Honda BF40D Owner's Manual
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Honda BF40D Owner's Manual

Honda power equipment outdoor motor owner's manual
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  • Page 2 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Keep this owner’s manual handy, so you can refer to it at any time. This owner’s manual is considered a permanent part of the outboard motor and should remain with the outboard motor if resold.
  • Page 3 Congratulations on your selection of a Honda outboard motor. We are certain you will be pleased with your purchase of one of the finest outboard motors on the market. We want to help you get the best results from your new outboard motor and to operate it safely.
  • Page 4 INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this outboard motor safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.

  • Page 5: Table Of Contents

    OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION SAFETY LABEL LOCATIONS CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES COMPONENT AND CONTROL LOCATIONS CONTROLS LH Type (tiller handle) Ignition Switch Emergency Stop Switch Clip and Emergency Stop Switch Throttle Grip Throttle Friction Adjuster Gearshift Lever Steering Friction Adjuster Transom Angle Adjusting Rod...
  • Page 6 CONTENTS OTHER FEATURES Overrev Limiter Portable Fuel Tank (optional equipment) Fuel Filler Cap Vent Knob Fuel Priming Bulb Anodes BEFORE OPERATION ARE YOU READY TO GET UNDER WAY? IS YOUR OUTBOARD MOTOR READY TO GO? Tiller Handle Height/Angle Adjustment (LH type) OPERATION SAFE OPERATING PRECAUTIONS BREAK-IN PROCEDURE...
  • Page 7 . 67 STORAGE PRECAUTIONS . 69 REMOVAL FROM STORAGE . 70 TRANSPORTING . 70 WITH OUTBOARD MOTOR INSTALLED . 71 ON BOAT . 72 WITH OUTBOARD MOTOR REMOVED . 74 FROM BOAT . 74 . 76 . 77 . 78 .
  • Page 8 CONTENTS TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START HARD STARTING OR STALLS AFTER STARTING ENGINE OVERHEATS FUSES Electric Starter Will Not Operate Battery Will Not Charge Fuse Replacment OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMITED OVERHEAT INDICATOR COMES ON AND ENGINE SPEED IS LIMITED SUBMERGED MOTOR...

  • Page 9: Outboard Motor Safety

    IMPORTANT SAFETY INFORMATION The Honda BF40D/BF50D outboard motors are designed for use with boats that have a suitable manufacturer’s power recommendation. Other uses can result in injury to the operator or damage to the outboard motor and other property. Most accidents can be prevented if you follow all instructions in this manual and on the outboard motor.
  • Page 10 OUTBOARD MOTOR SAFETY Refuel With Care Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a well- ventilated area, with the engine stopped. Never smoke near gasoline, and keep other flames and sparks away. Refuel carefully to avoid spilling fuel.

  • Page 11: Safety Label Locations

    SAFETY LABEL LOCATION (LH type) 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: Controls And Features

    Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications. TYPE CODE (Example) T=Power Trim/Tilt None=Gas Assist Tilt H=Tiller Handle R=Remote Control L=20.5 in (521 mm) (Long Shaft) X=24.5 in (622 mm) (Extra Long Shaft) BF40D BF50D...

  • Page 13: Component And Control Locations

    COMPONENT AND CONTROL LOCATIONS LH Type (tiller handle) ENGINE COVER LATCH (front) TILLER HANDLE FUEL LINE CONNECTOR STERN BRACKET TRANSOM ANGLE ADJUSTING ROD ANODE METAL GEAR OIL CHECK SCREW WASH SCREW GEAR OIL DRAIN/FILL SCREW ENGINE OIL SPARK PLUG FILLER CAP (inside the cover) ENGINE COVER ENGINE COVER...
  • Page 14 CONTROLS AND FEATURES INDICATORS (Oil pressure, Overheat, Alternator, PGM-FI) EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH LANYARD EMERGENCY STOP SWITCH CLIP IGNITION SWITCH IGNITION SWITCH KEY GEARSHIFT LEVER STEERING FRICTION ADJUSTER THROTTLE FRICTION ADJUSTER THROTTLE GRIP...
  • Page 15 LRT and XRT Types (remote control) SPARK PLUG (inside the cover) ENGINE COVER LATCH (front) FUEL LINE CONNECTOR STERN BRACKET ANODE METAL GEAR OIL CHECK SCREW WASH SCREW GEAR OIL DRAIN/FILL SCREW ENGINE OIL FILLER CAP ENGINE COVER ENGINE COVER LATCH (rear) OIL LEVEL DIPSTICK...
  • Page 16 CONTROLS AND FEATURES Remote Control box (optional equipment) Side-Mount Control Type GEARSHIFT/THROTTLE CONTROL LEVER POWER TRIM/TILT SWITCH SPARE EMERGENCY STOP SWITCH CLIP BUZZER (inside) CONTROL LEVER FRICTION ADJUSTER NEUTRAL RELEASE LEVER INDICATORS (Oil pressure, Overheat, Alternator, PGM-FI) EMERGENCY STOP SWITCH LANYARD FAST IDLE LEVER IGNITION SWITCH IGNITION SWITCH...
  • Page 17 Fuel Tank (optional equipment) FUEL TANK (optional equipment) PRIMING BULB CONTROLS AND FEATURES FUEL GAUGE VENT KNOB FUEL FILLER CAP FUEL HOSE (standard equipment) FUEL HOSE CONNECTOR (female)
  • Page 18 CONTROLS AND FEATURES Trim Meter [optional equipment (LRT and XRT types)] Tachometer (optional equipment) Digital Speedometer (optional equipment) Digital Tachometer (optional equipment)

