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Honda BF40A 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 ........Common Controls ..........23 IMPORTANT SAFETY INFORMATION ....Power Trim/Tilt Switch (side-mount type) ... . 23 SAFETY LABEL LOCATIONS ........ Power Tilt Switch (LHT, LRT and XRT types) . 23 Manual Relief Valve CONTROLS AND FEATURES ........
  • Page 6 CONTENTS OTHER FEATURES ..........29 STARTING THE ENGINE ........37 Overrev Limiter ............29 LH and LHT Types (long tiller handle) ....37 Anodes ..............30 LRT and XRT Types (remote control) ....39 Portable Fuel Tank (optional equipment) .....
  • Page 7 CONTENTS SERVICING YOUR OUTBOARD MOTOR ....56 STORAGE ..............77 THE IMPORTANCE OF MAINTENANCE ... . 56 STORAGE PREPARATION ........77 MAINTENANCE SAFETY ........57 Cleaning and Flushing .......... . 77 SPARE EMERGENCY STOP SWITCH CLIP Fuel ................
  • Page 8 ............101 Fuse Replacement ..........89 CONSUMER INFORMATION ......103 OIL PRESSURE INDICATOR LIGHT GOES OFF Honda publications ..........103 AND ENGINE SPEED IS LIMITED ....90 Customer Service Information ......103 OVERHEAT INDICATOR LIGHT COMES Distributor’s Limited Warranty...

  • 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 BF40A and BF50A 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 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 dealer for a replacement.

  • Page 12: Controls And Features

    CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES Model BF40A BF50A Type Shaft Length Long Tiller Handle Remote Control Gas Assist Tilt Power Trim/Tilt Tachometer (optional equipment) Trim Meter (optional equipment) 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 LH and LHT Types (long tiller handle) OIL FILLER CAP FUEL HOSE CONNECTOR OIL LEVEL LONG TILLER ENGINE COVER DIPSTICK HANDLE POWER TILT SWITCH (LHT type) COOLING SYSTEM INDICATOR TILT LOCK LEVER STERN ENGINE OIL BRACKET DRAIN PLUG...
  • Page 14 CONTROLS AND FEATURES SWITCH CLIP OIL PRESSURE INDICATOR LIGHT GEARSHIFT LEVER OVERHEAT INDICATOR LIGHT EMERGENCY STOP SWITCH THROTTLE FRICTION ADJUSTER LANYARD POWER TRIM/TILT SWITCH STEERING FRICTION ADJUSTER (LHT type) THROTTLE GRIP IGNITION SWITCH IGNITION SWITCH KEY...

  • Page 15: Lrt And Xrt Types (Remote Control)

    CONTROLS AND FEATURES LRT and XRT Types (remote control) OIL FILLER CAP ENGINE COVER POWER TILT SWITCH FUEL HOSE TILT LOCK LEVER OIL LEVEL CONNECTOR DIPSTICK STEERING PLATE COOLING SYSTEM INDICATOR TRANSOM ANGLE ADJUSTING ROD STERN ENGINE OIL DRAIN BRACKET PLUG COVER MANUAL RELIEF TRIM TAB...
  • Page 16 CONTROLS AND FEATURES Remote Control box (side-mount type/optional equipment) GEARSHIFT/THROTTLE CONTROL LEVER POWER TRIM/TILT SWITCH 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 EMERGENCY STOP SWITCH...
  • Page 17 CONTROLS AND FEATURES Fuel Tank (optional equipment) Tachometer [optional equipment (LHT, LRT FUEL GAUGE and XRT types)] VENT KNOB FUEL TANK FUEL FILLER CAP Trim Meter [optional equipment (LHT, LRT and XRT types)] FUEL HOSE FUEL HOSE CONNECTOR (female) PRIMING BULB...

  • Page 18: Controls

    CONTROLS AND FEATURES CONTROLS Emergency Stop Switch and Turning the ignition switch key to the Switch Clip START position operates the starter LH and LHT Types motor. The key automatically returns EMERGENCY STOP SWITCH (long tiller handle) to the ON position when released from the START position.

  • Page 19: Throttle Grip

    CONTROLS AND FEATURES Throttle Grip The switch clip must be inserted in The throttle grip controls engine the engine stop switch in order for speed. the engine to start and run. The lanyard should be attached to the An index mark on the tiller arm operator’s PFD (Personal Flotation shows throttle position and is helpful Device) or worn around the wrist as...

