Honda BF200D Manual Download

Page: 127 / 152

127

MAINTENANCE

<Replacement>

1. Remove the engine cover (see page

57).

2. Disconnect the 2-pin coupler (blue).

3. Remove the suspension strap from

the fuel filter with water separator

bracket, then remove the

suspension strap from the fuel filter

with water separator.

4. Bind the two fuel tubes with the

tube clips to prevent the fuel

leakage, disconnect the fuel tubes.

5. Remove the three screws holding the fuel

filter with water separator, delete the water

or deposit from the inside of the cup.

6. Thoroughly clean the cup, and

replace with a new fuel filter.

7. Reassemble the water separator in the

reverse order of removal. Use a new O-ring.

TIGHTENING TORQUE:

3.4 N·m (0.34 kgf·m, 2.5 lbs·ft)

WATER SEPARATOR CUP

SCREWS

O-RING (Replace)

2 PIN COUPLER

(BLUE)

FUEL HOSES

WATER

SEPARATOR

BRACKET

SUSPENSION

STRAP

WATER

SEPARATOR

HOSE CLIPS

42ZVL600.book 127 ページ２０１８年７月１９日　木曜日　午前９時６分

Summary of Contents for BF200D

Page 1: ...hat equipment or property damage could result if instructions are not followed Gives helpful information If a problem should arise or if you have any questions about the Outboard Motor consult an authorized Honda Outboard Motor dealer Honda Motor Co Ltd 2018 All Rights Reserved DANGER Indicates serious injury or death WILL result if instructions are not followed WARNING Indicates a strong possibil...

Page 2: ...nsom Height 635 mm 25 0 in 762 mm 30 0 in Standard Rotating Propeller Shaft Counterrotating Propeller Shaft Mechanical wire Drive by Wire DBW TYPE CODE Example X C V Destination T Thailand V Indonesia Rotating direction of propeller shaft C Counterrotating propeller shaft is equipped None Standard rotating propeller shaft is equipped Transom Height X 635 mm 25 0 in U 762 mm 30 0 in R Remote Contro...

Page 3: ...ollowing three categories according to the control box position Check the type of your outboard motor and read this Owner s Manual thoroughly before operation Texts with no type indication are the information and or procedures common to all types WITHOUT GROOVE WITH GROOVE GROOVE Flush mount type DBW type D1 type Top mount type DBW type D2 type Side mount type R1 type Flush mount type Mechanical w...

Page 4: ...and when making technical or warranty inquiries The frame serial number is stamped on a plate attached on the left side of the stern bracket Frame serial number The engine serial number is stamped on the upper right side of the engine Engine serial number FRAME SERIAL NUMBER ENGINE SERIAL NUMBER 42ZVL600 book 4 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 5: ...ncy Stop Switch 39 Emergency Stop Switch Lanyard Clip 39 Spare Emergency Stop Switch Clip optional equipment 40 Tilt Lock Lever 41 Trim Tab 41 Anode 41 Cooling Water Check Hole 42 Cooling Water Intake Port 42 Engine Cover Latches 42 Tachometer optional equipment 43 NMEA Interface Coupler 43 Operating Hour Notification System 43 5 INSTALLATION 46 Transom Height 46 Location 47 Installation Height 47...

Page 6: ...ergency Engine Stop 107 Normal Engine Stop D1 D2 type 107 Normal Engine Stop D1 D2 without START STOP Switch type R1 R2 R3 type 109 10 TRANSPORTING 111 Fuel Line Disconnection 111 Transporting 111 Trailering 112 11 CLEANING AND FLUSHING 113 12 MAINTENANCE 114 Tool Kit and Spare Parts Tool Kit does not come with Counter Rotation Types 115 MAINTENANCE SCHEDULE 116 Engine Oil 118 Spark Plugs 120 Opti...

Page 7: ...rstand the use of all controls Do not exceed the boat manufacturer s power recommendation and be sure that the outboard motor is properly mounted Never permit anyone to operate the outboard motor without proper instruction Stop the engine immediately if anyone falls overboard Do not run the engine while the boat is near anyone in the water Attach the emergency stop switch lanyard securely to the o...

Page 8: ...system become very hot during operation and remain hot for a while after stopping Contact with hot engine components can cause burns and may ignite some materials Avoid touching a hot engine or exhaust system Allow the engine to cool before performing maintenance or transporting Carbon Monoxide Poisoning Hazard Exhaust contains poisonous carbon monoxide a colorless and odorless gas Breathing exhau...

Page 9: ...injury The label is considered permanent part of your outboard motor Read the label and safety notes and precautions described in this manual carefully If the label comes off or becomes hard to read contact your Honda outboard motor dealer for a replacement READ OWNER S MANUAL GEAR SHIFTING 42ZVL600 book 9 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 10: ...E ANODE PROPELLER ANTICAVITATION PLATE ANODE IDLE PORT FLUSH PLUG CONNECTOR COOLING WATER CHECK HOLE TRIM TAB ENGINE COVER LATCH each side ENGINE OIL DRAIN BOLT EXHAUST PORT WATER OUTLET PORT FRAME SERIAL NUMBER ANODE COOLING WATER INTAKE PORT each side POWER TILT SWITCH TILT LOCK LEVER 42ZVL600 book 10 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 11: ...11 COMPONENT IDENTIFICATION SPARK PLUGS under coil OIL LEVEL DIPSTICK FUEL FILTER with WATER SEPARATOR R1 R2 R3 type THROTTLE ARM SHIFT ARM SHAFT 42ZVL600 book 11 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 12: ...12 COMPONENT IDENTIFICATION JUNCTION BOX FUSES INTERFACE COUPLER SPARK PLUGS under coil R1 R2 R3 type THROTTLE REEL OIL FILLER CAP 42ZVL600 book 12 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 13: ...OUTBOARD MOTOR TYPE FLUSH MOUNT TYPE D1 type REMOTE CONTROL LEVER NEUTRALRELEASE LEVER POWER TRIM TILT SWITCH REMOTE CONTROL LEVER POWER TRIM TILT SWITCH FUNCTION SWITCHES DUAL OUTBOARD MOTOR TYPE REMOTE CONTROL LEVER POWER TRIM TILT SWITCH FUNCTION SWITCHES 42ZVL600 book 13 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 14: ...rizontal type Honda Smart Key type Horizontal type EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD EMERGENCY STOP SWITCH ENGINE SWITCH START STOP SWITCH START STOP SWITCH ALL ENGINE START FOR MULTIPLE OUTBOARD MOTORS SINGLE TYPE OUTBOARD MOTOR START STOP SWITCH START STOP SWITCH DUAL TYPE OUTBOARD MOTOR TRIPLE TYPE OUTBOARD MOTOR BUZZER Normal Key without START STOP switch type Horizontal...

