Honda Marine BF40A Owner's Manual
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Honda Marine BF40A Owner's Manual

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BF40A/50A
Owner's
Manual
2001
© HONDA MOTOR CO., LTD. 2000

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  • Page 1 BF40A/50A Owner’s Manual 2001 © HONDA MOTOR CO., LTD. 2000...
  • Page 2 The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever.
  • Page 3 We suggest you read the warranty policy Congratulations on your selection of a to fully understand its coverage and your Honda outboard motor. We are certain responsibilities of ownership. The you will be pleased with your purchase warranty policy is a separate document of one of the finest outboard motors on the market.
  • Page 4 INTRODUCTION You will find important safety information a variety of forms, including: A FEW WORDS ABOUT SAFETY a Safety Labels - on the outboard motor. Your safety and the safety of others are very important. And using this outboard Safety Messages - preceded by a safety alert symbol A and one of three signal words, DANGER, WARNING, or CAUTION.
  • Page 5 TYPES OF HONDA BF40A/50A OUTBOARD MOTORS It may be necessary to refer to this chart for reference purposes when reading this manual. TYPE CODE (example) R = Remote Control H = Tiller Handle X = Extra Long Shaft L = Long Shaft...
  • Page 6 IDENTIFICATION NUMBERS PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER Record the Product Identification The Product Identification Number is Number (P.I.N.) and the Engine Serial stamped on a plate and attached to the Number for your reference. Refer to the right stem bracket. The Engine Serial Product Identification Number when Number is stamped on the cylinder block under the starter motor which is...

  • Page 7: Table Of Contents

    CONTENTS Tachometer ............1. OUTBOARD MOTOR SAFETY Manual Relief Valve ..........24 lMPORTANT SAFETY INFORMATION ... 7 GAS ASSISTED TILT TYPE SAFETY LABEL LOCATIONS ......9 Tilt Lever ............... 2. COMPONENT IDENTIFICATION ......10 CONTROLS (COMMON) 3. CONTROLS Tilt Lock Lever ............25 TlLLER HANDLE TYPE Trim Tab ..............
  • Page 8 CONTENTS Fuel Line Connection ..........38 High Altitude Operation......... 73 STARTING THE ENGINE (TILLER HANDLE TYPE). .. 40 7. STOPPING THE ENGINE STARTING THE ENGINE (REMOTE CONTROL TYPE). .. 44 TILLER HANDLE TYPE........74 Emergency Starting ..........47 REMOTE CONTROL TYPE ........

  • Page 9: Outboard Motor Safety

    Flotation Device) while on the boat. INFORMATION It is the operator’s responsibility to Familiarize yourself with all laws and Honda BWOA and BFSOA outboard provide the necessary safeguards to motors are designed for use with boats protect people and property. Know regulations relating to boating and the that have a suitable manufacturer’s...
  • Page 10 1. OUTBOARD MOTOR SAFETY Refuel With Care Carbon Monoxide Hazard Gasoline is extremely flammable, and Exhaust gas contains poisonous carbon gasoline vapor can explode. Refuel monoxide. Avoid inhalation of exhaust gas. Never run the engine in a closed outdoors, in a well-ventilated area, with the engine stopped.

  • Page 11: Safety Label Locations

    1. OUTBOARD MOTOR SAFETY SAFETY LABEL LOCATIONS GASOLINE($g These labels are in the locations shown. They warn you of potential hazards that EXTREMELY FLAMMABLE FORUS*S*~aTCRnaOKI-W”-~~~-~~-CDPaMS could seriously injure you. Read these DANGER labels carefully. I DO NOT SNlm TO REVERSE SUDDENLY AT NIGH I CHECK OIL l&YE,.
  • Page 12 2. COMPONENT IDENTIFICATION (TILLER HANDLE TYPE) THROTTLE GRIP FUEL LINE OIL FILLER CONNECTOR OIL LEVEL TILLER GEAR SHIFT LEVER ENGINE YOVER DIPSTICK OIL PRESSURE INDICATOR LIGHT HAN?LE OVERHEAT INDICATOR TILT LEVER TIVENTILATION STOP SWITCH HAUST PORT STOP SWITCH CLIP STOP SWITCH LANYARD...
  • Page 13 2. COMPONENT IDENTIFICATION (REMOTE CONTROL TYPE) ENGINE COVER PfiUTITR - v . ..A-. “llr F Ll.dLc.rR LAA- FUEL LINE ~ SWITCH CHOKE KNOB CONNECTOR (except LR type) NEUTRAL POWER TRIM/TILT OIL LEVEL RELEASE LEVER SWITCH \/++-I OIL PRESSURE INDICATOR LIGHT CONTROL --_.-___ LEVER...

  • Page 14: Component Identification

    2. COMPONENT IDENTIFICATION POWER TRIM/TILT TYPES VENT KNOB FUEL GAUGE FUEL CAP FUEL TACHOMETER FUEL FUEL HOSE CONNECTOR TRIM METER (FEMALE) PRIMER BULB...

