Honda BF45A Service Manual Download

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Summary of Contents for BF45A

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Page 269: ...tice No part of this publication may be reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of the publisher This includes text figuresandtables 0 Honda Motor Co Ltd Service Publication Office CONTENTS OUTLINE OF CHANGES SPECIFICATIONS SERVICE INFORMATION MAINTENANCE FUEL SYST...

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Page 271: ...ter hosejoint 9 CDI unit 2 After change 5 ECT sensor installationpositionchanged ECTSENSOR 8 inner diameter I D changed I811 WATER HOSE JOINT lo Change t odigital CDI unit I II 1 1 3 Beforechange 6 ECT switch 611 ECTSWITCH PI 1 WATER HOSE JOINT l 11 Analogue CDI unit i ...

Page 272: ...nge S Connectingterminal connection method changed 151 1 OIL PRESSURESWITCH 5 4 MALECONNECTOR p Changeto power coil from exciter coil ml POWER COIL eE1 POWER TRlMmLT ASSEMBLY 3 Before change 1 5 l 3 TERMINALSCREW I 151 2 OIL PRESSURE 4xQmm SWITCH m 2EXCITERCOIL M 1 I POWER TRIMmLT ASSEMBLY 2 ...

Page 273: ...Mount frame 8 Stern bracket 2 After change 5 Erectedtype 5 1GAS ASSISTED DAMPER m 1 MOUNT FRAME FRICTIONPLATE MOUNTINGSECTION 81 1 STERN BRACKET 3 Beforechange 1 6 1Invertedtype 6 1 GAS ASSISTED DAMPER m 1 MOUNTFRAME 181 1 STERN BRACKET 3 ...

Page 274: ... change 1 4 1 1 STEERINGFRlNCTlONSTUD INSTALLATIONHOLE CASE 6 Longtiller handletype added M 1 LONGTILLER HANDLE 8 Tiller handlefriction lever being added in connection with addition of the long tiller handle type 181 1 FRICTIONPLATE PI 2 FRICTION ADJUSTING LEVER 3 Before change CASE 4 ...

Page 275: ...Item 4 Carburetor 151Remotecontrol box 2 After change 141 2 SE THERMAL VALVE 6 Choke switch is no longer installed 3 Beforechange 4 3 CHOKEVALVE 4 5 CHOKE ARM 4 4 CHOKE SOLENOID REMOTECONTROL TYPE 161 1 CHOKE SWITCH 5 ...

Page 276: ...BF40AaBF50A 1 l Item 4 Fuse holder bracket 2 After change 5 Newly provided 51 1 FUSE HOLDER BRACKET 5 3 REGULATOWRECTIFIER BRACKET 3 Before change 5 2 FUSE HOLDER REGULATOWRECTlFIER BRACKET ...

Page 277: ...94 Ib 301 Ib 301 Ib 307 Ib 96 kg 98 kg 100 kg 91 5 kg 93 5 kg 93 5 kg 95 5 kg 317 Ib 324 Ib 322 Ib 302 Ib 309 Ib 309 Ib 316 Ib 416 mm 521 mm 20 5 in 416 mm 16 4 in 521 mm 20 5 in 16 4 in 5 stage adjustment 8 12 16 20 24 4 63 DIMENSIONSAND WEIGHTS Trimming angle Swivel angle 1 Model I BF40A 1 4 12 I I 4 12 j I 4 12 37 5 right and left I LRT I L 0 0 0 0 Types of Honda BF40A Outboard Motors It may be...

Page 278: ...5 mm 27 0 in Overall height Dry weight With propeller mounted I Trimmina anale I I 4 12 1 1 260 mm 49 6in 1 365 mm 53 7 in 1 400mm 55 1in 1 470mm 57 9 in 91 kg 201 Ib 91 kg 201 Ib 93 kg 205 Ib 94 kg 207 Ib 97 kg 214 Ib Operatingweight Transom height Transom angle Tiltina anale Types of Honda BF50A Outboard Motors It may be necessary to refer to this chart for reference purposes when reading this m...

Page 279: ...r circulation by impeller pump with thermostat CDI 329 g 11 6 oz kWh 335 g 11 9 oz kWh 5 26 B T D C DR7EA NGK X22ESR U DENSO Horizontalbutterfly valve type vertical 3 carburetors Forcedlubrication by trochoid pump 2 4 e 2 54 US qt 2 11 Imp qt 2 0 e 2 12 US qt 1 76 Impqt at oil change SAE 5W 30 API Serviceclassification SG SH SJ Electricstarter Ignitionprimary circuit ground Automotive unleadedgaso...

Page 280: ... 1 260 49 6 LType 1 365 53 7 LLType 1 400 57 9 2 DIMENSIONAL DRAWING Tiller HandleType T S 416 805 16 4 31 7 521 900 20 5 35 4 556 930 21 9 36 6 1 470 622 ULType I 57 9 I 24 5 1 370 14 57 r 1 1 Unit mm in 1 284 5 50 57 i ...

Page 281: ... RemoteControlType Unit mm in T cu 5 v r 370 14 57 m m i V I 770 30 31 1 5 ...

Page 282: ...e only SEvalve heater resistance con 15 8 24 2 Q 10 min co Measurinaidle soeed 7 0 max 950 1 150min I rpm I I NOX I 546oom max I 0 7 51 25 16 4 5 I 1 Powercoil I Resistance I 7 02 8 58 Q I 2 TORQUE VALUES Item Engine Crankcase cover bolt Cylinder head bolt Oil strainer bolt Water tube joint Flywheel bolt Gear case Propeller castle nut Gear case end nut Gear case nut UL type Gear case stud UL type ...

Page 283: ...t lever nut M6 x 1 O 6 5 0 65 4 7 NOTE Apply oil to the thread and seating surface Tighten to the specifiedtorque first then tighten an additional 90 120 Clean off oil or grease from the crankshaft and flywheel mating surfaces see page 6 1 Apply oil to the thread and seating surface of the flywheel bolt then tighten them to the specified torque If the split pin cannot be set by tightening the cast...

Page 284: ... about 1 5 mm 0 04 0 20 in width Wait for 15 minutes after assembly Do not add oil dur ing this period PRIMARYGEAR CASE GASKET 1 Clean the engine and primary gear case mating sur faces with a degreasing cleaning agent or a clean shop towel see base shop manual 2 Apply liquid sealant to the position shown on both side of a new primarygear case gasket OIL PANGASKET 1 Clean the engine and oil pan mat...

Page 285: ...eck for clogged fuel tank breather hole Close the tank and open the vent knob listen for hiss Checkfor air leaks past primer bulb and check whether fuel reached the carburetor 5 Check compression of each cylinder See base shop manual __ I Reachingthe carburetor bustion chamber Squeeze the primer bulb and be sure that the fuel is reachingthe car buretor Check for clogged fuel filter fuel tubes and ...

Page 286: ...g bolts and or damaged carbure tor insulatorand gasket Drain the carburetor and prime again If still not good check the carburetorfloat valve Retighten the carburetor mounting bolts or intake manifold bolts if they are loose Make sure the carburetorand insulator are installed correct ly Replace the gaskets if they are damaged Valve clearance misadjusted Adjust see base shop manual Low cylinder com...

Page 287: ...Throttle cable misadjusted Readjust see base shop manu al ...

Page 288: ...ted under such conditions as light pro peller load or propellerventilation Hard Starting Abnormal 1 Measure the spark plug gap and perform the spark test See base shop manual Standard plug DR7EA NGK X22ESR U DENSO Plug gap 0 6 0 7 mm 0 24 0 28 in I No spark or weak spark 2 Perform the spark test again using a new spark plugs No spark 3 Check that the switch clip is installed on the emergency stop ...

Page 289: ...l wire connector and check for resis tance Resistance 288 352 R I Normal 7 Check for voltage leakage caused by damaged high tension wire insu lation Check the ignition coil resis tances see base shop manual Resistance Primary 0 19 0 23 R Secondary 2 8 3 4 kR Abnormal 4 Replacethe ignition coil I Normal Abnormal resistance between the terminals P 16 1 Normal open circuit Replace or repair the wire ...