Page 15: ...7 㻰㻺㼁㻼㻰㻺㼁㻼㻰㻺㼁㻼 3257 67 17 5 EMERGENCY STOP STOP POWER TRIM TILT SWITCH FUNCTION SWITCHES DUAL TYPE EMERGENCY STOP SWITCH PANEL optional equipment TRIPLE TYPE EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD DISPLAY ASSY optional equipment POWER TRIM TILT SWITCH for FLUSH MOUNT type 42ZVL600 book 15 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 16: ...SWITCH BUZZER inside CONTROL LEVER FRICTION ADJUSTER EMERGENCY STOP SWITCH LANYARD EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH ENGINE SWITCH FAST IDLE LEVER INDICATORS Oil pressure Overheat ACG PGM FI NEUTRAL RELEASE LEVER REMOTE CONTROL LEVER POWER TRIM TILT SWITCH FAST IDLE BUTTON NEUTRAL RELEASE LEVER 42ZVL600 book 16 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 17: ...ON SWITCH PANEL optional equipment FLUSH MOUNT TOP MOUNT INDICATORS Oil pressure Overheat ACG PGM FI BUZZER ENGINE SWITCH EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD REMOTE CONTROL LEVERS POWER TRIM TILT SWITCH RIGHT POWER TRIM TILT SWITCH LEFT FAST IDLE BUTTON for TOP MOUNT DUAL type 42ZVL600 book 17 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 18: ...nt FLUSH MOUNT TOP MOUNT SINGLE ENGINE SWITCH KEY BUZZER ENGINE SWITCH EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD for DUAL OUTBOARD MOTORS type for TRIPLE OUTBOARD MOTORS type For the switch panel without indicators type use it along with the NMEA2000 compatible device 42ZVL600 book 18 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 19: ...will increase the throttle opening and the boat forward speed NEUTRAL Engine power is cut off from the propeller REVERSE Moving the lever to the REVERSE position i e approximately 20 from the NEUTRAL position engages the gear into reverse Moving the lever further from the REVERSE position will increase the throttle opening and the boat reverse speed Remote Control Lever D1 type REMOTE CONTROL LEVE...

Page 20: ...NEUTRAL Engine power is cut off from the propeller REVERSE Moving the lever to the REVERSE position i e approximately 20 from the NEUTRAL position engages the gear into reverse Moving the lever further from the REVERSE position will increase the throttle opening and the boat reverse speed Remote Control Lever D2 type SINGLE TYPE REMOTE CONTROL LEVER FORWARD NEUTRAL REVERSE REMOTE CONTROL LEVERS DU...

Page 21: ...r from the FORWARD position will increase the throttle opening and the boat forward speed NEUTRAL Engine power is cut off from the propeller REVERSE Moving the lever to the REVERSE position i e approximately 32 from the NEUTRAL position engages the gear into reverse Moving the lever further from the REVERSE position will increase the throttle opening and the boat reverse speed REMOTE CONTROL LEVER...

Page 22: ...ill increase the throttle opening and the boat forward speed NEUTRAL Engine power is cut off from the propeller REVERSE Moving the lever to the REVERSE position i e approximately 35 from the NEUTRAL position engages the gear into reverse Moving the lever further from the REVERSE position will increase the throttle opening and the boat reverse speed Remote Control Lever R2 type REMOTE CONTROL LEVER...

Page 23: ...L Engine power is cut off from the propeller REVERSE Moving the lever to the REVERSE position i e approximately 35 from the NEUTRAL position engages the gear into reverse Moving the lever further from the REVERSE position will increase the throttle opening and the boat reverse speed Remote Control Lever R3 type SINGLE TYPE REMOTE CONTROL LEVER FORWARD NEUTRAL REVERSE REMOTE CONTROL LEVERS DUAL TYP...

Page 24: ...pe theengineswitch locates at the center of the switch panel Key positions START to start the engine ON to run the engine after starting OFF tostoptheengine IGNITIONOFF Do not leave the engine switch ON key in ON position when the engine is not running as the battery will discharge The starter motor will not work unless the remote control lever is in the NEUTRAL position and the clip is in the eme...

Page 25: ...o not leave the power switch ON when the engine is not running as the battery will discharge For Honda Smart Key type the power will not be turned ON unless the Honda Smart Key is authenticated The power will not be turned OFF if the engine is running Honda Smart Key Use the Honda Smart Key to authenticate to your remote control box The Honda Smart Key has an immobilizer system The immobilizer sys...

Page 26: ...or of the corresponding switch comes on The starter motor will not work unless the remote control lever is in the NEUTRAL position and the clip is in the emergency stop switch START STOP SWITCH START STOP SWITCH INDICATOR ALL ENGINE START FOR MULTIPLE OUTBOARD MOTORS SINGLE TYPE OUTBOARD MOTOR START STOP SWITCH DUAL TYPE OUTBOARD MOTORS TRIPLE TYPE OUTBOARD MOTORS START STOP SWITCH INDICATOR 67 57...

Page 27: ...control lever to adjust the engine speed without gearshift when warming up the engine Keeping the switch pressed when the remote control lever is in the NEUTRAL position turn the lever forward Keep turning the lever forward The throttle opens and the engine speed increases after the lever passed the shift point Note that the gearshift mechanism does not function when the switch is pushed once and ...

Page 28: ...d for operations in the fast idle mode trolling mode one lever mode and station select mode Fast Idle Mode The fast idle mode is only needed for starting carbureted outboard models The BF200D BF225D and BF250D models use programmed fuel injection so this mode will not be needed for starting After the engine starts and if the outside temperature is below 5 C 41 F the fast idle mode can be used to a...

Page 29: ... mode If you press and hold the switch while cruising with the throttle closed the mode changes to trolling mode One Lever Mode For multiple outboard motors type Shifting gear and the engine speed adjustment of the all outboard motors can be performed with one remote control lever when in one lever mode If you press and hold the switch when all remote control lever is in the NEUTRAL position the m...

Page 30: ...ver will not move unless the fast idle lever is in the lowest position Lower the fast idle lever to the lowest position to decrease the fast idle Fast Idle Button R2 type Pushing the fast idle button turn the remote control lever forward Keep turning the lever forward The throttle opens and the engine speed increases after the lever passed the shift point Note that the gearshift mechanism does not...

Page 31: ...e shift point Note that the gearshift mechanism does not function when the fast idle button is pushed once and then released after the remote control lever is moved The PGM FI indicator turns on and the buzzer sounds when the engine control system is faulty Fast Idle Button R3 type NEUTRAL FORWARD REVERSE REMOTE CONTROL LEVER FAST IDLE BUTTON Push PGM FI Indicator Buzzer R1 type RED RED BUZZER PGM...

Page 32: ...tem is faulty ACG Indicator Buzzer R1 type RED RED ACG INDICATOR BUZZER R2 R3 type ACG INDICATOR BUZZER Display assy ACG INDICATOR RED Oil Pressure Indicator Buzzer R1 type GREEN OIL PRESSURE INDICATOR R2 R3 type BUZZER OILPRESSURE INDICATOR GREEN BUZZER 42ZVL600 book 32 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 33: ...down gradually this time The overheat indicator turns on and the buzzer sounds when the engine cooling circuit is faulty The engine speed slows down this time Display assy OIL PRESSURE INDICATOR RED Overheat Indicator Buzzer R1 type RED RED OVERHEAT INDICATOR R2 R3 type OVERHEAT INDICATOR BUZZER BUZZER Display assy OVERHEAT INDICATOR RED 42ZVL600 book 33 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 34: ...34 CONTROLS AND FEATURES Water Separator Buzzer The water separator buzzer sounds when water has accumulated in the water separator 42ZVL600 book 34 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 35: ...ility and maintain optimum fuel consumption The outboard motor trim angle of 4 to 16 is the angle when the outboard motor is installed on the boat at 12 Excessive trim tilt angle during operation can cause the propeller to raise out of the water and cause propeller ventilation and engine over revving Excessive trim tilt angle can also damage the water pump R1 type REMOTECONTROL LEVER POWER TRIM TI...

Page 36: ...e of each outboard motor is adjusted by using each power trim tilt switch on the panel D1 type REMOTE CONTROL LEVER POWER TRIM TILT SWITCH D2 type SINGLE TYPE REMOTE CONTROL LEVER POWER TRIM TILT SWITCH DUAL TYPE POWER TRIM TILT SWITCH REMOTE CONTROL LEVERS DUAL TYPE TRIPLE TYPE POWER TRIM TILT SWITCH PTT SWITCH PANEL 㻰㻺㼁㻼㻰㻺㼁㻼 3257 67 㻰㻺㼁㻼㻰㻺㼁㻼㻰㻺㼁㻼 3257 67 17 5 42ZVL600 book 36 ページ２０１８年７月１...