  • Page 15: Controls

    3. CONTROLS (TILLER HANDLE TYPE) Engine Start Button Shift Lever Choke Knob (reverre) (reverse) EN&B START SHIFT LEVER BUTTON CHOti KNOB Move the gearshift lever to the N There are three gearshift lever posi- When the engine is cold, pull the (neutral) position before starting.

  • Page 16: Throttle Grip

    3. CONTROLS (TILLER HANDLE TYPE) Throttle Grip Throttle Opening Indicator Throttle Friction Knob THRO’lTLE OPENING INDICATOR THROTl’LE FRICTION KNO THROTTLE GRIP RELEASE The label on the grip indicates throttle Turn the grip clockwise or counter- Use the throttle friction knob to set the clockwise to adjust the engine speed.

  • Page 17: Engine Stop Switch

    3. CONTROLS (TILLER HANDLE TYPE) Emergency Stop Switch Lanyard Engine Stop Switch ENGINE STOP SWITCH EMERGENCY STOP SWITCH CLIP ENGINE STOP SWITCH EMERGENCY STOP SWITCH LANYARD Push the engine stop switch to stop the The emergency stop switch lanyard is Attach the emergency stop switch lan- engine.

  • Page 18: Oil Pressure Indicator Light

    3. CONTROLS (TILLER HANDLE TYPE) Oil Pressure Indicator Light Overheat Indicator Light SPARE EMERGENCY STOP SWITCH CLIP LIGHT OVERHEAT INDICATOR LIGHT OIL PRESSURE iNDICA+bR When the engine cooling system is A spare emergency stop switch clip is The green oil pressure indicator light faulty, the red overheat indicator light provided near the engine stop switch.

  • Page 19: Remote Control Lever

    3. CONTROLS (REMOTE CONTROL TYPE) Remote Control Lever (NEU:RAL) CONTROL LEVER THROTI REMOTE CONTROL LEVER The remote control lever controls gear selection and throttle opening posi- F (forward): R (reverse): tions. Moving the lever to the F position Moving the lever to the R position It is necessary to pull up the neutral (approximately 30”...

  • Page 20: Neutral Release Lever

    3. CONTROLS (REMOTE CONTROL TYPE) Neutral Release Lever Ignition Switch START run the engine after starting (the battery will discharge f the key is left in this position with the engine not running). To stop the engine (IGNITION OFF). To prevent the battery from dis- charging, keep the key in the OFF position when the engine is not run- The remote control box is equipped...

  • Page 21: Emergency Stop Switch Lanyard

    3. CONTROLS (REMOTE CONTROL TYPE) Emergency Stop Switch Lanyard SPAkE EMERGENCY STOP SWITCH CLIP The emergency stop switch lanyard is The emergency engine stop switch A spare emergency stop switch clip is provided to stop the engine immedi- should not he used to normally stop provided on the remote control box.

  • Page 22: Choke/Fast Idle Lever

    TYPE) 3. CONTROLS (REMOTE CONTROL Manual Choke Knob Lever Idle Choke/Fast (neutral) CHOKE XIMUM FAST IDLE OWEST POSITION IDLE LEVER CHOKE KNOB Lift and hold the choke/fast idle lever A manual choke knob is provided on The choke/fast idle lever provides two the right side of the motor which can up fully, this will provide a rich fuel functions:...

  • Page 23: Oil Pressure Indicator Light/Buzzer

    3. CONTROLS (REMOTE CONTROL TYPE) Oil Pressure Indicator Light/Buzzer Overheat Indicator Light/Buzzer The green oil pressure indicator light The red overheat indicator light turns turns OFF and the buzzer sounds ON and the buzzer sounds when the when the oil level is low and/or the engine cooling system is faulty.

  • Page 24: Power Trim/I-Ilt Type Power Triflilt Switch

    Honda Marine dealer. Power Tilt propeller ventilation and engine over- Press the power trim/tilt switch on the revving. Excessive trimltilt angle can remote control lever (remote control type) also damage the water pump.

  • Page 25: Power Tilt Switch (Motor Pan)

    3. CONTROLS (POWER TRIM/TILT TYPE) Trim Meter Power Tilt Switch (motor pan) XRTA type outboard Power Trim Do not trim this engine when you are using a large amount of throttle opening. If you do try to trim the engine (for example, wide open throttle), under certain conditions, propeller thrust may override the power trim hydraulics and...

  • Page 26: Tachometer

    Should this Refer to the tachometer when using the happen it will be necessary to consult power trim/tilt switch to achieve proper your authorized Honda Marine dealer boat and motor performance. and have the system refilled.

  • Page 27: Gas Assisted Tilt Type

    (GAS ASSISTED TILT TYPE) 3. CONTROLS (COMMON) Trim Tab Tilt Lever (GAS ASSISTED Tilt Lock Lever TIGHTENING PROPELLER Moving the tilt lever to the FREE When making a turn, if an unequal Use the tilt lock lever to hold the motor position allows the motor to be tilted and in the highest tilt position when the boat amount of effort is required to turn the...

