Honda BF4A Operation And Maintenance Ma Download Page 3

Page: 3 / 112

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.

Record the frame and engine serial

numbers for your reference. Refer to

the serial numbers when ordering

parts, 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.

The engine serial number is located

on the cylinder block.

Frame serial number:

Engine serial number:

FRAME SERIAL

NUMBER

ENGINE SERIAL NUMBER

32ZVC6000.book Page 3 Thursday, April 28, 2016 10:51 AM

Summary of Contents for BF4A

Page 1: ...death WILL result if instructions are not followed Indicates a strong possibility that serious personal injury or death may result if instructions are not followed Indicates a possibility that personal injury or equipment damage could result if instructions are not followed Indicates that equipment or property damage could result if instructions are not followed Gives helpful information If a prob...

Page 2: ...pes of the outboard motor differ according to the countries where they are sold Model BF4A BF5D BF6A Type SHND SHNU LHND LHNU SHND SHNU SHD SHU LHND LHNU LHD LHU SHND SHNU SHD SHU LHND LHNU LHD LHU Shaft Length S L Fuel Tank Internal fuel tank Portable fuel tank Charging System TYPE CODE Example S H N U Destination U Europe D General export Charging System N Without System Throttle type H Tiller H...

Page 3: ...erial numbers for your reference Refer to the serial numbers when ordering parts 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 The engine serial number is located on the cylinder block Frame serial number Engine serial number FRAME SERIAL NUMBER ENGINE SERIAL NUMBER 32ZVC6000 book Page 3 Thursday April 2...

Page 4: ...Vent Knob Fuel Gauge 22 Fuel Filler Cap Vent Knob 23 Clamp Screws 23 Fuel Inlet Cap and Fuel Inlet BF5D and BF6A 23 Fuel Line Connector 24 5 INSTALLATION 25 Transom Height 25 Location 25 Installation Height 26 Outboard Motor Attachment 27 Outboard Motor Angle Cruising 27 Battery Connections 29 Battery Charge Cable 30 6 PRE OPERATION CHECKS 31 Removing Engine Cover 31 Installing Engine Cover 31 Eng...

Page 5: ...1 MAINTENANCE SCHEDULE 72 Engine Oil Change 74 Gear Oil Change 76 Starter Rope Check 77 Spark Plug Service 78 Battery Service 80 Lubrication 82 Fuel Filter Check Replacement 83 Fuel Tank Cleaning and Tank Filter Cleaning 85 Replacing the Fuse 86 Propeller and Shear Pin Change 87 Servicing a Submerged Outboard Motor 88 13 STORAGE 90 Fuel 90 Draining the Gasoline 90 Outboard Motor Storage 91 Battery...

Page 6: ... if swallowed Keep the fuel tank out of reach of children Gasoline is extremely flammable and is explosive under certain conditions Refuel in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stored Do not overfill the fuel tank After refueling make sure that the fuel filler cap is closed properly and securely Be...

Page 7: ... on board Do not operate the outboard motor without the engine cover Exposed moving parts can cause injury Do not remove any guards labels shields covers or safety devices they are installed for your safety Fire and Burn Hazards Gasoline is extremely flammable and gasoline vapor can explode Use extreme care when handling gasoline KEEP OUT OF REACH OF CHILDREN Remove the portable fuel tank from the...

Page 8: ...use 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 exhaust can cause loss of consciousness and may lead to death If you run the engine in an area that is confined or even partiall...

Page 9: ... labels indications and safety notes and precautions described in this manual carefully If a label comes off or becomes hard to read contact your Honda outboard motor dealer for a replacement READ OWNER S MANUAL EMERGENCY ENGINE STARTING READ OWNER S MANUAL GEAR SHIFTING 32ZVC6000 book Page 9 Thursday April 28 2016 10 51 AM ...