Page 37: ...of the outboard motor Refer to the trim meter when using the power trim tilt switch to achieve proper boat performance The outboard motor trim angle of 4 to 16 is the angle when the outboard motor is installed on the boat at 12 Power Tilt Switch outboard motor pan The power tilt switch located on the outboard motor pan is a convenience switch for tilting the outboard motor for trailering or perfor...

Page 38: ...he manual relief valve under the left stern bracket no more than 1 or 2 turns counterclockwise using a screwdriver After tilting the outboard motor turn the manual relief valve clockwise securely The manual relief valve must be tightened securely before operating the outboard motor or the outboard motor could tilt up when operating in reverse MANUAL RELIEF VALVE POWER To hold MANUAL To release 42Z...

Page 39: ...he emergency stop switch clip must be engaged with the emergency stop switch or the engine will not start When the emergency stop switch clip becomes disengaged with the emergency stop switch the engine will stop immediately EMERGENCY STOP SWITCH STOP D1 D2 type R1 type STOP STOP EMERGENCY STOP SWITCH R2 R3 type EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH LANYARD EMERGENCY STOP SWITCH CLIP 42ZVL60...

Page 40: ...ur outboard motor dealer A spare emergency stop switch clip can be stored in the tool bag see page 115 WARNING If the emergency stop switch lanyard is not set the boat might run out of control when the operator for example falls overboard and is not able to operate the outboard motor EMERGENCY STOP SWITCH CLIP STOP D1 D2 type EMERGENCY STOP SWITCH EMERGENCYSTOP SWITCH LANYARD R1 type STOP STOP EME...

Page 41: ...ide while running at full speed adjust the trim tab so that the boat runs straight ahead Loosen the tightening bolt and turn the trim tab right or left to adjust Anode The anode is a sacrificial material which helps to protect the outboard motor from corrosion Do not paint the anode It deteriorates the function of the anode which can lead to rust and corrosion damage to the outboard motor TILT LOC...

Page 42: ...ck hole whether the cooling water is circulating through the engine Cooling Water Intake Port The engine cooling water is drawn into the engine through this port Engine Cover Latches Pull the engine cover latches to remove the engine cover COOLING WATER CHECK HOLE COOLING WATER INTAKE PORT each side Front ENGINE COVER LATCH Side ENGINE COVER LATCH each side 42ZVL600 book 42 ページ２０１８年７月１９日木曜日午前９時...

Page 43: ...ounts the number of operating hours since the last periodic maintenance When the next periodic maintenance is due the engine notifies the NMEA2000 network and a maintenance indication is displayed on an NMEA2000 compatible device After periodic maintenance is performed reset the hour counter by DBW type 1 Stopping the engine 2 Turning the ignition switch or power switch ON 3 Setting the gearshift ...

Page 44: ...f months since the last maintenance before the alert based on engine operating hours displays see Maintenance Schedule on page 116 Reset the hour counter whenever maintenance is performed whether based on the time interval or the number of operating hours Operating hour notification timing Display Steps 1 2 3 4 Outboard motor Engine switch ON Start engine Gear at F or R Display Switch ON Maintenan...

Page 45: ... the type of display When Periodic Maintenance is indicated 1 Have the periodic maintenance performed without delay after returning to port 2 Reset the hour counter If not reset the maintenance indication will remain in the display and the hour count until the next maintenance will be in error When the periodic maintenance is conducted before Periodic Maintenance is indicated reset the hour counte...

Page 46: ...onal Parts equipments installation and operation Applicable Boat Select the boat suitable for the engine power Engine power BF200D 147 1 kW 200 PS BF225D 165 5 kW 225 PS BF250D 183 9 kW 250 PS Power recommendation is indicated on most of the boats Transom Height Select the outboard motor which is correct for the boat transom height of your boat WARNING Do not exceed the boat manufacturer s power r...

Page 47: ... boats Follow the manufacture s recommended installation height The water level must be at least 100 mm 4 in above the anticavitation plate otherwise the water pump may not receive sufficient cooling water and the engine will overheat Adverse effect to the engine can occur if the installation position of the outboard motor is too low Trim tilt down the outboard motor with the boat fully loaded and...

Page 48: ...erial of the boat Consult with an authorized Honda outboard motor dealer Before installing the outboard motor on the boat hang the outboard motor with thehoistorequivalentdevisebyattaching the three lifting eyes to the outboard Use the hoist which allowable load is 300 kg 661 lbs or above BOLT 6 NUT 12 STERN BRACKET WASHER 6 WASHER 12 CAUTION Install the outboard motor securely Loosely mounted out...

Page 49: ...ing to the combination of the boat outboard motor and propeller and the operating conditions Adjust the outboard motor so that it is perpendicular to the water surface i e axis of the propeller is parallel with the water surface Outboard Motor Angle Inspection Cruising INCORRECT CAUSES BOAT TO SQUAT INCORRECT CAUSES BOAT TO PLOW INCORRECT CAUSES BOAT TO PLOW CORRECT GIVES MAXIMUM PERFORMANCE 42ZVL...

Page 50: ...near the fuel tank WARNING Batteries produce explosive gases If ignited an explosion can cause serious injury or blindness Provide adequate ventilation when charging CHEMICAL HAZARD Battery electrolyte contains sulfuric acid Contact with eyes or skin even through clothing may cause severe burns Wear a faceshield and protective clothing Keep flames and sparks away and do not smoke in the area ANTID...

Page 51: ...isconnecting the cables disconnect the side first then the side Unless the cables are properly connected to the terminals the starter motor may fail to operate normally Be careful to avoid connecting the battery in reverse polarity as this will damage the battery charging system in the outboard motor Do not disconnect the battery cables while the engine is running Disconnecting the cables while th...

Page 52: ... voltage reaching the engine Remote Control Installation optional equipment Improperly installed steering system remote control box and remote control cable or installing those of the different types could cause unpredictable accident Consult an authorized Honda outboard motor dealer for proper installation The control box is available in types as shown Select the most suitable control box for you...

Page 53: ...X FOR DUAL OUTBOARD MOTOR TYPE NORMAL KEY WITH START STOP SWITCH TYPE NORMAL KEY WITHOUT START STOP SWITCH TYPE ALL ENGINE START FOR MULTIPLE OUTBOARD MOTORS DUAL TYPE OUTBOARD MOTOR TRIPLE TYPE OUTBOARD MOTOR 67 57 6723 67 57 6723 3257 67 57 6723 17 5 67 57 6723 67 67 57 6723 3257 67 57 6723 67 HONDA SMART KEY TYPE SINGLE TYPE OUTBOARD MOTOR 67 57 6723 42ZVL600 book 53 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 54: ...E CONTROL BOX FOR SINGLE OUTBOARD MOTOR TYPE AND SWITCH PANEL FLUSH MOUNT TYPE CONTROL BOX AND SWITCH PANEL TOP MOUNT TYPE CONTROL BOX AND SWITCH PANEL FOR DUAL OUTBOARD MOTOR TYPE SIDE MOUNT TYPE CONTROL BOX 42ZVL600 book 54 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 55: ...l box to the outboard motor along the cable routing Recommended cable length is 300 450 mm 11 8 17 7 in longer than the measured distance Set the cable along the predetermined route and be sure that it is long enough to the route Connect the cable to the engine and be sure it is not kinked bent sharp pulled taut or interfered while steering Do not bend the remote control cable as sharp as its rout...