  • Page 28: Anode Metal

    3. CONTROLS (COMMON) Anode Metal Distribute the load evenly in the boat and run the boat in straight course at full throttle. Slightly turn the steering wheel or tiller handle for both right and left turns to determine if an equal amount of effort is required.

  • Page 29: Cooling System Indicator

    3. CONTROLS (COMMON) Water Intakes Cooling System Indicator WATER INTAKES COOIiNG SYSTEM INDICATOR The engine cooling water is drawn into The cooling system is monitored here to the water pump through these water make sure cooling water is circulating intakes. through the engine.

  • Page 30: Transom Angle Adjusting Rod

    3. CONTROLS (COMMON) ‘hansom Angle Adjusting ANGLE TRANSOM ~0 CHANGE ADJUSTING ROD UNLOCKED POSM’ION lk LOCK LOCKED POSITION ADJUSTING ROD TRANSOM ANGLE som, lower the motor and operate the The transom angle adjusting rod is used to adjust the motor angle to boat at full speed.

  • Page 31: Fuel Cap/Gauge/Vent Knob

    3.CONTROLS (COMMON) Over-Rev Limiter Fuel Cap/Gauge/Vent Knob Before transporting or storing the fuel This outboard motor is equipped with VENT KNOB tank turn the vent knob fully clock- an engine over-rev limiter which limits wise to the closed position. the maximum engine rpm. This over- Anytime the fuel tank is in the boat with rev limiter protects the engine from the vent knob closed, disconnect the fuel...

  • Page 32: Pre-Operation Checks

    4. PRE-OPERATION CHECKS Engine Cover Removal/Installation (FRONT) (=AR) LATCHES To remove, release the front and rear engine cover latches and remove the engine cover. To install, position the engine cover over the engine and hook and lock the front and rear latches.

  • Page 33: Engine Oil

    4. PRE-OPERATION CHECKS NOTE:- This oil is usually identified Engine Oil by words such as: “Energy Conserving Engine oil is a major factor affecting II.” “Gas Saving, ” “Fuel Saving,” etc. UPPER engine performance and service life. LIMIT MARK NOTICE Running the engine with insufficient oil can cause serious engine damage.

  • Page 34: Fuel Level

    4. PRE-OPERATION CHECKS Fuel Level VENT KNOB SAFE FILL LEVEL b I c FUEi Check the fuel gauge and refill the Refilling FILL level mark if tank to the SAFE Remove the fuel tank from the boat extremely flammable, and gaso- necessary.

  • Page 35: Fuel Recommendations

    If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda Marine dealer. Running the engine with persistent spark knock or pinging can cause engine damage.

  • Page 36: Oxygenated Fuels

    4. PRE-OPERATION CHECKS Oxygenated Fuels METHANOL -(methyl or wood alcohol) 5% by volume Some conventional gasolines are being blended with alco- You may use gasoline containing up to hol or an ether compound. These gasolines are collec- 5% methanol by volume, as long as it tively referred to as oxygenated fuels.

  • Page 37: Propeller And Cotter Pin

    Never operate the outboard genuine Honda stainless steel cotter pin. Remove the clip of the motor with a damaged propeller. emergency stop switch to prevent...

  • Page 38: Steering Friction Adjustment (Common)

    4. PRE-OPERATION CHECKS Remote Contu-ol Friction Steering Friction Adjustment Adjustment (common) TO DECREASE TO INCREASE FRICTION Operate the remote control lever into Operate the steering wheel or tiller forward and reverse gears and check for handle right and left and check for the the amount of drag felt.

  • Page 39: Other Checks

    4. PRE-OPERATION CHECKS Other Checks 3 Tool kit The following materials should be kept with the boat: 1. Owner’s Manual. Tool Kit. 3. Spare engine oil, spark plugs, propeller, propeller cotter pins and FLAT SCREWDRIVER nut. PHILLIPS 4. Required information regarding SCREWDRIVER SCREWDRIVER HANDLE...

  • Page 40: Starting The Engine

    5. STARTING THE ENGINE Fuel Line Connection Fuel Tank and Vent Knob VENT KNOB FUEL HOSE CONNECTOR (FUEL TANK END)\ Inspect the fuel hose, and the O-ring 1. Open the fuel tank vent by tum- The fuel tank must be properly secured seals in the fuel hose connectors.
  • Page 41 5. STARTING THE ENGINE SE CONNECTOR OUTLET END OUTLET END PRIMER BULB PRIMER BULB (TANK) (TANK) 3. Hold the primer bulb so that the Zf the outboard endfuel hose 2. Connect the fuel hose connector outlet end is higher than the inlet to the outboard motor.