  • Page 19: Controls

    CONTROLS LH Type (tiller handle) Ignition Switch START IGNITION SWITCH IGNITION SWITCH The ignition switch controls the ignition system and the starter motor. Turning the ignition switch key to the START position operates the starter motor. The key automatically returns to the ON position when released from the START position.

  • Page 20: Throttle Grip

    CONTROLS AND FEATURES The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The emergency stop switch lanyard must be attached securely to the operator or to the operator’s PFD (Personal Flotation Device).

  • Page 21: Throttle Friction Adjuster

    STEERING FRICTION ADJUSTER The steering friction adjuster adjusts steering resistance. Less friction allows the outboard motor to turn more easily. More friction helps to hold a steady course while cruising or to prevent the outboard motor from swinging while trailering the boat.

  • Page 22: Transom Angle Adjusting Rod

    LOCK (RUN) position locks the motor in the desired position. Use the tilt lever to temporarily tilt the motor when the boat is operating in shallow water, or mooring in shallow water. The tilt lever must be in the LOCK...

  • Page 23: Lrt And Xrt Types

    LRT and XRT Types (remote control/optional equipment) For panel-mount or top-mount remote control information, refer to the instructions provided with the remote control equipment. Side-Mount Control Type Ignition Switch IGNITION SWITCH EMERGENCY STOP SWITCH SWITCH CLIP The ignition switch controls the ignition system and the starter motor.

  • Page 24: Emergency Stop Switch Clip And Emergency

    CONTROLS AND FEATURES Emergency Stop Switch Clip and Emergency Stop Switch EMERGENCY STOP SWITCH EMERGENCY EMERGENCY STOP STOP SWITCH CLIP SWITCH LANYARD EMERGENCY EMERGENCY STOP STOP SWITCH SWITCH CLIP LANYARD The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run.

  • Page 25: Gearshift/Throttle Control Lever

    Gearshif t/Throttle Control Lever GEARSHIFT/THROTTLE CONTROL LEVER NEUTRAL RELEASE LEVER The gearshift/throttle control lever controls engine speed and selects F (forward), N (neutral), or R (reverse) gears. F (FORWARD) SHIFT MAXIMUM GEARSHIFT/THROTTLE CONTROL LEVER Moving the control lever 30° from N (neutral) selects the gear, and further movement increases engine speed.

  • Page 26: Fast Idle Lever

    CONTROLS AND FEATURES Fast Idle Lever FAST IDLE LEVER Use the fast idle lever to accelerate engine warm-up after starting the engine. Do not use the fast idle lever when starting the engine. See page for engine warm-up instructions. N (neutral) MAXIMUM FAST IDLE START (LOWEST...

  • Page 27: Power Trim/Tilt Switch

    You can use the power trim/tilt switch anytime whether the boat is underway, stopped, or the ignition switch is in the OFF position. It is necessary for the ignition switch to be in the ON position for the trim meter to indicate the motor angle.

  • Page 28: Manual Relief Valve

    CONTROLS AND FEATURES Manual Relief Valve RIGHT STERN BRACKET POWER MANUAL (To fix) (To release) MANUAL RELIEF VALVE The outboard motor can be tilted manually after opening the manual relief valve. This allows the outboard motor to be tilted up or down when no battery is connected.

  • Page 29: Common Controls

    The tilt lock lever is used to support the outboard motor in the fully-raised position. When the boat is to be moored for a long time, tilt the outboard motor up as far as it will go. Then move the tilt...

  • Page 30: Instruments

    The trim meter indicates the relative trim angle of the outboard motor. Refer to the trim meter when using the power trim/tilt switch to achieve the best performance from the boat. Tachometer [optional equipment (all types)] TACHOMETER The tachometer shows engine speed in revolutions per minute.

  • Page 31: Digital Speedometer (Optional Equipment)

    Digital Speedometer [optional equipment (LRT and XRT types)] Digital Speedometer includes the following functions. Speedometer Fuel Level Meter Voltmeter Tripmeter Fuel Integration Meter Fuel Economy Meter Fuel Flow Meter Refer to the Operation Guide included with the Digital Speedometer for operation information.

  • Page 32: Indicators

    CONTROLS AND FEATURES INDICATORS Alternator (ACG) Indicator LH Type (RED) ACG INDICATOR (internal buzzer) LRT and XRT Types (side-mount control) ACG INDICATOR (RED) BUZZER The ACG indicator turns on and the buzzer sounds in one-second intervals when the charging system is faulty.