Page 56: ...serious problem Use of the correct propeller assures powerful acceleration top speed excellency in terms of economy and cruising comfort and it assures longer engine life as well Consult with your authorized Honda outboard motor dealer for proper propeller selection Fuel Line Connection Connect the fuel line to the tank and the outboard motor Follow the boat manufacturer s instructions WARNING Gas...

Page 57: ...oline leaks Engine Cover Removal Installation 1 Pull all the engine cover latches 2 Remove the engine cover by taking it up Installation 1 Place the engine cover on the main body 2 Slide the engine cover so that the cover lock on the cover is mated with the lock in the main body CAUTION Perform the following pre operation checks with the engine stopped Front ENGINE COVER LATCH Side ENGINE COVER LA...

Page 58: ...ng the engine with insufficient oil can cause serious engine damage Recommended oil Use Honda 4 stroke oil or an equivalent high detergent premium quality motor oil certified to meet or exceed U S automobile manufacturer s requirements for API Service category SG SH SJ or SL Motor oils classified SG SH SJ or SL will show this designation on the container ENGINE COVER LATCH Front ENGINE COVER LATCH...

Page 59: ... the upper level mark with the recommended oil Tighten the oil filler cap securely Do not overtighten When the engine oil is contaminated or discolored replace with the fresh engine oil see page 118 for replacement interval and procedure 4 Install the engine cover and lock it securely see page 57 Do not overfill the engine oil Check the engine oil after refilling Excessive engine oil as well as th...

Page 60: ...d fuel mixes with the oil increasing the volume of oil The engine oil deteriorates becomes less efficient as a lubricant and causes an engine malfunction Frequent starting and stopping without allowing the engine to warm up Fuel Check the fuel level and refill if necessary Do not fill the fuel tank above the UPPER LIMIT Refer to the boat manufacturer s instructions Use unleaded gasoline with a Res...

Page 61: ...s alcohol if it does find out the type and percentage of alcohol used If you notice any undesirable operating symptoms while using a particular gasoline Switch to a gasoline that you know contains less than the recommended amount of alcohol WARNING Gasoline is extremely flammable and is explosive under certain conditions Refuel in a well ventilated area with the engine stopped Do not smoke or allo...

Page 62: ...de the full throttle speed range will adversely affect the engine and cause a serious problem Use of the correct propeller assures powerful acceleration top speed excellency in terms of economy and cruising comfort and it assures longer engine life as well Consult with your authorized Honda outboard motor dealer for proper propeller selection 1 Check the propeller for damage wear or deformation 2 ...

Page 63: ...ction CONTROL LEVER FRICTION ADJUSTER BOLT NUT Check whether the remote control lever moves smoothly 1 Remove the cover of the remote control lever 2 Loosen the nut 3 Adjust the lever friction when increasing throttle opening and boat speed by turning the control lever friction adjuster bolt right or left 4 Tighten the nut to lock the lever friction 5 Reinstall the cover of the remote control leve...

Page 64: ... can be adjusted by turning the control lever friction screw right or left R3 type To increase friction To decrease friction R1 type CONTROL LEVER FRICTION ADJUSTER Fuel Filter with Water Separator The fuel filter with water separator is located near the junction box Check the fuel filter with water separator for water accumulation If water is accumulated drain them see page 126 FUEL FILTER with W...

Page 65: ... terminals see page 130 WARNING Batteries produce explosive gases If ignited an explosion can cause serious injury or blindness Provide adequate ventilation when charging CHEMICAL HAZARD Battery electrolyte contains sulfuric acid Contact with eyes or skin even through clothing may cause severe burns Wear a faceshield and protective clothing UPPER LEVEL LOWER LEVEL Keep flames and sparks away and d...

Page 66: ... it must be exposed directly to the water whenever the outboard motor is in use Replace the anodes when they have been reduced to about two thirds of their original size or if they are crumbling The possibility of corrosion damage is increased if the anode is painted over or allowed to deteriorate Parts materials which should be installed on board Owner s Manual Tool kit Spare parts spark plugs en...

Page 67: ...rting the Engine D1 D2 types To prevent damage to the outboard from overheating never run the engine with the propeller out of water WARNING Be careful not to spill any fuel Spilled fuel vapor may ignite If any fuel is spilled make sure the area is dry before starting the engine PRIMING BULB WARNING Exhaust contains poisonous carbon monoxide which can cause unconsciousness and may lead to death Ne...

Page 68: ...ator The engine does not start unless the emergency stop switch clip is set on the emergency stop switch A spare emergency stop switch clip can be stored in the tool bag see page 115 WARNING If the operator does not attach the emergency stop switch lanyard and is thrown from the seat or out of the boat the out of control boat can seriously injure the operator passengers or bystanders Always proper...

Page 69: ...eturn to the ON position Go to step 5 Do not turn the engine switch key to the START position while the engine is running Normal Key with START STOP switch type 3 Insert the key to the power switch and turn it to the ON position 4 Push the start stop switch Honda Smart Key type 3 Turn the power switch to the right ENGINE SWITCH KEY ON OFF START POWER SWITCH ON OFF 67 57 6723 START STOP SWITCH POWE...

Page 70: ... the cooling water is flowing out of the cooling water check hole Amount of water flowing out of the check hole might vary due to the thermostat operation but this is normal If water does not flow out or if steam comes out stop the engine Check to see if the screen in the cooling water intake port is obstructed and remove foreign materials if necessary Check the cooling water check hole for cloggi...

Page 71: ...ws Above 5 C 41 F run the engine for 2 or 3 minutes Below 5 C 41 F run the engine for at least 5 minutes at 2 000 min 1 rpm Failure to completely warm up the engine will result in poor engine performance If the engine is not properly warmed up before raising the engine speed the warning buzzer and overheat indicator may activate and the engine speed will be automatically reduced Before leaving the...

Page 72: ...ch clip can be stored in the tool bag see page 115 WARNING Exhaust contains poisonous carbon monoxide which can cause unconsciousness and may lead to death Never run the outboard motor in a boat house or other confined area EMERGENCY STOP SWITCH STOP EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD WARNING If the operator does not attach the emergency stop switch lanyard and is thrown from...

Page 73: ... the key allowing it to return to the ON position The starter motor consumes a large amount of current Do not therefore run it continuously for more than 5 seconds at a time If the engine does not start within 5 seconds wait at least 10 seconds before running the starter motor again Do not turn the engine switch key to the START position while the engine is running NEUTRAL REMOTE CONTROL LEVER NEU...

Page 74: ...o not operate the engine until the problem has been corrected 5 Check to see if the oil pressure indicator turns ON If it does not turn on stop the engine and perform the following inspections 1 Check the oil level see page 59 2 If the oil level is normal and the oil pressure indicator does not turn ON consult with an authorized Honda outboard motor dealer 6 Warm up the engine as follows Above 5 C...

Page 75: ...gency stop switch clip at one end of the emergency stop switch lanyard into the emergency stop switch Attach the other end of the lanyard securely to the operator WARNING Exhaust contains poisonous carbon monoxide which can cause unconsciousness and may lead to death Never run the outboard motor in a boat house or other confined area EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP EMERGENCY STOP ...

Page 76: ...p switch clip can be stored in the tool bag see page 115 2 Set the control lever in the NEUTRAL position The engine does not start unless the control lever is set in the NEUTRAL position EMERGENCY STOP SWITCH CLIP NEUTRAL REMOTE CONTROL LEVER R2 type NEUTRAL REMOTE CONTROL LEVER R3 type NEUTRAL NEUTRAL 42ZVL600 book 76 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 77: ...ore running the starter motor again Do not turn the engine switch key to the START position while the engine is running When the boat is mounted with the two outboard motors perform the above procedure on the right and left outboard motors respectively 4 After starting check whether the cooling water is flowing out of the cooling water check hole Amount of water flowing out of the check hole might...