Page 10: ...ABLE DANGEREUX DANGER HARMFUL OR FATAL IF SWALLOWED KEEP OUT OF REACH OF CHILDREN IF SWALLOWED DO NOT INDUCE VOMITING CALL A PHYSICIAN IMMEDIATELY CAUTION KEEP TOTALLY CLOSED WHEN NOT IN USE KEEP AWAY FROM HEAT SPARKS AND OPEN FLAME SECURE ABOVE DECK IN WELL VENTILATED AREA DO NOT USE FOR LONG TERM FUEL STORAGE DO NOT USE FUEL OIL MIXTURE U type 32ZVC6000 book Page 10 Thursday April 28 2016 10 51 ...

Page 11: ... Year code G H J K L M Year of manufacture 2016 2017 2018 2019 2020 2021 1 Model Name 2 Engine family name 3 Year code 4 Rated power 5 Dry mass weight with propeller 6 Country of manufacture 7 Frame number 8 Manufacture and address 9 Name and address of authorized representative and importer 10 The identification number of the notified body 1 2 3 6 4 5 7 8 9 10 32ZVC6000 book Page 11 Thursday Apri...

Page 12: ... KNOB TILLER HANDLE FUEL VALVE LEVER FUEL FILLER CAP VENT KNOB THROTTLE GRIP STARTER GRIP OIL FILLER CAP DIPSTICK SPARK PLUG ENGINE COVER LATCH ENGINE OIL DRAIN BOLT WASH PLUG ANODE METAL EXHAUST GEAR OIL DRAIN PLUG GEAR OIL LEVEL PLUG STEERING FRICTION BOLT STERN BRACKET COOLING WATERCHECK HOLE HANDLE STOPPER FUEL FILLER CAP 32ZVC6000 book Page 12 Thursday April 28 2016 10 51 AM ...

Page 13: ...MERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD BATTERY CHARGE CABLE Equipped type FUEL INLET BF5D and BF6A only Optional equipment for BF5D and BF6A PORTABLE FUEL TANK FUEL GAUGE FUEL FILLER CAP FUEL FILLER CAP VENT KNOB FUEL LINE PRIMER BULB FUEL LINE CONNECTOR 32ZVC6000 book Page 13 Thursday April 28 2016 10 51 AM ...

Page 14: ... the shift lever to run the boat in forward or reverse gear or to cut off the engine power from the propeller There are three positions for the shift lever The starter rope can be pulled out for starting the engine with the shift lever in the NEUTRAL position FORWARD The boat moves ahead NEUTRAL The engine power is cut off from the propeller The boat does not move REVERSE The boat reverses STARTER...

Page 15: ...nal fuel tank position and portable fuel tank position When using the internal fuel tank turn the fuel valve lever to the internal fuel tank position When not connecting the portable fuel tank fuel is shut off at the portable fuel tank position When using the portable fuel tank turn the fuel valve lever all the way to the portable fuel tank position ON BF4A or INTERNAL FUEL TANK POSITION OFF BF4A ...

Page 16: ... Fuel from the internal fuel tank is supplied PORTABLE FUEL TANK Fuel from the portable fuel tank is supplied If the portable fuel tank is not connected fuel supply is shut off Set the fuel valve lever to the PORTABLE FUEL TANK position during transporting or storing the outboard motor Handle Stopper The tiller handle can be moved to the bottom direction by turning the handle stopper HANDLE STOPPE...

Page 17: ...wn by arrow increases the engine speed Throttle Friction Knob The throttle friction knob adjusts resistance to throttle grip rotation Turn the throttle friction knob clockwise to increase friction for holding a throttle setting while cruising Turn the throttle friction knob counterclockwise to decrease friction for easy throttle grip rotation CHOKE KNOB FAST THROTTLE GRIP FAST START SLOW THROTTLE ...

Page 18: ...rgency stop switch once to stop the engine Emergency Stop Switch Lanyard Clip The emergency stop switch lanyard is provided to stop the engine immediately when the operator falls overboard or away from the outboard motor The engine stops when the clip at the end of the emergency stop switch lanyard is pulled out of the emergency stop switch When operating the outboard motor be sure to attach one e...

Page 19: ...clip is set on the emergency stop switch A spare emergency stop switch clip is provided in the tool bag Use the spare emergency stop switch clip to make the emergency engine start when the emergency stop switch lanyard is not available as for example the operator falls outboard motor Oil Pressure Indicator Light When the engine oil level is low or the engine lubrication system is faulty the oil pr...