Page 290: ...essure light comes I NO wire Does the oil pressure light I YES 4 Check the oil pressure switch see base shop manual Is the oil pres Replacethe oil pressureswitch sure switch good I YES 1 5 Check the oil pressure Is the oil pressure normal YES c Check the CDI unit P 16 1 Replace or repair the wire harness if the CDI unit is in good condition Check the oil strainer for clogging Clean the oil straine...

Page 291: ...ith the engine idling Does cooling water constantly flow through the cooling system indicator System is OK engine temperature was high NO 6 Check the ECT sensor P 16 3 Is the ECT sensor in good condition NO Replacethe ECT sensor NO J 4 Check the thermostat Is the ther mostat good YES Check the discharge port for clog ging clean the discharge port if necessary Check the water pump for wear or damag...

Page 292: ...ht see base shop manual YES 4 Disconnect the oil pressure switch wire Does the buzzer stop Replacethe oil pressureswitch base shop manual Is the oil pres NO Check the CDI unit P 16 1 YES 16 Check the oil NO 4 Check the oil strainer for clogging pressurenormal L I Clean the oil strainer if necessary Check the oil pump Replace or YES I overhaul the oil pump if necessary t Check the CDI unit P 16 1 R...

Page 293: ...r NO NO I YES cool down the engine Check the overheat indicator light Does the overheat indicator light come OFF 1 recheck J Check the discharge port for clog ging clean the discharge port if necessary Check the water pump for wear or damage Replace or repair the water pump Check the water tube for clogging or damage Clean or replace the water tube if necessary System is OK engine temperature was ...

Page 294: ...e Shift leverdoes not move smoothly Gear shift mechanism motor Overhaul See base shop manu side shift arm and or shift link damaged al Overhaul Section 15 Overhaul Section 15 Readjust Section 15 Shiftcablecorroded Replace Section 15 2 13 ...

Page 295: ...dleType Throttle arm tiller handle side stuck or damaged Replace Section 15 Throttle grip does not move smoothly Throttle arm motor side dam aged Replace Section5 Throttlecable misadjusted Readjust P 3 6 Throttlecablecor Replace Section 14 2 14 ...

Page 296: ...3 1thru 13 5 I Does not hold t Tilt lever is in TILT position Turn to RUN position Faultygas assistedtilt Replace P 13 1thru 13 5 g POWER TRIM TILT PowerTriMilt Does Not Move Turn TROUBLESHOOTING on page Check the motor sound Sounds Does not sound Loose Tight Faulty power trim tilt assembly PowerTriMilt Does Not Hold Tight 1 Faulty power trim tilt assembly I 2 45 ...

Page 297: ...the power trimhlt relay See base shop manual Checkfor open circuit in the motorwire If there is open circuit replace or If there is no open circuit replace repair the motor wire 1 power trimhlt assembly Does not turn Abnormal I Normal I Normal t Check the power trimhilt line for open or short circuit Repair or replace the wire harness if necessary 2 16 ...

Page 298: ...NG ll BAlTERY CABLES lo TILLER HANDLE WIRE HARNESS Longtiller handletype REMOTE CONTROL BOX WIRE HARNESS Remote controltype lo 1 CASE GROMMET CABLE TIES Remote control type only Align the cable ties with the case grommet as shown 2 17 ...

Page 299: ...OSITIVECABLE Install the battery positive cable and power trimhilt relay wire power trimhilt type only and starter motor cable as shown PI 1 BATTERY POSITIVE CABLE TI 3 POWER TRIM TILT POWER SUPPLY WI Powertrimhilt r71 2 STARTER MOTOR CABLE 6 WIRE HARNESS CLIP mal valve heater wire power trim tilt relay wire regulatorhectifier ground wire and starter magnetic switch wire with the open end facing u...

Page 300: ...ELAY WIRE No 1IGNITION COIL No 2 IGNITION COIL MAIN WIRE HARNESS 12 MAIN WIRE HARNESS 1151PURSE LOCK CLIP trimhilt switch wire power SENSOR WIRE 1 161 open end facing up as shown POWER TRIMRILT TRIM ANGLE MOTOR WIRE 1261 1 121 BAlTERY CABLE MAIN FUSEWIRE BI B I MAINWIRE HARNESS YiBu YlBu 28 CDI UNIT WIRE L W 1211 POWERTRIMILT RELAYWIRE W W 1241REGULATOWRECTIFIERWIRE W e W 27 STARTER MAGNETICSWITCH...

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Page 302: ... CONNECTOR pulse generator wire and No 1 high tension 8 HIGH TENSION CORD CLAMP 4P CONNECTOR No 2 IGNITION COIL No 3 IGNITION COIL 121MAIN WIRE HARNESS 131REGULATOWRECTIFIER WIRE 41 NEUTRAL SWITCH WIRE Gr V G r 151 WBI WlBl 1 MAINWIRE HARNESS G V G CHARGE COILWIRE I31 REGULATOWRECTIFIERWIRE Gr r 12 21 CDI UNITWIRE L W 1131REGULATOWRECTIFIERWIRE 20 STARTER MAGNETIC SWITCHWIRE D 2 21 ...

Page 303: ...BF40AoBF50A l CHARGE COILS n 2 POWER COIL P I WIRE HOLDER B 1 7 1 CAM 5 POWER COIL WIRE I 6 WIRE HOLDER A 2 22 ...

Page 304: ...NAL Install the ground terminal to the engine as shown I 1 2 9 0 POWER TRIM TILT SWITCH 151POWER TRIMnILT RELAY 8 POWER TRIMnILT MOTOR WIRE 6 POWER TRIMnILT SWITCH WIRE open end facing up I shown L J TRIM ANGLE SENSOR WIRE 14 14mm TUBE CLIP lo TRIM ANGLE SENSOR protector after clamping the SENSOR WIRE 9 WIRE HARNESS CLIP MOTOR CORD BUSH ll WIRE BAND C 8 POWER TRlM TlLT MOTOR WIRE 2 23 ...

Page 305: ...AND 5 131 EMERGENCYSTOP SWITCH P I POWER TRIMRILT SWITCH 1 9 1 POWER TRlMRlLT W BI W BI l INDICATOR 14 WIRE TIE 141 5 WARNING BUZZER IGNITIONSWlT 131 EMERGENCYSTOP SWITCH REMOTE CONTROL l l Starboardrnou POWER TRlMRlLT BOX WIRE HARNESS SWITCH WIRE edge of the control box as lo Port mount type 2 24 ...

Page 306: ...BF40AoBF50A LongTiller HandleType l SHIFT CABLE ROTTLE CABLE 3 CABLE BRACKET cable with the cutout of the 2 25 ...

Page 307: ...E wire does not interferewith the 5 x 10 mm hex bolt head SWITCH I 3 WIRE TIE 2 lo WIRE BAND CLIP 3 d k 10 20 m m 0 4 0 8 in lo 1 After securing the wires with wire band clips cut the end as projected length is 10 20 mm 0 4 0 8 in provided that the length is not specified in the corresponding drawings J 9 2 WIRE TIE 9 1GROMMET Align the wire tie with the 2 26 ...

Page 308: ...Wire Connectioninthe LongTiller Handle l WIRE BAND CLIP 3 EMERGENCY STOP SWITCH r COVER B A IGNITION SWITCH L 7 I i I I 141 30 mm CONNECTOR COVER 1 3 1 TILLER HANDLE WIRE HARNESS 2 27 ...

Page 309: ...UBE A SE TUBE 2 AIR VENT TUBE B 27 VINYL TUBE 160 mm 26 FUEL TUBE CLAMP FUEL CONNECTOR 25 FUEL TUBE 240 mm 24 VACUUM TUBE D 23 FUEL TUBE CLAMP A 221 FUEL TUBE CLIP 21 FUEL TUBE F 20 FUEL PUMP DASHPOT CHECK VALVE 141FUEL FILTER FUEL TUBE B 2 28 ...

