Honda maintenance and overhaul procedures.
  • Page 114 Please include the following not apply to normal wear or information in your communication: deterioration associated with using Your new Honda is covered by the your Honda outboard motor. Your name, address and telephone following warranties: number (complete with area code) Your warranty coverage will not be Distributor’s Limited Warranty...
  • Page 115 (such as spark plug(s), water pump, contact the owner of the dealership or etc.). their designated representative. As the owner of a Honda product, your servicing dealer may ask you to authorize an inspection. If the problem is covered under warranty, your dealer will perform any warranty repairs for you at no cost.

  • Page 116: Warranty Statements

    TECHNICAL AND CONSUMER INFORMATION Warranty Statements The American Honda Distributor’s Limited Warranty applies to outboards purchased in the United States, Puerto Rico, or the U.S. Virgin Islands. The Honda Canada Distributor’s Warranty applies to outboards purchased in Canada. The product warranty is only valid in the country where the product was purchased.
  • Page 117 First, contact the owner of the Warranty: dealership involved; normally this should resolve the American Honda will repair or replace, at its option, any problem. However, if you should require further part that is proven to be defective in material or...
  • Page 118 Parts affected or damaged by an abuse, submersion implied warranties: and/or collision American Honda disclaims any responsibility for loss of Normal wear and tear time or use of the outboard, revenue, or the equipment in Fuel contamination and water entering engine through...
  • Page 119 TECHNICAL AND CONSUMER INFORMATION Accessories and Replacement Parts This warranty is limited to Honda Marine parts, accessories and apparel when distributed by American Honda Motor Co., Inc., 1919 Torrance Blvd., Torrance, California 90501-2746. Products Covered by Warranty: Length of Warranty: (from date of original retail purchase)
  • Page 120 TECHNICAL AND CONSUMER INFORMATION To Obtain Warranty Service: how long an implied warranty lasts and/or do not allow You must, at your expense, take the Honda Outboard the exclusion or limitation of incidental or consequential Motor product accessory or replacement part or the...

  • Page 121: Emission Control System Warranty

    Emission Control System Warranty outboard engine at no cost to you including diagnosis, parts and labor. Your new Honda outboard engine complies with both the U.S. EPA and State of California emission regulations. Your emission control system may include such parts as...
  • Page 122 American has failed due to abuse, neglect, improper maintenance, Honda Motor Co., Inc. A list of warranty parts is on page or unapproved modifications. 122 . Normal maintenance items, such as spark plugs and...
  • Page 123 American Honda Motor Co., alteration of any part. Inc. to sell and service that Honda Marine product during This warranty does not cover replacement of expendable his normal business hours. Claims for repair or...
  • Page 124 TECHNICAL AND CONSUMER INFORMATION EMISSION CONTROL SYSTEM WARRANTY PARTS: SYSTEMS COVERED BY THIS PARTS DESCRIPTION WARRANTY: Fuel Metering Carburetor assembly, Throttle body, Fuel injector, Fuel pump, Fuel pressure regulator, Throttle position sensor, Intake air temperature sensor, Engine temperature sensor, Manifold absolute pressure sensor, Idle air control valve, Barometric pressure sensor, Fuel line solenoid valve, Intake manifold, Intake valves, and Oxygen sensor or Air fuel ratio sensor Evaporative...

  • Page 125: Distributor's Warranty

    Honda Canada Inc. and/or Honda Motor Co. Ltd., as an authorized Honda dealer which has been registered appropriate from the context. at the time of purchase on a form provided by Honda, which has had set-up and pre-delivery service HONDA WARRANTS THAT each new Honda marine...
  • Page 126 Any marine products modified, altered, disassembled expense, during normal service hours, to any authorized or remodelled; Honda Marine dealership. If you are unable to obtain or Normal maintenance services, including tightening of are dissatisfied with the warranty service you receive, nuts, bolts and fittings and engine tune-up and the first contact the owner of the dealership involved;...
  • Page 127 New genuine Honda replacement parts or accessories responsibility for loss of time or use of the product, sold to a consumer or installed by an authorized Honda transportation or towing costs or any other indirect, Marine dealer which are not covered by the...

  • Page 128: Index

    INDEX Alternator (ACG) Indicator ..........33 Electric Starter Will Not Operate ......91, 96 Anodes ................36 Emergency Stop Switch Clip and Emergency Stop Replacement .............. . 82 Switch ARE YOU READY TO GET UNDERWAY? ....37 Panel-Mount Type .............
  • Page 129 . 94 OUTBOARD MOTOR SAFETY ........HOISTING THE OUTBOARD MOTOR ..... 88 Overheat Indicator ............34 Honda Publications ............111 OVERHEAT INDICATOR COMES ON AND ENGINE SPEED IS LIMITED ........ . 99 Ignition Switch Panel-Mount Type .............
  • Page 130 INDEX SAFE OPERATING PRECAUTIONS ......39 Tachometer (optional equipment) ........31 SAFETY LABEL LOCATION ........TAKING CARE OF UNEXPECTED PROBLEMS . 91 ..Serial Number Locations ..........103 TECHNICAL AND CONSUMER SERVICING YOUR OUTBOARD MOTOR ....59 INFORMATION .............

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