You are on page 1of 103

BF5A

Owners Manual

BF5AK2 Includes US and Canadian Models


31ZV1660
00X31-ZV1-6600 N 2eY1500.2011.04
Printed in China

PANTONE 288 CVC DIC F101 BLACK


00X31-ZV1-6600 BF5A
11/03/07 16:26:14 31ZV1660_001

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 Owners Manual handy, so you can refer to it at any time. This Owners
Manual is considered a permanent part of the outboard motor and should remain with
the outboard motor if resold.

2011 Honda Motor Co., Ltd. All Rights Reserved

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. No part of this publication may be reproduced
without written permission.
11/03/07 16:26:20 31ZV1660_002

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 (see page 84 ).
outboard motors on the market.
When your outboard motor needs
We want to help you get the best scheduled maintenance, keep in mind
results from your new outboard that your Honda Marine dealer is
motor and to operate it safely. This specially trained in servicing Honda
manual contains information on how outboard motors. Your Honda
to do that; please read it carefully. Marine dealer is dedicated to your
satisfaction and will be pleased to
As you read this manual you will answer your questions and concerns.
find information preceded by a
Best Wishes,
symbol. That information Honda Motor Co., Ltd.
is intended to help you avoid damage
to your outboard motor, other
property, or the environment.

1
11/03/07 16:26:33 31ZV1660_003

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.
responsibility.
These signal words mean:
To help you make informed
decisions about safety, we have You WILL be KILLED or SERIOUSLY
provided operating procedures and HURT if you dont follow instructions.
other information on labels and in
this manual. This information alerts You CAN be KILLED or SERIOUSLY
you to potential hazards that could HURT if you dont follow instructions.
hurt you or others.
You CAN be HURT if you dont follow
Of course, it is not practical or instructions.
possible to warn you about all the
hazards associated with operating or Safety Headings such as IMPORTANT SAFETY INFORMATION.
maintaining an outboard motor. You
must use your own good judgment. Safety Section such as OUTBOARD MOTOR SAFETY.

Instructions how to use this outboard motor correctly and safely.

This entire book is filled with important safety information please read it
carefully.

2
11/03/07 16:26:37 31ZV1660_004

CONTENTS

OUTBOARD MOTOR SAFETY .................................... 6 INDICATORS............................................................ 18


IMPORTANT SAFETY INFORMATION ................. 6 Oil Pressure Indicator ............................................. 18
SAFETY LABEL LOCATIONS ................................. 8 Cooling System Indicator ...................................... 18
OTHER FEATURES ................................................. 18
CONTROLS AND FEATURES ................................... 11 Rev Limiter ............................................................ 18
CONTROL AND FEATURE Anode ..................................................................... 19
IDENTIFICATION CODES ................................. 11 Portable Fuel Tank ................................................. 19
COMPONENT AND CONTROL LOCATIONS ..... 12 Fuel Filler Cap Vent Knob ..................................... 19
CONTROLS ............................................................... 14 Fuel Priming Bulb .................................................. 20
Emergency Stop Switch Clip and Emergency
Stop Switch ........................................................ 14 INSTALLATION ........................................................... 21
Choke Knob ........................................................... 14 POWER REQUIREMENTS...................................... 21
Throttle Grip........................................................... 15 INSTALLATION POSITION ................................... 21
Throttle Friction Knob ........................................... 15 ATTACHMENT ........................................................ 22
Gearshift Lever ...................................................... 15 TRANSOM ANGLE ADJUSTMENT ...................... 22
Starter Grip ............................................................. 16
Engine Cover Lock Lever ...................................... 16 BEFORE OPERATION................................................. 23
Transom Angle Adjusting Rod .............................. 16 ARE YOU READY TO GET UNDER WAY?......... 23
Steering Friction Bolt ............................................. 17 IS YOUR OUTBOARD MOTOR
Tilt Lever ................................................................ 17 READY TO GO? ................................................... 23
INSTRUMENTS ........................................................ 17
Fuel Gauge ............................................................. 17

3
11/03/07 16:26:41 31ZV1660_005

CONTENTS

OPERATION ................................................................. 25 TOOL KIT AND EMERGENCY STARTER


SAFE OPERATING PRECAUTIONS ..................... 25 ROPE...................................................................... 40
BREAK-IN PROCEDURE........................................ 25 MAINTENANCE SCHEDULE ................................ 41
TRANSOM ANGLE ADJUSTMENT ...................... 25 ENGINE COVER REMOVAL AND
PORTABLE FUEL TANK ........................................ 26 INSTALLATION................................................... 43
FUEL HOSE CONNECTIONS ................................. 26 Engine Oil Level Check ......................................... 43
FUEL PRIMING ........................................................ 27 Engine Oil Change ................................................. 44
INFREQUENT OR OCCASIONAL USE ................ 27 Engine Oil Recommendations ............................... 45
STARTING THE ENGINE ....................................... 28 Gear Case Oil Level Check .................................... 45
EMERGENCY STARTING ...................................... 30 Gear Case Oil Change ............................................ 46
STOPPING THE ENGINE ........................................ 32 Lubrication Points .................................................. 48
Emergency Engine Stopping ................................. 32 Spark Plug Service ................................................. 49
Normal Engine Stopping........................................ 32 REFUELING.............................................................. 50
GEARSHIFT AND THROTTLE OPERATION ...... 33 FUEL RECOMMENDATIONS ................................ 52
STEERING ................................................................ 34 Fuel Filter Inspection and Replacement ................ 53
CRUISING ................................................................. 35 Portable Fuel Tank and Tank Filter Cleaning........ 55
SHALLOW WATER OPERATION ......................... 36 Recoil Starter Rope Inspection .............................. 56
MOORING, BEACHING, LAUNCHING ................ 37 Anode Replacement ............................................... 56
Propeller and Shear Pin Replacement .................... 57
SERVICING YOUR OUTBOARD MOTOR ............... 38
THE IMPORTANCE OF MAINTENANCE ............ 38
MAINTENANCE SAFETY ...................................... 39

4
11/03/07 16:26:45 31ZV1660_006

CONTENTS

CLEANING AND FLUSHING..................................... 59 TECHNICAL AND CONSUMER INFORMATION... 74


Cleaning and Flushing ........................................... 59 TECHNICAL INFORMATION ................................ 74
Serial Number locations ......................................... 74
STORAGE ..................................................................... 61 Carburetor Modification for High Altitude
Fuel ......................................................................... 61 Operation ............................................................ 75
Engine Oil .............................................................. 63 Emission Control System Information .................. 76
STORAGE PRECAUTIONS .................................... 63 Star Label ............................................................... 78
REMOVAL FROM STORAGE ................................ 64 Specifications ......................................................... 80
CONSUMER INFORMATION ................................ 81
TRANSPORTING ......................................................... 65 Honda Publications ................................................ 81
WITH OUTBOARD MOTOR INSTALLED Customer Service Information ............................... 81
ON BOAT .............................................................. 65 Warranty Statements .............................................. 84
WITH OUTBOARD MOTOR REMOVED Distributors Limited Warranty ............................. 84
FROM BOAT ........................................................ 65 Emission Control System Warranty ...................... 89
Distributors Warranty ........................................... 93
TAKING CARE OF UNEXPECTED
PROBLEMS........................................................... 66 INDEX............................................................................ 96
ENGINE WILL NOT START ................................... 66
HARD STARTING OR STALLS AFTER
STARTING ............................................................ 68
ENGINE OVERHEATS ............................................ 69
ENGINE WILL NOT DRIVE THE PROPELLER... 70
OIL PRESSURE INDICATOR GOES OFF AND
ENGINE SPEED IS LIMITED ............................. 71
SUBMERGED OUTBOARD MOTOR .................... 72

5
11/03/07 16:26:56 31ZV1660_007

OUTBOARD MOTOR SAFETY


IMPORTANT SAFETY Operator Responsibility Attach the emergency stop switch
INFORMATION lanyard securely to the operator.
It is the operators responsibility to
The Honda BF5A outboard motor is provide the necessary safeguards Always wear a PFD (Personal
designed for use with boats that have to protect people and property. Flotation Device) while on the
a suitable manufacturers power Know how to stop the engine boat.
recommendation. Other uses can quickly in case of emergency.
result in injury to the operator or Understand the use of all controls. Familiarize yourself with all laws
damage to the outboard motor and and regulations relating to boating
other property. Stop the engine immediately if and the use of outboard motors.
anyone falls overboard, and do not
Most injuries or property damage can run the engine while the boat is Be sure that anyone who operates
be prevented if you follow all near anyone in the water. the outboard motor receives proper
instructions in this manual and on the instruction.
outboard motor. The most common Always stop the engine if you
hazards are discussed in this chapter, must leave the controls for any Be sure the outboard motor is
along with the best way to protect reason. properly mounted on the boat.
yourself and others.
Do not remove the engine cover
while the engine is running.

6
11/03/07 16:27:05 31ZV1660_008

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. Never smoke near lead to death.
gasoline, and keep other flames
and sparks away. If you run the engine in an area that
is confined, or even partly enclosed,
Remove any portable fuel tank the air you breathe could contain a
from the boat for refueling. Keep dangerous amount of exhaust gas.
the portable fuel tank away from
the battery or other potential spark Never run your outboard inside a
sources. garage or other enclosure.

Refuel carefully to avoid spilling


fuel. Avoid overfilling the fuel
tank.

After refueling, tighten the filler


cap securely. If any fuel is spilled,
make sure the area is dry before
starting the engine.

7
11/03/07 18:16:03 31ZV1660_009

OUTBOARD MOTOR SAFETY

SAFETY LABEL LOCATIONS


US, Puerto Rico, and US Virgin Islands Types
GASOLINE FLAMMABLE DANGER

PORTABLE FUEL TANK

GASOLINE FLAMMABLE DANGER


CAUTION
KEEP TOTALLY CLOSED WHEN
NOT IN USE. KEEP AWAY FROM
HEAT, SPARKS, AND OPEN FLAME.
SECURE ABOVE DECK IN WELL
VENTILATED AREA. DO NOT USE
FOR LONG TERM FUEL STORAGE. DANGER
HARMFUL OR FATAL IF SWALLOWED.
KEEP OUT OF REACH OF CHILDREN.
IF SWALLOWED, DO NOT INDUCE
VOMITING. CALL A PHYSICIAN
IMMEDIATELY.

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.
8
11/03/07 16:27:23 31ZV1660_010

OUTBOARD MOTOR SAFETY

Canadian Types
GASOLINE FLAMMABLE DANGER FUEL CAUTION
GAZOLINE INFLAMMABLE DANGEREUX
GASOLINA PELIGRO FLAMABLE

PORTABLE FUEL TANK

GASOLINE FLAMMABLE DANGER


GAZOLINE INFLAMMABLE DANGEREUX

CAUTION
KEEP TOTALLY CLOSED WHEN
NOT IN USE. KEEP AWAY FROM
HEAT, SPARKS, AND OPEN FLAME.
SECURE ABOVE DECK IN WELL
VENTILATED AREA. DO NOT USE DANGER
FOR LONG TERM FUEL STORAGE. HARMFUL OR FATAL IF SWALLOWED.
KEEP OUT OF REACH OF CHILDREN.
IF SWALLOWED, DO NOT INDUCE
VOMITING. CALL A PHYSICIAN
READ OWNERS MANUAL IMMEDIATELY.

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.
9
11/03/07 16:27:31 31ZV1660_011

OUTBOARD MOTOR SAFETY

Canadian Types
Be careful not to spill any
fuel while refueling. Spilled
fuel or fuel vapor may
ignite. If any fuel is spilled,
Gasoline is harmful or fatal make sure that the area is
if swallowed. Keep the fuel dry before starting the
Honda outboard motor is tank out of reach of engine.
designed to give safe and children.
dependable service if Gasoline is extremely
operated according to flammable and is explosive
instructions. under certain conditions.
Read and understand the Refuel in a well-ventilated
Owners Manual before area with the engine
operating the outboard stopped.
motor. Failure to do so Do not smoke or allow
could result in personal flames or sparks where the
injury or equipment engine is refueled or where
damage. gasoline is stored.
Do not overfill the fuel tank.
After refueling make sure
that the fuel filler cap is
closed properly and
securely.

10
11/03/07 16:27:41 31ZV1660_012

CONTROLS AND FEATURES


CONTROL AND FEATURE IDENTIFICATION CODES
Model BF5A

Type SA LA
SC LC

Shaft Length S

Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.