Page 78: ... see if the oil pressure indicator turns ON If it does not turn on stop the engine and perform the following inspections 1 Check the oil level see page 59 2 If the oil level is normal and the oil pressure indicator does not turn ON consult with an authorized Honda outboard motor dealer 6 Warm up the engine as follows Above 5 C 41 F run the engine for 2 or 3 minutes Below 5 C 41 F run the engine fo...

Page 79: ...e emergency stop switch Station Select Mode For multiple station type use the switch to change the operating station If you press and hold the switch of the inactive station when all remote control lever is in the NEUTRAL position you can operate the outboard motors using this station A long buzz sounds once and the ACT indicator comes on when the station can be operated ACT INDICATOR PRESS and HO...

Page 80: ... motor up to a maximum of 2 000 to 3 000 min 1 rpm or 10 to 30 throttle opening Next 60 minutes Run the outboard motor up to maximum of 4 000 to 5 000 min 1 rpm or 50 to 80 throttle opening Short bursts of full throttle are acceptable but do not operate the outboard motor continuously at full throttle Next 8 hours Avoid continuous full throttle operation 100 throttle opening Do not run the outboar...

Page 81: ...at speed The control lever will not move unless the neutral release lever is pulled up CAUTION Avoid sharp and abrupt operation of the control lever Operate it moderately Operate the control lever and raise the engine speed after making sure that the gear was shifted securely Gear Shifting D1 type REMOTE CONTROL LEVER NEUTRAL RELEASE LEVER REMOTE CONTROL LEVER FORWARD NEUTRAL REVERSE FORWARD REVER...

Page 82: ...he control lever s further from approximately 20 will increase throttle opening and boat speed CAUTION Avoid sharp and abrupt operation of the control lever Operate it moderately Operate the control lever and raise the engine speed after making sure that the gear was shifted securely Gear Shifting D2 type SINGLE TYPE REMOTE CONTROL LEVERS DUAL TYPE FORWARD NEUTRAL REVERSE FORWARD NEUTRAL REVERSE R...

Page 83: ...rol lever will not move unless the neutral release lever is pulled up CAUTION Avoid sharp and abrupt operation of the control lever Operate it moderately Operate the control lever and raise the engine speed after making sure that the gear was shifted securely Gear Shifting R1 type NEUTRAL RELEASE LEVER REMOTE CONTROL LEVER Pull up MAXIMUM OPENING FORWARD NEUTRAL 32 FORWARD REVERSE NEUTRAL REVERSE ...

Page 84: ...at speed The control lever will not move unless the neutral release lever is pulled up CAUTION Avoid sharp and abrupt operation of the control lever Operate it moderately Operate the control lever and raise the engine speed after making sure that the gear was shifted securely Gear Shifting R2 type REMOTE CONTROL LEVER NEUTRAL RELEASE LEVER REMOTE CONTROL LEVER FORWARD NEUTRAL REVERSE FORWARD REVER...

Page 85: ...the control lever s further from approximately 35 will increase throttle opening and boat speed CAUTION Avoid sharp and abrupt operation of the control lever Operate it moderately Operate the control lever and raise the engine speed after making sure that the gear was shifted securely Gear Shifting R3 type SINGLE TYPE REMOTE CONTROL LEVER REMOTE CONTROL LEVER DUAL TYPE FORWARD NEUTRAL REMOTE CONTR...

Page 86: ...le type POWER TRIM TILT SWITCH dual type POWER TRIM TILT SWITCH LEFT RIGHT 㻰㻺㼁㻼㻰㻺㼁㻼 3257 67 㻰㻺㼁㻼㻰㻺㼁㻼㻰㻺㼁㻼 3257 67 17 5 POWER TRIM TILT SWITCH POWER TRIM TILT SWITCH single type POWER TRIM TILT SWITCH dual type POWER TRIM TILT SWITCH panel type 42ZVL600 book 86 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 87: ...rd motors trimmed at the lowermost position adjust the trim angle of the each outboard motor using the switch on the panel R3 type When the two outboard motors are mounted 1 Press on the DN down of the power trim tilt switch on the remote control lever and trim the outboard motors at the lowermost position 2 With the outboard motors trimmed at the lowermost position adjust the trim angle of the ri...

Page 88: ...d increases the engine speed R2 R3 type Moving about 35 engages the gear Moving the control lever further opens the throttle and increase the boat speed For the sake of fuel economy open the throttle about 80 FORWARD NEUTRAL REVERSE REMOTE CONTROL LEVER FORWARD NEUTRAL REVERSE FORWARD NEUTRAL REVERSE FORWARD REMOTE CONTROL LEVER FORWARD FORWARD FORWARD NEUTRAL REVERSE REMOTE CONTROL LEVER FORWARD ...

Page 89: ...lation betweenthepropellerandtheenginespeed For best performance passengers and equipment should be distributed evenly to balance the boat Trolling Mode Switch Reduce engine speed Switch Increase engine speed After the engine has warmed up keeping switch pushed when cruising with the throttle fully closed changes the mode to trolling mode CAUTION Donotoperatewithouttheenginecover Exposed moving pa...

Page 90: ... 1 000 min 1 rpm limit If you try to do this a short buzz sounds twice The throttle may be operated while in trolling mode The trolling mode is cancelled when you reach 3 000 min 1 rpm One Lever Mode For multiple outboard motors type Shifting gear and the engine speed adjustment of the all outboard motors can be performed with one remote control lever when in one lever mode If you press and hold t...

Page 91: ...switch on the panel Trimming the Outboard Motor VERTICAL LINE when transom angle is 12 68 0 0 12 4 TRIM ANGLE 16 TILT ANGLE D1 type REMOTE CONTROL LEVER POWER TRIM TILT SWITCH Press UP to raise bow Press DN to lower bow D2 type single type REMOTE CONTROL LEVER POWER TRIM TILT SWITCH dual type POWER TRIM TILT SWITCH REMOTE CONTROL LEVERS Press UP to raise bow Press DN to lower bow Press UP to raise...

Page 92: ... power trim tilt switch on the remote control lever and the trim tilt angle of each outboard motor is adjusted by using each power trim tilt switch on the panel POWER TRIM TILT SWITCH PTT SWITCH PANEL DUAL TYPE Press UP to raise bow Press DN to lower bow POWER TRIM TILT SWITCH TRIPLE TYPE Press UP to raise bow Press DN to lower bow 㻰㻺㼁㻼㻰㻺㼁㻼 3257 67 㻰㻺㼁㻼㻰㻺㼁㻼㻰㻺㼁㻼 3257 67 17 5 POWER TRIM TILT...

Page 93: ...ation and racing of the propeller and trimming up the outboard motor excessively can cause damage to the impeller pump When cruising A Into a high wind trim the outboard motor down slightly to lower the bow and improve boat stability B With a tail wind trim the outboard motor up slightly to raise the bow and improve boat stability C Through rough waves do not trim the outboard motor too low or too...

Page 94: ...tion of the power trim tilt switch With the outboard motor trimmed high the trim meter will read as shown To lower the bow decrease the outboard motor trim angle by pressing the DN down portion of the power trim tilt switch WARNING When the boat is mounted with two outboard motors adjust with the switch on the control lever side Adjustment with the switch on the console side will impair the balanc...