  • Page 42: Starting The Engine (Tiller Handle Type)

    5. STARTING THE ENGINE (TILLER HANDLE TYPE) ENGINE STOP SWITCH SPARE EMERGENCY STOP SWITCH CLIP LEVER GEAR SHIh A spare emergency stop switch clip is 2. Move the gearshift lever to the N NOTICE The water intakes must be (neutral) position. provided near the engine stop switch.
  • Page 43 5. STARTING THE ENGINE (TILLER HANDLE TYPE) THRO’ITL-E GRIP 3. Align the engine start symbol 4. When the engine is cold or ambient Do not press the start button ” cu ” on the throttle grip with the temperature is low pull the choke while the engine is running.
  • Page 44 Check the water intake screens and the cooling system indicator discharge port and if necessary remove any obstructions. If the problem continues, contact your closest authorized Honda Marine dealer. Running the outboard motor with an obstruc- tion in the cooling system can damage the water pump and overheat the engine.
  • Page 45 Stop the engine if the oil pressure indicator light does not tum ON. Check the engine oil level (see page 3 1). If the oil level is normal and the oil pressure indicator light does not turn ON, contact your closest author- ized Honda Marine dealer.

  • Page 46: Starting The Engine (Remote Control Type)

    5. STARTING THE ENGINE (REMOTE CONTROL TYPE) EMERGENCY (neutral) CONTRO LEVER A spare emergency stop switch clip is NOTICE 1 The water intakes must be If the operator does provided on the remote control box. lowered into the water. Running the not attach the emeigency stop switch lanyard, and is thrown...
  • Page 47 5. STARTING THE ENGINE (REMOTE CONTROL TYPE) XIMUM FAST CHOKJUFAST IDLE LEVER 3. When the engine is cold or the 4. Holding the choke/fast idle lever in Do not turn the ignition key position, turn the ignition key to the ambient temperature is low, lift the to the start position while the engine is START position and release the key...
  • Page 48 Check the water intake turn ON, contact your closest authorized Honda Marine screens and the cooling system indicator discharge port dealer.

  • Page 49: Emergency Starting

    5. STARTING THE ENGINE (EMERGENCY STARTING) Emergency Starting BOLTS (FRONT) WAR) WAS1 ENGINE COVER LATCHES If the electric starting system will not 2. Remove the four 6 x 25 mm bolts and the three washers then remove start the engine the engine can be the flywheel cover.
  • Page 50 5. STARTING THE ENGINE (EMERGENCY STARTING) ENGINE STOP SWITCH (neutral) SHD+ LEVER EMEkGENCY SPARE EMERGENG STOP SWITCH STOP SWITCH (TILLER HANDLE TYPE) (REMOTE CONTROL TYPE) CLIP 4. If your outboard motor is a tiller 3. Depending on what type of out- handle type, engage the emergency board motor you have, move the stop switch clip, located at one end...
  • Page 51 5. STARTING THE ENGINE (EMERGENCY STARTING) IGNITIqN KEY 4, \ -I?\. EMERGENCY __ . --_ .- STOP SWITCH CHO&EkNOB EMERGENCY (TILLER HANDLE TYPE) STOP SWITCH CLIP 6. If the engine is cold or the ambient 5. If your outboard motor is a remote spare emergency stop switch clip is control type, turn the ignition key to temperature is low, pull the manual...
  • Page 52 5. STARTING THE ENGINE (EMERGENCY STARTING) ENGINE STARTPYMBOL POINTER THROTTLE GRIP (TILLER HANDLE TYPE) (REMOTE CONTROL TYPE) (REMOTE CONTROL TYPE) It should only be necessary lo pull the 7. On the tiller handle type align the engine start symbol ” QI ” on the engine 1 or 2 times with the choke knob throttle grip with the pointer ”...
  • Page 53 Lock the engine cover latches. Attach the emergency stop switch lanyard securely to the operator and return to the closest boat landing. Contact your closest authorized Honda Marine dealer and have the out- board motor and the electrical sys- tem checked.

  • Page 54: Troubleshooting Starting Problems

    5. STARTING THE ENGINE Troubleshooting Starting Problems POSSIBLE CAUSE REMEDY SYMPTOM 1. Shift lever not in 1. Set shift lever in Starter motor neutral position. neutral position. doesn’t turn over. 2. Blown fuse. 2. Replace fuse. (refer to page 99) 3.

  • Page 55: Operation

    6. OPERATION Break-in Procedure Next 60 minutes: Run the outboard motor up to maxi- Break-in period 10 hours. mum of 4,000 to 5,000 rpm or 50% to 80% throttle opening. Short Break-in operation allows the moving bursts of full throttle are acceptable parts to wear-m evenly and thus but do not operate the motor continu- ensures proper performance and...

  • Page 56: Gear Shifting

    6. OPERATION (TILLER HANDLE TYPE) Gear Shifting N heutral) R (reverse) FAST POINTER INbICATOR 2. On the Gas assisted type, put the tilt Gearshift lever has 3 positions: The throttle mechanism is designed to position to prevent lever in the LOCK FORWARD, NEUTRAL, and limit the throttle grip travel when the outboard...