  • Page 33: Oil Pressure Indicator

    When the engine control system detects a PGM-FI malfunction, the PGM-FI indicator turns on and the buzzer sounds at one-second intervals. Under normal conditions, when the ignition key is turned on the following will occur: Both the PGM-FI indicator and ACG indicator will turn on.

  • Page 34: Overheat Indicator

    CONTROLS AND FEATURES Overheat Indicator LH Type (RED) OVERHEAT INDICATOR (internal buzzer) LRT and XRT Types (side-mount control) OVERHEAT INDICATOR (RED) BUZZER When the alert triggers, the overheat indicator comes on and the buzzer sounds a steady tone as the engine speed is reduced to 1,800 rpm.

  • Page 35: Other Features

    The cooling system indicator discharge port can also become plugged. OTHER FEATURES 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 speed, if the outboard motor is trimmed or tilted up excessively, or when propeller ventilation occurs...

  • Page 36: Fuel Filler Cap Vent Knob

    FUEL FILLER CAP The cap is provided with a vent knob to seal the portable fuel tank for carrying it to and from the boat. Open the vent knob 2 or 3 turns before starting the engine. Fuel Priming Bulb...

  • Page 37: Anodes

    Anodes ANODE (stern bracket) The anodes are made of a sacrificial material that helps to protect the outboard motor from corrosion. There are two anodes on the gear case, one on the stern bracket and two small anodes in the water passages of the engine block.

  • Page 38: Before Operation

    Safety Always wear a PFD (Personal Flotation Device) while on the boat. Attach the emergency stop switch clip securely to the operator or to the operator’s PFD (Personal Flotation Device).
  • Page 39 If you are using the portable fuel tank (optional equipment), make sure it is in good condition and properly secured in the boat Check that the fuel hose is undamaged and properly connected.

  • Page 40: Tiller Handle Height/Angle Adjustment (Lh Type)

    BEFORE OPERATION Tiller Handle Height/Angle Adjustment (LH type) The tiller handle height and angle can be adjusted to three positions by changing the installation direction of the height adjustment block. Select a suitable height and angle for the operator and secure the block. Raise the tiller handle and remove the 8 ×...

  • Page 41: Operation

    First 15 minutes: Run the engine at trolling speed. Use the minimum throttle opening necessary to operate the boat at a safe trolling speed. Next 45 minutes: Run the engine up to a maximum of 2,000 to 3,000 rpm, which is about 10% to 30% of maximum throttle opening.

  • Page 42: Transom Angle Adjustment (Lh Type)

    OPERATION TRANSOM ANGLE ADJUSTMENT (LH Type) STERN BRACKET TRANSOM ANGLE ADJUSTING ROD TRANSOM ANGLE ADJUSTING ROD TO CHANGE UNLOCKED POSITION TO LOCK LOCKED POSITION The transom angle adjusting rod limits the tilt angle of the outboard motor when fully lowered. Proper adjustment prevents the outboard motor from being trimmed too low (p.

  • Page 43: Portable Fuel Tank (Optional Equipment)

    3 feet below the fuel connector on the outboard motor. Secure the portable fuel tank in the boat so that it won’t move around and become damaged. Before use, open the fuel tank vent by turning the vent knob at least 2 or 3 turns counterclockwise.

  • Page 44: Fuel Priming

    OPERATION FUEL PRIMING OUTLET END (motor) PRIMING BULB INLET END (tank) Hold the priming bulb up in the direction of the arrow; then squeeze the priming bulb several times until it feels firm, indicating that fuel has reached the engine. Check to be sure there are no fuel leaks before starting the engine.

  • Page 45: Starting The Engine

    Always attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD before starting the engine.
  • Page 46 OPERATION START POSITION POINTER THROTTLE GRIP Align the engine start symbol ‘‘ ’’ on the tiller handle with the pointer ‘‘ ’’ on the throttle grip. Turn the ignition switch key to the ON position; the buzzer will sound two times. IGNITION SWITCH KEY Turn the ignition switch key to the START position and hold it there...
  • Page 47 Before getting underway, allow the engine to warm-up sufficiently to ensure good performance. Above 41°F (5°C), warm-up the engine for at least 3 minutes. Below 41°F (5°C), warm-up the engine for at least 5 minutes at 2,000 rpm. If the engine is not properly warmed up bef ore raising the engine speed, the buzzer and overheat indicator may activate...

  • Page 48: Lrt And Xrt Types (Remote Control)

    Always attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD before starting the engine.
  • Page 49 START (LOWEST POSITION) FAST IDLE RANGE Leave the fast idle lever in the START (fully lowered) position. The fast idle lever cannot be raised unless the control lever is in the N (neutral) position. The control lever cannot be moved away from the N (neutral) position unless the fast idle lever is lowered.
  • Page 50 OPERATION MAXIMUM FAST IDLE FAST IDLE RANGE Before getting underway, allow the engine to warm-up sufficiently to ensure good performance. Above 41°F (5°C), warm-up the engine for at least 3 minutes. Below 41°F (5°C), warm-up the engine for at least 5 minutes at 2,000 rpm.