Page 20: ...esulting in an accidental injury to the passenger s Anode Metal The anode metal is a sacrificed metal which protects the outboard motor from corrosion Do not paint the anode metal It deteriorates the function of the anode metal which can lead to rust and corrosion damage to the outboard motor Cooling Water Check Hole The cooling water is checked here to see whether it is circulating inside the eng...

Page 21: ...t adjusts steering resistance Turn the steering friction bolt clockwise to increase friction for holding a steady course while cruising or to prevent the outboard motor from swinging while trailering the boat Turn the steering friction bolt counterclockwise to reduce steering friction COOLING WATER INTAKE PORT ENGINE COVER LATCH STEERING FRICTION BOLT TO DECREASE FRICTION TO INCREASE FRICTION 32ZV...

Page 22: ... and remove the fuel filler cap Open the vent by turning the fuel filler cap vent knob 2 or 3 turns counterclockwise all the way before starting the engine Turn the fuel filler cap vent knob clockwise and close it securely before transporting or storing the outboard motor The fuel filler cap vent knob shuts off the fuel tank from the open air TRANSOM ANGLE ADJUSTING ROD Fuel Filler Cap Vent Knob F...

Page 23: ...b clockwise and close it securely before transporting tilting or storing the outboard motor Clamp Screws Use the clamp screws to secure the stern brackets to the transom Fuel Inlet Cap and Fuel Inlet BF5D and BF6A Remove the fuel inlet cap and connect the fuel line connector to the fuel inlet when using the portable fuel tank Always install the fuel inlet cap if the fuel line connector is not conn...

Page 24: ... line between the separate fuel tank and the outboard motor OUTBOARD MOTOR SIDE FUEL LINE CONNECTOR FUEL LINE CONNECTOR FUEL TANK SIDE Fuel Line Connector Optional equipment for BF5D and BF6A Portable Fuel Tank 32ZVC6000 book Page 24 Thursday April 28 2016 10 51 AM ...

Page 25: ...plicable Boat Select the boat suitable for the engine power Engine power BF4A 2 9 kW 4 PS BF5D 3 68 kW 5 PS for U type 3 7 kW 5 PS for D type BF6A 4 4 kW 6 PS Power recommendation is indicated on most of the boats Do not exceed the boat manufacturer s power recommendation Damage and injury may result Transom Height Select the outboard motor which is correct for the boat transom height of your boat...

Page 26: ... recommended installation height If the outboard motor is installed too low the boat will squat and be hard to plane and the engine will spray water that may enter the boat It will tend to porpoise and high speed stability will be reduced If the outboard motor is installed too high that will cause propeller ventilation The water level must be at least 100 mm 4 in above the antiventilation plate wi...

Page 27: ...otor Install the outboard motor at the best trim angle for stable cruising and maximum power Trim angle too large Incorrect causes boat to squat Trim angle too small Incorrect causes boat to plow The trim angle differs according to the combination of the boat outboard motor and propeller and the operating conditions STERN BRACKET SAFETY ROPE CLAMP SCREWS Outboard Motor Angle Cruising INCORRECT CAU...

Page 28: ...ds 2 to the unlocked position and pull out to remove 2 Inserting the transom angle adjusting rod in the proper hole twist it down to lock After locking pull the transom angle adjusting rod and be sure it is not withdrawn To prevent damage to the outboard motor or boat make sure the adjusting rod is locked TRANSOM ANGLE ADJUSTING ROD 2 1 TO LOCK LOCKED POSITION TRANSOM ANGLE ADJUSTING ROD UNLOCKED ...

Page 29: ... least 15 minutes and call a physician immediately POISON Electrolyte is poison ANTIDOTE External Flush thoroughly with water Internal Drink large quantities of water or milk Follow with milk of magnesia or vegetable oil and call a physician immediately KEEP OUT OF REACH OF CHILDREN Place the battery in the battery box and fix the battery box securely to the hull Install the battery box in a locat...