  • Page 57: Steering

    The tiller handle is moved in the oppo- DN portion of the power trim/tilt switch site direction in which you want the boat (optional part) and tilt the motor to the to turn. lowest position. A power trim/tilt foot switch is available from your authorized Honda dealer.
  • Page 58 6. OPERATION (TILLER HANDLE TYPE) (forward) CTION KNOB THROTTLE GRIP RELEASE To set the throttle at a steady speed, turn With the gearshift lever in the F (for- the throttle friction knob clockwise. To ward) position, turn the throttle grip release the throttle grip for manual speed toward the FAST mark to increase control, turn the friction knob...

  • Page 59: Gear Shifting

    6. OPERATION (REMOTE CONTROL TYPE) Gear Shifting (neutral) (neutral) (forward) 30” (reverse) 30” NEUTRAL RELEASE LEVER While pulling up the neutral release Moving the control lever further from The control lever will not move unless lever, move the control lever 30” 30’...

  • Page 60: Cruising

    6. OPERATION (REMOTE CONTROL TYPE) Cruising (neutral) POWER TRIMlI’ILT (fo:ward) SWITCH 2. Move the control lever from N 1. On the Power trim/tilt type, press the DN portion of the power (neutral) 30’ toward F (forward) to trim/tilt switch and tilt the motor to engage the F (forward) gear.

  • Page 61: Gas Assisted Tilt Type

    6. OPERATION (GAS ASSISTED TILT TYPE) Tilt Lever ENGINE COVER GRIP /ii~+ (neutral) GEARSHIFI- LEVER TILT LEVER SWITCH Tilt the motor up to prevent the pro- 2. To tilt the motor up, move the tilt peller and gear case from hitting the lever to the FREE position, then pull bottom when beaching or stopping in the engine cover grip and raise the...
  • Page 62 6. OPERATION (GAS ASSISTED TILT TYPE) 3. With the outboard motor tilted up to 4. To lower the motor back down, the desired position, move the tilt move the tilt lever to the FREE lever to the LOCK position to lock position, while holding the engine the motor.
  • Page 63 6. OPERATION (GAS ASSISTED TILT TYPE) 3. Move the tilt lever to the LOCK TILT LOCK ,\C-E LEVER position. ^ (lock position) 4. To lower the motor, move the tilt lever to the FREE position. Lift up on the engine cover grip and swing the tilt lock lever to the FREE position.

  • Page 64: Power Trim/I?Lt Type

    ‘pm and the ventilation plate authorized Honda Marine dealer. propeller ventilation and engine over- is level with the water. rewing. Excessive trimltilt angle can also damage the water pump and Press either the Up or DN portion of the overheat the engine.
  • Page 65 6. OPERATION (POWER TRIM/TILT TYPE) MOTOR TRIMMED MOTOR TRIMMED TOO HIGH TOO LOW MOTOR TRIMMED 60’ ;;\z; CORRECTLY T ANGLE ’ 2o” O” TRIM ANGLE Decrease the trim angle on high speed When cruising: turns to reduce the possibility of propel- (A) Into a high wind, trim the motor ler ventilation.

  • Page 66: Trim Meter

    6. OPERATION (POWER TRIM/TILT TYPE) Trim Meter The trim meter indicates the trim angle of the motor. Refer to the trim meter, and press the UP or DN portion of the power trim/tilt switch to adjust the motor trim angle to achieve boat performance and stability.

  • Page 67: Power Tilt Switch (Motor Pan)

    This power tilt switch should only be your closest authorized Honda Marine operated when the boat is stopped and dealer and have the system refilled. the motor is off.

  • Page 68: Tilt Lock Lever

    6. OPERATION (POWER TRIM/TILT TYPE) It may be necessary to lift the engine cover grip slightly to swing the tilt lock lever into the LOCK position. 3. To lower the motor, tilt the motor up slightly, move the tilt lock lever FREE to the position, and lower the...

  • Page 69: Trim Tab Adjustment

    6. OPERATION ‘Mm Tab Adjustment RIGHT TIGHTENING Make small adjustments at a time and The trim tab is provided to adjust for If less effort is required to make left “torque steer” which is a reaction of turns: retest. Incorrect trim tab adjustment the propeller rotation or propeller Loosen the trim tab tightening bolt can cause adverse steering.

  • Page 70: Engine Oil Pressure And Overheat Warning System

    6. OPERATION (MOTOR PROTECTI.ON SYSTEM) Engine Oil Pressure and Overheat Warning System If the engine oil pressure drops and/or I PREssuRE\\~ the engine overheats, either or both warning systems could be activated. When activated the engine speed will decrease gradually and the green oil pressure indicator light will turn OFF and the red overheat indicator light will turn ON.
  • Page 71 When the overheat warning system is If the throttle was closed suddenly after and contact your closest authorized activated: Honda Marine dealer. cruising at full throttle, the engine speed may drop below the specified idle speed. 1. Return the gearshift lever or control...