  • Page 20: Throttle Friction Adjuster

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

  • Page 21: Tilt Lever (Gas Assist/Lh Type)

    CONTROLS AND FEATURES Tilt Lever LRT and XRT Types Moving the tilt lever to the TILT (gas assist/LH type) (remote control/optional position allows the motor to be tilted equipment) and moving the tilt lever to the RUN (LOCK) position locks the motor in the desired position.

  • Page 22: Emergency Stop Switch And Switch Clip (Side-Mount Type)

    CONTROLS AND FEATURES Emergency Stop Switch and Turning the ignition switch key to the The switch clip must be inserted in Switch Clip (side-mount type) START position operates the starter the emergency stop switch in order motor. The key automatically returns for the engine to start and run.

  • Page 23: Fast Idle Lever (Side-Mount Type)

    CONTROLS AND FEATURES Fast Idle Lever Gearshif t/Throttle Control (side-mount type) Lever (side-mount type) GEARSHIFT/THROTTLE N (neutral) CONTROL LEVER GEARSHIFT/THROTTLE FAST IDLE CONTROL LEVER START NEUTRAL RELEASE LEVER FAST IDLE LEVER The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the The fast idle lever is used to set idle...
  • Page 24 CONTROLS AND FEATURES The gearshift/throttle control lever controls engine speed and selects F (forward), N (neutral), or R (reverse) gears. GEARSHIFT/THROTTLE CONTROL LEVER Moving the control lever 30° from N (neutral) selects the gear, and further movement increases engine speed. N (neutral) F (forward) R (reverse)

  • Page 25: Common Controls

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

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

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

  • Page 27: Transom Angle Adjusting Rod

    CONTROLS AND FEATURES Transom Angle Adjusting Rod Trim Tab The transom angle adjusting rod limits the tilt angle of the outboard TRIM TAB BOLT motor when fully lowered. STERN BRACKET Proper adjustment prevents the outboard motor from being trimmed too low (p. TRIM TAB PROPELLER The trim tab compensates for...

  • Page 28: Instruments

    CONTROLS AND FEATURES INSTRUMENTS Tachometer Fuel Gauge [optional equipment (LHT, (optional equipment) Trim Meter LRT and XRT Types)] [optional equipment (LHT, LRT and XRT Types)] FUEL GAUGE A fuel gauge is built into the cap of the portable fuel tank (optional TACHOMETER equipment).

  • Page 29: Indicators

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

  • Page 30: Overheat Indicator

    CONTROLS AND FEATURES Overheat Indicator LRT and XRT Types If the engine overheats, the red light (side-mount type) will come on, and the engine LH and LHT Types protection system will limit engine speed. When normal engine temperature is restored, the engine speed will gradually rise to normal engine speed.

  • Page 31: Cooling System Indicator

    CONTROLS AND FEATURES Cooling System Indicator OTHER FEATURES The cooling system indicator discharge port can also become Overrev Limiter plugged. 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 speed, if the outboard motor is tilted COOLING SYSTEM INDICATOR...

  • Page 32: Anodes

    CONTROLS AND FEATURES Anodes Portable Fuel Tank The anodes are made of a sacrificial (optional equipment) material that helps to protect the outboard motor from corrosion. There are two anodes on the gear case, one on the stern bracket, and another is the trim tab.

  • Page 33: Fuel Filler Cap Vent Knob (Optional Equipment)

    CONTROLS AND FEATURES Fuel Filler Cap Vent Knob Fuel Priming Bulb (optional equipment) VENT KNOB OUTLET END (MOTOR) PRIMING BULB FUEL FILLER CAP INLET END (TANK) The cap is provided with a vent knob A priming bulb is built into the fuel to seal the portable fuel tank for hose that connects the fuel tank to the carrying it to and from the boat.

  • Page 34: 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 35 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 36: 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 37: 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 STERN BRACKET exhaust port or the engine can be Proper adjustment prevents the damaged.