Page 95: ...ltaneously when you mount the dual type outboard motor 1 Move the shift lever or the control lever to the NEUTRAL position and stop the engine 2 Press the UP of the power trim tilt switch and tilt the outboard motor to the best position in compliance D1 type POWER TRIM TILT SWITCH D2 type single type dual type POWER TRIM TILT SWITCH POWER TRIM TILT SWITCH 42ZVL600 book 95 ページ２０１８年７月１９日木曜日午前９時６分...

Page 96: ...ngle of all outboard motors is adjusted at the same time by using the power trim tilt switch on the remote control lever and the trim tilt angle of each outboard motor is adjusted by using each power trim tilt switch on the panel POWER TRIM TILT SWITCH PTT SWITCH PANEL DUAL TYPE POWER TRIM TILT SWITCH TRIPLE TYPE 㻰㻺㼁㻼㻰㻺㼁㻼 3257 67 㻰㻺㼁㻼㻰㻺㼁㻼㻰㻺㼁㻼 3257 67 17 5 42ZVL600 book 96 ページ２０１８年７月１９日木曜...

Page 97: ...he outboard motor 1 Raise the outboard motor as full as it goes using the power trim tilt switch 2 Move the tilt lock lever to the LOCK position and lower the outboard motor until the lock lever contacts the stern bracket 3 Press the DN down of the power trim tilt switch and fully shorten the trim rods 4 To tilt down raise the outboard motor slightly move the tilt lock lever to the FREE position A...

Page 98: ...rn bracket 1 or 2 turns counterclockwise using a screwdriver Check that no person is under the outboard motor before carrying out this operation because if the manual relief valve is loosened turned counterclockwise when the outboard motor is tilted up the outboard motor will suddenly tilt down After tilting up down manually close the manual relief valve to lock the outboard motor in the position ...

Page 99: ... determine the amount of effort required If less effort is required to make left turns Loosen the trim tab tightening bolt and turn the rear end of the trim tab toward the left Tighten the bolt securely If less effort is required to make right turns Loosen the trim tab tightening bolt and turn the rear end of the trim tab toward the right Tighten the bolt securely Make small adjustments at a time ...

Page 100: ...he engine overheats the engine will stop in 20 seconds after the engine protection system will limit engine speed Each warning system of PGM FI ACG oil pressure overheat and water separator is activated as described in the following table OIL PRESSURE INDICATOR GREEN ACG INDICATOR RED OVERHEAT INDICATOR RED BUZZER R1 type PGM FI INDICATOR RED BUZZER OVERHEAT INDICATOR RED OILPRESSURE INDICATOR GRE...

Page 101: ...ESPONDING SYSTEM At starting ON 2 sec ON 2 sec ON ON 2 sec With the engine key turned on ON 2 times During operation ON OFF OFF OFF OFF Low oil pressure OFF OFF OFF OFF ON continuously Overheat ON ON OFF OFF ON continuously ACG warning ON OFF ON OFF alternating ON and OFF at long intervals PGM FI warning ON OFF OFF ON alternating ON and OFF at long intervals Water contamination ON OFF OFF OFF alte...

Page 102: ...G SYSTEM During operation OFF OFF OFF OFF OFF OFF OFF Low oil pressure ON OFF OFF OFF ON continuously ON Overheat OFF ON OFF OFF ON continuously ON ACG warning OFF OFF ON OFF alternating ON and OFF at long intervals OFF PGM FI warning OFF OFF OFF ON alternating ON and OFF at long intervals OFF Water contamination OFF OFF OFF OFF alternating ON and OFF at short intervals OFF Warning level 1 Warning...

Page 103: ...eturn to the closest boat landing and contact your closest authorized Honda outboard motor dealer When the overheat warning system is activated 1 Return the gearshift lever or control lever to the N neutral position immediately Check to see if water is flowing out of the cooling water check hole 2 If water is flowing out of the cooling water check hole continue idling for 30 seconds If the overhea...

Page 104: ...ard motor dealer When the PGM FI activated 1 Consult with an authorized Honda outboard motor dealer When the ACG warning system is activated 1 Check the battery see page 129 If the battery is OK consult with an authorized Honda outboard motor dealer When the water separator buzzer sounds 1 Check the water separator for water contamination If water is accumulated drain them see page 126 COOLING WAT...

Page 105: ...s necessary by contacting your authorized Honda outboard motor dealer Anode The anode is a sacrificial material which helps to protect the outboard motor from corrosion Painting or coating the anode will lead to rust and corrosion damage to the outboard motor There are also 4 small sacrificial anodes in the water passages of the engine block Power Reduction This outboard motor is equipped with the...

Page 106: ...outboard motor is not tilted so high that the water intakes are out of the water Multiple Outboard Motors On boats equipped with more than one outboard motor all motors normally operate at the same time If one or more motor s is stopped while the other s is running put the stopped motor in N neutral and tilt it up so its propeller is above the water s surface If the propeller of the stopped motor ...

Page 107: ...me to be sure that the emergency stop switch is operating properly Normal Engine Stop D1 D2 type 1 Move the shift lever to NEUTRAL position After sailing with the throttle fully open cool down the engine by running it at the idle speed for a few minutes EMERGENCY STOP SWITCH CLIP EMERGENCYSTOP SWITCH LANYARD STOP EMERGENCYSTOP SWITCH LANYARD STOP EMERGENCY STOP SWITCH CLIP R2 R3 type EMERGENCY STO...

Page 108: ...ove and store it Honda Smart Key type 3 Turn the power switch to the right or press the lock button on the Honda Smart Key to turn the power OFF If you are using a portable fuel tank disconnect the fuel line if you will be storing or transporting the outboard motor NEUTRAL REMOTE CONTROL LEVER NEUTRAL D1 type NEUTRAL REMOTE CONTROL LEVER NEUTRAL D2 type POWER SWITCH 67 57 6723 START STOP SWITCH OF...

Page 109: ... down the engine by running it at the idle speed for a few minutes NEUTRAL REMOTE CONTROL LEVER R1 type REMOTE CONTROL LEVER NEUTRAL R2 type NEUTRAL NEUTRAL REMOTE CONTROL LEVER R3 type NEUTRAL D1 D2 without START STOP Switch type R1 R2 R3 type NEUTRAL REMOTE CONTROL LEVER NEUTRAL D1 type NEUTRAL REMOTE CONTROL LEVER NEUTRAL D2 type NEUTRAL 42ZVL600 book 109 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 110: ...onnect the fuel line connector from the outboard motor 3 Remove the engine switch key and store it If you are using a portable fuel tank disconnect the fuel line if you will be storing or transporting the outboard motor ENGINE SWITCH KEY ENGINE SWITCH R1 type OFF OFF ENGINE SWITCH KEY R2 R3 type OFF D1 D2 without START STOP Switch type 42ZVL600 book 110 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 111: ... lifting eyes and hang the outboard motor to remove it from the boat WARNING Gasoline is extremely flammable and gasoline vapor can explode causing serious injury or death Be careful not to spill fuel Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before storing or transporting the outboard motor Do not smoke or allow flames or sparks where fuel is drained o...

Page 112: ...sition Do not trailer or transport the boat with the outboard motor in the tilted position The boat or outboard motor could be severely damaged if the outboard motor drops The outboard motor should be trailered in the normal running position If there is insufficient road clearance in this position then trailer the outboard motor in the tilted position using an outboard motor support device such as...

Page 113: ...e cleaning and flushing 1 Disconnect the fuel line from the outboard motor 2 Tilt down the outboard motor 3 Wash the outside of the outboard motor with clean fresh water 4 Remove the flush plug connector from the outboard motor 5 Install the water hose joint commercially available 6 Connect a fresh water hose to the water hose joint 7 Turn on the fresh water supply to the hose and flush the engine...