Page 310: ...UBE 3 3 5 x 45 mm 3 TUBE CLIP B10 3 WAY JOINT A 2 AIR VENT TUBE C 20 3 WAY JOINT B 7 FUEL TUBE F AIR VENT TUBE D FUEL TUBE CLIP 18 TUBE CLAMP 17 AIR VENT TUBE 16 AIR VENT TUBE 3 WAY JOINT PIPE BE CLIP B10 5 4 5 x 170 mm 2 29 ...

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Page 312: ...e No 1 vacu um gauge adapter The No 2 vacuum gauge hose to the No 2 vacu um gauge adapter The No 3 vacuum gauge hose to the No 3 vacu um gauge adapter 4 Attach an engine tachometerand restartthe engine Follow the tachometer manufacturer sinstructions 5 Run the outboard motor in an outboard test tank with the water at least 4 inches above the antiventilation plate Allow the engine to warm up to nor...

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Page 314: ... 6 x 16 mm torx bolts using a commercial ly available torx bit T30H 4 Disconnect the vacuum tube from the dashpot check valve 5 Move the throttle cam in the direction pointed by arrow until the throttle cam roller is set free from the throttle cam and hold the throttle cam 121 THROTTLE ROD 1 11 TORX BIT T30H Commercially available I I VACUUM TUBE PI DASHPOT CHECK VALVE CAM ROLLER 3 4 ...

Page 315: ...2 Move the throttle arm to the fully open position and be sure that the throttle arm contacts the fully open stopper 3 Check that the throttle cam is also at the fully open position and that there is clearance of 1 mm 0 04 in or less betweenthe carburetorthrottle lever and stop per on the No 3 carburetor 4 If either the throttle arm or throttle cam is not at the fully open position adjust as follo...

Page 316: ... the throttle cable length after adjusting the throttle rod length 1 Turn the throttle grip to the fully open position and check that the throttle arm contacts the fully open stopper 2 Returnthe throttle grip to the fully close position 3 Pushing the throttle arm lightly i e by the amount of throttle link play in the direction of arrow check whether the center of throttle cam roller is at the righ...

Page 317: ...to the throttle arm that is set in the fully open position i e throttle arm is lightly in contact with the fully open stopper 9 Connect the throttle cable to the throttle arm and tighten the shift pivot lock nut securely 10 Installthe throttle rod pivot on the throttle cam 11 Turn the throttle grip to the fully closed position Pushing the throttle arm lightly in the direction of arrow check whethe...

Page 318: ...smoothly into all positions STEERING FRICTIONADJUSTMENT LongTiller HandleType Move the friction adjusting lever to the left side fully until the friction lever contacts to the stopper as shown Check the starting torque by measuring the starting force using a spring scale at the center of the throttle grip as shown The motor should start to move with 100 N 10 0 kgf 22 0 Ibf If it does not loosen th...

Page 319: ...off the vinyl tubes from the engine under case 5 Remove the 6 mm flange bolts washers and cover nut then remove the silencer cover from the silencer plate 6 Install the removed parts in the reverse order of removal GI VINYL TUBE 2 111 COVER NUT ASSEMBLY Insert the vinyl tubes into the holes in the engine under case as shown 6 1 VINYL 2 BREATHER TUBE ASSEMBLY Insert until the white line aligns with...

Page 320: ...he flywheel cover P 6 1 3 Drainthe carburetor by looseningthe drain screws 4 Pull off the breathertube from the silencer cover 5 Remove the 14P connector remote control box wire harness or tiller handle main wire harness and 2P connector SE thermal valve heater wire from the connector holders and disconnectthe 2P connector 6 Disconnectthe throttle rod from the throttle cam I l BREATHER TUBE r i i ...

Page 321: ...r supply line from the fuel pump AIR VENT TUBES 8 Pinchthe fuel tube with a commerciallyavailabletube clip and disconnect the fuel tube E No 2 and 3 car buretor supply line from the fuel pump 1I 2 FUEL TUBE TUBE CLIP r i i L A FUEL TUBE E PI TUBE CLIP Commercially FUEL PUMP available l VINYL TUBES 9 Pull off the vinyl tubes from the engine under case I ENGINE UNDER CASE 5 3 ...

Page 322: ...BF40AoBF50A 11 Remove the two 6 mm cap nuts and five 6 x 32 mm flange bolts then remove the carburetor and manifold assemblyfrom the crankcase ...

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Page 325: ...cam assist spring assist plate be made with the engine installed throttle opener cam opener cam returnspring 6 7 x 12 5x 24 mm collar P I THROTTLE CAM 1 6 1 ASSIST SPRING 151 THROlTLE OPENER CAM 4 1 6 7x 12 5x 24 mm 6x 40 l 6 mm WASHER 2 ASSIST PLATE 131 OPENER CAM RETURN SPRING 4 Remove the 6 x 16 rnm torx bolts using a commer cially available torx bit T30H and remove the dash pot diaphragm 3 1 D...

Page 326: ...aking care not to bend it 2 Removethe six 6 x 97 mm flange bolts 3 Separate the intake manifold and carburetor as shown 51 6 x 16 mm TORX BOLT 2 4 INTAKE MANIFOLD 6 DASHPOT DIAPHRAGM 7 5x 10 mm PLUG 3 lo 6x 18 mm SCREW 1151 SILENCER PLATE 6 x 97 6 ...

Page 327: ...n han dling fuel Keep heat sparks and flame away Handlefuel only outdoors Wipe up spills immediately 1 No 1 carburetor only Remove the screw and set plate then remove the SE thermal valve and O ring with care not to damage the needle 2 Remove the four washer screws and remove the float chamber and bowl gasket 3 Remove the drain screw and O ring from the float chamber if necessary l SE THERMAL EW 3...

Page 328: ...he knurled section of the float pin 5 Removethe float and float valve 6 Remove the main jet taking care not to damage the mainjet 7 Remove the plug screw main nozzle and jet nozzle taking care not to damage them I 2 0 mm PIN DRIVER Commerciallyavailable 51 141 2 FLOAT KNURLED SECTION FLOAT PIN 1 11 PLUG SCREW 151 MAIN NOZZLE 141 MAINJET JET NOZZLE 3 O RING Do not reuse 5 10 ...

Page 329: ...and float chamber with cleaning solvent 2 Use low air pressure and blow off the removed jets nozzles and passages of the carburetor body and float chamber d INSPECTION Float LevelHeight Place the carburetor as shown and measurethe distance between the float top and carburetor body when the float just contacts the seat without compressing the valve spring If the height is out of specification adjus...

Page 330: ...ssary 15 8 24 2 n SE Starter Enrichment THERMAL VALVE 1 Check the valve piston and needle for wear or scratches Replaceas assembly if necessary 3 Installa vinyl tube as shown 4 At room temperature gently blow into the tube and verify air passesthrough the passage 11 VALVE PISTON 2 NEEDLE 1 11 VINYL TUBE 2 Blow 5 12 ...

Page 331: ...inal for about five minutes A gentle puff of air should not pass through Note that inspection with the battery connected must be made quickly The SE thermal valve heater becomes very hot when the battery is connected Take care not to touch it 1 11 121 BLACKI BROWN GREEN WHITE NEGATIVE POSITIVE 3 Blow 4 VINYL TUBE 5 13 ...

Page 332: ...ER SCREW 4 8 O RING DRAIN SCREW 9 1 BOWL GASKET 1131 4 17 PLUG SCREW 16 MAIN NOZZLE 14 O RING 15 THROTTLE STOP PILOT SCREW t b P I FLOAT CHAMBER 1 4 JET NOZZLE P 5 MAIN JET I 6 FLOAT PIN ASSEMBLY P 5 23 7 CARBURETOR BODY 9 SE THERMAL VALVE ASSEMBLY P 5 12 I21 SPRING l l SCREW lo SET PLATE 5 14 ...