  • Page 51: Emergency Starting

    EMERGENCY STARTING If the battery is discharged or the starter motor is inoperative, you can start the engine manually using the emergency starter rope supplied with the motor. (front) UNLOCK ENGINE COVER LATCH (rear) UNLOCK ENGINE COVER LATCH Turn the engine switch key to the OFF position.
  • Page 52 OPERATION Set the controls the same as for − normal starting (see pages 44 46 − Turn the ignition switch key to the ON position. KNOT ALTERNATOR PULLEY EMERGENCY STARTER ROPE Set the alternator pulley so the cutouts are on the right and left sides of the alternator pulley as shown.
  • Page 53 If the fast idle control(s) was used to start the engine, return the control(s) to the normal operating position as the engine warms up. During the warm-up period, check the oil pressure indicator (p. overheat indicator (p. ), and cooling system indicator (p. Leave the alternator cover off, but install the engine cover (p.

  • Page 54: Stopping The Engine

    OPERATION STOPPING THE ENGINE Emergency Engine Stopping LH Type (tiller handle) EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD LRT and XRT Types (remote control) Side-Mount Control Type EMERGENCY STOP SWITCH PULL EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD To stop the engine in an emergency, pull the emergency stop switch clip...

  • Page 55: Normal Engine Stopping

    Normal Engine Stopping LH Type (tiller handle) SLOW THROTTLE GRIP N (neutral) GEARSHIFT LEVER LRT and XRT Types (remote control) Side-Mount Control Type N (neutral) CONTROL LEVER Move the throttle grip to the slowest speed and the gearshift lever or control lever to the N (neutral) position.
  • Page 56 (p. When the boat is not in use, remove and store the ignition switch key and the emergency stop switch clip and lanyard.

  • Page 57: Gearshift And Throttle Operation

    GEARSHIFT AND THROTTLE OPERATION LH Type (tiller handle) POINTER THROTTLE GRIP SLOW FAST (neutral) (forward) (reverse) GEARSHIFT LEVER To shift gears, turn the throttle grip to the SLOW position; then move the gearshift lever to select F (forward), N (neutral), or R (reverse) gears. The engine can be started with the gearshift lever in the N (neutral) position only.

  • Page 58: Side-Mount Control Type

    OPERATION LRT and XRT Types (remote control) Side-Mount Control Type CONTROL LEVER NEUTRAL RELEASE LEVER N (neutral) F (forward) R (reverse) To shift gears, move the control lever to select the F (forward), N (neutral), or R (reverse) gear. The control lever cannot be moved from the N (neutral) position unless the neutral release lever is squeezed.

  • Page 59: Steering

    Do not apply grease or oil on the f riction plate. Grease or oil will reduce the f riction of the adjuster. OPERATION LRT and XRT Types (remote control) Steer the boat in the same manner as an automobile.

  • Page 60: Cruising

    You can use the power trim/tilt switch at any time, whether the boat is underway or stopped. Press the UP or DN (down) side of the switch to adjust the angle of the outboard motor.
  • Page 61 When cruising into a high wind, trim the outboard motor down slightly to level the boat and improve stability. With a tail wind, trim the outboard motor up slightly. Excessive trim/tilt angle during...

  • Page 62: Trim Tab

    OPERATION TRIM TAB If steering effort is not equal in both directions, adjust the trim tab to compensate for ‘‘torque steer,’’ which is the reaction of the outboard motor to propeller rotation. TRIM TAB BOLT TRIM TAB PROPELLER Adjust the trim tab with the engine stopped.
  • Page 63 ENGINE COVER GRIP TILT LEVER To tilt the outboard motor, move the tilt lever to the FREE (TILT) position, then raise the outboard motor to the desired position by pulling on the engine cover grip. Do not use the tiller handle as a lever to raise the outboard motor.

  • Page 64: Mooring, Beaching, Launching

    LH, LRT and XRT Types To raise the outboard motor out of the water while the engine is stopped and the boat is moored, or for maximum clearance when beaching or launching, use the power tilt switch (LRT and XRT types) on the engine pan to tilt the outboard motor up as far as it will go.
  • Page 65 RIGHT STERN BRACKET MANUAL RELIEF VALVE The outboard motor can also be tilted manually after opening the manual relief valve. This feature enables the outboard motor to be tilted up or down when no battery is connected. For manual tilting, use a flat blade screwdriver to turn the valve counterclockwise 2 and a half turns.

  • Page 66: Servicing Your Outboard Motor

    SERVICING YOUR OUTBOARD MOTOR THE IMPORTANCE OF MAINTENANCE Proper maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. Improperly maintaining this outboard motor, or failure to correct a problem before operation, can cause a malfunction in which you could be seriously hurt or killed.

  • Page 67: Maintenance Safety

    MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or...