BF5A is provided with the following types Shaft Length (Example)


according to the shaft length. S: Short Shaft L A
L: Long Shaft
Destination
A=American, C=Canadian
S=Short Shaft
L=Long Shaft

11
11/03/07 16:27:50 31ZV1660_013

CONTROLS AND FEATURES

COMPONENT AND CONTROL LOCATIONS


GEARSHIFT LEVER CHOKE KNOB OIL FILLER CAP/DIPSTICK SPARK PLUG

EMERGENCY STARTER GRIP


ENGINE COVER
STOP SWITCH
ENGINE COVER
TILLER THROTTLE GRIP LOCK LEVER
HANDLE

TILT LEVER
THROTTLE
FRICTION KNOB
TRANSOM ANGLE COOLING SYSTEM
ADJUSTING ROD EMERGENCY STOP INDICATOR
SWITCH CLIP
OIL PRESSURE
INDICATOR ENGINE OIL
DRAIN BOLT
EMERGENCY STOP CLAMP SCREW
SWITCH LANYARD WASH SCREW
(FLUSH SCREW)
STERN BRACKET
FUEL HOSE ANODE
CONNECTOR
(MALE) STEERING
ANTIVENTILATION
PLATE FRICTION BOLT

WATER INTAKE PORT


(each side) EXHAUST PORT
GEAR OIL
PROPELLER LEVEL SCREW

GEAR OIL DRAIN/FILL SCREW

12
11/03/07 16:27:54 31ZV1660_014

CONTROLS AND FEATURES

Portable Fuel Tank


FUEL GAUGE

VENT KNOB PORTABLE FUEL TANK

PRIMING BULB
FUEL FILLER CAP

FUEL HOSE
(standard equipment)

FUEL HOSE CONNECTOR


(FEMALE)

13
11/03/07 16:28:07 31ZV1660_015

CONTROLS AND FEATURES

CONTROLS The emergency stop switch clip must Choke Knob


be inserted in the emergency stop CHOKE KNOB
Emergency Stop Switch Clip switch in order for the engine to start
and Emergency Stop Switch and run. The emergency stop switch
lanyard must be attached securely to
EMERGENCY the operator or to the operators PFD
STOP SWITCH (Personal Flotation Device).
OFF
When used as described, the
emergency stop switch and ON
emergency stop switch lanyard
system stops the engine if the
PUSH operator falls away from the controls.
EMERGENCY
STOP SWITCH A spare emergency stop switch clip is The choke knob opens and closes the
CLIP supplied with the tool kit. choke valve in the carburetor.
EMERGENCY STOP
SWITCH LANYARD The ON position enriches the fuel
mixture for starting a cold engine.
EMERGENCY STOP
SWITCH CLIP
The OFF position provides the
correct fuel mixture for operation
after starting, and for restarting a
warm engine.

EMERGENCY STOP
SWITCH LANYARD

14
11/03/07 16:28:24 31ZV1660_016

CONTROLS AND FEATURES

Throttle Grip Throttle Friction Knob Gearshift Lever


INDEX MARK
TO DECREASE R (reverse) N (neutral) F (forward)
FRICTION

TO INCREASE
FRICTION

THROTTLE
THROTTLE GRIP FRICTION KNOB
GEARSHIFT LEVER

The throttle grip controls engine The throttle friction knob adjusts The gearshift lever is used to select F
speed. resistance to throttle grip rotation. (forward), N (neutral), or R (reverse)
gears.
An index mark on the tiller handle Turn the knob clockwise to increase
shows throttle position and is helpful friction for holding a throttle setting The engine can be started with the
for setting the throttle correctly when while cruising. gearshift lever in the N (neutral)
starting (p. 28 ). position only.
Turn the knob counterclockwise to
decrease friction for easy throttle grip If the gearshift lever is in the F
rotation. (forward) or R (reverse) position, the
recoil starter will not operate.

15
11/03/07 16:28:37 31ZV1660_017

CONTROLS AND FEATURES

Starter Grip Engine Cover Lock Lever Transom Angle Adjusting Rod
ENGINE COVER LOCK LEVER
The transom angle adjusting rod
adjusts the transom angle of the
Direction to pull outboard motor when fully lowered.

UNLOCK
STARTER GRIP
Pulling the starter grip operates the The engine cover lock lever fastens
recoil starter to crank the engine for the engine cover to the outboard
starting. motor. TRANSOM ANGLE ADJUSTING ROD

The engine will start only when the Proper adjustment prevents the
gearshift lever (p. 28 ) is in the N outboard motor from being adjusted
(neutral) position, and the emergency too low (p. 35 ).
stop switch clip is in the emergency
stop switch.

16
11/03/07 16:28:59 31ZV1660_018

CONTROLS AND FEATURES

Steering Friction Bolt Tilt Lever INSTRUMENTS


ENGINE COVER GRIP
STEERING FRICTION BOLT TILT LEVER Fuel Gauge
TO DECREASE
FRICTION FUEL GAUGE

TO INCREASE
FRICTION

The steering friction bolt adjusts The tilt lever enables the outboard A fuel gauge is built into the fuel
steering resistance. motor to be raised for shallow water tank connector of the portable fuel
operation, beaching, launching, or tank.
Less friction allows the outboard mooring.
motor to turn more easily. More
friction helps to hold a steady course To tilt, raise the outboard motor by
while cruising or to prevent the pulling on the cover grip until the tilt
outboard motor from swinging while mechanism engages at 18, 38, or
trailering the boat. 58 (p. 36 and 37 ).

17
11/03/07 16:29:15 31ZV1660_019

CONTROLS AND FEATURES

INDICATORS Cooling System Indicator OTHER FEATURES


Oil Pressure Indicator Rev Limiter
OIL PRESSURE INDICATOR
The engine is equipped with a rev
limiter to prevent the possibility of
mechanical damage from excessive
engine speed.

The rev limiter may be activated


during operation, limiting engine
speed, if the outboard motor is tilted
COOLING SYSTEM INDICATOR excessively, or when propeller
ventilation occurs during a sharp turn.
When the oil pressure indicator is lit, Water should flow from the cooling
oil pressure is OK. system indicator while the engine is If the rev limiter is activated, check
running. This shows that water is the tilt angle of the outboard motor.
If oil pressure becomes low, the oil circulating through the cooling
pressure indicator will go off, and the system. Improper propeller selection may
engine protection system will limit also cause the rev limiter to activate.
engine speed. Refer to TAKING If water stops flowing while the
CARE OF UNEXPECTED engine is running, that indicates a Check to see if the correct propeller
PROBLEMS, p. 71 . cooling system problem, such as is installed.
clogged water intakes, which will
Low oil pressure indicates that the cause engine overheating.
engine oil level is low or that there is
a problem with the engine lubrication
system.
18
11/03/17 10:53:05 31ZV1660_020

CONTROLS AND FEATURES

Anode Portable Fuel Tank Fuel Filler Cap Vent Knob

ANODE VENT KNOB

OPEN

CLOSE

FUEL HOSE FUEL FILLER CAP


(standard equipment)

The anode is made of a sacrificial The portable fuel tank has a capacity The fuel filler cap is provided with a
material that helps to protect the of 3.2 US gal (12 L) and has a fuel vent knob to seal the portable fuel
outboard motor from corrosion. gauge built into the fuel tank tank for carrying it to and from the
connector. boat. Open the vent by turning the
There is an anode on the vent knob counterclockwise all the
antiventilation plate. way before starting the engine.

19
11/03/07 16:29:31 31ZV1660_021

CONTROLS AND FEATURES

Fuel Priming Bulb

UP

OUTLET END
(outboard motor side)

PRIMING BULB

INLET END
(tank side)

A priming bulb is built into the fuel


hose that connects the fuel tank to the
outboard motor.

Before starting the engine, hold the


priming bulb up in the direction of
the arrow, then squeeze the priming
bulb until it feels firm. This will
ensure that fuel is supplied to the
engine.
20
11/03/07 16:29:42 31ZV1660_022

INSTALLATION
Correct and secure installation is INSTALLATION POSITION
essential for safe boating and good
performance. Follow the installation CENTER LINE
instructions provided in this manual.
IDLE PORT
OUTBOARD
POWER REQUIREMENTS MOTOR
TRANSOM BOAT
HEIGHT TRANSOM
Before installation, check to be sure HEIGHT
that the outboard motor does not
exceed the recommended maximum
horsepower for the boat on which it Install the outboard motor on the
is to be installed. Refer to the boats center of the boat transom.
certification plate for recommended ANTIVENTILATION 02 in
PLATE (050 mm)
maximum horsepower. If the The antiventilation plate of the
certification plate information is not outboard motor should be 0 2 in
available, contact the boat dealer or (0 50 mm) below the bottom of Type: Outboard Motor
manufacturer. the boat. Transom Height
The correct dimensions differ S: 17.1 in (434 mm)
For most applications, the outboard according to the type of boat and the L: 22.1 in (561 mm)
motor should have a horsepower configuration of the bottom of the
rating which provides 80% of the boat. Follow the manufacturers When the outboard motor is installed
maximum recommended horsepower recommended installation height. extremely low, the idle port may be
for the boat. immersed and the engine may
become hard to start or may run
poorly. Check that the idle port is
high enough from the water level
when the engine is stopped with the
boat fully loaded.
21
11/03/07 16:29:56 31ZV1660_023

INSTALLATION

If the outboard motor is installed too ATTACHMENT


low, the boat will squat and be hard IDLE PORT
to plane, and the outboard motor will
spray water that may enter the boat. It 5.9 in
will tend to porpoise, and high-speed (150 mm) or more
stability will be reduced. STERN
BRACKET
If the outboard motor is installed too WATER LEVEL
high, that will cause propeller FULLY TRIM/ SAFETY ROPE CLAMP SCREWS
ventilation. TILT DOWN
Attach the stern bracket to the boat
Optimum installation height varies Adverse effect to the engine can transom by tightening the clamp
with boat type and bottom shape. occur if the installation position of screws.
Contact the boat manufacturer for the outboard motor is too low. Trim/
any special recommendations that are tilt down the outboard motor with the Attach a rope from the boat to the
unique to a specific model of boat. boat fully loaded and stop the engine. hole in the stern bracket. This will
Check that the idle port is 5.9 in (150 help to prevent accidental loss of the
If the transom needs to be modified mm) or more above the water level. outboard motor.
to accommodate the outboard motor,
contact the boat manufacturer and TRANSOM ANGLE
follow their recommendations for ADJUSTMENT
corrective action.
Use the transom angle adjustment rod
(p. 25 ) to adjust the angle of the
outboard motor so the propeller is
perpendicular to the surface of the
water.

22
11/03/07 16:30:08 31ZV1660_024

BEFORE OPERATION
ARE YOU READY TO GET Safety
UNDERWAY?
Always wear a PFD (Personal Improperly maintaining
Your safety is your responsibility. A Flotation Device) while on the boat. this outboard motor or
little time spent in preparation will failing to correct a problem
significantly reduce your risk of Attach the emergency stop switch before operation can cause
injury. lanyard securely to the operator or to a malfunction in which you
the operators PFD. could be seriously hurt or
Knowledge killed.
IS YOUR OUTBOARD
Read and understand this manual. MOTOR READY TO GO? Always perform a pre-
Know what the controls do and how operation inspection before
to operate them. For your safety, and to maximize the each operation, and correct
service life of your equipment, it is any problem.
Familiarize yourself with the very important to take a few
outboard motor and its operation moments before you operate the
before you get underway. Know outboard motor to check its condition. Before beginning your pre-operation
what to do in case of an emergency. Be sure to take care of any problem checks, be sure the emergency stop
you find, or have your authorized switch clip is removed from the
Familiarize yourself with all laws Honda Marine dealer correct it, emergency stop switch.
and regulations relating to boating before you operate the outboard
and the use of outboard motors. motor.

23
11/03/07 16:30:23 31ZV1660_025

BEFORE OPERATION

Safety Inspection Check that all fasteners are in Make sure the tool kit and
place and securely tightened. emergency starter rope are
Look around the outboard motor onboard (p. 40 ). Replace any
for signs of oil or gasoline leaks. Check the emergency stop switch missing items.
for proper operation (p. 14 , 27 ).
If you are using the portable fuel Start the engine (p. 27 ). Make sure Check the fuel level in the fuel
tank, make sure it is in good the engine stops by pulling the tank (p. 50 ).
condition and properly secured in emergency stop switch clip from
the boat (p. 26 ). the emergency stop switch (p. 32 ).

Check that the fuel hose is Maintenance Inspection


undamaged and properly
connected (p. 26 ). Check the engine oil level (p. 43 ).
Running the engine with a low oil
Wipe up any spills before starting level can cause engine damage.
the engine.
Check to be sure the propeller and
Check the stern bracket to be sure shear pin are undamaged (p. 57 ).
the outboard motor is securely
installed. Check that the anode is securely
attached to the antiventilation plate
Check that all controls are (p. 56 ) and is not excessively
operating properly. worn. The anode helps to protect
the outboard motor from corrosion.
Replace any damaged parts.

24
11/03/07 16:30:38 31ZV1660_026

OPERATION
SAFE OPERATING BREAK-IN PROCEDURE The transom angle adjusting rod is
PRECAUTIONS used to adjust the angle of the
Proper break-in procedure allows the outboard motor in the normal
To safely realize the full potential of moving parts to wear in smoothly for operating position (p. 35 ).
this outboard motor, you need a best performance and long service
complete understanding of its life. 1. To adjust, first tilt the outboard
operation and a certain amount of motor so it is not resting on the rod.
practice with its controls. For the first 10 hours, run the
outboard motor at low speed, and 2. Push the rod in and turn the end of
Before operating the outboard motor avoid full-throttle operation. the rod up, so the latch will fall
for the first time, please review the into line with the rod.
IMPORTANT SAFETY TRANSOM ANGLE
INFORMATION on page 6 and the ADJUSTMENT 3. Remove the rod and reinsert it in
chapter titled BEFORE OPERATION. TRANSOM ANGLE the desired position.
ADJUSTING ROD
For your safety, do not start or run TO CHANGE UNLOCKED 4. Push the rod in and turn the end of
the engine in a confined or partly POSITION the rod down, so the latch will fall
enclosed area. Your engines exhaust to the locked position. Then
contains poisonous carbon monoxide, release the rod.
a colorless, odorless gas that can
collect rapidly. Breathing carbon
monoxide can cause loss of
consciousness and may lead to death.
TO LOCK
LOCKED POSITION

25
11/03/07 16:30:49 31ZV1660_027

OPERATION

PORTABLE FUEL TANK Secure the portable fuel tank in the FUEL HOSE CONNECTIONS
boat so that it wont move around
and become damaged. Turn the portable fuel tank vent knob
counterclockwise to the open
position.