Page 333: ...EW 4 14 FLOAT 1151 BOWL GASKET 13 PLUG SCREW 12 MAIN NOZZLE d l lo O RING I Do not reuse k II I 11 THROTTLE STOP SCREW I 2 FLOAT CHAMBER 31 FLOAT VALVE 4 JET NOZZLE JET r rioi O RING 8 SPRING 9 PILOT SCREW 6 FLOAT PIN ASSEMBLY P 5 23 I CARBURETOR BODY 5 15 ...

Page 334: ... CHAMBER 16 DRAINSCREW 115 1 BOWL GASKET 13 PLUG SCREW 3 FLOAT VALVE 1111 O RING II w 1 DOnot reuse w 1 1 ll O RING C e Y 1 Do not reuse I i h m lo PILOTSCREW 4 JET NOZZLE 5 MAINJET 6 FLOAT PIN 8 SPRING 1 ASSEMBLY P 5 23 r 7 1 CARBURETOR BODY 8 SPRING r91 THROTTLE STOP SCREW 5 16 ...

Page 335: ...he pin at the knurled section side of the float pin SE THERMAL VALVE INSTALLATION 1 Install a new O ring to the SE thermal valve 2 Install the SE thermal valve with the set plate and loosely install the screw 3 Set the SE thermal valve as shown noting the direc tion and tighten the screw securely 1 11 KNURLEDSECTION 2 0 mm PIN DRIVER Commercially available l SE THERMAL VALVE EW 4 INTAKE k ETHERMAL...

Page 336: ... 6 1 DO not reuse I 3 6x 15 mm DOWEL PIN 6 4 INTAKE MANIFOLD 1 Installthe throttle link rod with the UP 1 J I n s c ma tor I link rod 13 1 13 THROTTLE LINK ROD Irk facing toward the No 1 carbure Take care not to bend the throttle CARBURETOR 7 j No 1 CARBURETOR 8 No 2 CARBURETOR 9 SILENCER PLATE lo COLLAR 6 6x 97 6 I 10 N m 1 0 kgf m 7 Ibf ft I 5 18 ...

Page 337: ...ASHPOT DIAPHRAGM I 5 Align the point A of the assist spring with the groove in the throttle cam 6 Set the projectionof the assist plate in the hook of the assist spring and align the flat surface of the throttle cam with the tab of the assist plate 7 Install the throttle cam assist spring and assist plate on to the collar as an assembly 8 Install the 6 mm washer and tighten the 6 x 40 mm flange bo...

Page 338: ...ps vinyl tube l AIR VENT TUBE 3 4 5 x93 mm 2 VACUUMTUBE 3 3 AIR VENT TUBE A 3 5 x 45 mm I 4 TUBE CLIP B10 1231 AIR VENT TUBE C VACUUM TUBE 21 3 WAY JOINT B 8 FUEL TUBE F AIR VENT TUBE D FUELTUBE CLIP 19 TUBE CLAMP 18 AIR VENT TUBE ll 3 WAY JOINT PIPE 17 AIR VENT TUBE 12 TUBE CLIP B10 5 WAY JOINT A 4 5 x 170 mm 5 20 ...

Page 339: ...uum tube D and dashpot check valve fuel tube clamp A air vent tubes SE tube B and tube clips SE tube A and tube clip B10 PI 31 SE TUBE B 2 TUBE CLIP 4 VENT TUBE D AIR VENT TUBE B VACUUM TUBE D CLAMP A 6 DASHPOT CHECK VALVE 7 ARROW MARK 5 21 ...

Page 340: ...y and loosely install the 6 mm cap nuts fuel tube clamp and 6 x 32 mm flange bolts 1 CARBURETORlMANlFOLD 12 N m 1 2 kgf m 9 Ibf ft INTAKE MANIFOLD GASKET 4 FUEL TUBE CLAMP Tighten the 6 x 32 mm flange bolts and 6 mm cap nuts to the specified torque in the numbered sequence shown in 2 3 steps TORQUE 26 N m 2 7 kgfem 20 IbfO f t 6 x 32 5 5 22 ...

Page 341: ...fuel tube No 1 carburetor supply line to the 0 markedfitting 6 Connect the SE thermal valve heater wire 2P connec tor and set the 2P connector to the lower connector holder then set the 14P connector to the upper con nector holder 7 Insert the breather tube in the silencer cover until the white mark aligns with the hole edge as shown l AIR VENT TUBES CASE I l FUEL TUBE 240 mm TUBE E 2 2P CONNECTOR...

Page 342: ... engine under case 9 Connectthe throttle rod to the throttle cam 10 After installation adjust the throttle linkage P 3 5 11 Install the removed parts in the reverse order of removal I l VINYL TUBES 121 I ENGINE UNDER CASE P I THROTTLE 121 THROTTLE ROD ...

Page 343: ...e bolts to the specified torque in part and threaded part drips from the thread of the bolt crisscross pattern in 2 3 steps Torque 65 N m 6 6 kgf m 48 Ibf ft 6 x 32 4 2 FLYWHEEL ASSEMBLY Wipe the flywheel and crankshaft mounting surfaces with a clean shop towel sprayed with degreasingagent 10 x 25 4 0 Apply engine oil A Degrease r v IA A A A A A1 121 1 FLYWHEEL T T T T PI 2 CRANKSHAFT 6 1 ...

Page 344: ...Y 1 Remove the engine cover and tiller handle P 15 1 2 Remove the 8 mm self locking nut 3 Remove the 8 mm washer friction adjusting lever 8 mm nylonwasher and friction disc 4 Remove the two 6 x 12 mm flange bolts and friction plate 5 Remove the friction disc 71 FRICTIONADJUSTING x LEVER 6 x 1 2 GI FRICTIONPLATE w i n i L n NYLON WASHER 141 FRICTIONDISC 12 1 ...

Page 345: ...tall one of the fric tion disc onto the friction lever shaft by aligning the cutout with the boss on the swivel case and facing the disc surface toward the friction plate as shown 5 Installthe friction plate to the mount frame by aligning the groove with the friction lever shaft and loosely install the two 6 x 12 mm flange bolts 6 Push the friction plate toward the mount frame in the direction sho...

Page 346: ...ing lever to the left side fully and hold it in this position and tighten the 8 mm self locking nut to the specifiedtorque TORQUE 9 5 N m 0 95 kgf m 6 9 Ibfoft 10 Check the starting torque by measuring the starting force using a spring scale at the center of the throttle grip P 3 8 I1 2 8 mm ADJUSTING LEVER NUT FRICTION SELF LOCKING 131 8 mm WASHER I I 141 8 mm NYLON WASHER I 5 FRICTION ADJUSTING ...

Page 347: ...on Remove the 10 mm E ring from the upper cylinder pin and then remove the upper cylinder pin Remove the upper mount of the gas assisted damper from the swivel case Removethe upper cylinder bushings if necessary Replace with new ones when the upper cylinder busings are removed Remove the transom angle adjusting rod Remove the 6 x 25 mm hex bolts 6 mm plain wash ers and anode metal Remove the 10 mm...

Page 348: ...gs if necessary Replace with new ones when the lower cylinder busing is removed TILT LEVER REPLACEMENT Before removing the tilt lever set the tilt lever in the RUN position Install the tilt lever by aligning the mounting hole of the lever with the tilt lever shaft and noting the installation direction as shown 1 11 10 mm DISTANCE COLLAR 2 GAS ASSISTED DAMPER LOWER CYLINDER BUSHING 2 3 26 mm WAVE W...

Page 349: ...hamber oil escaping under high pressure may cause serious personal injury Do not use a dull drill bit which could cause a build up of excessive heat and pressure inside the damper leading to explosion and severe personal injury Always wear eye protection to avoid getting metal shaving in your eyes when the gas pres sure is released The plastic bag is only intend ed to shield you from the escaping ...

Page 350: ...E RING CYLINDER PIN ANODE METAL 1 101 LOWER CYLINDER BUSHING 2 IDo not reuse I I I DAMPER 171 UPPER CYLlNDER BUSHING 2 I Do not reuse I After installing the gas assisted damper tighten the 7 8 14 UNF self locking nut to the specified torque Then turn it back 1 2 3 4 turns TORQUE 39 Nom 4 0 kgfom 29 Ibfoft 1 11 7 8 14 UNF SELF LOCKING NUT 13 4 ...