  • Page 68: Starter Rope

    FUSE PULLER The owner’s manual and tool kit can be used to perform simple maintenance procedures and emergency repairs. Keep these items on the boat so that they will always be available if you need them. If your tool kit needs replacement, it is not available as a kit and each item must be ordered individually.

  • Page 69: Maintenance Schedule

    MAINTENANCE SCHEDULE Follow the MAINTENANCE SCHEDULE table and service your outboard motor accordingly. Please note, a claim for warranty coverage will not be denied simply because the maintenance schedule for your outboard was not followed. However, any part(s) that fails specifically due to lack of maintenance, or improperly performed maintenance, would not be covered under the Distributor’s Limited Warranty REGULAR SERVICE PERIOD...
  • Page 70 SERVICING YOUR OUTBOARD MOTOR REGULAR SERVICE PERIOD Perform at every indicated month or operating hour interval, whichever comes first. ITEM Fuel filter Check (Low pressure side) Replace Fuel filter Check (High pressure side) Replace Fuel line Check Replace Battery and cable Check level-tightness connection Bolts and nuts...

  • Page 71: Trim Tab Adjustment

    TRIM TAB BOLT If less effort is required to make right turns, move the back of the trim tab right. Adjust the trim tab in small increments, and retest steering effort with the boat evenly loaded and running at cruising speed.

  • Page 72: Manual Relief Valve

    SERVICING YOUR OUTBOARD MOTOR MANUAL RELIEF VALVE LRT and XRT Types RIGHT STERN BRACKET MANUAL RELIEF VALVE The outboard motor can be tilted manually after opening the manual relief valve. This feature enables the outboard motor to be tilted up or down when no battery is connected.

  • Page 73: Engine Oil Level Check

    Engine Oil Level Check Check the engine oil level with the engine stopped and the outboard motor in the vertical position. Unlatch and remove the engine cover (p. Remove the dipstick and wipe it clean. UPPER LIMIT LOWER LIMIT OIL LEVEL DIPSTICK Insert the dipstick all the way in, then remove it and check the oil level shown on the dipstick.

  • Page 74: Engine Oil Change

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Change 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 75 SEALING WASHER DRAIN BOLT Remove the engine oil drain bolt and washer. Allow the used oil to drain completely, then install a new sealing washer on the engine oil drain bolt, and tighten it securely. Reinstall the drain bolt cover. SERVICING YOUR OUTBOARD MOTOR Improper disposal of engine oil can be harmf ul to the environment.

  • Page 76: Engine Oil Recommendations

    SERVICING YOUR OUTBOARD MOTOR Engine Oil Recommendations Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. SAE 5W-30 is recommended for general use. Honda recommends that you use API service category SG, SH or SJ oil with the ‘‘starburst’’...
  • Page 77 SIDE ELECTRODE 0.024 − 0.028 in − (0.6 0.7 mm) SEALING WASHER INSULATOR Measure the spark plug electrode gap with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode. The gap should be: 0.024 0.028 in −...

  • Page 78: Lubrication Points

    SERVICING YOUR OUTBOARD MOTOR Lubrication Points Apply marine waterproof grease to the parts shown below: Lubrication interval: After the first 20 hours or 1 month, then every 100 hours or 6 months (refer to the maintenance schedule on page To prevent corrosion, apply anticorrosion oil to pivot surf aces where grease cannot penetrate.

  • Page 79: Refueling

    (optional equipment) FUEL TANK CAPACITY: 6.6 US gal (25 ) Check the fuel gauge and refill the tank when necessary. Remove the fuel tank from the boat for refueling. VENT KNOB FUEL FILLER CAP To refuel, turn the vent knob...

  • Page 80: Fuel Recommendations

    SERVICING YOUR OUTBOARD MOTOR Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. Never refill the fuel tank inside a building where gasoline fumes may reach flames or sparks.

  • Page 81: Fuel Filter/Water Separator Inspection And Service

    Fuel Filter/Water Separator Inspection and Service The fuel filter is located under the engine cover between the fuel coupling and the fuel pump. Water or sediment accumulation in the filter can cause loss of power or hard starting. To prevent engine malfunction, inspect the filter and replace when necessary.
  • Page 82 SERVICING YOUR OUTBOARD MOTOR FUEL FILTER (inside strainer cup) Inspect the filter for water and/or sediment accumulation. If water and/or sediment are present, clean the strainer cup and filter or replace the filter as described in the following steps. Always replace the filter at the scheduled replacement interval (p.
  • Page 83 Unscrew the strainer cup from the filter body. Thoroughly clean the strainer cup and fuel filter. If the fuel filter is contaminated, replace it with a new one. SERVICING YOUR OUTBOARD MOTOR FILTER BODY O-RING FUEL FILTER FLOAT (red ring) STRAINER CUP Install the fuel filter, float, O-rings and strainer cup.