Gasoline is highly FUEL HOSE CONNECTOR


flammable and explosive.

You can be burned or


seriously injured when
handling fuel.

FUEL HOSE Stop the engine and keep


(standard equipment) heat, sparks, and flame (FUEL TANK SIDE)
away.
Place the portable fuel tank in a well- Handle fuel only
ventilated location, away from direct outdoors.
sunlight, to reduce the possibility of a Wipe up spills
gasoline vapor explosion. immediately.

To ensure that the outboard motor


will be able to draw fuel from the
tank, place the tank within 6 feet (2 FUEL HOSE CONNECTOR
m) of the outboard motor and not (OUTBOARD MOTOR SIDE)
more than 3 feet (1 m) below the fuel
connector on the outboard motor.

26
11/03/07 16:30:59 31ZV1660_028

OPERATION

Connect the fuel hose to the tank and FUEL PRIMING INFREQUENT OR
the outboard motor, as shown. Be OCCASIONAL USE
sure both connectors snap securely If you are using a portable fuel tank,
into place. Always disconnect the turn the portable fuel tank vent knob If your outboard motor will be used
fuel hose when storing or counterclockwise to the open on an infrequent or intermittent basis,
transporting the outboard motor. position. please refer to the fuel section of the
STORAGE chapter (p. 61 ) for
UP OUTLET END additional information regarding fuel
(outboard motor side) deterioration.

PRIMING BULB

INLET END (tank side)

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.

Do not touch the priming bulb with


the engine running or when tilting up
the outboard motor. The carburetor
could overflow.
27
11/03/07 16:31:11 31ZV1660_029

OPERATION

STARTING THE ENGINE The engine will not start or run


unless the emergency stop switch
EMERGENCY STOP SWITCH CLIP clip is in the emergency stop N (neutral)
switch.
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.

Always attach the emergency stop GEARSHIFT LEVER


switch lanyard securely to the
EMERGENCY STOP operator or to the operators PFD 2. Check the position of the gearshift
SWITCH LANYARD before starting the engine. lever. It must be in the N (neutral)
position for starting.
1. Put the emergency stop switch clip
in the emergency stop switch, and The engine will not start if the
attach the emergency stop switch gearshift lever is in the F (forward)
lanyard securely to the operator or or R (reverse) position.
to the operators PFD (Personal
Flotation Device).

28
11/03/07 16:31:24 31ZV1660_030

OPERATION

CHOKE KNOB 6. If the choke knob was pulled to


the ON position to start the engine,
Direction to pull gradually push it to the OFF
position as the engine warms up.

Also, as the engine warms up, the


OFF throttle grip can be turned to the
ON
SLOW position without stalling.

7. Before getting underway, allow


STARTER GRIP the engine to warm-up sufficiently
to ensure good performance.
3. To start a cold engine, pull the 5. Pull the starter grip lightly until
choke knob to the ON position. To you feel resistance, then pull During the warm-up period, check
restart a warm engine, leave the briskly in the direction of the the oil pressure indicator (p. 18 )
choke knob in the OFF position. arrow as shown above. and cooling system indicator
(p. 18 ).
MARK
Return the starter grip gently.
If the indicators show any
abnormal condition, immediately
stop the engine and determine the
cause of the problem. Refer to
TAKING CARE OF
UNEXPECTED PROBLEMS on
THROTTLE GRIP p. 69 and 71 .

4. Align the START position with


the mark for starting the engine.
29
11/03/07 16:31:39 31ZV1660_031

OPERATION

EMERGENCY STARTING 6 mm CAP NUTS


EMERGENCY STARTER ROPE
If the recoil starter is inoperative, you
can start the engine manually using
the emergency starter rope supplied
with the tool kit.
ENGINE COVER LOCK LEVER

6 mm FLANGE
BOLTS
FLYWHEEL COVER

2. Remove the two 6 mm cap nuts 5. Pull the emergency starter rope
UNLOCK and 6 mm flange bolts, and slowly until resistance is felt, then
remove the flywheel cover. pull briskly.

1. Unlock and remove the engine 3. Set the controls the same as for Keep away from moving parts
cover. normal starting (see pages 27 while pulling the rope.
28 ). Use the choke control if
needed.

4. Set the knotted end of the


emergency starter rope in the notch
in the flywheel. Wind the rope
clockwise around the flywheel.

30
11/03/07 16:31:48 31ZV1660_032

OPERATION

If necessary, rewind the rope and 6. If the choke control was used to 8. If it was necessary to remove the
pull again. If the engine does not start the engine, return the control emergency stop switch lanyard
start after several attempts, refer to to the normal operating position as from you to perform the
TAKING CARE OF the engine warms up. emergency starting procedure, be
UNEXPECTED PROBLEMS, sure the lanyard is attached
p. 66 . During the warm-up period, check securely to operator before
the oil pressure indicator (p. 18 ), operating the outboard motor.
and cooling system indicator (p.
18 ). 9. Have your closest authorized
Exposed moving parts can Honda Marine dealer check your
cause injury. 7. Install the engine cover (p. 43 ), system and correct the problem, so
and lock it in place by locking the you can use the recoil starter.
Do not operate the engine cover lock lever.
outboard motor without
the engine cover.

Use extreme care when


installing the engine
cover.

31
11/03/07 16:32:04 31ZV1660_033

OPERATION

STOPPING THE ENGINE Normal Engine Stopping


EMERGENCY STOP SWITCH
Emergency Engine Stopping
EMERGENCY STOP SWITCH
EMERGENCY
STOP SWITCH
LANYARD

PUSH
THROTTLE GRIP

PULL N (neutral)
After cruising at full throttle, cool
EMERGENCY STOP down the engine by idling for a few
SWITCH CLIP minutes before stopping the engine.
To stop the engine in an emergency,
pull the emergency stop switch clip 2. Press the emergency stop switch
out of the emergency stop switch by until the engine stops.
pulling the emergency stop switch
lanyard. 3. When the boat is not in use,
GEARSHIFT LEVER remove and store the ignition
We suggest that you stop the engine switch key and the emergency stop
this way occasionally to verify that 1. Move the throttle grip to the switch clip and lanyard. If you are
the engine and emergency stop slowest speed and gearshift lever using a portable fuel tank,
switch are operating properly. to the N (neutral) position. disconnect the fuel hose if you
will be storing or transporting the
outboard motor.
32
11/03/07 16:32:19 31ZV1660_034

OPERATION

GEARSHIFTING AND To shift gears, turn the throttle grip to


THROTTLE OPERATION the SLOW position; then move the
gearshift lever to select the F TO DECREASE
(forward), N (neutral), or R (reverse) FRICTION
gears.

The engine can be started with the


gearshift lever in the N (neutral) TO INCREASE
position only. FRICTION

The throttle grip can be turned to the THROTTLE


THROTTLE GRIP FRICTION KNOB
FAST position only when the
gearshift lever is in the F (forward)
R (reverse) N (neutral) F (forward) position.
Use the throttle friction knob to help
hold a constant throttle setting while
cruising.

Turn the knob clockwise to increase


throttle grip friction for holding a
constant speed.
GEARSHIFT LEVER Turn the knob counterclockwise to
decrease friction for easy grip
rotation.

33
11/03/07 16:32:33 31ZV1660_035

OPERATION

STEERING
STEERING FRICTION BOLT
TO DECREASE
FRICTION

TO INCREASE
FRICTION

Steer by moving the tiller handle Use the steering friction bolt to help
opposite the direction you want the hold a steady course while cruising.
boat to turn.
Turn the bolt clockwise to increase
steering friction for holding a steady
course.

Turn the bolt counterclockwise to


decrease friction for easy turning.

34
11/03/07 16:32:46 31ZV1660_036

OPERATION

CRUISING Transom Angle


Engine Speed Install the outboard motor at the best Excessive transom angle during
transom angle for stable cruising and operation can cause propeller
For best fuel economy, limit the maximum power. ventilation, overheating, and water
throttle opening to 80%. Use the pump damage. This type of damage
throttle friction control (p. 33 ) to Transom angle too large: Causes boat is not covered by the Distributors
help you hold a steady speed. to squat. Limited Warranty (p. 84 ).

For rough water conditions or large Transom angle too small: Causes Transom Angle (Cruising)
waves, slow down to prevent the boat to bow steer.
propeller from rising out of the water. OUTBOARD OUTBOARD
It is necessary to adjust the transom MOTOR ANGLE MOTOR ANGLE
angle of the outboard motor to ADJUSTED TOO ADJUSTED TOO
LOW HIGH
compensate for changes in boat load,
weight distribution, water conditions,
or propeller selection.

Under normal running conditions, the


boat will perform best when the OUTBOARD MOTOR
antiventilation plate is level with the ROUGH ANGLE ADJUSTED
water surface. WAVES CORRECTLY

When cruising into a high wind,


adjust the outboard motor down
slightly to level the boat and improve
stability. With a tail wind, adjust the CORRECT
outboard motor up slightly (p. 25 ). GIVES MAXIMUM PERFORMANCE

35
11/03/07 16:32:55 31ZV1660_037

OPERATION

SHALLOW WATER To tilt the outboard motor, raise the


OPERATION outboard motor to the 30 position by
pulling on the engine cover grip. An excessive tilt angle during
When operating in shallow water, tilt operation can cause propeller
the outboard motor, using the tilt ventilation, overheating, and water
lever, so the propeller and gear case Do not use the tiller handle as a pump damage. This type of damage
wont hit the bottom. lever to raise the outboard motor. is not covered by the Distributors
Applying excessive f orce to the tiller Limited Warranty (p. 84 ).
ENGINE COVER GRIP handle can damage it.

While the outboard motor is tilted,


proceed at a low speed, and do not
operate the outboard motor in reverse.
The outboard motor will rise
suddenly if operated in reverse.

Monitor water flow from the cooling


system indicator (p. 18 ) to be sure
18 the outboard motor is not tilted so
high that the water intakes are out of
the water.

36
11/03/07 16:33:08 31ZV1660_038

OPERATION

TILT LEVER MOORING, BEACHING,


LAUNCHING ENGINE COVER GRIP
Before tilting up, leave the outboard
motor in the running position for one
minute after stopping the engine to
drain the water from inside the
engine.

Stop the engine and disconnect the


fuel hose from the outboard motor
before tilting the outboard motor. 38, 58 (when mooring)

To return the outboard motor to the To raise the outboard motor out of
normal operating position, raise the the water while the boat is moored, or
outboard slightly by pulling on the for maximum clearance when
engine cover grip, then pull the tilt beaching or launching, tilt the
lever to release the outboard, and outboard motor to the 38 or 58
then slowly lower the outboard motor. position.

Stop the engine before tilting the


outboard motor. The 38 or 58
position is not an operating position.

Raise and lower the outboard motor


as described on p. 36 .

37
11/03/07 16:33:16 31ZV1660_039

SERVICING YOUR OUTBOARD MOTOR


THE IMPORTANCE OF To help you properly care for your Remember that your authorized
MAINTENANCE outboard motor, the following pages Honda Marine dealer knows your
include a maintenance schedule, outboard motor best and is fully
Proper maintenance is essential for routine inspection procedures, and equipped to maintain and repair it.
safe, economical, and trouble-free simple maintenance procedures using
operation. It will also help reduce air basic hand tools. Other service tasks To ensure the best quality and
pollution. that are more difficult or require reliability, use only new, 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 repair of the emission control
failure to correct a problem The maintenance schedule applies to devices and systems may be
before operation can cause normal operating conditions. If you performed by any marine engine
a malfunction in which you operate your outboard motor under repair establishment or individual,
could be seriously hurt or unusual conditions, consult an using parts that are certified to
killed. authorized Honda Marine dealer for EPA standards.
recommendations applicable to your
Always follow the individual needs and use.
inspection and
maintenance
recommendations and
schedules in this Owners
Manual.

38
11/03/07 16:33:28 31ZV1660_040

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. This will eliminate several To reduce the possibility of fire or
conceivable hazard that can arise in potential hazards: explosion, be careful when
performing maintenance. Only you working around gasoline. Use only
can decide whether or not you should Carbon monoxide poisoning a nonflammable solvent, not
perform a given task. from engine exhaust. gasoline, to clean parts. Keep
Do not start or run the engine in cigarettes, sparks, and flames away
a confined or partly enclosed from all fuel-related parts.
area.
Failure to properly follow Wear gloves when handling the
maintenance instructions Burns from hot parts. propeller to protect your hands
and precautions can cause Let the engine and exhaust from sharp edges.
you to be seriously hurt or system cool before touching.
killed.
Injury from moving parts.
Always follow the Do not run the engine unless
procedures and instructed to do so.
precautions in the Owners
Manual.