  • Page 38: Portable Fuel Tank (Optional Equipment)

    OPERATION PORTABLE FUEL TANK FUEL HOSE CONNECTIONS Secure the portable fuel tank in the (optional equipment) 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 39: Fuel Priming

    OPERATION FUEL PRIMING STARTING THE ENGINE The engine will not start or run, unless the clip is in the switch. LH 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 40 OPERATION N (neutral) START START POSITION POINTER THROTTLE GRIP IGNITION SWITCH KEY GEARSHIFT LEVER Check the position of the gearshift Align the engine start symbol Turn the ignition switch key to the lever. It must be in the N (neutral) ‘‘...

  • Page 41: Lrt And Xrt Types (Remote Control)

    OPERATION LRT and XRT Types During the warm-up period, check (remote control) the oil pressure indicator (p. Using the electric starter f or more overheat indicator (p. ) and than 5 seconds at a time will cooling system indicator (p. For panel mount or top mount remote overheat the starter motor and can control information, refer to the...
  • Page 42 OPERATION The engine will not start or run, N (neutral) unless the clip is in the switch. FAST IDLE The emergency stop switch clip and lanyard system is a safety device that will stop the engine if START you fall away from the controls CONTROL while operating the boat.
  • Page 43 OPERATION FAST IDLE LEVER START Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can damage it. Turning the ignition switch key to the START position while the engine is running can damage the starter motor and f lywheel.

  • Page 44: Emergency Starting

    OPERATION EMERGENCY STARTING Before getting under way, allow 25 mm the engine to warm up sufficiently BOLTS to ensure good performance. If the battery is discharged, or the starter motor is inoperative, you can Above 41°F (5°C), warm up the start the engine manually using the engine for 2 or 3 minutes.
  • Page 45 OPERATION If the fast idle control(s) was used FLYWHEEL to start the engine, return the control(s) to the normal operating EMERGENCY position as the engine warms up. STARTER ROPE During the warm-up period, check the oil pressure indicator (p. overheat indicator (p. ), and cooling system indicator (p.
  • Page 46 Have your closest authorized Honda marine dealer check your electrical system and correct the problem, so you can use the electric starter.

  • Page 47: Stopping The Engine

    OPERATION STOPPING THE ENGINE To stop the engine in an emergency, N (neutral) pull the clip out of the emergency Emergency Engine Stopping stop switch by pulling the lanyard. LH and LHT Types We suggest that you stop the engine (long tiller handle) this way occasionally to verify that EMERGENCY...
  • Page 48 OPERATION LH and LHT Types When the boat is not in use, (long tiller handle) remove and store the ignition key and the emergency stop switch clip and lanyard. IGNITION SWITCH KEY LRT and XRT Types (remote control) IGNITION SWITCH KEY Turn the ignition switch key to the OFF position to stop the engine.

  • Page 49: 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 LH and LHT Types N (neutral) or R (reverse) gears. GRIP (long tiller handle) The engine can be started with the gearshift lever in the N (neutral)

  • Page 50: Lrt And Xrt Types (Remote Control)

    OPERATION LRT and XRT 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 51: Steering

    OPERATION STEERING Steering Friction Adjuster LRT and XRT Types (remote control) STEERING FRICTION ADJUSTER LH and LHT Types FRICTION (long tiller handle) PLATE Steer the boat in the same manner as an automobile. TO DECREASE FRICTION (FREE) Steer by moving the tiller handle Use the steering friction adjuster to opposite the direction you want the help hold a steady course while...

  • Page 52: Cruising

    OPERATION CRUISING If engine speed becomes unstable at antiventilation plate is level with the high speed due to activation of the water surface. Engine Speed overrev limiter, reduce speed and check the trim angle of the outboard When cruising into a high wind, trim For best fuel economy, limit the motor.
  • Page 53 OPERATION LH and LHT Types It is necessary to trim the angle of the MOTOR ANGLE MOTOR ANGLE ADJUSTED TOO ADJUSTED 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.

  • Page 54: Trim Tab

    OPERATION TRIM TAB SHALLOW WATER LH Type OPERATION If steering effort is not equal in both When operating in shallow water, tilt LHT, LRT and XRT Types directions, adjust the trim tab to the outboard motor, using the tilt compensate for ‘‘torque steer’’, lever, so the propeller and gear case which is the reaction of the outboard When operating in shallow water, use...
  • Page 55 OPERATION While the outboard motor is tilted, To return the outboard motor to the ENGINE COVER GRIP proceed at a low speed, and do not normal operating position, move the operate the outboard motor in reverse. tilt lever to the RUN (LOCK) The outboard motor will rise position, you may need to raise the suddenly if operated in reverse.