Page 351: ...motor to the uppermost position and set the tilt stopper in the TILT position Remove the engine cover and CDI unit cover see base shop manual Pullthe fuse holder from the fuse holder bracket Removethe 6 x 12 mm flange bolt and main wire har ness ground terminal Removethe 6 x 25 mm flange bolt 6 mm plain wash er and fuse holder bracket Removethe CDI unit case mountingthree 6 x 25 mm flange bolts an...

Page 352: ... clip und pull out the trim angle sensor wire through the hole of the CDI unit case 12 Loosenthe rivet screw and remove the 14 mm clip 13 Remove the upper case grommet C from the engine under case and pull the power trimhilt motor and trim angle sensor wires from the engine under case CONNECTOR rn I l CONNECTOR HOLDER 2 CONNECTORS I SENSOR WIREY SENSOR WIRE TRIM ANGLE SENSOR WIRE GROMMET 13 6 ...

Page 353: ...s and anode metal 18 Remove the 10 mm E ring from the upper cylinder 19 Remove the upper mount of the power trimhilt from 20 Remove the upper cylinder bushings if necessary pin and then remove the upper cylinder pin the swivel case Replace with new ones when the upper cylinder busing is removed I1 2 WIRE HARNESS CLIP TRlW I L T MOTORAND 0 TRIMANGLE CORD BUSHING SENSOR WIRES P I TRANSOM ADJUSTING R...

Page 354: ...25 Remove the 28 mm wave washer 19 4 x 6 mm thrust 26 Remove the lower cylinder bushings if necessary trim tilt assembly washer and distance collar Replace with new ones when the lower cylinder busings are removed 112 1 111 7 1 8 14UNF SELF LOCKING NUT 11 1 7 8 14 UNF SELF LOCKING NUT I Loosen h i 2 TRIM ANGLE SENSOR INSPECTION See base I V n I V V 111111 4 1 6x 20 mm HEX ll 10 mm PLAIN WASHER lo1...

Page 355: ...pper cylinder pin lower cylinder bushings 28 mm wave washer distance collar and 19 4x 6 mm thrust washer If the upper cylinder bushing and lower cylinder bushing have been removed replace with new ones l MOTOR WIRE BUSHING 131 7 8 14 UNF SELF LOCKING NUT 12 DISTANCE COLLAR 1 3 19 4x 6mm THRUST WASHER 114 1 LOWER CYLINDER BUSHING 2 I DO not reuse 1 13 9 ...

Page 356: ...nsor wire together with the power trimhilt switch wire and power trimhilt relay wires as shown 2 PURSE LOCK CLIP trim tilt switch wire power trimhlt relay wires and trim 151 TRIM ANGLE SENSOR WIRE 3 POWER TRIMITILT A I MOTOR WIRE 3 POWER TRIMITILT 9 14 mm TUBE CLIP MOTOR WIRE 141 TRIM ANGLE SENSOR Clamp the center of the gray tape position of the power trimhilt motor wire with the wire harness cli...

Page 357: ...d tighten the bolts securely 6 Install the fuse holder bracket with the 6 x 28 mm flange bolt then install the fuse holder 7 Set the ground terminal as shown and tighten the 6 x 12 mm flange bolt securely noting the terminal direc tion 11 P I 6 mm PLAIN WASHER CDI UNIT CASE 71 FUSE HOLDER BRACKET 3 BLACK LIGHT GREEN YELLOWlBLUE TRIM ANGLE SENSOR WIRE P I GROUND TERMINAL 6x12 13 11 ...

Page 358: ...e two 6 x 28 mm flange bolts two 6 x 40 mm flange bolts and four 6 mm plain washers and remove the separator cover 3 Removethe 14P connectorfrom the connector holder and disconnectthe 14Pconnector 4 Remove the 6 mm lock pins and 6 mm washers the disconnectthe throttle and shift cables 111 6 mm PLAIN SEPARATOR 6 x 40 2 P I 14P 121 CONNECTOR HOLDER I l THROTTLE CABLE 2 SHIFT CABLE 31 6 mm WASHER 4 1...

Page 359: ...e from the control cable set plate 6 Remove the under case grommet 7 Remove the two 10 mm self locking nuts and two 10 mm washers then remove the long tiller handle assembly 111 THROTTLE CABLE GROMMET A 41 I TILLER HANDLE WIRE HARNESS 15 2 ...

Page 360: ...trol cables from the throttle arm and shift arm Removethe control cables and grommet Removethe 6 x 12 mm bolt washer and cable holder I 2 UNDER COVER SCREW 6 T Q 2 THROTTLE ARM A y F i R O n L E CABLE 81 4 mm E CLIP 2 7 SHIFT CABLE PI PI Release the wire band clip and disconnect the emer gency stop switch wire connectors WIRE BAND CLIP EMERGENCY STOP SWITCH 15 3 ...

Page 361: ...nector cover 9 Slide the connector cover A and disconnect the con nectors and then remove the tiller handle wire har ness 10 Remove the 6 x 12 mm bolt washer and connector bracket I1 2 CONNECTOR COVER B WIRE BAND CLIP 3 31 TILLER HANDLE WIRE HARNESS 1101 POWER TRIM TILT SWITCH WIRE 91 CONNECTOR COVER A 8 IGNITION SWITCH WIRE 71 INDICATOR WIRE 161 6x 12 mm BOLT 1 4 1 30 mm CONNECTOR COVER 151 CONNE...

Page 362: ...n remove the 6 x 12 mm flange bolt 2 Remove the throttle friction grip and throttle friction pad 3 Remove the throttle grip pipe by turning clockwise viewed from the grip end and remove the throttle fric tion disc FRICTION GRIP FRICTION DISC 4 GRIP PIPE 15 5 ...

Page 363: ...the 5 x 10 mm screws and remove the wire cover 2 Remove the 5 x 8 mm hex bolt and 5 mm washer and remove the power trim tilt switch and switch grommet Gas Assisted Tilt Type 1 Remove the 5 x 8 mm hex bolt and 5 mm washer and remove the switch bracket and switch hole grom met l 10 mm WASHER 2 9 mm E CLIP El THROTTLE ROD El THROTTLE ROD 131 1 I 4 7 5 x 10 mm SCREW 2 1 1 H t X EULI pa 1WASHEl WIRE CO...

Page 364: ...3 Remove the three 5 x 12 mm hex bolts and three 5 mm washers 4 Removethe guide plate and throttle arm 5 Removethe two 6 x 12 mm bolt washers and remove the shift unit 1 111 HOLE CAP I 121 8 x 50 mm SOCKET BOLT FT LEVER STOPPER SHIFT LEVER BUSHING P 51 41 SHIFT LEVER l 5 x 12 mm HEX BOLT 3 1215 mmWASHER 3 4 THROTTLE ARM P I 5 6 x 12 mm BOLT WASHER 2 15 7 ...

Page 365: ...ING 81 ROLLER 7 SHIFT FRAME STEERING BRACKET 1 Remove the 12 mm lock nut 12 mm hex nut 14 mm wave washer and distance collar 1 3 1 Remove the 12 x 80 mm hex bolt and 12 mm washer Remove the steering bracket Remove the 12 mm thrust washer Remove the steering handle bushings if necessary Replace with new ones when the steering handle busings are removed STEERING BRACKET 12mm 1 9 1 12mm LOCK NUT 12mm...

Page 366: ...op switch clip and 16 mm lock nut and remove the emergency stop switch 2 Removethe lock nut and remove the ignition switch 3 Removethe indicator SWITCH INDICATOR 3 EMERGENCY STOP SWITCH INSPECTION See base shop manual 1 11 SWITCH 5 INDICATOR I INSPECTION P 16 4 I 1519 ...