39
11/03/07 16:33:38 31ZV1660_041

SERVICING YOUR OUTBOARD MOTOR

TOOL KIT AND


EMERGENCY STARTER
ROPE FLAT SCREWDRIVER
10 12 mm WRENCH PLIERS

TOOL BAG
PHILIPS SCREWDRIVER

SPARK PLUG
WRENCH SPARE EMERGENCY
STOP SWITCH CLIP SPARE SPARK PLUG
8 mm WRENCH

EMERGENCY STARTER ROPE

COTTER PINS FLUSH KIT


The following tools are supplied with
the outboard motor for simple
maintenance procedures and
emergency repairs. An emergency WATER MOUTH
SEAT
starter rope is also supplied. Keep
these items on the boat so that they WATER HOSE
CONNECTOR
will always be available if you need
them. WATER MOUTH NUT
If your tool kit needs replacement, it
is not available as a kit and each item
must be ordered individually.
SHEAR PINS

40
11/03/07 16:33:50 31ZV1660_042

SERVICING YOUR OUTBOARD MOTOR

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 motor 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 Distributors Limited Warranty.
REGULAR SERVICE PERIOD (3)
Perform at every indicated month or First month Every 6 months Every year
operating hour interval, whichever Each use After use or or or
comes first. 20 hrs. 100 hrs. 200 hrs.
ITEM
Engine oil Check level
Change
Gear case oil Change
Starter rope Check
Carburetor linkage Check-adjust (2) (2)
Valve clearance Check-adjust (2)
Spark plug Check-adjust/Replace
Propeller and cotter pin Check
Anode Check
Idling speed Check-adjust (2) (2)
Lubrication Grease (1) (1)

(1) Lubricate more frequently when used in salt water.

(2) 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.

(3) For professional commercial use, log hours of operation to determine proper maintenance intervals.

41
11/03/07 16:34:05 31ZV1660_043

SERVICING YOUR OUTBOARD MOTOR

REGULAR SERVICE PERIOD (3)


Perform at every indicated month or First month Every 6 months Every year
operating hour interval, whichever Each use After use or or or
comes first. 20 hrs. 100 hrs. 200 hrs.
ITEM
Fuel tank and tank filter Clean
Thermostat Check (2)
Fuel filter Check
Replace
Fuel line Check (5)
Replace Every 2 years (If necessary) (2) (6)
Bolts and nuts Check-tightness (2) (2)
Crankcase breather tube Check (2)
Cooling water passages Clean (4)
Water pump Check (2)
Emergency stop switch Check

(1) Lubricate more frequently when used in salt water.

(2) 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.

(3) For professional commercial use, log hours of operation to determine proper maintenance intervals.

(4) When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

(5) Check the fuel line for leaks, cracks or damage. If it is leaking, cracked or damaged, take it to your servicing dealer for replacement
before using your outboard.

(6) Check the fuel line for leaks, cracks, or damage. Replace the fuel line if there are signs of leaks, cracks or damage.

42
11/03/07 16:34:19 31ZV1660_044

SERVICING YOUR OUTBOARD MOTOR

ENGINE COVER REMOVAL Engine Oil Level Check OIL FILLER CAP/DIPSTICK
AND INSTALLATION
ENGINE COVER LOCK LEVER
Check the engine oil level with the
engine stopped and the outboard
motor in the vertical position.

1. Unlock and remove the engine


cover.
UPPER
2. Remove the oil filler cap/dipstick LIMIT
and wipe it clean. LOWER
UNLOCK LIMIT
OIL FILLER CAP/DIPSTICK

The engine cover lock lever fastens 4. If the oil level is low, add oil to
the engine cover to the outboard reach the upper limit mark shown
motor. on the dipstick. Use the oil
recommended on p. 45 .
To remove the engine cover, turn the
lock lever to the unlocked position,
then lift the engine cover off the Running the engine with a low oil
outboard motor. level can cause engine damage.

To install the engine cover, place the 5. Install the oil filler cap/dipstick
cover on the outboard motor, then 3. Insert the dipstick without and tighten it securely.
turn the lock lever to the locked screwing it in, then remove it and
position. check the oil level shown on the 6. Install and lock the engine cover.
dipstick.
43
11/03/07 16:34:31 31ZV1660_045

SERVICING YOUR OUTBOARD MOTOR

Engine Oil Change


An engine oil evacuation device may Improper disposal of engine oil
be used to remove the engine oil. can be harmf ul to the environment.
If you change your own oil, please
Drain the used oil into a suitable dispose of the used oil properly.
container while the engine is warm. Put it in a sealed container, and
Warm oil drains quickly and take it to a recycling center. Do
completely. not discard it in a trash bin, dump
it on the ground, or pour it down a
1. Unlock and remove the engine drain.
cover (p. 43 ).
DRAIN BOLT 4. With the outboard motor in a
vertical position, fill to the upper
2. Remove the oil filler cap, and limit mark on the dipstick (p. 43 )
remove the engine oil drain plug with the recommended oil.
and washer.
5. Install the oil filler cap and tighten
3. Allow the used oil to drain it securely.
completely, then reinstall the
engine oil drain plug and a new 6. Install and lock the engine cover.
washer, and tighten it securely.

44
11/03/07 16:34:43 31ZV1660_046

SERVICING YOUR OUTBOARD MOTOR

Engine Oil Recommendations If Honda 10W-30 FC-W oil is not Gear Case Oil Level Check
available, Honda recommends that
Oil is a major factor affecting you use API service category SG, SH Check the gear case oil level with the
performance and service life. Use or SJ oil. The SAE oil viscosity and engine stopped and the outboard
4-stroke detergent oil. service category are in the API label motor in the vertical position.
on the oil container.

GEAR OIL
LEVEL SCREW

AMBIENT TEMPERATURE GEAR OIL


DRAIN/FILL
SCREW
Honda 10W-30 FC-WTM outboard Remove the oil level screw and see
motor oil is recommended for whether oil flows from the oil level
general use. hole.

If oil flows from the oil level hole,


the oil level is OK. Reinstall the
screw and tighten it securely.

OIL LEVEL SCREW TORQUE:


4.8 lbfft (6.5 Nm , 0.66 kgfm)

45
11/03/07 16:34:50 31ZV1660_047

SERVICING YOUR OUTBOARD MOTOR

If no oil flows from the oil level hole, Gear Case Oil Change 2. Allow the used oil to drain
add the recommended oil (p. 47 ) completely, then install an oil
following the procedure described in Change the gear case oil with the pump adapter in the oil drain hole.
Gear Case Oil Change. engine stopped and the outboard
motor in the vertical position. If water or contaminated (milky-
colored) oil flows out the drain
hole when the screw is removed,
have the outboard motor checked
by an authorized Honda Marine
dealer.

1. Place a suitable container below


the oil drain hole to catch the used
oil, then remove the oil level screw
and oil drain/fill screw.

46
11/03/07 16:34:59 31ZV1660_048

SERVICING YOUR OUTBOARD MOTOR

OIL LEVEL SCREW TORQUE:


4.8 lbfft (6.5 Nm, 0.66 kgfm)

Avoid losing more than 1 fl oz (30


cm3) while reinstalling the drain/
fill screw.

OIL DRAIN SCREW TORQUE:


4.8 lbfft (6.5 Nm, 0.66 kgfm)

GEAR OIL BOTTLE


3. Add oil through the oil drain hole
until it flows out the oil level hole,
and then install the oil level screw.
Remove the pump adapter and
install the oil drain/fill screw.

GEAR OIL CAPACITY:


0.11 US qt (0.10 L)

Outboard motor SAE 90 hypoid


gear oil API Service category
(GL-4)

47
11/03/07 16:35:21 31ZV1660_049

SERVICING YOUR OUTBOARD MOTOR

Lubrication Points
Apply Honda Marine waterproof grease to the parts
shown below:
Lubrication interval:
20 operating hours or one month after the date of
ENGINE COVER
purchase or the initial use, then every 100 hours or 6 LOCK LEVER
months (refer to the maintenance schedule on page 41 ). THROTTLE
CABLE AND
PIVOT
SHIFT SHAFT
To prevent corrosion, apply anticorrosion oil to pivot AND PIVOT
surf aces where grease cannot penetrate.
SWIVEL CASE

TILLER
HANDLE PIVOT TRANSOM ANGLE
ADJUSTING ROD

TILT RELEASE LEVER


CLAMP SCREWS AND REVERSE LOCK
ROD PROPELLER SHAFT
Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover and any exposed metal
surfaces.
48
11/03/07 16:35:35 31ZV1660_050

SERVICING YOUR OUTBOARD MOTOR

Spark Plug Service SIDE ELECTRODE

RECOMMENDED SPARK PLUGS: New plug Plug needing


replacement 0.028 0.031 in
BPR5ES (NGK) (0.7 0.8 mm)
W16EPR-U (DENSO)

Incorrect spark plug can cause SEALING WASHER


engine damage.
SPARK PLUG WRENCH INSULATOR

4. Inspect the spark plug. Replace it 5. Measure the spark plug electrode
if the electrode is worn, or if the gap with a wire-type feeler gauge.
insulator is cracked or chipped. Correct the gap, if necessary, by
carefully bending the side
1. Unlock and remove the engine electrode.
cover (p. 43 ).
The gap should be:
2. Disconnect the spark plug cap 0.0280.031 in (0.70.8 mm)
from the spark plug.

3. Remove the spark plug with a


spark plug wrench and screwdriver
supplied in the tool kit.

49
11/03/17 14:39:59 31ZV1660_051

SERVICING YOUR OUTBOARD MOTOR

6. Install the spark plug carefully, by REFUELING 1. Turn the vent knob
hand, to avoid cross-threading. counterclockwise all the way to
If you do not anticipate cycling open the vent.
7. After the spark plug seats, tighten through at least one complete tank of
with a spark plug wrench supplied fuel within a 30 day period, we VENT KNOB
in the tool kit to compress the recommend adding Honda Marine
sealing washer. Fuel Stabilizer each time you refuel. OPEN

If reinstalling the used spark plug, Portable Fuel Tank


tighten 1/81/4 turn after the
spark plug seats. FUEL TANK CAPACITY:
3.2 US gal (12 L)
If installing new spark plug,
tighten 1/2 turn after the spark Check the fuel gauge and refill the
plug seats. tank when necessary. 2. Turn the fuel filler cap
counterclockwise so that it touches
Remove the fuel tank from the boat the pressure relief tab.
A loose spark plug can overheat for refueling.
and damage the engine. FUEL FILLER CAP
Overtightening the spark plug can FUEL GAUGE
damage the threads in the cylinder
head.

8. Attach the spark plug cap.

9. Install and lock the engine cover.


PRESSURE RELIEF TAB

50
11/03/17 10:53:28 31ZV1660_052

SERVICING YOUR OUTBOARD MOTOR

3. Press down the pressure relief tab, SAFE FILL LEVEL


and then turn the fuel filler cap 1/4
counterclockwise. Release the Gasoline is highly
pressure relief tab. Wait to relieve flammable and explosive.
pressure.
You can be burned or
FUEL FILLER CAP seriously injured when
handling fuel.
After refueling, install the cap and
tighten it until you hear it click. Close Stop the engine and keep
the vent by turning the vent knob heat, sparks, and flame
clockwise all the way, and return the away.
fuel tank to the boat. Handle fuel only
PRESS outdoors.
FUEL FILLER CAP Wipe up spills
VENT KNOB immediately.
PRESSURE RELIEF TAB

4. The fuel filler cap will lock again. CLOSE Never refill the fuel tank inside a
Press down the pressure relief tab, building where gasoline fumes may
and turn counterclockwise to reach flames or sparks. Keep
remove the fuel filler cap. gasoline away from appliance pilot
lights, barbecues, electric appliances,
Refuel in a well-ventilated area. Fill Fuel can damage paint and plastic. power tools, etc.
the tank to the SAFE FILL LEVEL Be caref ul not to spill f uel when
line. f illing your f uel tank. Damage Spilled fuel is not only a fire hazard,
caused by spilled f uel is not covered it causes environmental damage.
under warranty. Wipe up spills immediately.
51
11/03/07 16:36:09 31ZV1660_053

SERVICING YOUR OUTBOARD MOTOR

FUEL RECOMMENDATIONS Engine damage or performance


problems that result from using a fuel
Use unleaded gasoline with a pump with percentages of ethanol or
octane rating of 86 or higher. methanol greater than shown above
are not covered under warranty.
Your outboard motor is certified to
operate on unleaded gasoline. If your outboard motor will be used
Unleaded gasoline produces fewer on an infrequent or intermittent basis,
engine and spark plug deposits and please refer to the fuel section of the
extends exhaust system life. STORAGE chapter (p. 61 ) for
additional information regarding fuel
Never use stale or contaminated deterioration.
gasoline or an oil/gasoline mixture.
Avoid getting dirt or water in the fuel
tank.

You may use unleaded gasoline


containing no more than 10% ethanol
(E10) or 5% methanol by volume. In
addition, methanol must contain
cosolvents and corrosion inhibitors.

Use of fuels with content of ethanol


or methanol greater than shown
above may cause starting and/or
performance problems. It may also
damage metal, rubber, and plastic
parts of the fuel system.
52
11/03/07 16:36:24 31ZV1660_054

SERVICING YOUR OUTBOARD MOTOR

Fuel Filter Inspection and 3. Disconnect the fuel hose connector


Replacement ENGINE COVER LOCK LEVER from the outboard motor, and
place commercially available hose
The fuel filter is located under the clips on the fuel hoses on each side
engine cover, on the right side of the of the filter to prevent fuel leakage
engine. when the fuel hoses are
Water or sediment accumulation in disconnected.
the filter can cause loss of power or
hard starting. To prevent engine
malfunction, inspect the filter and
replace when necessary.
UNLOCK

Gasoline is highly 1. Unlock and remove the engine


flammable and explosive. cover for access to the fuel pump
filter.
You can be burned or
seriously injured when 2. Inspect the filter for water and/or
handling fuel. sediment accumulation.