Page 30: ...tor s electrical system Do not place the fuel tank near the battery The battery charge cable provides a 12 volt 6 amp output for battery charging The charging circuit is protected by a 15 amp fuse that is attached to the battery charge cable Reversing the battery leads will damage the charging system and or the battery When it is not in use keep the DC charging cable dry and clean by covering it w...

Page 31: ... remove unlatch the engine cover latch and slide the engine cover forward Unhook the engine cover hook as shown Remove the engine cover while turning a starter grip to the upward Do not operate the outboard motor without the engine cover Exposed moving parts can cause injury Installing Engine Cover To install lower the engine cover while turning a starter grip to the upward Hook the engine cover h...

Page 32: ...ufacturer s requirements for Service category SG SH or SJ Outboard motor oils category SG SH or SJ will show this designation on the container SAE 10W 30 is recommended for general all temperature use Inspection and Refilling 1 Position the outboard motor vertically and remove the engine cover see page 31 2 Remove the oil filler cap dipstick and wipe it with a clean rag 3 Insert the dipstick and s...

Page 33: ... dipstick you might notice the engine oil appears milky or the oil level has increased If you notice either condition change the engine oil See the following table for an explanation of these conditions Operating Method Result Effect Running the engine below 3 000 rpm for more than 30 of the time so the engine does not warm up Water condenses in the engine and mixes with the oil resulting in a mil...

Page 34: ...rt dust or water in the fuel tank FUEL TANK CAPACITY 1 5 L 0 40 US gal 0 33 Imp gal Gasoline is extremely flammable and is explosive under certain conditions Refuel in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored Do not overfill the fuel tank there should be no fuel in the filler neck Afte...

Page 35: ...uel tank FUEL TANK CAPACITY 12 L 3 2 US gal 2 6 Imp gal Gasoline is extremely flammable and is explosive under certain conditions Refuel in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored Do not overfill the fuel tank there should be no fuel in the filler neck After refueling make sure the fu...

Page 36: ...s not also contain co solvents and corrosion inhibitors for methanol Fuel system damage or engine performance problems resulting from the use of gasoline that contains more alcohol than recommended is not covered under the warranty Before buying gasoline from an unfamiliar station first determine if the gasoline contains alcohol if it does find out the type and percentage of alcohol used If you no...

Page 37: ...rious 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 minutes a...

Page 38: ...d motor from corrosion damage it must be exposed directly to the water whenever the outboard motor is in use Replace the anode when it has been reduced to about two thirds of the original size or if it is crumbling The possibility of corrosion damage is increased if the anode metal is painted over or allowed to deteriorate Parts materials which should be installed on board Owner s Manual Tool kit ...

Page 39: ... to the carburetor may be insufficient 1 Fill fuel to upper level of the internal fuel tank 2 Open the internal fuel filler cap vent knob 2 to 3 turns counterclockwise 3 Turn the fuel valve lever to the ON position BF4A or internal fuel tank position BF5D and BF6A 4 Move the shift lever to the NEUTRAL position The starter cannot be operated unless the shift lever is set in the NEUTRAL position OPE...

Page 40: ...r or lower than 1 meter 3 3 feet below the outboard motor end fuel line connector 1 Turn the internal and portable side fuel filler cap vent knobs 2 or 3 turns counterclockwise all the way to open the vent Allow the air pressure inside the fuel tank to equalize with the outside air With the vent open air can enter the fuel tank to displace the fuel as the fuel level goes down 2 Remove the fuel fil...

Page 41: ...acked damaged or leak fuel Be sure the fuel line is not kinked 1 Connect the fuel line connector to the fuel tank Be sure the fuel line connector is securely snapped in place Fuel Line Connection When using the portable fuel tank FUEL LINE CONNECTOR FUEL TANK SIDE Optional equipment for BF5D and BF6A 32ZVC6000 book Page 41 Thursday April 28 2016 10 51 AM ...

Page 42: ...tion the fuel line connector O ring seal can be damaged A damaged O ring seal can cause a fuel leak 5 Hold the primer bulb so that the outlet end is higher than the inlet end The arrow on the primer bulb points upward Squeeze the primer bulb several times until it feels firm indicating that fuel has reached the carburetor Check for fuel leaks and repair any leaks before starting the engine Do not ...