  • Page 56: Mooring, Beaching, Launching

    OPERATION MOORING, BEACHING, If more clearance is needed to swing LAUNCHING the tilt lock lever into the LOCK TILT LOCK LEVER (lock position) position, rock the outboard motor LH Type forward slightly by pulling on the Use the tilt lever to raise and lower engine cover grip.
  • Page 57 OPERATION Be sure the valve is closed before RIGHT STERN BRACKET operating the outboard motor. If the valve is not closed, the outboard MANUAL RELIEF motor will tilt up when operated in VALVE reverse. The outboard motor can also be tilted manually after opening the manual relief valve.

  • Page 58: 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 59: 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 60: Spare Emergency Stop Switch Clip

    Individual items in the tool kit shown above can be purchased from an stop switch clip and the emergency authorized Honda marine dealer and may be used for simple maintenance starter rope onboard. The spare clip procedures and/or emergency repairs. Keep this tool kit or an equivalent may either be stored in the optional onboard, so they will always be available if you need them.

  • Page 61: Maintenance Schedule

    Clean 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 62 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 63: 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. TRIM TAB TRIM TAB If uncompensated, torque steer would RIGHT LEFT make the outboard motor tend to turn to one side.

  • Page 64: Manual Relief Valve

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

  • Page 65: 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 66: Engine Oil Change

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Change DRAIN PLUG COVER An engine oil evacuation device may be used to remove the engine oil. Drain the used oil while the engine is warm. Warm oil drains quickly and completely. Unlatch and remove the engine cover (p.
  • Page 67 SERVICING YOUR OUTBOARD MOTOR With the outboard motor in a SEALING WASHER vertical position, fill to the upper Improper disposal of engine oil limit mark on the dipstick (p. can be harmf ul to the environment. with the recommended oil. If you change your own oil, please dispose of the used oil properly.

  • Page 68: Engine Oil Recommendations

    Engine Oil Recommendations The SAE oil viscosity and service classification are in the API label on Oil is a major factor affecting the oil container. Honda recommends performance and service life. Use that you use API SERVICE category 4-stroke automotive detergent oil.

  • Page 69: Lubrication Points

    To prevent corrosion, apply anticorrosion oil to pivot surf aces where grease cannot penetrate. SWIVEL CASE PROPELLER SHAFT Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover and any exposed metal surfaces except the belts.

  • Page 70: Spark Plug Service

    SERVICING YOUR OUTBOARD MOTOR Spark Plug Service SIDE ELECTRODE RECOMMENDED SPARK PLUGS: 0.024 0.028 in DR7EA (NGK) (0.60 0.70 mm) X22ESR-U (DENSO) Incorrect spark plugs can cause engine damage. SEALING WASHER SPARK PLUG WRENCH Unlatch and remove the engine cover (p. SPARK PLUG CAPS Disconnect the spark plug caps from the spark plugs.
  • Page 71 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 72: Refueling

    SERVICING YOUR OUTBOARD MOTOR REFUELING Portable Fuel Tank Gasoline is highly (optional equipment) flammable and explosive. You can be burned or FUEL TANK CAPACITY: 6.6 US gal (25 ) seriously injured when handling fuel. FUEL GAUGE Stop the engine and keep heat, sparks, and flame Check the fuel gauge and refill the SAFE FILL LEVEL...

  • Page 73: 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 74: Fuel Filter Inspection And Replacement

    SERVICING YOUR OUTBOARD MOTOR Fuel Filter Inspection and Replacement Gasoline is highly flammable and explosive. The fuel filter is located under the engine cover between the fuel coupling and the fuel pump. You can be burned or seriously injured when Water or sediment accumulated in handling fuel.
  • Page 75 SERVICING YOUR OUTBOARD MOTOR Place clamps on the fuel hoses on HOSE CLAMP GRIPPERS each side of the filter to prevent (commercially available) fuel leakage when the fuel hoses FUEL HOSE CLIPS are disconnected. FUEL FUEL PUMP HOSE CLIPS SPRING RETAINER FUEL FILTER FUEL HOSES...