Page 114: ... Use only Honda Genuine parts or their equivalents for maintenance or repair The use of replacement parts which are not of equivalent quality may damage the outboard motor WARNING Shut off the engine before performinganymaintenance If the engine must be run make sure the area is well ventilated Never run the engine in an enclosed or confined area Exhaust contains poisonous carbon monoxide gas expo...

Page 115: ...Emergency Stop Switch Clip A spare emergency stop switch clip is available from your outboard motor dealer Always carry a spare emergency stop switch clip onboard The spare clip may either be stored in the tool bag or in an easily accessible location on the boat OWNER S MANUAL TOOL BAG 10 mm BOX WRENCH 19 mm EYE WRENCH 6 mm HEX WRENCH PHILLIPS SCREWDRIVER GRIP SPARK PLUG WRENCH 42ZVL600 book 115 ペ...

Page 116: ...il Check level o 59 Change o o 118 Engine oil filter Replace o 2 Gear case oil Change o 2 o 2 Timing belt Check adjust o 2 ACG belt Check adjust o 2 ThrottlelinkageandControlCable 10 Check adjust o 2 o 2 Valve clearance Check adjust o 2 Spark plug nickel Check adjust Replace o 120 Spark plug iridium Optional part Check o Optional part Clean o 2 Optional part Replace o Propeller and Cotter pin Chec...

Page 117: ... Replace the fuel line if there are signs of leaks cracks or damage 10 Mechanical Remote Control type only Each use After use First month or 20 hrs Every 6 months or 100 hrs Every year or 200 hrs Every 2 years or 400 hrs Every 3 years or 600 hrs Every 6 years or 1200 hrs Refer to page Fuel filter High pressure side Replace o 2 Thermostat and thermostat cover Check Replace o 2 Fuel line Check o 8 6...

Page 118: ...10W 30 engine oil or equivalent API Service category SG SH SJ or SL Engine Oil Replacement Drain the oil while the engine is still warm to assure rapid and complete draining 1 Position the outboard motor vertically and remove the engine cover see page 57 Remove the oil filler cap 2 Place a suitable container under the guide 3 Remove the engine oil drain bolt and sealing washer using the 12 mm wren...

Page 119: ...tboard motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station for reclamation Do not throw it in the trash or pour it on the ground Wash your hands with soap and water after handling used oil OIL LEVEL DIPSTICK UPPER LEVEL MARK LOWER LEVEL MARK OIL FILLER CAP 42ZVL600 book 119 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 120: ...Use only the recommended spark plugs or equivalent Spark plugs which have an improper heat range may cause engine damage 1 Disconnect the battery negative terminal 2 Unlock and remove the engine cover see page 57 CAUTION The spark plug becomes very hot during operation and will remain hot for a while after stopping the engine Allow the engine to cool before servicing the spark plug 42ZVL600 book 1...

Page 121: ...ion coil if drop it 5 Use the spark plug wrench and 19 mm eye wrench to remove the spark plugs 6 Inspect the spark plugs 1 If the electrodes are heavily corroded or carbon soiled clean with a wire brush 2 Replace a spark plug if the central electrode is worn The spark plug can wear out in different ways If the sealing washer shows signs of wear or if the insulators are cracked or chipped replace t...

Page 122: ...hten 1 2 turn after the spark plug seats to compress the washers If reinstalling used spark plugs tighten 1 8 1 4 turn after the spark plug seats to compress the washers The spark plugs must be securely tightened An improperly tightened plug can become very hot and may cause engine damage 10 Install the ignition coil Reinstall the bolt 11 Push the wire connector onto the ignition coil Make sure it...

Page 123: ...dium spark plugs Do not clean the spark plugs If an electrode is contaminated with accumulated objects or dirt replace the spark plug with a new one The cleaning of the iridium spark plugs consult with your servicing dealer unless the owner has the proper tools and is mechanically proficient Use only a wire type feeler gauge to check the spark plug gap if necessary To prevent damaging the iridium ...

Page 124: ... with a cloth dipped in clean oil Apply marine anticorrosion grease to the following parts Lubrication interval 20 hours or a month after the date of purchase for initial lubrication then every 100 hours or 6 months Apply anticorrosion oil to pivot surfaces where grease cannot penetrate Lubricate more frequently when used in salt water ENGINE COVER LATCH LOCK each side SHIFT LINK PIVOT SHIFT LINK ...

Page 125: ... 6 months Replacement interval Every 400 operating hours or 2 years FUEL FILTER with WATER SEPARATOR WARNING Gasoline is extremely flammable and gasoline vapor can explode causing serious injury or death Do not smoke or allow flames or sparks in your working area Always work in a well ventilated area Be sure that any fuel drained from the outboard motor is stored in a safe container Be careful not...

Page 126: ...er accumulation and clogging If the fuel filter with water separator is clogged refer to page 127 to remove the filter and clean it If a water is remained in the fuel filter with water separator refer to page 127 to remove the strainer cup and empty the water from the inside of the cup FUEL FILTER with WATER SEPARATOR 42ZVL600 book 126 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 127: ...kage disconnect the fuel tubes 5 Remove the three screws holding the fuel filterwithwaterseparator deletethewater or deposit from the inside of the cup 6 Thoroughly clean the cup and replace with a new fuel filter 7 Reassemble the water separator in the reverse order of removal Use a new O ring TIGHTENING TORQUE 3 4 N m 0 34 kgf m 2 5 lbs ft WATER SEPARATOR CUP SCREWS O RING Replace 2 PIN COUPLER ...

Page 128: ...combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide dose not react in the same way but it is toxic Problems that May Affect Outboard Motor Emissions If you are aware of any of the following symptoms have the outboard motor inspected an...

Page 129: ...e serious injury or blindness Provide adequate ventilation when charging CHEMICAL HAZARD Battery electrolyte contains sulfuric acid Contact with eyes or skin even through clothing may cause severe burns Wear a faceshield and protective clothing Keep flames and sparks away and do not smoke in the area ANTIDOTE If electrolyte gets into your eyes flush thoroughly with warm water for at least 15 minut...

Page 130: ...ghly 3 Connect the battery positive cable to the battery positive terminal then the battery negative cable to the battery negative terminal Tighten the bolts and nuts securely Coat the battery terminals with grease NEGATIVE TERMINAL POSITIVE TERMINAL CAUTION When disconnecting the battery cable be sure to disconnect at the battery negative terminal first To connect connect at the positive terminal...

Page 131: ...e cover see page 57 4 Open the junction box cover 5 Pull the old fuse out of the clip with the fuse puller supplied in the fuse box 6 Push a new fuse into the clips WARNING Never use a fuse with a different rating from that specified Serious damage to the electrical system or a fire may result Disconnect the battery cable at the battery negative terminal before replacing the fuse Failure to do so ...

Page 132: ...p High pressure side 9 15 A Injector ECU 10 10 A DLC Fuel pump Low pressure side 11 15 A PTC Fuse No Rating Component s or Circuit s Protected 1 150 A ACG Battery 4 30 A STARTER SOLENOID AND RELAYS IN JUNCTION BOX 5 7 5 A REMOTE CONTROL SYSTEM 6 30 A SHIFT ACTUATOR 7 15 A THROTTLE BODY 8 10 A Fuel pump High pressure side 9 15 A Injector ECU 10 10 A DLC Fuel pump Low pressure side 11 15 A PTC 42ZVL...