Page 367: ... switch with the flat section of the installation hole as shown Tighten the lock nut to the specifiedtorque Torque Ignition switch lock nut 7 N m 0 7 kgfom 5 1 Ibf ft 16 mm lock nut 1 5 N m 0 15 kgf m 1 1 Ibfuft l CUTOUT 121 IGNITIONSWITCH FLAT SECTION t41 IGNITIONSWITCH LOCK NUT I 7 N m 0 7 kgf rn 5 1 Ibfoft I 6 16 mm LOCK NUT 1 3N m CUTOUT 31 FLAT SECTION PI EMERGENCY Y STOP SWITCH 15 10 ...

Page 368: ...ER SHIFT UNIT THROlTLE ARM 8 SCREW 2 r7i SPRING 6 SHIFT ARM PIN 2 5 x 12 mm HEX BOLT 3 CDPINIE E I i i n c cgf m 3 3Ibfoft 1 4 5N m 0 45 E 11 5 mm WASHER 3 GUIDE PLATE SHIFT FRAME SHIFT LEVER STOPPER 1 171 1141 BUSHING 1541 ...

Page 369: ...l the shift gear and spring guide assembly with shown the shift arm set in vertical position as shown Apply grease to the pivot point of the throttle arm Tighten the 5 x 12 mm hex bolt to the specifiedtorque TORQUE 4 5 N m 0 45 kgFm 3 3 IbM 3 SHIFT FRAME SIDE SHIFT ARM PIN 6 SPRING GUIDE 9 SHIFT GEAWSPRING 171 GUIDE ASSEMBLY SHIFT ARM SHIFT FRAME l 5x 12 mm HEX BOLT 3 121 THROTTLE ARM 4 5 N m 0 45...

Page 370: ... the shift arm in a vertical position to align the shift unit square and shift gear Installthe shift lever Install the shift lever by aligning the square of the lever stopper and that of the shift gear 1 4 1 3 SHIFT UNIT I 6 12rnrnBOLT P I SHIFT LEVER STOPPER SOCKET BOLT 7 8 rnrn WASHER I 6 BUSHING 5 SHIFT LEVERAJ 15 13 ...

Page 371: ...with a new wire band cut the end of the wire band so the projected end length is 10 20 mm 0 4 0 8 in Tighten the 5 x 10 mm hex bolt to the specified torque Torque 4 5 N m 0 45 kgf m 3 3Ibfuft 2 POWER TRIWILT 131 SWITCH GROMMET 4 UP MARK Power trim tilt type only Check whether the power tilt switch wire does not interfere with the 5 x 8 mm hex bolt head 131 1 5 x 10 mm SCREW 2 1 101 5 mm WASHER SWI...

Page 372: ...ROTTLE ROD THROTTLEGRIP 1 4 1 3 LOCK NUT I 1 3 N m 0 13 kgfom 0 9 Ibf ft 1 51 10mm WASHER 2 I 111 THROTTLE CABLE PIN ll GRIP PIPE 6 9mm E CLIP 4 1 8 1 THROTTLE 6x12 1 7 N m 0 7kgf m 5 1 Ibf ft I lo GRIP RUBBER 15 15 ...

Page 373: ...ower trim tilt type only Check whether the power tilt switch wire does not interfere with throttle rod Apply grease to the throttle grip installation surface of the tiller handle and friction disc Install the friction disc by aligning the grooves of the throttle friction disc with the bosses of the tiller handle as shown Install the throttle cable pin on the cable pivot with the projected length a...

Page 374: ...ighten the throttle friction grip against the thrqttle fric tion disc by aligning the cutout of the friction pad with the boss of the friction disc Tighten the 6 x 12 mm flange bolt securely Turn the grip pipe to the fully close position and install the grip rubber by aligning the A mark with fully close mark l BOSS 1 6 1 CUTOU FRICTIONDISC 4 7 Inside FRICTIONPAD 7 Inside A PIPE 7 FRICTIONPAD 1 5 ...

Page 375: ... of the 12 x 80 mm hex bolt then tighten the 12 mm hex nut to the specified torque TORQUE 29 N m 3 0 kgfam 22 Ibfdt nut to the specifiedtorque TORQUE 54 N m 5 5 kgf m 40 Ibfdt Hold the 12 mm hex nut and tighten the 12 mm lock 3 DISTANCE COLLAR 141 i STEERING BRACKET 2 14mm WAVE WASHER l 12mm LOCK NUT 1 54 N m 5 5 kgf m 40 Ibf ft 1 29 N m 3 0 kgfmrn 22 Ibfsft L A h 1 8 1 12mm THRUST W P 1 5 12mm WA...

Page 376: ...ecuring the connectors and wires with a new wire band cut the end of the wire band so the project ed end length is 10 20 mm 0 4 0 8 in Installthe tiller handle wire harness by aligning the wire tie with the grommet as shown 4 WIRE BAND CLIP 10 20 mm 0 4 0 8 in 4 GROMMET PowerTrimniIt Type 6 WIRE BAND CLIP 3 r51 POWER TRIM TILT 1141 CONNECTOR COVERA 121 r31 TILLER HANDLE WIRE TIE WIRE HARNESS L r71...

Page 377: ...d Tilt Type l WIRE BAND CLIP 3 EMERGENCY STOP SWITCH WIRE CONNECTOR COVER B lo1 COVER A TILLER HANDLE WIRE HARNESS CONNECTOR 141 r91 IGNITION SWITCH WIRE 181 30 mm CONNECTOR INDICATOR WIRE CONNECTOR BRACKET BOLT WASHER 15 20 ...

Page 378: ...he cable with the cutout of the mountingpoint Set the throttle cable by aligning the groove with the cutout of the cable holder Route the throttle and shift cable through the grommet upper hole shift cable lower hole throttle cable holes and set the grommet in the case correctly Power trimhilt type only Check whether the power tilt switch wire does not interfere with the throttle cable Tighten the...

Page 379: ...g plate into the groove of the under case Passthe control cables through the under case grom met and set the control cables by aligning the groove of the control cable with the cutout of the control cable setting plate Adjust the control cables throttle control cable length P 3 6 shift control cable length P 3 8 Connect the control cables to the shift arm and throt tle arm with the 6 mm plain wash...

Page 380: ...wo 6 x 28 mm flange bolts and two 6 x 40 mm hex bolts securely l 6 mm PLAIN WASHER 2 131 6 mm PLAIN WASHER 2 6 x 40 2 10 Connect the 14P connector of the long tiller handle wire harness to the main wire harness and set the 14P connectorto the connector holder 11 After installation check the throttle operation and gear shift operation 15 23 ...

Page 381: ...sure the tester s battery is fully charged and check the meter before using the tester Use a R x 1 scale of an commercially available multi meter and meter shows current flowing from negative to positive 60 300 20 150 24 150 90 400 15 60 60 300 m 22 100 m 17 70 9 5 38 m 9 3 6 14 60 30 150 7 2 8 22 90 m 11 45 m 8 3 2 4 8 20 m 4 4 17 5 2 0 26 150 7 2 8 22 90 m 11 45 m 8 3 2 4 8 20 m 4 4 17 5 2 0 t 4...

Page 382: ...BF40AoBF50A l unit kQ 2 Tester probe 23 0 4 1 6 m 2 8 2 8 3 6 15 3 8 18 1 6 7 4 16 3 8 16 0 2 4 10 24 3 2 13 m 5 5 24 6 2 4 6 5 23 7 2 8 4 6 19 8 3 4 7 3 0 2 6 11 2 6 11 16 2 ...

Page 383: ...sor and measure the resistance between the sensor ter minals at the room temperature Standard resistance 1 5 k 2 2 Connect the 2P connector and start the engine and warm up the engine to normal operatingtemperature 3 Stop the engine and disconnect the 2P connector and measurethe resistance Standard resistance 200 400 R ECT sensor installation removal is almost the same as installation removal of t...

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Page 391: ...ury or lossof lifeif instructions are notfollowed CAUTION Indicates a possibility of personal injury or equipmentdamage if instructionsare notfollowed All information illustrations directions and specifications include in this publication are based on the latest prod uct informationavailable at the time of approvalfor print ing Honda Motor Co Ltd reserves the right to make changes without incurrin...