  • Page 76: Portable Fuel Tank And Filter Cleaning (Optional Equipment)

    SERVICING YOUR OUTBOARD MOTOR Portable Fuel Tank and Filter Fuel Tank Connect the fuel hoses to the fuel Cleaning filter securely with the hose clips. (optional equipment) Remove the fuel hose clamps used FUEL HOSE to close the fuel hoses. Securely connect the fuel hose connector to the outboard motor Gasoline is highly...

  • Page 77: Anode Replacement

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

  • Page 78: 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 steel cotter pin or equivalent cotter protect your hands.

  • Page 79: Storage

    Touch up any damaged paint, and coupler. coat areas that may rust with Honda WASH PLUG Corrosion Inhibitor, or equivalent. Install the flush kit coupler into the (flush plug)
  • Page 80 STORAGE Move the gearshift lever or control lever to the N (neutral) position. 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 81: Fuel

    STORAGE Fuel Allow the engine to run at idle for Gasoline will oxidize and deteriorate at least 5 minutes to clean the in storage. Old gasoline will cause inside of the motor. hard starting, and it leaves gum Depending on the region where you deposits that clog the fuel system.
  • Page 82 STORAGE Adding a Fuel Stabilizer Distributor’s Limited Warranty With the outboard motor in a When adding a fuel stabilizer, fill the ) does not cover fuel system vertical position, place an fuel tank with fresh gasoline. If only damage or engine performance approved gasoline container below partially filled, air in the tank will problems resulting from neglected...

  • Page 83: Engine Oil

    STORAGE Engine Oil Repeat this procedure to drain 1 CARBURETOR carburetor. DRAIN SCREW Change the engine oil (p. 2 CARBURETOR After all three carburetors are DRAIN SCREW drained, reinstall the drain tube on Remove the spark plugs (p. 1 carburetor. and remove the clip from the emergency stop switch.

  • Page 84: Storage Precautions

    STORAGE STORAGE PRECAUTIONS 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 Select a well-ventilated storage area. we recommend storing it vertically dust cover.

  • Page 85: Transporting

    TRANSPORTING WITH OUTBOARD MOTOR LRT and XRT Types WITH OUTBOARD MOTOR INSTALLED ON BOAT (remote control) REMOVED FROM BOAT When trailering a boat with the Use a motor support bar to prevent Secure the outboard motor in either outboard motor attached, leave the the outboard motor from moving the vertical or horizontal position engine in the normal running position,...

  • Page 86: 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 87: Engine Will Not Start

    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. 38 or 40 ). in neutral position.

  • Page 88: Taking Care Of Unexpected Problems

    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 89: Hard Starting Or Stalls After Starting

    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). Fast idle lever raised (remote Lower fast idle lever, unless control/side-mount type).

  • Page 90: Engine Overheats

    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 91: 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 FUSE COVER 10A FUSE 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 a spare fuse in each The battery-charging circuit and the fuse holder.

  • Page 92: Oil Pressure Indicator Light Goes Off And Engine Speed Is Limited

    (GREEN) If the engine protection system remains activated after 30 seconds, return to the nearest boat landing, and have the outboard motor inspected by an authorized Honda BUZZER marine dealer. (remote control type)

  • Page 93: Overheat Indicator Light Comes On And Engine Speed Is Limited

    TAKING CARE OF UNEXPECTED PROBLEMS OVERHEAT 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 94: Submerged Motor

    If there is a Honda marine dealer for half an hour. indicator again. nearby, take the motor to the dealer immediately.
  • Page 95 As soon as possible, take the times to lubricate the inside of the outboard motor to an authorized cylinders. Honda marine dealer for inspection and service. Reinstall the spark plugs, and put the emergency stop switch clip into the switch.