  • Page 72: Over-Rev Limiter

    6. OPERATION (MOTOR PROTECTION SYSTEM) Power Trim Warning System Over-Rev Limiter This outboard motor is equipped with an engine over-rev limiter which acti- vates when the engine speed increases excessively. The over-rev limiter can be activated while cruising, tilting up the motor, or when ventilation occurs during a sharp turn.

  • Page 73: Anodes

    6. OPERATION (MOTOR PROTECTION SYSTEM) Anodes ANODE(stern bracket) ’ When the power trim warning system The anodes are a sacrificial material is activated: which helps to protect the outboard 1. Immediately decrease the trim motor from corrosion. angle by pressing the DN portion of the power trim/tilt switch.

  • Page 74: Shallow Water Operation

    6. OPERATION an excessive amount of throttle is Shallow Water Operation used when operating in forward gear, NOTICE Excessive trim/tilt angle the motor will return to the transom during operation can cause the pro- angle adjusting rod. peller to raise out the water and cause (Gas assisted tilt type).

  • Page 75: High Altitude Operation

    For use at low return High altitude performance can be improved by specific modifi- altitudes, have an authorized Honda Marine dealer cations to the carburetors. If you always operate your outboard carburetors to original factory specifications.

  • Page 76: Stopping The Engine Tiller Handle Type

    7. STOPPING THE ENGINE (TILLEJR HANDLE TYPE) Emergency Engine Stop Normal Engine Stop ENGINE STOP SWITCH EMERGENCY STOP SWITCH LANYARD THROTTLE GRIP - LSWITCH CLIP Disengage the emergency stop switch Turn the throttle grip to SLOW clip from the engine stop switch by position and move the gearshift lev- pulling the emergency stop switch lan- er to N(neutral).
  • Page 77 7. STOPPING THE ENGINE (TILLER HANDLE TYPE) 2. Push the engine stop switch until the engine stops.

  • Page 78: Remote Control Type

    7. STOPPING THE ENGINE (REMOTE CONTROL TYPE) Emergency Engine Stop Normal Engine Stop EMERGENCY N (neutral) ;TOP SWITCH EMERGENCY STOP SWITCH LANYARD IGNITION EMERGENCY STOP SWITCH CLIP Disengage the emergency stop switch 1. Move the control lever to the N When the boat is not in use, remove clip from the emergency engine stop...

  • Page 79: Transporting

    8. TRANSPORTING If there is insufficient road clearance Trailering Horizontal Transport with the motor in the normal run po- STEERING FRICTION sition, then trailer the motor in the tilted position using a commercially available motor support bar (refer to your motor support bar manufacturer’s instructions) or remove the motor from the boat.

  • Page 80: Cleaning And Flushing

    9. CLEANING AND FLUSHING 5. Move the gearshift lever or control lever to the N (neutral) position. FLUSH KIT COUPLER Flush the outboard motor in the neutral position only. 6. Turn on the fresh water supply to the flush kit coupler. Running the outboard motor without sufJicient cooling water will damage the water pump and overheat...
  • Page 81 9. CLEANING AND FLUSHING 8. Allow the engine to run at idle for at least 5 minutes to clean the inside of the motor. 9. Stop the motor and remove the flush kit coupler. 10. Remove the sealing washer from the flush kit coupler and install the CdOLINi;...

  • Page 82: 10. Maintenance

    Some of the most important safety are best handled by professionals and are precautions follow. However, we cannot normally performed by a Honda techni- Good maintenance is essential for safe, warn you of every conceivable hazard cian or other qualified mechanic.

  • Page 83: Emission Control System Information

    Let the engine cool before touch- reliability, use only new, genuine and other systems to reduce the emis- ing. Honda parts or their equivalents for sions of oxides of nitrogen and hydro- repair and replacement. carbons. - Injury from moving parts.
  • Page 84 Rough idle. The following instructions and proce- dures must be followed in order to keep Misfiring or backfiing under load. the emissions from your Honda engine within the emission standards. Afterburning (backfiring). Tampering and Altering Black exhaust smoke or high fuel consumption.
  • Page 85 Replacement Parts Maintenance The emission control systems on your Follow the maintenance schedule on Honda engine were designed, built, and page 87. Remember that this schedule is certified to conform with EPA and based on the assumption that your California emission regulations. We...

  • Page 86: Star Label

    10. MAINTENANCE The Star Label means Cleaner Marine Engines STAR LABEL A Star label was applied to this outboard This engine has been certified as a: I motor in accordance with the require- ments of the California Air Resources Board. The Symbol for Cleaner Marine Engines: Cleaner Air and Water - for a healthier lifestyle and environment.
  • Page 87 10. MAINTENANCE Two Stars One Star Three Stars Very Low Emission Low Emission Ultra Low Emission The two-star label identifies engines that The one-star label identifies engines that The three-star label identifies engines meet the Air Resources Board’s 2004 meet the Air Resources Board’s 2001 that meet the Air Resources Board’s exhaust emission standards.