  • Page 84: Portable Fuel Tank And Tank Filter Cleaning (Optional Equipment)

    SERVICING YOUR OUTBOARD MOTOR Connect the fuel hoses to the fuel filter securely with the hose clamps. Remove the fuel hose clips used to close the fuel hoses. Securely connect the fuel hose connector to the outboard motor (refer to page Prime the engine using the priming bulb (p.

  • Page 85: Anode Replacement

    Fuel Tank Filter TANK FILTER JOINT (Fuel Hose Connector) O-RING FUEL TANK FILLER Unscrew the fuel hose connector by turning it counterclockwise; then remove the fuel hose connector and fuel tank filter from the tank. Clean the filter in nonflammable solvent.

  • Page 86: Propeller Replacement

    SERVICING YOUR OUTBOARD MOTOR Propeller Replacement Before replacing the propeller, remove the emergency stop switch clip from the emergency stop switch to prevent any possibility of the engine being started while you are working with the propeller. The propeller blades may have sharp edges, so wear heavy gloves to protect your hands.
  • Page 87 Be sure to replace the cotter pin with a new one. Use a Honda Genuine stainless steel cotter pin or equivalent cotter pin and bend the pin ends as shown. Note that these wrenches are not included with the tool set that comes with the outboard motor.

  • Page 88: Storage

    STORAGE STORAGE PREPARATION Proper storage preparation is essential for keeping your outboard motor trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your outboard motor’s function and appearance, and will make the engine easier to start when you use the outboard motor again.
  • Page 89 GARDEN HOSE ADAPTER (FLUSH KIT CPUPLER) Remove the sealing washer from the wash screw and install the sealing washer on the flush kit coupler. Install the flush kit coupler into the WASH screw hole and connect a fresh water hose to the garden hose adapter.
  • Page 90 STORAGE WATER INTAKES WATER INTAKES Allow the engine to run at idle for at least 5 minutes to clean the inside of the motor. Stop the motor and remove the garden hose adapter. Remove the sealing washer from the garden hose adapter and install the sealing washer on the wash screw.

  • Page 91: Fuel

    Fuel Gasoline will oxidize and deteriorate 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 92 STORAGE Draining the Fuel System You can avoid fuel deterioration problems by draining the fuel tank and vapor separator. Before draining and checking the fuel system, check the fuel filter for contamination and/ or water accumulation. The fuel filter must be free of any contamination before proceeding (p.
  • Page 93 Tilt the outboard motor up until gasoline flows out of the drain tube. Leave it in that position until the gasoline stops flowing. After thoroughly draining, tighten the drain screw securely. Check the drained gasoline for the presence of water or contamination.

  • Page 94: Engine Oil

    Unlatch and remove the engine cover (p. Attach the hoist hook to the lifting eye. Disconnect the outboard motor from the boat, hoist the outboard motor, and move it to the storage area. After the outboard motor is placed in storage and disconnected from the hoist, install the engine cover.

  • Page 95: Removal From Storage

    OUTBOARD MOTOR STAND (commercially available) If the outboard motor will be removed from the boat for storage, we recommend storing it vertically by mounting it on a commercially available stand. CASE PROTECTOR PROTECTOR If it is necessary to store the outboard motor horizontally as shown, drain the vapor separator (p.

  • Page 96: Transporting

    LRT and XRT Types (remote control) Use a motor support bar to prevent the outboard motor from moving while trailering the boat. Refer to the manufacturer’s instructions for using a motor support bar. All Types If there is insufficient road clearance...

  • Page 97: Taking Care Of Unexpected Problems

    ENGINE WILL NOT START Check emergency stop switch clip. Check control positions. TAKING CARE OF UNEXPECTED PROBLEMS Possible Cause Clip not inserted in emergency stop switch. Gearshift lever or control lever not in neutral position. Throttle grip not in START position (tiller handle type).

  • Page 98: Taking Care Of Unexpected Problems

    − tank optional equipment). Fuel hose not primed. Fuel filter or fuel tank filter clogged. Bad fuel; boat stored without treating or draining gasoline, or refueled with bad gasoline. Correction Refuel (p. Open fuel filler cap vent (p. Squeeze priming bulb (p.
  • Page 99 ENGINE WILL NOT START (continued) Check battery. Check fuses. Remove and inspect spark plugs. Use starting procedure (p. ); if engine still will not start, then take outboard motor to an authorized Honda Marine dealer, or refer to the shop manual. TAKING CARE OF UNEXPECTED PROBLEMS Possible Cause Battery connections loose or...

  • Page 100: Hard Starting Or Stalls After Starting

    − optional equipment). Fuel hose not primed. Fuel filter or fuel tank filter clogged. Bad fuel; boat stored without treating or draining gasoline, or refueled with bad fuel. Correction Turn throttle grip to START Leave fast idle lever in the START position (p.

  • Page 101: Engine Overheats

    HARD STARTING OR STALLS AFTER STARTING (continued) Remove and inspect spark plugs. Take outboard motor to an authorized Honda Marine dealer, or refer to the shop manual. ENGINE OVERHEATS Check water intake screens. Take outboard motor to an authorized Honda Marine dealer, or refer to the shop manual.