Stop the engine and keep If the filter is OK, reinstall it. If
heat, sparks, and flame water and/or sediment are present,
away. replace the filter as described in
Handle fuel only the following steps. Always
outdoors. replace the filter at the scheduled
Wipe up spills replacement interval (p. 42 ).
immediately.
53
11/03/07 16:36:39 31ZV1660_055

SERVICING YOUR OUTBOARD MOTOR


FUEL FILTER ARROW FUEL FILTER 7. Securely connect the fuel hose
(Fuel Flow Direction) connector to the outboard motor
FUEL HOSE
(refer to page 26 ).

8. Prime the engine using the priming


bulb (p. 27 ). Check for fuel leaks.
Repair any fuel leaks if necessary.

9. Install and lock the engine cover.

If loss of power or hard starting are


found to be caused by excessive
HOSE CLAMPS FUEL HOSE HOSE CLAMPS water or sediment accumulation in
the fuel filter, inspect the fuel tank.
4. Remove the fuel hoses from the 5. Install the new filter on the fuel
used filter, and discard the filter. hoses, with the fuel flow arrow Clean the fuel tank and tank filter if
pointing toward the fuel pump as necessary. It may be necessary to
To ease hose removal, release the shown. Fuel flow will be impeded drain the fuel tank completely and
hose clamps by squeezing the if the filter is installed backward. refill with fresh gasoline.
clamp ends together with pliers
while pulling off the hoses. 6. Connect the fuel hoses to the fuel
filter securely with the hose
clamps. Remove the fuel hose
clips used to close the fuel hoses.

54
11/03/07 16:36:48 31ZV1660_056

SERVICING YOUR OUTBOARD MOTOR

Portable Fuel Tank and Tank Fuel Tank


Filter Cleaning

Gasoline is highly
flammable and explosive.

You can be burned or


seriously injured when
handling fuel.
FUEL HOSE
Stop the engine and keep (standard equipment)
heat, sparks, and flame
away. Empty the portable fuel tank into an
Handle fuel only approved gasoline container. Use a
outdoors. funnel to avoid spilling fuel. Rinse
Wipe up spills the fuel tank with nonflammable
immediately. solvent to remove any accumulated
sediment.

55
11/03/07 16:37:03 31ZV1660_057

SERVICING YOUR OUTBOARD MOTOR

Fuel Tank Filter Recoil Starter Rope Inspection Anode Replacement


ANODE
5 mm SCREWS (4) CONNECTOR
GASKET

BOLT

FUEL TANK
FILTER The anode is located on the
RECOIL STARTER ROPE antiventilation plate. It is made of a
FUEL TANK FILTER JOINT
(Fuel Hose Connector) sacrificial material that helps to
Inspect the recoil starter rope, and protect the outboard motor from
1. Remove the four 5 mm screws replace it if it becomes frayed. corrosion.
using a flat screwdriver, then
remove the fuel hose connector Always keep the emergency starter Replace the anode when it has been
and fuel tank filter from the tank. rope on the boat in case the recoil reduced to about half its original size,
starter rope fails. or if it is crumbling.
2. Clean the filter in nonflammable
solvent. Inspect the fuel tank filter
and the connector gasket. Replace Painting or coating the anodes will
them if damaged. def eat their purpose and will lead to
rust and corrosion damage to the
3. Reinstall the filter and hose outboard motor. The anodes must be
connector in the fuel tank. Tighten exposed to the water in order to
the four 5 mm screws securely. protect the outboard motor.
56
11/03/07 16:37:14 31ZV1660_058

SERVICING YOUR OUTBOARD MOTOR

Propeller and Shear Pin Removal 1. Remove the cotter pin, the
Replacement PROPELLER CAP propeller cap, and the propeller.

A shear pin is used to protect the 2. Remove the broken shear pin and
propeller and drive mechanism from replace it with a new one.
damage when the propeller strikes an
obstruction.

Before replacing the propeller or the


shear pin, remove the emergency
stop switch clip from the emergency
stop switch to prevent any possibility
of the engine being started while you COTTER PIN
are working with the propeller.

The propeller blades may have sharp


edges, so wear heavy gloves to
protect your hands.

Operating the outboard motor at


higher altitudes will reduce available
power. This may require decreasing
the propeller pitch to maintain correct
engine RPM.
SHEAR PIN

57
11/03/07 16:37:22 31ZV1660_059

SERVICING YOUR OUTBOARD MOTOR

Installation Spare shear pins and cotter pins are


COTTER PIN
provided in the engine compartment
(p. 40 ).

1. Install the shear pin and the


propeller, then install the propeller
cap finger tight.

2. 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.

58
11/03/07 16:37:39 31ZV1660_060

CLEANING AND FLUSHING


Cleaning and Flushing Flushing With the Honda WATER HOSE CONNECTOR
Water Hose Connector
After each use in saltwater or dirty
water, thoroughly clean and flush the 1. Tilt down the outboard motor.
outboard motor with fresh water.
2. Remove the flush screw from the
Cleaning WASH screw hole and install the
water hose connector.
Wash the outside of the outboard
motor with clean, fresh water to 3. Attach a hose from a fresh water
remove mud, salt, seaweed, etc. faucet to the water hose connector
of the flush kit.
Disengage the emergency stop switch WATER HOSE
clip from the emergency stop switch, 4. Remove the propeller (P. 57 ).
and pull the recoil starter rope several 7. After flushing, stop the engine,
times to expel any water remaining in 5. Turn on the fresh water supply to and disconnect the fuel hose from
the water pump. hose. the outboard motor. Remove the
hose connector, and leave the
Touch up any damaged paint, and 6. Start the engine and run in N outboard motor in the running
coat areas that may rust with Honda (neutral) for 10 minutes. position for one minute to drain
Corrosion Inhibitor, or equivalent. the water from inside the engine.
Lubricate controls with a silicone
spray lubricant. 8. Reinstall the flush screw and the
propeller (p. 58 ).

9. Tilt up the outboard motor and


move the tilt lever to the TILT
position.
59
11/03/07 16:37:50 31ZV1660_061

CLEANING AND FLUSHING

Flushing Without the Honda 6. Tilt up the outboard motor and


Water Hose Connector move the tilt lever to the TILT
Running the engine without good position.
It is necessary to run the engine water circulation can cause
during the flushing procedure. For overheating and water pump
safety, remove the propeller from the damage.
outboard motor (p. 57 ).
Damage caused by running the
outboard motor without sufficient
cooling water is not covered by the
Distributors Limited Warranty
(p. 84 ).

3. Start the engine and run in the N


(neutral) position at low speed for
at least 10 minutes.

4. After flushing, stop the engine,


and disconnect the fuel hose from
ANTIVENTILATION PLATE the outboard motor and leave the
outboard motor in the running
1. Tilt down the outboard motor. position for one minute to drain
the water from inside the engine.
2. Place a container under the
outboard motor, and fill it with 5. Reinstall the propeller (p. 58 ).
clean, fresh water. The water level
must be at least 2 inches (5 cm)
above the antiventilation plate.
60
11/03/07 16:38:05 31ZV1660_062

STORAGE
Fuel The length of time that gasoline can Adding a Fuel Stabilizer
be left in your fuel tank and When adding a fuel stabilizer, fill the
carburetor without causing functional fuel tank with fresh gasoline. If only
Depending on the region where you problems will vary with such factors partially filled, air in the tank will
operate your outboard, f uel as gasoline blend, your storage promote fuel deterioration during
f ormulations may deteriorate and temperatures, and whether the fuel storage. If you keep an additional
oxidize rapidly. Fuel deterioration tank is partially or completely filled. container of gasoline for refueling,
and oxidation can occur in as little The air in a partially filled fuel tank be sure that it contains only fresh
as 15 days and may cause damage to promotes fuel deterioration. Very gasoline.
the carburetor and f uel system. warm storage temperatures accelerate
Please check with your servicing fuel deterioration. Fuel deterioration 1. Add Honda Marine fuel stabilizer
dealer f or local storage problems may occur in less than 15 following the instructions on the
recommendations. days, if the gasoline was not fresh label.
when you filled the fuel tank.
Gasoline will oxidize and deteriorate 2. After adding a fuel stabilizer, run
in storage. Deteriorated gasoline will You can extend fuel storage life by the engine in water for 10 minutes
cause hard starting, and it leaves gum adding a gasoline stabilizer that is to be sure that the treated gasoline
deposits that clog the fuel system. If formulated for that purpose, or you has replaced the untreated gasoline
the gasoline in your fuel tank and can avoid fuel deterioration problems in the carburetor.
carburetor deteriorates during storage, by draining all the fuel from the fuel
you may need to have the carburetor tank and carburetor. 3. Turn the engine OFF.
and other fuel system components
serviced or replaced. The Distributors Limited Warranty
(p. 84 ) does not cover fuel system
damage or engine performance
problems resulting from neglected
storage preparation.

61
11/03/07 16:38:18 31ZV1660_063

STORAGE

Draining the Fuel System 3. With the outboard motor in a 4. After the fuel has drained from the
You can avoid fuel deterioration vertical position, place an carburetor, tighten the drain screw
problems by draining the fuel tank approved gasoline container below securely.
and carburetor. the fuel drain outlet, and use a
funnel to avoid spilling fuel. 5. Reconnect the drain tube to the air
1. Disconnect the fuel hose from the Loosen the drain screw to drain guide.
outboard motor. fuel from the carburetor.
2. Disconnect the drain tube from the 6. Drain the fuel tank into an
air guide, then connect it to the approved gasoline container, or if
carburetor drain port as shown. you need to store fuel in the fuel
Gasoline is highly tank, you can extend fuel storage
flammable and explosive. life by filling the fuel tank with
CARBURETOR AIR GUIDE
DRAIN PORT fresh gasoline and adding Honda
You can be burned or Marine fuel stabilizer following
seriously injured when the directions on the container.
handling fuel. Close the fuel cap vent.

Stop the engine and keep If using the portable fuel tank,
heat, sparks, and flame close the fuel filler cap vent knob.
away. Store the portable fuel tank in a
Handle fuel only cool dry place out of direct
outdoors. sunlight.
DRAIN DRAIN
SCREW TUBE
Wipe up spills
immediately.

62
11/03/07 16:38:33 31ZV1660_064

STORAGE

Engine Oil STORAGE PRECAUTIONS To carry the outboard motor, hold it


by the carrying handle, or hold by the
1. Change the engine oil (p. 44 ). Select a well-ventilated storage area. carrying handle and the lug beneath
If possible, avoid storage areas with the engine cover lock lever, as shown.
2. Remove the spark plug (p. 49 ), high humidity.
and remove the emergency stop CARRYING HANDLE
switch clip from the emergency Lif ting the outboard motor by the
stop switch. engine cover, or using the installed
outboard motor as a handle or lever
3. Pour 12 teaspoons (5 10 cm3) to move the boat, can damage the
of clean engine oil into the outboard motor.
cylinder.
If your portable fuel tank contains
4. Pull the starter grip several times gasoline, store it away from any
to distribute the oil in the cylinder. appliance that operates with a flame,
such as a furnace, water heater, or
5. Reinstall the spark plug (p. 50 ). clothes dryer. Also avoid any area
with a spark-producing electric motor,
or where power tools are operated.

63
11/03/07 16:38:44 31ZV1660_065

STORAGE

Cover the outboard motor to keep out


dust. Do not use plastic sheet as a
dust cover. A nonporous cover will
trap moisture, promoting rust and
corrosion.

REMOVAL FROM STORAGE


Check your outboard motor as
CASE PROTECTORS described in the BEFORE
OPERATION chapter of this manual.

If storing horizontally, be sure to fold If the cylinder was coated with oil
the tiller handle, and rest the during storage preparation, the
Store the outboard motor either outboard motor on its case protectors. engine may smoke briefly at startup.
vertically or horizontally with the Be sure all water has drained from This is normal.
tiller handle side up. the outboard motor before placing it
on its side, so no residual water can
enter the engine exhaust port.

Any other horizontal storage position


may cause damage to the outboard
motor or oil leakage.

64
11/03/07 16:38:56 31ZV1660_066

TRANSPORTING
WITH OUTBOARD MOTOR WITH OUTBOARD MOTOR To carry, hold the outboard motor by
INSTALLED ON BOAT REMOVED FROM BOAT the carrying handle, or hold by the
carrying handle and the lug beneath
When trailering a boat with the Remove the outboard motor from the the engine cover lock latch, as shown.
outboard motor attached, always boat and secure the outboard motor
disconnect the fuel line from the in either the vertical or horizontal
portable fuel tank and tighten the position shown on p. 64 . Lif ting the outboard motor by the
steering friction bolt securely (p. 34 ). CARRYING HANDLE engine cover, or using the
installed outboard motor as a
The preferred method is to leave the handle or lever to move the boat,
engine in the normal running position, can damage the outboard motor.
but if there is insufficient road
clearance, you can tilt the outboard
motor using a commercially available
outboard motor support bar available
through your dealer. Refer to the
manufacturers instructions for using
an outboard motor support bar.

OUTBOARD MOTOR SUPPORT BAR


(commercially available)

65
11/03/07 16:39:08 31ZV1660_067

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START Possible Cause Correction

1. Check emergency stop switch Clip not inserted in emergency Insert clip in emergency stop
clip. stop switch. switch.

2. Check control positions. Gearshift lever not in neutral Shift to neutral (p. 28 ).
position.

Choke OFF. Pull choke knob to ON position,


unless engine is warm (p. 28 ).