Page 392: ...INDEX BF40A B F50A 2 SERVICE INFORMATION 2 1 1 MAINTENANCE STANDARDS 2 1 2 TORQUE VALUES 2 1 3 SPECIAL TOOLS 2 2 4 TROUBLESHOOTING 2 3 13 GAS ASSISTED POWER TILT 13 1 1 POWER TRlM TlLT ASSEMBLY 13 1 ...

Page 393: ...35 kgf cmz 2 802 3 342 psi 2 TORQUE VALUES Torque Item Power trimhilt Upper joint metal Oil hole cap bolt Oil tank socket bolt Outer tube Outer tube guide Gear pump socket bolt Spool valve cap Manual valve 2 Way valve Motor screw Yoke screw Thread dia x pitch M14 x 1 5 M5 x 0 8 M41 x 1 5 M52 x 1 5 M5 x 0 8 M22 x 1 O M12 x 1 75 M12 x 1 0 M5 x 0 8 3 8 16UNC 1 4 20UNC NOTE 1 Apply LOCTITEO 271 to the...

Page 394: ...ool number Application Blow pressure inspection Gaugejoint A 07OPJ V150100 Gaugejoint B 07OPJ V150200 Lock nut wrench 0709A ZW40100 Outer tube guide removal installation Lock nut wrench 30 x 40 07916 9690000 Outer tube rernovaVinstallation 0 0 0 2 2 ...

Page 395: ...valve Faulty power trim tilt assembly Check and repair the power trim tilt assembly according to the table on Tight A_ 7 Check for oil leakage from each mating part Not leaking Check the oil level with the piston rod fully extended P 13 28 Normal 1 I Check or air in the system No air 4 Loose I Tighten the manualvalve securely Leaking Replace the O ring and or oil seal at the leaking point Low Air ...

Page 396: ...il leakage from each mating Leaking Replace the O ring and or oil seal at the leaking point part Not leaking Check the oil level with the piston rod fully extended P 13 28 Normal c b h e c kfor air in the system No air _ _ _ _ _ Low 1 Fill with ATF P 13 28 Air I Bleed air P 13 27 and recheck 1 2 4 ...

Page 397: ...op manual Open Replacethe front bracket Abnormal Replacethe power trim tilt relay Normal j 1Check the motor f o v e r h e a t i n g Overheats 4Cool down the motor Normal Jl J ____ Check for water or oil ATF in motor Replacethe motor Normal Disassemble and replace the I faulty parts in the motor T Check the power trimhilt switch See base shop manual Normal Abnormal Replacethe power trimhlt switch C...

Page 398: ...r as the upper relief valve is built in the SDOO valve 0 0 0 0 0 Lower cham ber check valve Check the check valve for dam age wear or foreign material Clean and reassemble the lower chamber checkvalve properly 0 0 0 8Gear pump ReDlacethe aear DumD assemblv 0 0 I Down relief valve Check the valve for damage wear or foreign material Clean and reassemble the down relief valve DroDerlv 0 0 I Thermal v...

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Page 400: ...rts POWER TRIM TILT MOTOR 1 Connect the power trimhilt motor 2P connector and operate the power trimhilt motor assembly until the piston rod extends fully 2 Loosen the manual valve fully 3 Remove the oil hole cap and drain ATF in a suitable container through the bolt hole 4 Remove the O ring from the oil hole cap bolt and dis card it Replace the O ring with a new one during reassembly Do not drain...

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Page 402: ... shop towel or soft jaws as shown CAUTION Take care not to tighten the vise too tight as it damagesthe valve body 2 Holdthe piston rod and removethe upperjoint metal Clean of locking agent from the threaded points of the piston rod l UPPERJOINT METAL 2 PISTON ROD 13 3 ...

Page 403: ...ring reassembly 5 Remove the oil seal using small screw driver as shown Discard the oil seal Replace it with new one during reassembly CAUTION Take care not to damage the oil seal installation sectionwhen removingthe oil seal l 5 mm SOCKET BOLT 4 5 MOTOR CORD BRACKETB 2 OIL TANK 41 WIRE BAND I CLIP 2 3 O RING Do not reuse 1 1 l OIL SEAL 1 p z z r P I OIL SEAL INSTALLATION SECTION 13 4 ...

Page 404: ... valve body and cylinder assembly from the vise 8 Remove the cylinder piston assembly from the valve body and drain ATF from the cylinder assembly and valve body 9 Remove the O ring from the bottom piece and discard it Replace the O ring with new one during reassem bly r11 LOCK NUT WRENCH 070PA ZW40100 GUIDE 3 O RINGS pzizr r11 2 BOTTOM PIECE CYLINDEWPISTON I I 131 IDo not reuse 1 VALVE BODY 1315 ...

Page 405: ...magesthe bottom piece 11 Remove the outer tube by loosening the outer tube slowly and drain the residual ATF from the outer tube and cylinder Remove the O ring from the outer tube using a small screw driver taking care not damage the O ring instal lation section and discard the O ring Replace the 0 ring with new one during reassembly Clean the threads of the outer tube s TooII l LOCKNUT WRENCH 30 ...

Page 406: ...d the O rings and discard them Replace the O rings with new ones during reassem bly VALVE BODY 1 Remove the socket bolts and gear pump assembly Do not disassemble the gear pump assembly If it is faulty replace it as an assembly 2 Remove the two O rings from the valve body and dis card them Replace the O rings with new ones during reassembly l BOTTOM PIECE 161 CYLlNDER I 141 151 FREE PISTON PISTONR...

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Page 408: ...ap Remove the O rings from the spool valve cap and valve B and discard them Replace the O rings with the new ones during reassembly P I DRIVER BIT 2 8 mm I Commerciallyavailable l VALVE B 121 SPOOL 1 o n o t reuse 1 8 Remove the spool valve from the valve body l SPOOL VALVE Check the backup ring on the spool valve for damage and scratches Replace the backup ring if it is dam aged or scratched l SP...

Page 409: ...ody Remove the O ring from the sleeve and discard it Replace the O ring with a new one during reassembly 8 Set the valve body as shown Apply small squirt of air pressure to the manual valve installation hole to remove the valve B Remove the valve B from the valve body Remove the O ring from the valve B Replace the 0 ring with a new one during reassembly l About 50 m m 1 O in i i 3 4 mm 0 12 0 15 i...

Page 410: ...y valve and discard it Replace the O ring with a new one during reassem bly 2 2 WAY VALVE 3 UPPER CHAMBER 2 SPRING l SPRING GUIDE 5 STEEL BALL 4 DOWNRELIEF VALVE SEAT CYLINDER Make sure the piston rod is straight and has no damage Replace the piston rod assembly with a new one if neces sary PISTON FREE PISTON Check the inner and outer surfaces of the cylinder for damage and scratches Replace the c...

Page 411: ... 4 in 2 WAY VALVE Check the 2 way valve for damage scratches and wear Replace if necessary Service limit 6 mm 0 2 in OIL TANK Visually inspect the oil seal installation section of the oil tank Replace the oil tank if scratched or damaged POWER TRlMfllLT MOTOR Brush Measurethe brush length I l SLEEVE SPOOL VALVE I f l l OIL SEAL INSTALLATION SECTION 13 12 ...

Page 412: ...ves and measure the depth again If the measurement is less than the service limit replacethe armature Service limit 1 3 mm 0 05 in 4 Check for continuity between each segment If an open circuit exists between any two segments replace the armature 5 Check for continuity between the commutator and armature coil core If continuity exists replace the armature P I MICA I I I N f 6 Check for continuity ...

Page 413: ...e parts in the fresh ATF and blow each port of the parts with compressed air Check that the parts are free from contamination with dust and dirt before reassembly l SOCKET BOLT A 3 5 N m 0 5 kgf m 3 6 Ibf ft VALVE SPRING SPRING GUIDE 5 2 WAY VALVE STEEL BALL DOWN RELIEF VALVE SEAT O RING 1 5 x 3 5 mm 17 BACKUP RING 16 SPOOL VALVE l SPOOL VALVE C A i 22 N m 2 2 kgf m 16 Ibf ft 13 O RING 1 5 x 15 5 ...