  • Page 102: Fuses

    TAKING CARE OF UNEXPECTED PROBLEMS FUSES Electric Starter Will Not Operate The 10A, 15A, and 30A fuses protect the electric starter relay and related circuits. The 10A fuse protects the ignition switch and related circuits. If this fuse blows, the engine will not start or run, and the power trim/tilt switch will not activate the trim/tilt mechanism.

  • Page 103: Fuse Replacement

    Fuse Replacement Disconnect the battery cable at the battery negative ( ) terminal bef ore − replacing the f use. Failure to do so may cause a short circuit. Main Fuse Stop the engine and disconnect the battery cable. Remove the electrical parts cover. Remove the fuse case lid.

  • Page 104: Oil Pressure Indicator Goes Off And Engine Speed Is Limited

    TAKING CARE OF UNEXPECTED PROBLEMS OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMITED LH Type (tiller handle) (GREEN) (internal buzzer) LRT and XRT Types (remote control) Side-Mount Control Type (GREEN) BUZZER Digital Tachometer Normal Abnormal If oil pressure becomes low, the oil pressure indicator will go off, and the engine protection system limits engine speed.

  • Page 105: Overheat Indicator Comes On And Engine Speed Is Limited

    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 Marine dealer. TAKING CARE OF UNEXPECTED PROBLEMS...
  • Page 106 If there is still no water flowing from the cooling system indicator, or 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 Marine dealer.

  • Page 107: Submerged Motor

    SUBMERGED MOTOR A submerged outboard motor must be serviced immediately after it is recovered from the water in order to minimize corrosion. If there is a Honda Marine dealership nearby, take the motor to the dealer immediately. If you are far from a dealer, proceed as follows: Remove the engine cover, and rinse the outboard motor with...
  • Page 108 TAKING CARE OF UNEXPECTED PROBLEMS Pour a teaspoon of engine oil into each spark plug hole, then pull the emergency starter rope several times to lubricate the inside of the cylinders. Reinstall the spark plugs and alternator cover, and put the emergency stop switch clip into the emergency stop switch.

  • Page 109: Technical And Consumer Information

    TECHNICAL INFORMATION 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. TECHNICAL AND CONSUMER INFORMATION LEFT STERN...

  • Page 110: Battery

    TECHNICAL AND CONSUMER INFORMATION Battery For complete information, refer to the battery manufacturer’s instructions. Minimum Requirements 12V 55Ah/5HR (65Ah/5HR) − Be caref ul to avoid connecting the battery in reverse polarity, as this will damage the battery-charging system in the outboard motor. Do not disconnect the battery cables while the engine is running.
  • Page 111 PGM-FI System The PGM-FI system uses sequential multiport fuel injection. It has two subsystems: Engine Control, and Fuel Control. The Engine Control Module (ECM) uses various sensors to determine how much air is going into the engine. It then controls how much fuel to inject under all operating conditions.
  • Page 112 TECHNICAL AND CONSUMER INFORMATION Problems That May Af f ect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring).

  • Page 113: Star Label

    Star Label A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board. TECHNICAL AND CONSUMER INFORMATION The Star Label means Cleaner Marine Engine This engine has been certified as a: The Symbol for Cleaner Marine Engines: Cleaner Air and Water - for healthier lifestyle and environment.
  • Page 114 TECHNICAL AND CONSUMER INFORMATION One Star Emission Two Stars Very Low Emission Three Stars Ultra Low Emission Four Stars Super Ultra Low Emission The one-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2001 exhaust emission standards.

  • Page 115: Specifications

    ＊ Without battery cable, with propeller Honda outboards are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23. TECHNICAL AND CONSUMER INFORMATION BF40D Specified oil BBDJ 27.3 in (694 mm) Oil capacity CARB star label 216 lbs (98 kg) D.C.
  • Page 116 TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description Code Type Overall length 27.3 in (694 mm) 14.6 in (372 mm) Overall width Overall height 53.7 in (1,364 mm) 20.5 in (521 mm) Transom height (when transom angle is 12°) Dry weight ＊...
  • Page 117 BF40D/BF50D Tune up Spark plug gap (do not adjust) Idle speed Valve clearance Other specifications TECHNICAL AND CONSUMER INFORMATION 0.024 0.028 in (0.6 0.7 mm) − − ± 50 rpm Intake: 0.15 ± 0.02 mm Exhaust: 0.23 ± 0.02 mm...

  • Page 118: Consumer Information

    TECHNICAL AND CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing your outboard motor. Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician.
  • Page 119 Please include the following information in your communication: Your name, address and telephone number (complete with area code) Model and complete serial number Date of purchase Name and location of selling dealer Name and location of servicing dealer (if different) A detailed description of your concerns TECHNICAL AND CONSUMER INFORMATION...
  • Page 120 TECHNICAL AND CONSUMER INFORMATION Warranty Service Please remember that recommended maintenance interval servicing is not included in your warranty coverage. Additionally, your warranty does not apply to the normal wear of items (such as spark plug(s), water pump, etc.). As the owner of a Honda product, your servicing dealer may ask you to authorize an inspection.