  • Page 96: Technical And Consumer Information

    TECHNICAL AND CONSUMER INFORMATION TECHNICAL INFORMATION STARTER MOTOR SWIVEL CASE Serial Number Locations 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 97: 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 98: 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 99: 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 100 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 101: 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 102 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 103: Specifications

    See shop manual Valve clearance Intake: 0.15 0.02 mm See shop (cold) Exhaust: 0.23 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 104 See shop manual Valve clearance Intake: 0.15 0.02 mm See shop (cold) Exhaust: 0.23 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 105: Consumer Information

    Marine Division additional information for cover most of the questions you Customer Relations Office maintaining and repairing your might ask about your Honda. Any 4900 Marconi Drive outboard motor. You may purchase questions not answered in the owner’s Alpharetta, GA 30005-8847 them from your Honda marine dealer.
  • Page 106 Please include the following deterioration associated with using information in your communication: your Honda outboard. Your new Honda is covered by the Your name, address and telephone following warranties: Your warranty coverage will not be number (complete with area code) voided if you choose to perform your Distributor’s Limited Warranty...
  • Page 107 (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 108: Distributor's Limited Warranty 2006

    WHAT AMERICAN HONDA WILL REPAIR OR REPLACE UNDER WARRANTY: This warranty is limited to Honda Outboard Motors American Honda will repair or replace, at its option, any distributed by American Honda Motor Co., Inc., Power part that is proven to be defective in material or...
  • Page 109 DISCLAIMER OF CONSEQUENTIAL DAMAGE PARTS AFFECTED OR DAMAGED BY AN AND LIMITATION OF IMPLIED WARRANTIES: ACCIDENT AND/OR COLLISION AMERICAN HONDA DISCLAIMS ANY NORMAL WEAR RESPONSIBILITY FOR LOSS OF TIME OR USE OF FUEL CONTAMINATION AND WATER THE OUTBOARD, REVENUE, OR THE EQUIPMENT...
  • Page 110 This warranty is limited to Honda Power Equipment parts, REPLACE UNDER WARRANTY: accessories and apparel when distributed by American American Honda will repair or replace, at its option, any Honda Motor Co., Inc., 1919 Torrance Blvd., Torrance, marine product accessories or replacement parts that are California 90501-2746.
  • Page 111 TECHNICAL AND CONSUMER INFORMATION TO OBTAIN WARRANTY SERVICE: MATERIAL OR WORKMANSHIP OF THE You must take the Honda Outboard Motor product PRODUCT. accessory or replacement part or the outboard motor or boat on which the accessory or replacement part is...

  • Page 112: Emission Control System Warranty

    Emission Control System Warranty All States American Honda Motor Co., Inc. must warranty the Your new Honda outboard engine complies with both the emission control system on your outboard engine for the U.S. EPA and State of California emission regulations.
  • Page 113 American Honda Motor Co., Inc. A list of that American Honda Motor Co., Inc. may deny you warranty parts is on page 113. Normal maintenance items,...
  • Page 114 REPLACEMENT OF EXPENDABLE dealer who is authorized by American Honda Motor Co., MAINTENANCE ITEMS MADE IN CONNECTION Inc. to sell and service that Honda marine product during WITH REQUIRED MAINTENANCE SERVICE his normal business hours. Claims for repair or AFTER THE ITEM’S FIRST SCHEDULED...
  • Page 115 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 Air Induction...

  • Page 116: Index

    INDEX Anodes ................30 Distributor’s Limited Warranty 2006 ..... 106 Replacement .............. . 75 ARE YOU READY TO GET UNDER WAY? .... . 32 ELECTRIC STARTER WILL NOT OPERATE ..84 EMERGENCY STARTING ......... . 42 Battery ................
  • Page 117 GEARSHIFTING AND THROTTLE OPERATION . 47 MOORING, BEACHING, LAUNCHING ....54 LH and LHT Types (long tiller handle) ..... 47 LRT and XRT Types (remote control) ..... . 48 HARD STARTING OR STALLS AFTER STARTING ..............87 Honda Publications ............103...
  • Page 118 INDEX Oil Pressue Indicator ............27 SAFE OPERATING PRECAUTIONS ......34 OIL PRESSURE INDICATOR LIGHT GOES SAFETY LABEL LOCATIONS ........OFF AND ENGINE SPEED IS LIMITED ....90 Serial Number Locations ..........94 OPERATION ..............34 SERVICING YOUR OUTBOARD MOTOR ....
  • Page 119 INDEX Tachometer (optional equipment) ........26 TAKING CARE OF UNEXPECTED PROBLEMS . 84 ..TECHNICAL AND CONSUMER INFORMATION . 94 TECHNICAL INFORMATION ........94 THE IMPORTANCE OF MAINTENANCE ....56 Throttle Friction Adjuster ..........18 Throttle Grip ..............
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