  • Page 88: Tool Kit And Spare Parts

    10. MAINTENANCE Tool Kit and Spare Parts TOOL The following tools and spare parts are supplied with the outboard motor for maintenance, adjustment, and emergency repairs. 10 x 12 mm WRENCH 8 mm WRENCH FLAT SCREWDRIVER PLIERS PHILLIPS SCREWDRIVER SCREWDRIVER HANDLE TOOL BAG OIL CHECK SCREWDRIVER 18 x 19 mm...

  • Page 89: Maintenance Schedule

    10. MAINTENANCE MAINTENANCE SCHEDULE Use only genuine HONDA parts or their equivalent for maintenance or repair. Replacement parts which are not of equivalent quality may damage the motor.
  • Page 90 0 Emission-related items NOTE: 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 Honda Shop Manual for service procedures.

  • Page 91: Engine Oil

    10. MAINTENANCE OIL CAPACITY: Engine Oil 2.1 US qt (2.0 e, 1.8 Imp qt) Engine oil is a major factor affecting . . .When oil filter is not replaced engine performance and service life. Oil check interval: 2.5 US qt (2.4 k?, 2.1 Imp qt) .
  • Page 92 10. MAINTENANCE SEALING WASHER DRAIN PLUG 4. Remove the engine oil drain bolt 3. Place the drain plug cover as shown 2. Loosen the drain plug cover screw and washer using a 12 mm wrench to use it as an oil drain guide. Place a using a flat blade screwdriver and and drain the engine oil.

  • Page 93: Gear Oil

    10. MAINTENANCE 8. Reinstall the oil filler cap. Gear Oil Oil check interval: Always wash your hands after handling Every 100 hours or 6 months. used oil. Also, please dispose of used motor oil in Oil change interval: a manner that is compatible with the After the first 20 hours or 1 month, environment.
  • Page 94 3. Use new sealing washers and rein- the water will flow out first when the stall the level plug and drain plug drain plug is removed, or the oil will securely. be milky colored. If the oil appears abnormal contact your closest authorized Honda Marine dealer.

  • Page 95: Spark Plugs

    10. MAINTENANCE Spark Plugs To ensure proper engine operation, the '0.024-0.028 in spark plugs must be properly gapped (0.6-0.7 mm) and free of deposits. Check-Adjust interval: Every 100 hours or 6 months. Replace interval: Every 200 hours or 1 year. (Refer to the maintenance schedule page 87.) 6.

  • Page 96: Battery (Not Included)

    10. MAINTENANCE Battery (not included) NOTICE Tha spark plugs must he Minimum requirements securely tightened. A loose spark 12V-70AH marine cranking battery. plug can become very hot and may cause engine &nage. To protect the battery from mechani- Overtightening the spark plugs can cal damage and to prevent the bat- damage the threads.

  • Page 97: Lubrication

    10. MAINTENANCE 1. Install the battery in the battery box. Lubrication 2. Connect the positive (+) battery Lubrication interval: After the first 20 hours or 1 month, then every 100 hours or cable fist, then connect the nega- 6 months. (Refer to the maintenance schedule page 87.) tive (-) battery cable.

  • Page 98: Engine Fuel Filter

    10. MAINTENANCE Engine Fuel Filter CONNECTOR Gasoline FUEL HOSE flammable, and gaso- extremely line vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area. KEEP OUT OF REACH OF CHILDREN. Always work in a well-ventilated area.
  • Page 99 10. MAINTENANCE FUEL HOSES RETAINER ARROW (Fuel Flow Direction) FUEL FILTF!R 2. Install the new fuel filter so the Change 3. Pull the spring retainer toward you, arrow on the fuel filter points and raise the fuel filter. 1. Remove the fuel filter. toward the fuel pump.

  • Page 100: Fuel Tank And Filter

    10. MAINTENANCE 4. Securely connect the fuel hose Fuel Tank and Filter Fuel Tank Cleaning connector to the outboard motor 1. Disconnect the fuel hose from the (refer to page 38). fuel tank. 5. Prime the engine using the primer Gasoline is 39).

  • Page 101: Fuse Replacement

    10. MAINTENANCE Fuse Replacement FUSE COVER FUEL TANK HOSE CONNECTOR - FUEL TANK FILTER BLOWN FUSE If the fuse is blown, running the engine Replacement Fuel Tank Filter 1. Stop the engine. will not charge the battery and the Cleaning/Replacement 2.

  • Page 102: Propeller

    The propeller is thin and sharp. in the nut. To protect your hands, wear the heavy gloves during Use a new genuine Honda cotter pin and replacement. bend the cotter pin ends as shown.