  • Page 121: Distributor's Limited Warranty

    Distributor’s Limited Warranty This warranty is limited to Honda Outboard Motors distributed by American Honda Motor Co., Inc., Power Equipment Division, 4900 Marconi Drive, Alpharetta, Georgia 30005-8847. Products Covered by Warranty: All Models: Model Year 2000 and Newer Models BF115/BF130: All Model Years −...
  • Page 122 TECHNICAL AND CONSUMER INFORMATION Exclusions: This warranty does not extend to the following: Conditions caused by lack of routine maintenance (as outlined in the owner’s manual) Conditions caused by the use of propeller (s) that do not allow the outboard motor to run in its recommended full throttle rpm range Operation inconsistent with the recommended operation/duty cycle (as outlined in the owner’s...
  • Page 123 Accessories and Replacement Parts This warranty is limited to Honda Power Equipment parts,accessories and apparel when distributed by American Honda Motor Co., Inc., 1919 Torrance Blvd., Torrance, California 90501-2746. Products Covered by Warranty: Accessories Replacement Parts To Qualify for This Warranty:...
  • Page 124 Disclaimer of consequential damage and limitation of implied warranties: American Honda disclaims any responsibility for loss of time or use of the outboard motor, or the boat on which the product is installed, transportation, commercial loss, or any other incidental or consequential damage. Any implied warranties are limited to the duration of this written warranty.

  • Page 125: Emission Control System Warranty

    Emission Control System Warranty Your new Honda outboard engine complies with both the U.S. EPA and State of California emission regulations. American Honda provides the same emission warranty coverage for outboard engines sold in all 50 states. YOUR WARRANTY RIGHTS AND OBLIGATION California The California Air Resources Board and American Honda Motor Co., Inc.
  • Page 126 TECHNICAL AND CONSUMER INFORMATION OWNER’S WARRANTY RESPONSIBILITY: As the outboard engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. American Honda Motor Co., Inc. recommends that you retain all receipts covering maintenance on your outboard engine, but American Honda Motor Co., Inc.
  • Page 127 TO OBTAIN WARRANTY SERVICE: You must take your Honda outboard engine, along with your sales registration card or other proof of original purchase date, at your expense, to any Honda Marine dealer who is authorized by American Honda Motor Co., Inc.
  • Page 128 TECHNICAL AND CONSUMER INFORMATION EMISSION CONTROL SYSTEM WARRANTY PARTS: SYSTEMS COVERED BY THIS WARRANTY: Fuel Metering Air Induction Ignition Lubrication system Crankcase Emission Control Exhaust Valve Control System Miscellaneous Parts ＊ Covered up to the first required replacement only. See the Maintenance Schedule (P. 67). PARTS DESCRIPTION Carburetor assembly, Throttle body, Fuel injector, Fuel pump, Fuel pressure regulator, Throttle position sensor, Intake air temperature sensor, Engine temperature...

  • Page 129: Index

    Alternator (ACG) Indicator Anodes Replacement ARE YOU READY TO GET UNDERWAY? Battery Will Not Charge BEFORE OPERATION BREAK-IN PROCEDURE Common Controls COMPONENT AND CONTROL LOCATIONS CONSUMER INFORMATION CONTROL AND FEATURE IDENTIFICATION CODES CONTROLS CONTROLS AND FEATURES Cooling System Indicator CRUISING Customer Service Information Digital Speedometer (optional equipment) Digital Tachometer (optional equipment)
  • Page 130 INDEX Fast Idle Lever Fuel Filler Cap Vent Knob (optional equipment) Filter/Water Separator Inspection and Service Gauge (optional equipment) HOSE CONNECTIONS PRIMING Priming Bulb RECOMMENDATIONS Fuse Replacement FUSES Gearshift Lever (LH Type) Gearshift/Throttle Control Lever (LRT and XRT Types) Side-Mount Control Type GEARSHIFT AND THROTTLE OPERATION HARD STARTING OR STALLS AFTER STARTING...
  • Page 131 Oil Pressure Indicator OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMITED OPERATION OTHER FEATURES OUTBOARD MOTOR SAFETY Overheat Indicator OVERHEAT INDICATOR COMES ON AND ENGINE SPEED IS LIMITED Overrev Limiter PORTABLE FUEL TANK (optional equipment) . 33, 41 and Tank Filter Cleaning (optional equipment) Power Tilt Switch Power Trim/Tilt Switch...
  • Page 132 Grip (LH Type) Tiller Handle Height/Angle Adjustment (LH Type) Tilt Lock Lever TOOL KIT and OWNER’S MANUAL TRANSPORTING WITH OUTBOARD MOTOR INSTALLED ON BOAT WITH OUTBOARD MOTOR REMOVED FROM BOAT Trim Meter (optional equipment) Trim Tab TRIM TAB ADJUSTMENT . 28 .
  • Page 133 MEMO...
  • Page 134 MEMO...

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