Throttle grip not in START Turn throttle grip to START


position. position (p. 28 ).

66
11/03/07 16:39:25 31ZV1660_068

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START Possible Cause Correction


(continued)

3. Check fuel. Out of fuel. Refuel (p. 50 ).

Fuel vent closed (portable fuel Open fuel filler cap vent knob (p.
tank). 26 ).

Fuel hose not primed. Squeeze priming bulb (p. 27 ).

Fuel filter or fuel tank filter Replace restricted filters (p. 53 or


restricted. 56 ).

Bad fuel; outboard motor stored Drain fuel tank and carburetor
without treating or draining gasoline, (p. 62 ). Refill with fresh
or refueled with bad gasoline. gasoline (p. 50 ).

4. Remove and inspect spark plug. Spark plug faulty, fouled, or Gap or replace spark plug (p. 49 ).
improperly gapped.

Spark plug wet with fuel (flooded Dry and reinstall spark plug. Start
engine). engine with choke and throttle open.

5. 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.

67
11/03/07 16:39:39 31ZV1660_069

TAKING CARE OF UNEXPECTED PROBLEMS

HARD STARTING OR STALLS Possible Cause Correction


AFTER STARTING

1. Check control positions. Choke OFF. Pull choke knob to ON position,


unless engine is warm (p. 28 ).

Throttle grip not in START Turn throttle grip to START


position. position (p. 28 ).

2. Check fuel. Fuel vent closed (portable fuel Open fuel filler cap vent knob (p.
tank). 26 ).

Fuel hose not primed. Squeeze priming bulb (p. 27 ).

Fuel filter or fuel tank filter Replace restricted filters (p. 53 or


restricted. 56 ).

Bad fuel; outboard motor stored Drain fuel tank and carburetor
without treating or draining (p. 62 ). Refill with fresh
gasoline, or refueled with bad fuel. gasoline (p. 50 ).

68
11/03/07 16:39:53 31ZV1660_070

TAKING CARE OF UNEXPECTED PROBLEMS

HARD STARTING OR STALLS


AFTER STARTING Possible Cause Correction
(continued)

3. Remove and inspect spark plug. Spark plug faulty, fouled, or Gap or replace spark plug (p. 49 ).
improperly gapped.

4. 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 Possible Cause Correction

1. Check water intakes. Water intakes clogged. Clean water intakes.

2. Take outboard motor to an Faulty thermostat or water pump. Replace or repair faulty
authorized Honda Marine dealer, components as necessary.
or refer to the shop manual.

69
11/03/07 16:40:01 31ZV1660_071

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT DRIVE Possible Cause Correction


THE PROPELLER

1. Check shear pin. Broken shear pin. Replace shear pin (p. 57 ).

2. Take outboard motor to an Damaged gearshift mechanism. Replace or repair faulty


authorized Honda Marine dealer, components as necessary.
or refer to the shop manual.

70
11/03/07 16:40:09 31ZV1660_072

TAKING CARE OF UNEXPECTED PROBLEMS

OIL PRESSURE INDICATOR If oil pressure becomes low, the If the throttle is closed suddenly after
GOES OFF AND ENGINE green indicator will go off. If you are full throttle operation, engine speed
SPEED IS LIMITED at cruising speed, engine speed will may drop below the specified idle
decrease gradually. rpm, and that could activate the
OIL PRESSURE INDICATOR engine protection system
Low oil pressure may be the result of momentarily.
a low engine oil level, or there may
be a problem with the engine If low oil pressure activates the
lubrication system. engine protection system, stop the
engine, check the engine oil level
(p. 43 ), and add oil if needed.

With the engine oil at the


recommended level, restart the
engine. If the lubrication system is
OK, the green indicator should come
on within 30 seconds, and the engine
will respond normally to throttle grip
operation.

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.

71
11/03/07 16:40:19 31ZV1660_073

TAKING CARE OF UNEXPECTED PROBLEMS

SUBMERGED OUTBOARD 3. Change the engine oil as described


MOTOR on p. 44 . If there was water in the
STARTER GRIP
engine crankcase, or if the used
A submerged outboard motor must engine oil showed signs of water
be serviced immediately after it is contamination, then a second
recovered from the water in order to engine oil change should be
minimize corrosion. performed after running the engine
for half an hour.
If there is a Honda Marine dealership
nearby, take the outboard motor to
the dealer immediately. If you are far
from a dealer, proceed as follows:

1. Remove the engine cover, and 4. Remove the spark plug (p. 49 ),
rinse the outboard motor with and remove the emergency stop
fresh water to remove salt water, switch clip from the emergency
sand, mud, etc. stop switch. Pull the starter grip,
rotate the flywheel a few
2. Drain the carburetor as described revolutions to completely expel
on p. 62 . any water from the cylinder.

If the engine was running when it


submerged, there may be
mechanical damage, such as a bent
connecting rod. If the engine binds
when cranked, do not attempt to
run the engine until it has been
repaired.
72
11/03/07 16:40:28 31ZV1660_074

TAKING CARE OF UNEXPECTED PROBLEMS

7. Attempt to start the engine. Be


sure the water level is at least 2
When cranking the engine with inches (5 cm) above the
an open ignition circuit (spark antiventilation plate.
plug removed f rom the ignition
circuit), remove the emergency If the engine fails to start, remove
stop switch clip f rom the the spark plug, clean and dry it,
emergency stop switch to then reinstall the spark plug and
prevent possible damage to the attempt to start the engine again.
ignition system.
If the engine starts, and no
mechanical damage is evident,
continue to run the engine for a
half hour or longer. Be sure the
5. Pour a teaspoon of engine oil into water level is at least 2 inches (5
the spark plug hole, and then pull cm) above the antiventilation plate
the starter grip several times to to avoid overheating and water
lubricate the inside of the cylinder. pump damage.

6. Reinstall the spark plug, and put 8. As soon as possible, take the
the emergency stop switch clip outboard motor to an authorized
into the emergency stop switch. Honda Marine dealer for
inspection and service.

73
11/03/07 16:40:40 31ZV1660_075

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. 82 ).
PRODUCT IDENTIFICATION ENGINE SERIAL NUMBER
NUMBER
The product identification number is The engine serial number is
stamped on the swivel case. stamped on the right side of the
engine.

Product identification number: Engine serial number:

Date of purchase:

74
11/03/07 16:40:48 31ZV1660_076

TECHNICAL AND CONSUMER INFORMATION

Carburetor Modification for Settings:


High Altitude Operation Standard setting is for sea level to
2,000 ft (600 meters). When the carburetor has been
At altitudes above 2,000 ft (600 Mid-altitude setting is for 2,000 ft modif ied f or operation at one of the
meters), the standard carburetor air- (600 meters) to 5,000 ft (1,500 higher altitude ranges, the air-f uel
fuel mixture will be too rich. meters). mixture will be too lean f or
Performance will decrease, and fuel High-altitude setting is for 5,000 ft operation at a lower altitude.
consumption will increase. A very (1,500 meters) and above. Operation at altitudes below the
rich mixture will also foul the spark range f or which the carburetor is set
plug and cause hard starting. Even with carburetor modification, may cause the engine to overheat
Operation at an altitude that differs engine horsepower will decrease and result in serious engine damage.
from that at which this engine was about 3.5% for each 1,000-foot (300- For use at lower altitudes, have an
certified, for extended periods of meter) increase in altitude. The effect authorized Honda Marine dealer
time, may increase emissions. of altitude on horsepower will be modif y the carburetor f or the
greater than this if no carburetor correct altitude range.
High altitude operation can be modification is made.
improved by specific modifications
to the carburetor. If you usually
operate your outboard motor at 2,000
ft (600 meters) or above, consult with
your authorized Honda Marine dealer.

Your dealer can determine the


appropriate carburetor settings for the
altitude at which you operate your
outboard motor.

75
11/03/07 16:40:58 31ZV1660_077

TECHNICAL AND CONSUMER INFORMATION

Emission Control System The U.S. and Calif ornia Clean Tampering and Altering
Information Air Acts
Tampering with or altering the
Source of Emissions EPA and California regulations emission control system may increase
require all manufacturers to furnish emissions beyond the legal limit.
The combustion process produces written instructions describing the Among those acts that constitute
carbon monoxide, oxides of nitrogen, operation and maintenance of tampering are:
and hydrocarbons. Control of emission control systems.
hydrocarbons and oxides of nitrogen Removal or alteration of any part
is very important because, under The following instructions and of the intake, fuel, or exhaust
certain conditions, they react to form procedures must be followed in order systems.
photochemical smog when subjected to keep the emissions from your
to sunlight. 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. parameters.

Honda utilizes appropriate air/fuel


ratios and other emissions control
systems to reduce the emissions of
carbon monoxide, oxides of nitrogen,
and hydrocarbons.

76
11/03/07 16:41:09 31ZV1660_078

TECHNICAL AND CONSUMER INFORMATION

Problems That May Af f ect Replacement Parts A manufacturer of an aftermarket


Emissions part assumes the responsibility that
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 manufacturer or rebuilder of the part
engine inspected and repaired by EPA and California emission must certify that use of the part will
your servicing dealer. regulations. We recommend the use not result in a failure of the engine to
of Honda Genuine parts whenever comply with emission regulations.
Hard starting or stalling after you have maintenance done. These
starting. original-design replacement parts are Maintenance
manufactured to the same standards
Rough idle. as the original parts, so you can be Follow the maintenance schedule on
confident of their performance. The (p. 41 and 42 ). Remember that this
Misfiring or backfiring under load. use of replacement parts that are not schedule is based on the assumption
of the original design and quality that your machine will be used for its
Afterburning (backfiring). may impair the effectiveness of your designed purpose. Sustained high-
emission control system. load operation, or use in unusual
Black exhaust smoke or high fuel conditions, will require more
consumption. frequent service.

77
11/03/07 16:41:27 31ZV1660_079

TECHNICAL AND CONSUMER INFORMATION

Star Label The Star Label means Cleaner Marine Engine


US, Puerto Rico, and US Virgin
Islands This engine has been certified as a:

A Star label was applied to this


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.

Better Fuel Economy - burns up to 30 - 40 percent less gas and oil than
conventional carbureted two-stroke engines, saving money and resources.

Longer Emission Warranty - protects consumer for worry-free operation.

78
11/03/07 16:41:38 31ZV1660_080

TECHNICAL AND CONSUMER INFORMATION

The one-star label identifies engines that meet the Air Resources Boards
One Star Personal Watercraft and Outboard marine engine 2001 exhaust emission
Low standards. Engines meeting these standards have 75% lower emissions than
Emission conventional carbureted two-stroke engines. These engines are equivalent to
the U.S. EPAs 2006 standards for marine engines.

The two-star label identifies engines that meet the Air Resources Boards
Two Stars Personal Watercraft and Outboard marine engine 2004 exhaust emission
Very Low standards. Engines meeting these standards have 20% lower emissions than
Emission One Star-Low Emission engines.

The three-star label identifies engines that meet the Air Resources Boards
Three Stars Personal Watercraft and Outboard marine engine 2008 exhaust emission
Ultra Low standards or the Sterndrive and Inboard marine engine 2003-2008 exhaust
Emission emission standards. Engines meeting these standards have 65% lower
emissions than One Star-Low Emission engines.

The four-star label identifies engines that meet the Air Resources Boards
Four Stars Sterndrive and Inboard marine engine 2009 exhaust emission standards.
Super Ultra Personal Watercraft and Outboard marine engines may also comply with
Low Emission these standards. Engines meeting these standards have 90% lower emissions
than One Star-Low Emission engines.

Cleaner Watercraft - Get the Facts


1-800-END-SMOG
www.arb.ca.gov
79
11/03/07 16:42:17 31ZV1660_081

TECHNICAL AND CONSUMER INFORMATION


Specifications
MODEL BF5A Spark plug BPR5ES (NGK) , W16EPR-U (DENSO)
Description code BADS Fuel pump Diaphragm type fuel pump
Type S L Fuel Unleaded gasoline
Overall length 20.7 in (525 mm) (86 pump octane or higher)
Overall width 13.8 in (350 mm) Tank capacity 3.2 US gal (12 L)
Overall height 39.6 in (1,005 mm) 44.7 in (1,135 mm) Gear change Forward-Neutral-Reverse (dog type)
Transom height 17.1 in (434 mm) 22.1 in (561 mm) Steering angle 45 right and left
(when transom Transom angle 5 stages (4,8,12,16,20)
angle at 12) Tilt up angle
Dry mass [weight] 59.5 lbs (27.0 kg) 60.6 lbs (27.5 kg) (when transom angle 3 stages adjustment (18, 38 and 58)
Rated power 3.7 kW (5 HP) at 12)
Full throttle range 4,5005,000 rpm Standard propeller
Engine type 4 stroke OHV 1 cylinder, water-cooled (No. of blades- 7-25/32 7-31/64 in (3-200 190 mm)
Displacement 7.7 cu-in (127 cm ) diameter pitch)
Spark plug gap 0.0280.031 in (0.70.8 mm)
Starter system Recoil starter Tuneup
Ignition system Digital Ignition Control Module (ICM) Spark plug gap 0.0280.031 in See page 49
Lubrication system Trochoid pump pressure lubrication (0.70.8 mm)
Specified oil Engine: API standard (SG, SH or SJ oil) Idle speed 1,550 100 rpm See shop
SAE 10W-30 manual
Gear case: API standard (GL-4) Valve clearance Intake: 0.10 0.04 mm See shop
SAE 90 outboard motor gear oil (cold) Exhaust: 0.15 0.04 mm manual
Oil capacity Engine: 0.58 US qt (0.55 L) Other specifications No other adjustment is needed
Gear case: 0.11 US qt (0.10 L)
CARB star label ULTRA LOW EMISSION
Cooling system Water cooling with thermostat
Exhaust system Underwater exhaust

Honda outboard motors are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.