  • Page 103: Submerged Motor

    A submerged motor must be serviced immediately after it is recovered from the water in order to minimize corrosion, Immediately take the outboard motor to the closest authorized Honda Marine dealer or if you are far from a dealership, proceed as follows: EMERGENCY STARTER ROPE 1.
  • Page 104 9. Take the outboard motor to your 8. Engage the emergency stop switch clip with the emergency closest authorized Honda Marine dealer for inspection and service stop switch and attempt to start the engine (be sure the water as soon as possible.
  • Page 105 11. STORAGENVINTERIZATION For longer service life of the outboard motor, have your outboard motor ser- viced by an authorized Honda Marine dealer before storage. If you are unable to take the motor to your dealer, proceed as follows: Draining the Carburetors Be careful not to spill gasoline.

  • Page 106: 1. Storage/Winterization

    11. STORAGE/WINTERIZATION Fuel Tank Outboard Motor Position VENT KNOB FUEL CAP Horizontal transport or storage: I. Close the fuel cap vent knob. Transport and store the motor either Rest the motor on the case protectors. vertically or horizontally, as shown 2.

  • Page 107: 12. Troubleshooting

    12. TROUBLESHOOTING (1) Engine does not start. Fuel Contamination - Spark plug No sparks - There is no gasoline Fuel is not fed is faulty. Incorrect gap across spark in fuel tank. to carburetor. Broken spark plug Vent knob is not open or plug gap vent clogged.
  • Page 108 12. TROUBLESHOOTING (2) Engine starts but immediately stops. Engine some times stops while cruising. Engine overheats Fuel Normal sparking Water intake screens No gasoline in fuel tank. are clogged. There is gasoline - Water is mixed with in fuel tank. gasoline.

  • Page 109: 13. Specifications

    13. SPECIFICATIONS 1 MODEL Starter system Electric starter C.D.1 Ignition system Trochoid pump pressure lubrication Lubrication system Specified oil Engine: API standard (Fuel Efficient SG, SI-I) SAE (725 mm) (685 mm) (725 mm) (685 mm) 5w-30 Gear case: API standard (GL-4/5) Overall height SAE 90 outboard motor gear oil Engine: 2.5 US qt (2.4 1,2.1 Imp qt)
  • Page 110 13. SPECIFICATIONS Electric starter MODEL BFSOA tarter system C.D.1 I Ignition system Descrintion Code BAZS Trochoid pump pressure lubrication Lubrication system Specified oil Engine: API standard 28.6 in 27.0 in Overall length 27.0 in (Fuel Efficient SG, SH) SAE (685 mm) (725 mm) (685 mm) 5W-30...
  • Page 111 13. SPECIFICATIONS BF40A&BF50A Tuneup Spark plug gap 0.024 - 0.028 in (0.6 - 0.7 mm) See page 93. Idle speed 950 f 50 rpm See shop manual. Valve clearance (cold) Intake: 0.15 f 0.02 mm See shop manual. Exhaust: 0.23 f 0.02 mm No other adjustments needed.

  • Page 112: Warranty Service

    Date of purchase If you are dissatisfied with the decision made by the dealership’s management, Your name, address, and telephone contact the Honda Marine Customer number Relations Office. You can write: A detailed description of the problem American Honda Motor Co., Inc.

  • Page 113: Wiring Diagram

    15. WIRING DIAGRAM TILLER HANDLE TYPE I f4sNllll...
  • Page 114 15. WIRING DIAGRAM REMOTE CONTROL TYPE...
  • Page 115 15. WIRING DIAGRAM REMOTE CONTROL, POWER TRIM/TILT TYPE r-------- ------ XRTA type outboard...

  • Page 116: 16. Index

    16. INDEX Over-Rev Limiter ................29 Anode Metal ..................26 Start Button ................... 13 CHECK ............37 PRE-OPERATION Stop Switch ................... MOTOR PROTECTION SYSTEM ..........7 I Fuel Battery (not included) ................94 Cap/Gauge/Vent/Knob ..............29 Break-in Procedure ................5 3 Level .....................

  • Page 117: Tilting Motor Gas Assisted Tilt Type

    16. INDEX steering ....................55 Neutral Release Lever ................. 18 Friction Adjustment (common) ............ .36 Oil Pressure Indicator Light ..............16 Oil Pressure Indicator Light/Buzzer ........... .2l Stem bracket CHECK ............37 PRE-OPERATION Other Checks ..................37 STOPPING THE ENGINE OUTBOARD MOTOR SAFETY REMOTE CONTROL TYPE ............
  • Page 118 16. INDEX Trim Tab Adjustment ................67 TROUBLESHOOTING ..............105 Starting Problems ................52 SERVICE ..............1 IO WARRANTY Water Intakes ................................1 11 WIRING DIAGRAM...
  • Page 120 30.2002.06 31ZW4604 PRINTED IN U.S.A 00X31-ZW4-6040...

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