Page 133: ...battery see page 130 3 Remove the engine cover see page 57 4 Open the junction box cover 5 Remove the old fuse by removing two 5 mm screws 6 Install a new fuse by tightening two 5 mm screws 7 After finishing replacement close the junction box cover JUNCTION BOX COVER 5 mm SCREWS ACG FUSE 150 A SPARE FUSE 150 A PAWLS 42ZVL600 book 133 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 134: ...s that come together with the outboard motor TIGHTENING TORQUE 1 N m 0 1 kgf m 0 7 lbf ft UPPER LIMIT OF TORQUE 44 1 N m 4 5 kgf m 32 5 lbf ft 4 Be sure to replace the cotter pin with a new one Install the thrust washer with the grooved side toward the gear case Use a genuine Honda cotter pin and bend the pin ends as shown WARNING Before replacing the propeller remove the emergency stop switch cli...

Page 135: ...er see page 57 and rinse the outboard motor with fresh water to remove salt water sand mud etc If the outboard motor was running when it submerged there may be mechanical damage such as bent connecting rods If the engine binds when cranked do not attempt to run the outboard motor until it has been repaired 2 Change the engine oil see page 118 3 Remove the spark plugs see page 120 Operate the start...

Page 136: ... showed signs of water contamination then a second engine oil change should be performed after running the engine for 1 2 hour If the engine starts and no mechanical damage is evident continue to run the engine for 1 2 hour or longer be sure the water level is at least 100 mm 4 in above the anticavitation plate 7 As soon as possible take the outboard motor to a Honda outboard motor dealer for insp...

Page 137: ...In worst cases gasoline can be contaminated within 30 days Using contaminated gasoline can seriously damage the engine fuel system clogged valve stuck Such damage due to spoiled fuel is disallowed from coverage by the warranty To avoid this please strictly follow these recommendations Only use specified gasoline see page 60 Use fresh and clean gasoline To slow deterioration keep gasoline in a cert...

Page 138: ...ly tighten the drain bolt securely 7 Clip the drain tube on the head cover WARNING Gasoline is extremely flammable and gasoline vapor can explode causing serious injury or death Do not smoke or allow flames or sparks in your working area Be careful not to spill fuel Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before storing or transporting the outboard mo...

Page 139: ...hly WARNING Batteries produce explosive gases If ignited an explosion can cause serious injury or blindness Provide adequate ventilation when charging CHEMICAL HAZARD Battery electrolyte contains sulfuric acid Contact with eyes or skin even through clothing may cause severe burns Wear a faceshield and protective clothing Keep flames and sparks away and do not smoke in the area ANTIDOTE If electrol...

Page 140: ...tically as shown above Attach the stern bracket to stand and secure the outboard motor with bolts and nuts Store the outboard motor in a well ventilated area free from direct sunlight and humidity LOWER LEVEL BATTERY CAP UPPER LEVEL Outboard Motor Position CAUTION Do not place the outboard motor on its side during a prolonged period of storage If you are obliged to place the outboard motor on its ...

Page 141: ...the environment do not dispose of this product battery engine oil etc carelessly by leaving them in the waste Observe the local laws and regulations or consult your dealer for disposal 42ZVL600 book 141 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 142: ...s have improper heat range Replace the spark plugs see page 120 Faulty water pump Thermostat clogged Faulty thermostat Cooling water passage clogged Exhaust gas invades cooling system Consult with an authorized Honda outboard motor dealer Oil pressure warning system comes on Oil pressure indicator does not come on Oil pressure warning buzzer sounds Engine speed decreases Engine speed cannot be inc...

Page 143: ... with an authorized Honda outboard motor dealer PGM FI warning system comes on PGM FI indicator comes on PGM FI warning buzzer sounds intermittently PGM FI warning system is faulty Consult with an authorized Honda outboard motor dealer ACG warning system comes on ACG indicator comes on ACG warning buzzer sounds intermittently Battery voltage is too high or low Check the battery see page 129 Faulty...

Page 144: ...utral by inserting the phillips screwdriver with the grip of the tool kit see page 115 into the hole of the shift actuator and moving the shaft 5 Start the engine see page 67 6 Shift gear into F Forward or R Reverse by moving the shaft of the shift actuator with the phillips screwdriver with the grip of the tool kit After returning to port stop the engine and anchor the boat HOLE SHIFT ACTUATOR GR...

Page 145: ...ied oil Engine API standard SG SH SJ SL SAE 10W 30 Gear case API standard GL 4 SAE 90 Hypoid gear oil Oil capacity Engine Without oil filter replacement 7 6 L 8 0 US qt 6 7 Imp qt With oil filter replacement 7 8 L 8 2 US qt 6 9 Imp qt Gear case 1 47 L 1 55 US qt 1 29 Imp qt D C output 12 V 60 A Cooling system Water cooling with thermostat Exhaust system Underwater exhaust Spark plugs ZFR6K 11E NGK...

Page 146: ...oid pump pressure lubrication Specified oil Engine API standard SG SH SJ SL SAE 10W 30 Gear case API standard GL 4 SAE 90 Hypoid gear oil Oil capacity Engine Without oil filter replacement 7 6 L 8 0 US qt 6 7 Imp qt With oil filter replacement 7 8 L 8 2 US qt 6 9 Imp qt Gear case 1 47 L 1 55 US qt 1 29 Imp qt D C output 12 V 60 A Cooling system Water cooling with thermostat Exhaust system Underwat...

Page 147: ...stem Trochoid pump pressure lubrication Specified oil Engine API standard SG SH SJ SL SAE 10W 30 Gear case API standard GL 4 SAE 90 Hypoid gear oil Oil capacity Engine Without oil filter replacement 7 6 L 8 0 US qt 6 7 Imp qt With oil filter replacement 7 8 L 8 2 US qt 6 9 Imp qt Gear case 1 47 L 1 55 US qt 1 29 Imp qt D C output 12V 60A Cooling system Water cooling with thermostat Exhaust system ...

Page 148: ... Switch Clip 40 Switch 39 Switch Lanyard Clip 39 Emission Control System 128 Engine Cover Latch 42 Removal Installation 57 Oil Change 118 Level Inspection 59 Refilling 59 Protection System 100 ACG Warning System 100 Anode 105 Oil Pressure Warning System 100 Overheat Warning System 100 Over rev Limiter 105 PGM FI Warning System 100 Water Separator Warning System 100 Serial Number 4 Switch 24 F Fast...

Page 149: ...1 82 83 84 85 Outboard Motor Installation 48 Storage Position 140 Outboard Motor Angle Inspection 49 Overheat Indicator Buzzer Function 33 Operation 100 Over rev Limiter 105 P PGM FI Indicator Buzzer 31 Power Tilt Switch Function 37 Operation 98 Power Trim Tilt Switch Function 35 Operation 86 Pre operation Checks 57 Battery 65 Engine Oil 58 Fuel 60 Fuel Filter 64 Other Checks 66 Propeller and Cott...

Page 150: ...107 Normal Stop 107 109 Storage 137 Submerged Outboard Motor Servicing 135 Switch Panel 17 T Tachometer 43 Tilt Lock Lever 41 Tilting the Outboard Motor Remote Control Type 95 Tool Kit and Spare Parts 66 115 Trailering 112 Transom Height 46 Transporting 111 Trim Meter Function 37 Operation 94 Trim Tab Adjustment 99 Operation 41 Trimming the Outboard Motor 91 Troubleshooting Warning System Operatio...

Page 151: ...151 MEMO 42ZVL600 book 151 ページ２０１８年７月１９日木曜日午前９時６分 ...

Page 152: ...152 MEMO 42ZVL600 book 152 ページ２０１８年７月１９日木曜日午前９時６分 ...

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Honda BF200D, Manual

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