80
11/03/07 16:42:32 31ZV1660_082

TECHNICAL AND CONSUMER INFORMATION

CONSUMER INFORMATION Accessory Catalog differences at the dealership level. If


Your authorized Honda Marine the service personnel are unable to
Honda Publications dealer offers a wide selection of assist you, please discuss your
(United States, Puerto Rico, and accessories (optional equipment, oils, concerns with the dealer management
U.S.Virgin Islands) and lubricants) to enhance your such as the Service Manager or the
boating experience. dealerships owner.
These publications will give you Visit www.honda-marine.com and If you need to contact Honda
additional information for click on PARTS & ACCESSORIES regarding your experiences with your
maintaining and repairing your to see the entire catalog of Honda product or with your dealer,
outboard motor. accessories. please contact the Honda office in
your region:
Shop Manual Customer Service Information American Honda Motor Co., Inc.
This manual covers complete Contacting Honda Marine Division
maintenance and overhaul procedures. Your Owners Manual was written to Customer Relations Office
It is intended to be used by a skilled cover most of the questions you 4900 Marconi Drive
technician. might ask about your Honda. Any Alpharetta, GA 30005-8847
Available through your Honda questions not answered in the Owners Telephone (770) 4976400
Marine dealer or through Helm Inc. Manual can be answered by your M-F 8:30 am-7:00 pm (Eastern Time
at Honda dealer. If your dealer doesnt Zone)
1 888-292-5395 or have an immediate answer, they Honda Canada Inc.
visit www.Honda-marine.com should be able to get it for you. Customer Relations Office
and click on OWNERS 180 Honda Boulevard
RESOURCES. Markham, Ontario L6 0H9
Parts Catalog If you have a difference of opinion Tel: 1-888-946-6329 (Toll free)
This manual provides complete, with your dealer, please remember Fax: 1-877-939-0909 (Toll free)
illustrated parts lists. that each dealership is independently
The catalog is available through your owned and operated. Thats why its
Honda Marine dealer. important to work to resolve any
81
11/03/07 16:42:44 31ZV1660_083

TECHNICAL AND CONSUMER INFORMATION

Please include the following Warranty Coverage deterioration associated with using
information in your communication: your Honda outboard motor.
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
Distributors Limited Warranty own maintenance. However, you
Model and complete serial number Emission Control System should have the proper tools and
Warranty service information and be
Date of purchase Please read the warranty statements mechanically qualified. Failures that
contained in this manual. There are occur due to modifications, improper
Name and location of selling responsibilities, restrictions, and maintenance, or service are not
dealer exclusions that apply to these covered.
warranties.
Name and location of servicing
dealer (if different) To obtain warranty service you must
take your Honda outboard motor,
A detailed description of your together with proof of original retail
concerns purchase date, at your expense, to a
Honda engine dealer or distributor
authorized to sell that product in the
United States, Puerto Rico, the U.S.
Virgin Islands or Canada.

It is important to realize that your


warranty applies to defects in
material or workmanship of your
Honda. Your warranty coverage does
not apply to normal wear or
82
11/03/07 16:42:50 31ZV1660_084

TECHNICAL AND CONSUMER INFORMATION

Warranty Service handling of the situation, we suggest


you discuss your problem with the
Please remember that recommended appropriate member of the
maintenance interval servicing is not dealerships management team. If the
included in your warranty coverage. problem has already been reviewed
Additionally, your warranty does not with the appropriate manager of the
apply to the normal wear of items Service, Parts, or Sales department,
(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.
However, you may be responsible for
additional non-warranty charges.

If you have questions about warranty


coverage or the nature of the repair, it
is best to talk to the service manager
of your Honda dealer.

Sometimes, in spite of the best


intentions of all concerned, a
misunderstanding may occur. If you
arent satisfied with your dealers
83
11/03/07 16:43:02 31ZV1660_085

TECHNICAL AND CONSUMER INFORMATION

Warranty Statements
The American Honda Distributors Limited Warranty applies to outboards purchased in the United States, Puerto Rico,
or the U.S. Virgin Islands. The Honda Canada Distributors Warranty applies to outboards purchased in Canada.
The product warranty is only valid in the country where the product was purchased.

United states, Puerto Rico and Virgin Islands


Distributors Limited Warranty
This warranty is limited to Honda Outboard Motors and related original equipment distributed by American Honda
Motor Co., Inc., Power Equipment Division, 4900 Marconi Drive, Alpharetta, Georgia 30005-8847.
Products Covered by Warranty: Length of Warranty: (from date of original retail purchase)
NONCOMMERCIAL/ COMMERCIAL/RENTAL STATE/LOCAL/FEDERAL
NONRENTAL GOVERNMENT
All models purchased before July 1, 2008(1) (2) 36 months 12 months 24 months
All Models purchased on or after July 1, 2008(2) 60 months 12 months 24 months
Related original equipment items:
BF2 through BF30 models: Portable fuel tank
and original propeller. The same duration as the outboard with which they were purchased.
All models: Primer bulb/fuel line assembly and
tiller handle.

(1) Models purchased prior to July 1, 2008 (unless previously purchased with True-5 warranty from a participating dealer).
(2) 35, 65, & 105 Jet models: Jet pump assembly is a dealer installed option. Jet pump warranty is provided by Specialty Manufacturing Co. (Outboard Jets).

84
11/03/07 16:43:10 31ZV1660_086

TECHNICAL AND CONSUMER INFORMATION

To Qualify for This Warranty: To Obtain Warranty Service:


The Honda Outboard Motor must be purchased from
American Honda or a dealer authorized by American You must, at your expense, take your Honda Outboard
Honda to sell Honda Outboard Motors in the United Motor and proof of the original purchase date to any
States, Puerto Rico, or the U.S. Virgin Islands. This dealer who is authorized to service Honda Outboard
limited warranty applies to the first retail purchaser and Motors in the United States, Puerto Rico, or the U.S.
each subsequent owner during the applicable warranty Virgin Islands, during the dealers normal business hours.
time period. If you are unable to obtain warranty service, or are
dissatisfied with the warranty service you receive, take
What American Honda Will Repair or Replace Under the following steps: 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 assistance, write or call the Honda Marine Customer
workmanship under normal use during the applicable Relations. Please see Contacting Honda page 81 .
warranty time period. Warranty repairs and replacements
will be made without charge for parts or labor. Anything
replaced under warranty becomes the property of
American Honda Motor Company, Inc.

All parts replaced under warranty will be considered as


part of the original product and any warranty on those
parts will expire coincidentally with the original product
warranty.

85
11/03/07 16:43:25 31ZV1660_087

TECHNICAL AND CONSUMER INFORMATION

Exclusions: Reimbursement for towing charges, in and out of


This warranty does not extend to the following: water charges, or technician travel time
Conditions caused by lack of routine maintenance or Growth of marine organisms on outboard motor
improper storage (as outlined in the Owners Manual) surfaces, external or internal
Conditions caused by the use of propeller (s) that do Any product that has ever been declared a total loss or
not allow the outboard motor to run in its sold for salvage by a financial institution or insurer, or
recommended full throttle rpm range that has been issued a salvage or similar title under
Operation inconsistent with the recommended any states law.
operation/duty cycle (as outlined in the Owners
Manual) Disclaimer of consequential damage and limitation of
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 which the outboard is installed, transportation,
the fuel intake, air intake or exhaust system commercial loss, or any other incidental or consequential
Operation with fuels, oils, additives and lubricants damage. Any implied warranties are limited to the
which are not suitable for use in the product duration of this written limited warranty.
Use in an application for which the outboard motor Some states do not allow limitations on how long an
was not designed, such as racing or competitive use or implied warranty lasts and/or do not allow the exclusion
any other misuse or neglect or limitation of incidental or consequential damages, so
Incorporation of unsuitable attachments or parts the above exclusions and limitations may not apply to
The unauthorized alteration, improper installation and/ you. This warranty gives you specific legal rights, and
or rigging, or any causes other than defects in material you may also have other rights which vary from state to
or workmanship state.
Corrosion to steering system or electrical components,
corrosion due to electrolysis, water born foreign
chemicals, improper service or corrosion caused by
damage or abuse
86
11/03/07 16:43:35 31ZV1660_088

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)
Non Commercial Commercial/Rental Local/State/Federal
Government
Accessories other than noted below 12 months 3 months 3 months
Emission related accessories:
Portable fuel tanks, fuel line assemblies, and 24 months 24 months 24 months
water/fuel separators
Replacement Parts 6 months 3 months 3 months

To Qualify for This Warranty: marine product accessories or replacement parts that are
1. The accessories or replacement parts must be proven to be defective in material or workmanship under
purchased from American Honda or a dealer, normal use during the applicable warranty time period.
distributor, or distributors dealer authorized by Anything replaced under warranty becomes the property
American Honda to sell those products in the United of American Honda Motor Company, Inc. All parts
States, Puerto Rico, and the U.S. Virgin Islands. Parts replaced under warranty will be considered as part of the
and Accessories must be purchased for installation on original product and any warranty on those parts will
original Honda equipment or engines to be eligible for expire coincidentally with the original product warranty.
warranty coverage. Installing parts and accessories on
non-Honda products or engines voids this warranty. Accessories and replacement parts, installed by a dealer
2. You must be the first retail purchaser. This warranty is who is authorized by American Honda to sell them, will
not transferable to subsequent owners. be repaired or replaced under warranty without charge for
parts or labor. If installed by anyone else, accessories and
What American Honda Will Repair or Replace Under replacement parts will be repaired or replaced under
Warranty: warranty without charge for parts, but any labor charges
American Honda will repair or replace, at its option, any will be the responsibility of the purchaser.
87
11/03/07 16:43:42 31ZV1660_089

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 damages, so the above exclusions and limitations may not
outboard motor or boat on which the accessory or apply to you. This warranty gives you specific legal
replacement part is installed, and proof of purchase to rights, and you may also have other rights which vary
any Honda Marine authorized service facility or dealer in from state to state.
the United States, Puerto Rico, or the U.S. Virgin Islands,
during normal business hours.

Exclusions:
This warranty does not extend to accessories or parts
affected or damaged by collision, normal wear, use in an
application for which the product was not designed or
any other misuse, neglect, incorporation or use of
unsuitable attachments or parts, unauthorized alteration,
improper installation, or any causes other than defects in
material or workmanship of the product.
Installing parts and accessories on non-Honda products or
engines voids this warranty.

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. Some states do not allow limitations on
88
11/03/07 16:43:52 31ZV1660_090

TECHNICAL AND CONSUMER INFORMATION

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
American Honda provides the same emission warranty the carburetor or fuel injection system and catalytic
coverage for outboard engines sold in all 50 states. converter. Also included may be hoses, connectors and
other emission-related assemblies.
YOUR WARRANTY RIGHTS AND OBLIGATION
MANUFACTURERS EMISSION CONTROL
California SYSTEM WARRANTY COVERAGE:
The California Air Resources Board and American Your 2010 and later outboard engine is warranted for a
Honda Motor Co., Inc. are pleased to explain the minimum of five years or 250 hours of operation,
emission control system warranty on your 2001 and later whichever comes first, or the length of Honda Marine
Honda outboard engine. In California, new outboard Distributors Limited warranty, whichever is longer.
engines must be designed, built, and equipped to meet However, warranty coverage based on the hourly period
Californias stringent anti-smog emission standards in is only permitted for outboard engines equipped with
addition to the U.S. EPA emissions standards. appropriate hour meters. If any emission-related part on
your outboard engine is defective under warranty, the
All States part will be repaired or replaced by American Honda
In all areas of the United States your outboard engine Motor Co., Inc.
must be designed, built, and equipped to meet the U.S.
EPA Emission Standard for spark ignited marine engines.
American Honda Motor Co., Inc. must warranty the
emission control system on your outboard engine for the
period of time listed below provided there has been no
abuse, neglect, or improper maintenance of your
outboard engine. Where a warranty condition exists,
American Honda Motor Co., Inc. will repair your
89
11/03/07 16:43:58 31ZV1660_091

TECHNICAL AND CONSUMER INFORMATION

OWNERS WARRANTY RESPONSIBILITY: WARRANTY COVERAGE:


As the outboard engine owner, you are responsible for Honda outboard engines certified to the CARB and EPA
the performance of the required maintenance listed in 2010 regulations are covered by this warranty for a
your owners manual. American Honda Motor Co., Inc. minimum of five years or 250 hours of operation,
recommends that you retain all receipts covering whichever comes first, or the length of the Honda Marine
maintenance on your outboard engine, but American Distributors Limited warranty, whichever is longer from
Honda Motor Co., Inc. cannot deny warranty solely for the date of delivery to the retail purchaser. This warranty
the lack of receipts or for your failure to ensure the is transferred to each subsequent purchaser for the
performance of all scheduled maintenance. duration of the warranty period.
As the outboard engine owner, you should, however, be Warranty repairs will be made without charge for
aware that American Honda Motor Co., Inc. may deny diagnosis, parts and labor. All defective parts replaced
you warranty coverage if your outboard engine or a part under this warranty become the property of American
has failed due to abuse, neglect, improper maintenance, Honda Motor Co., Inc. A list of warranty parts is on page
or unapproved modifications. 92 . Normal maintenance items, such as spark plugs and
You are responsible for presenting your outboard engine filters, that are on the warranted parts list are warranted
to a Honda Marine dealer as soon as a problem exists. up to their required replacement interval only.
The warranty repair should be completed in a reasonable American Honda Motor Co., Inc. is also liable for
amount of time, not to exceed 30 days. damages to other engine components caused by a failure
If you have any questions regarding your warranty rights of any warranted part during the warranty period.
and responsibilities, you should contact American Honda Only Honda approved replacement parts will be used in
Motor Co., Inc., Marine Division Customer Relations the performance of any warranty repairs and they will be
Office. Please see Contacting Honda page 81 . provided without charge to the owner. The use of
replacement parts not equivalent to the original parts may
impair the effectiveness of your engines emission
control system. If such a replacement part is used in the
repair or maintenance of your engine, and an authorized
Honda Marine dealer determines it is defective or causes
a failure of a warranted part, your claim for your engine
90
11/03/07 16:44:05 31ZV1660_092

TECHNICAL AND CONSUMER INFORMATION

may be denied. If the part in question is not related to the EXCLUSIONS:


reason that your engine requires repair, your claim will Failures other than those resulting from defects in
not be denied. material or workmanship are not covered by this warranty.
This warranty does not extend to emission control
TO OBTAIN WARRANTY SERVICE: systems or parts which are affected or damaged by owner
You must take your Honda outboard engine, along with abuse, neglect, improper maintenance, misuse, misfueling,
your sales registration card or other proof of original improper storage, and/or collision, the incorporation of,
purchase date, at your expense, to any Honda Marine or use of, unsuitable attachments, or the unauthorized
dealer who is authorized by 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 maintenance items made in connection with required
adjustment found to be caused solely by defects in maintenance service after the items first scheduled
material or workmanship will not be denied because the replacement as listed in the maintenance section of the
engine was not properly maintained and used. product owners manual, such as: spark plugs and filters.
If you are unable to obtain warranty service, or are
dissatisfied with the warranty service you received, DISCLAIMER OF CONSEQUENTIAL DAMAGE
contact the owner of the dealership involved. Normally AND LIMITATION OF IMPLIED WARRANTIES:
this should resolve your problem. However, if you American Honda Motor Co., Inc. disclaims any
require further assistance, write or call the Honda Marine responsibility for incidental or consequential damages
Customer Relations Office of American Honda Motor such as loss of time or the use of outboard engine, or any
Co., Inc. commercial loss due to the failure of the equipment; and
any implied warranties are limited to the duration of this
written warranty. This warranty is applicable only where
the California or U.S. EPA emission control system
warranty regulation is in effect.

91
11/03/07 16:44:17 31ZV1660_093

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 Portable fuel tank, Fuel cap, Fuel hoses, Primer bulb, Fuel hose joint
Air Induction Air intake duct, Vapor separator, Intake manifold tuning valve (Intake air bypass
control valve)
Ignition Flywheel magneto, Ignition pulse generator, Ignition coil assembly, Ignition control
module, Engine control module, Crankshaft position sensor, Spark plug cap,
Spark plug, Knock sensor, and Camshaft position sensor
Lubrication system Oil pump and internal parts
Crankcase Emission Control Crankcase breather tube, Positive crankcase ventilation valve, Oil filler cap
Exhaust Exhaust manifold and Exhaust valves
Valve Control System Rocker arm oil control valve
Miscellaneous Parts Tubing, fittings, seals, gaskets, and clamps associated with these listed systems.

Covered up to the first required replacement only. See the Maintenance Schedule on page (p.41 and p.42) .

92
11/03/07 16:44:29 31ZV1660_094

TECHNICAL AND CONSUMER INFORMATION

Canada WARRANTY PERIOD RETAILED ON OR


AFTER APRIL 1, 2005:
Distributors Warranty
HONDA CANADA INC., for and on behalf of Honda Non-commercial Commercial
Motor Co. Ltd., Tokyo, Japan, gives the following use use
written warranty on each new marine product All Honda Outboard
36 Months 12 Months
manufactured by Honda Motor Co. Ltd., Japan, Models
distributed in Canada by Honda Canada Inc. and sold by
authorized Honda Marine dealers. THIS WARRANTY COVERS
Whenever used herein, the word Honda refers to a) Any Honda marine product purchased in Canada from
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 performed by an authorized Honda dealer and which is
product will be free, under normal use and maintenance, normally operated in Canada;
from any defects in material or workmanship for the b) Any factory installed part (except normal maintenance
relevant warranty period set forth below. If any defects parts referred to in THIS WARRANTY DOES NOT
should be found in a Honda marine product within the COVER); and
relevant warranty period, necessary repairs and c) Any marine product on which required maintenance
replacements with a new part or the Honda equivalent services have been performed as prescribed in the
shall be made at no cost to the consumer for parts and Owners Manual.
labour, when Honda acknowledges that such defects are
attributable to faulty material or workmanship at the time
of manufacture.

93
11/03/07 16:44:41 31ZV1660_095

TECHNICAL AND CONSUMER INFORMATION

THIS WARRANTY DOES NOT COVER THE OWNERS OBLIGATION


a) Any repairs required as a result of collision, accident, In order to maintain the validity of this DISTRIBUTORS
striking any object, misuse or lack of required WARRANTY, the required maintenance services as set
maintenance; forth in the Owners Manual must be performed at the
b) Any repairs required as a result of any attachments, proper intervals and detailed receipts and records retained
parts or devices installed by or repairs done by a party as proof.
other than an authorized Honda dealer;
c) Any outboard that has been operated out of water, TO OBTAIN WARRANTY SERVICE
(Run Dry) damaging the water pump and or engine
components due to insufficient cooling water. You must take your Honda marine product, at your
d) 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
e) 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; this
replacement of parts made in connection with normal should resolve the problem. If you require further
maintenance services including filters, spark plugs and assistance, contact Honda Canadas Customer Relations
wires, fuses, belts, lubricants and other expendables Department at:
susceptible to natural wear;
f) Outboard propeller or shear pin. HONDA CANADA INC.
g) All accessories or attachments. Customer Relations Office
180 Honda Boulevard
Markham, Ontario L6 0H9

TELEPHONE: 1-888-946-6329 TOLL FREE


FAX : 1-877-939-0909 TOLL FREE

94
11/03/07 16:44:49 31ZV1660_096

TECHNICAL AND CONSUMER INFORMATION

REPLACEMENT PARTS AND ACCESSORY DISCLAIMER


WARRANTY
To the extent the law permits, Honda disclaims any
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 incidental or consequential damage, inconvenience or
DISTRIBUTORS WARRANTY are warranted for a commercial loss.
period of one year from date of purchase, provided,
however, that this Replacement Parts and Accessory NOTICE TO CONSUMER
Warranty does not apply to any replacement parts
modified, used with, or installed on a marine product for The provisions contained in these written warranties are
which the replacement parts were not intended. Electrical not intended to limit, modify, take away from, disclaim
components that are not installed by the dealer (sold over or exclude any warranties set forth in or the operation of
the counter) are not covered by warranty. The Consumer Products Warranties Act, 1977
(Saskatchewan), The Consumer Product Warranty and
ENTIRE WRITTEN WARRANTY Liability Act (New Brunswick), The Consumer
Protection Act (Quebec), or any other similar provincial
This DISTRIBUTORS WARRANTY and the or federal legislation.
REPLACEMENT PARTS AND ACCESSORY
WARRANTY are the only and the entire written
warranties given by Honda for Marine engines. No dealer
or his agent or employee is authorized to extend or
enlarge on these warranties on behalf of Honda by any
written or verbal statement or advertisement.

95
11/03/07 16:44:56 31ZV1660_097

INDEX

Anode ............................................................................. 19 EMERGENCY STARTING .......................................... 30


Replacement ............................................................... 56 Emergency Stop Switch Clip and Emergency
ARE YOU READY TO GET UNDERWAY?.............. 23 Stop Switch ................................................................ 14
ATTACHMENT ............................................................ 22 Emission Control System Information .......................... 76
Emission Control System Warranty............................... 89
BEFORE OPERATION................................................. 23 Engine
BREAK-IN PROCEDURE ............................................ 25 Cover
Lock Lever ............................................................. 16
Carburetor Modification for High Altitude Operation .. 75 REMOVAL AND INSTALLATION .................... 43
Choke Knob.................................................................... 14 Oil
CLEANING AND FLUSHING..................................... 59 Change.................................................................... 44
COMPONENT AND CONTROL LOCATIONS ......... 12 Level Check ........................................................... 43
CONSUMER INFORMATION .................................... 81 Recommendations .................................................. 45
CONTROLS ................................................................... 14 ENGINE OVERHEATS ................................................ 69
CONTROL AND FEATURE IDENTIFICATION ENGINE WILL NOT DRIVE THE PROPELLER....... 70
CODES ....................................................................... 11 ENGINE WILL NOT START ....................................... 66
CONTROLS AND FEATURES ................................... 11
Cooling System Indicator............................................... 18 Fuel
CRUISING ..................................................................... 35 Filler Cap Vent Knob ................................................. 19
Customer Service Information ....................................... 81 Filter Inspection and Replacement ............................. 53
Gauge.......................................................................... 17
Distributors Limited Warranty...................................... 84 HOSE CONNECTIONS ............................................ 26
Distributors Warranty ................................................... 93 PRIMING ................................................................... 27
Priming Bulb .............................................................. 20
RECOMMENDATIONS ........................................... 52

96
11/03/07 16:45:04 31ZV1660_098

INDEX

Gear Case Oil Oil Pressure Indicator ..................................................... 18


Change ........................................................................ 46 OIL PRESSURE INDICATOR GOES OFF AND
Level Check................................................................ 45 ENGINE SPEED IS LIMITED ................................. 71
GEARSHIFTING AND THROTTLE OPERATION ... 33 OPERATION ................................................................. 25
Gearshift Lever............................................................... 15 OTHER FEATURES ..................................................... 18
OUTBOARD MOTOR SAFETY .................................... 6
HARD STARTING OR STALLS AFTER
STARTING ................................................................ 68 Portable Fuel Tank ................................................... 19, 26
Honda Publications ........................................................ 81 Portable Fuel Tank and Tank Filter Cleaning ................ 55
POWER REQUIREMENTS.......................................... 21
IMPORTANT SAFETY INFORMATION ..................... 6 Propeller and Shear Pin Replacement ............................ 57
INDICATORS................................................................ 18
INFREQUENT OR OCCASIONAL USE .................... 27 Recoil Starter Rope Inspection....................................... 56
INSTALLATION ........................................................... 21 REFUELING.................................................................. 50
INSTALLATION POSITION ....................................... 21 REMOVAL FROM STORAGE .................................... 64
INSTRUMENTS ............................................................ 17 Rev Limiter..................................................................... 18
IS YOUR OUTBOARD MOTOR
READY TO GO? ....................................................... 23

Lubrication Points .......................................................... 48

MAINTENANCE SAFETY .......................................... 39


MAINTENANCE SCHEDULE .................................... 41
MOORING, BEACHING, LAUNCHING .................... 37

97
11/03/07 16:45:10 31ZV1660_099

INDEX

SAFE OPERATING PRECAUTIONS ......................... 25 TAKING CARE OF UNEXPECTED PROBLEMS..... 66


SAFETY LABEL LOCATIONS ..................................... 8 TECHNICAL AND CONSUMER INFORMATION... 74
Serial Number Locations................................................ 74 TECHNICAL INFORMATION .................................... 74
SERVICING YOUR OUTBOARD MOTOR ............... 38 THE IMPORTANCE OF MAINTENANCE ................ 38
SHALLOW WATER OPERATION ............................. 36 Throttle Friction Knob ................................................... 15
Spark Plug Service ......................................................... 49 Throttle Grip ................................................................... 15
Specifications ................................................................. 80 Tilt Lever ........................................................................ 17
Star Label ....................................................................... 78 TOOL KIT AND EMERGENCY STARTER ROPE ... 40
Starter Grip ..................................................................... 16 Transom Angle Adjusting Rod ...................................... 16
STARTING THE ENGINE ........................................... 28 TRANSOM ANGLE ADJUSTMENT .................... 22, 25
STEERING..................................................................... 34 TRANSPORTING ......................................................... 65
Steering Friction Bolt ..................................................... 17 WITH OUTBOARD MOTOR INSTALLED
STOPPING THE ENGINE ............................................ 32 ON BOAT .............................................................. 65
Emergency Engine Stopping...................................... 32 WITH OUTBOARD MOTOR REMOVED
Normal Engine Stopping............................................ 32 FROM BOAT ........................................................ 65
STORAGE ..................................................................... 61
Engine oil ................................................................... 63 Warranty Statements ...................................................... 84
Fuel ............................................................................. 61
STORAGE PRECAUTIONS......................................... 63
SUBMERGED OUTBOARD MOTOR ........................ 72

98
11/03/07 16:45:12 31ZV1660_100

MEMO

99
11/03/07 16:45:14 31ZV1660_101

MEMO

100
BF5A
Owners Manual

BF5AK2 Includes US and Canadian Models


31ZV1660
00X31-ZV1-6600 N 2eY1500.2011.04
Printed in China

PANTONE 288 CVC DIC F101 BLACK


00X31-ZV1-6600 BF5A

You might also like