Page 414: ...y noting the installationdirection 8 Apply ATF to a new O ring and install it on the valve 9 Apply ATF to the valve B and install it in the spool 10 Apply ATF to the new O rings and install the O rings 11 Tighten the spool valve cap to the specified torque 6 valve cap noting the installationdirection on the spool valve cap using a commercially available 2 8 mm driver bit TORQUE 22 N m 2 2 kgf m 16...

Page 415: ...ied torque and set the internal circlip in the groove in the valve body securely TORQUE 1 7 Nom 0 17 kgfom 1 2 Ibfoft 15 Apply ATF to new O ring and install it on the 2 way 16 Install the 2 way valve to the valve body and tighten valve the 2 way valve to the specifiedtorque TORQUE 7 Nom 0 7 kgfom 5 1 Ibfoft l MANUAL VALVE 3 O RING 1 2 x 5 8 mm 2 4x9 8 mm 4 SEAL WASHER 5 D RING 1 2 x 5 8 mm 2 4x9 8...

Page 416: ...r safety valve install it in the valve body noting the direction shown 22 Apply ATF to the two new O rings and install the 0 rings in the valve body in the positions shown 23 lnstall the gear pump assembly in the valve body by aligning the projection at the bottom of the gear pump assembly with the positioning hole in the valve body Take care not to let the O rings come out of posi tion in the val...

Page 417: ...d dirt before reassembly l UPPER JOINT METAL 44 N m 4 5 kgf m 33 Ibf ft 30 5 mm SOCKET BOLT 4 L p 22 O RING 2 0 x 49 5 mm 21 O RING 2 0 x 45 54 mm I I 20 O RING 2 4 x 15 8 mm i DO not reuse j 2 OIL SEAL j o n o t reuse 1 3 OIL TANK WIRE BAND CLIP 2 BRACKET B 10 82 x 1 78 mm O RING 2 0 x 52 5 mm 23 OUTER TUBE GUIDE 111VALVE BODY 12 PISTON ROD Do not disassemble I DO not reuse j LOWEREND 4 CYLINDER ...

Page 418: ...to damage the O ring and pour the fresh ATF on the free piston 6 Install the piston rod in the cylinder taking care not to damage the O ring rod 7 Push in the piston rod until the free piston end aligns with the bottom end as shown 8 Apply ATF to a new O ring and install it in the bottom piece 1 11 FREE PISTON 121 O RING 2 0 x28 5 mm a 1 11 PISTONROD PI O RING 2 0 x 28 5 mm 141 CYLINDER 1 11 2 0 x...

Page 419: ...ing the bottom piece CAUTlON Take care not to tighten the vise too tight as it damages the bottom piece 11 Pour the fresh ATF into the cylinder up to the top edge of the cylinder 12 Apply ATF to a new O ring and install it in the groove in the outer tube taking care not to damage the 0 ring 121 OUTER TUBE LOWER END ir y 2 OUTER TUBE ir y 2 OUTER TUBE 13 20 ...

Page 420: ...uter tube 2 or 3 turns then apply LOC TITEB 241 or equivalent to the thread of the outer tube as shown 16 Tighten the outer tube to the specified torque using the 30 mm lock nut wrench TORQUE 64 Nom 6 5 kgfom 47 Ibfoft 17 Remove the pistonkylinder assembly from the vise and clean off the residual LOCTITEB from the outer tube l OUTER TUBE P 1 L Apply sealingtape 1 21 l OUTER TUBE 1 2 1 Apply LOCTIT...

Page 421: ...nto the cylinder chamber up to the top edge of the valve body 21 Installthe cylinder piston assembly to the valve body 22 Apply ATF to new O rings and install them on the 23 Pour the fresh ATF into the cylinder chamber of the 24 Install the outer tube guide loosely outer tube guide valve body up to the top edge of the valve body 1I CYLINDEWPISTON ASSY PI O RING 7 3 5 x 41 7 mm I 1 11 O RING 21 OUT...

Page 422: ...nstall it on the outer tube guide 29 Apply ATF to the piston rod and install the oil tank by turning it taking care not to damage the oil seal in the oil tank 30 Set the oil tank as shown and tighten the four 5 mm socket bolts to the specified torque TORQUE 4 7 N m 0 48 kgfem 3 5 Ibf ft 31 Remove the sealing tape from the top end of the pis ton rod S LOCK NUT WRENCH 070PA ZW40100 121 OUTER TUBE GU...

Page 423: ...oke lightly tap on the outer sur face of the yoke with a plas tic hammer for snug fitting of the armature bearing S ARMATURE Remove the burrs at the armature shaft with a fine emery paper before assem bly Take care not to damage the oil seal during assem bly 5 FRONT BRACKET ASSEMBLY 2 5 mm SCREW 3 2 2 N m 0 22 kgf m 1 6 Ibf ft 13 24 ...

Page 424: ...nd install it on the front bracket 4 Make sure there is no metallic part e g washer etc on the magnets before installation 5 Apply grease to the yoke side end of the armature shaft Hold the armature shaft and install the yoke 6 Tighten the three 5 x 20 mm screws to the specified torque TORQUE 2 2 N m 0 22 kgfom 1 6 Ibfoft 7 After assembly lightly tap on the outer surface of the yoke with a plastic...

Page 425: ...dy gear pump chamber quickly Pour the fluid slowly Trapped air in the system causes faulty operation Remove the air bubbles in the fluid completely 4 Install the power trimhlt motor assembly on the valve body so that the motor wires is at the oil filler port on the oil tank and align the motor shaft with the groove of the drive joint as shown 5 Set the motor cord bracket A as shown and tighten the...

Page 426: ...t the manual valve is loose Using a syringe or equivalent tool pour ATF in the oil tank slowly to fill it up 4 After filling the oil tank tighten the manual valve securely Check that the oil hole cap bolt is not installed 5 Push the UP side of the power trimhilt switch to extend the piston rod fully While extending the piston rod pour ATF into the oil tank to keep the oil level in the oil tank at ...

Page 427: ...l filler port 13 Installthe new O ring on the oil cap and tighten the oil cap to the specified torque TORQUE 0 8 N m 0 08 kgfom 0 58 Ibf ft 14 Wipe up ATF spilled from the cylinder comp thor oughly Operate the power trimhilt switch and check that the piston rod moves smoothly 15 Check the blow pressure P 13 29 e UPPER JOINT METAL INSTALLATION 1 Apply LOCTITEa 271 or equivalent to the thread of 2 I...

Page 428: ...ressure gauge Use the pressure gauge which measures 40 MPa 400 kgf cm2 5 600 psi or above with P F 1 4 thread LOWER CHAMBER SIDE BLOW PRESSURE 1 Remove the internal circlip manual valve and sealing washer from the valve body Install the special tool gauge joint body B and the sealing washer and tighten the special tool to the specified torque TORQUE 1 7 N m 0 17 kgf m 1 2 Ibf ft Be sure to remove ...

Page 429: ......

Page 430: ...witch and extend the piston rod fully 5 Remove the special tool and pressure gauge from the valve body Install the sealing washer manual valve and the internal circlip in the valve body Be sure to remove the special tool with the piston rod fully extended or ATF spurts out A small amount of ATF flows out after removingthe tool Installthe manual valve quickly Install the sealing washer securely not...

Page 431: ...ankshaft Piston 116 130 11 Propeller Gear case Extension case 131 155 12 Oil pan Primary gear case Swivel case 156 166 13 Gas assist Power tilt 167 170 14 Steering rod Remote Control box Remote Control type only 171 182 15 Throttle bracket Shift lever Handlebar Tiller handle type only 183 188 16 Electrical equipment 189 211 17 Operation 212 234 BF35a 45a Y Supplement 235 246 BF40a 50a X Supplement...

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Honda BF45A, Service Manual

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