Page 43: ...ergency stop switch lanyard into the emergency stop switch Attach the other end of the emergency stop switch lanyard securely to the operator If the operator does not attach the emergency stop switch lanyard and is thrown from his seat or out of the boat the out of control boat can seriously injure the operator passengers or bystanders Always properly attach the lanyard before starting the engine ...

Page 44: ...using the portable fuel tank 2 When using the internal fuel tank Turn the fuel valve lever to the ON position BF4A or internal fuel tank position BF5D and BF6A When using the portable fuel tank Turn the fuel valve lever to the portable fuel tank position FUEL FILLER CAP VENT KNOB OPEN CLOSE FUEL FILLER CAP VENT KNOB OPEN CLOSE FUEL VALVE LEVER OFF BF4A or PORTABLE FUEL TANK POSITION BF5D and BF6A ...

Page 45: ...osition 4 Align the mark on the throttle grip with the projected end of the mark on the handle 5 When the engine is cold or ambient temperature is low pull the choke knob to the ON position It provides rich fuel mixture to the engine NEUTRAL SHIFT LEVER NEUTRAL THROTTLE GRIP MARK START CHOKE KNOB ON 32ZVC6000 book Page 45 Thursday April 28 2016 10 51 AM ...

Page 46: ... starting the engine unless the shift lever is set in the NEUTRAL position If the engine fails to start check the emergency stop switch clip 7 After the engine starts confirm that the engine oil pressure indicator light is lit In the event that the indicator is not lit stop the engine and perform the following checks 1 Is the oil quantity normal 2 If the oil quantity is correct but the indicator l...

Page 47: ...to see if the cooling water intake port is obstructed and remove foreign materials if necessary Check the cooling water check hole for clogging If water still does not flow out have your outboard motor checked by an authorized Honda outboard motor dealer Do not operate the engine until the problem has been corrected 9 If the choke was used push it in gradually as the engine warms up INTAKE OBSTRUC...

Page 48: ...he shift lever into NEUTRAL position to prevent start in gear when starting the engine in emergency Sudden unexpected acceleration could result in serious injury or death 2 Remove the engine cover see page 31 3 Release the throttle cables from the cover hook 4 Release the neutral start cable from the cover hooks 5 Disconnect the neutral start cable from recoil case NEUTRAL SHIFT LEVER NEUTRAL THRO...

Page 49: ...Install and tighten the 6 mm flange bolts by hand 8 Hook the throttle cables to the cable hook 9 Hook the neutral start cable to the under case RECOIL CASE 6 mm FLANGE BOLTS AND WASHERS 6 mm CAP NUTS AND WASHERS 6 mm FLANGE BOLT Tighten by hand THOROTTLE CABLES CABLE HOOK NEUTRAL START CABLE 6 mm FLANGE BOLT Tighten by hand 32ZVC6000 book Page 49 Thursday April 28 2016 10 51 AM ...

Page 50: ...ling water intake port must be lowered into the water running the outboard motor out of the water will damage the water pump and overheat the engine 11 Engage the emergency stop switch clip located at one end of the emergency stop switch lanyard with the emergency stop switch Attach the other end of the emergency stop switch lanyard securely to the operator EMERGENCY STOP SWITCH EMERGENCY STOP SWI...

Page 51: ...ted end of the mark on the handle 14 Set the knotted end of the emergency starter rope in the notch in the starter pulley and while pulling the emergency starter rope clockwise around the starter pulley 15 Pull the starter rope lightly until resistance is felt then pull briskly CHOKE KNOB ON THROTTLE GRIP MARK START STARTER ROPE KNOTTED END STARTER PULLEY NOTCH 32ZVC6000 book Page 51 Thursday Apri...

Page 52: ...over The flywheel is rotating Do not operate without the engine cover Exposed moving parts could cause injury and starter may damage the engine 18 Attach the emergency stop switch lanyard securely to the operator and return to the closest boat landing 19 After returning to the closest boat landing contact your closest authorized Honda outboard motor dealer and perform the following Have the starti...

Page 53: ...knob page 44 Fuel valve lever is not turned to the appropriate position Turn the fuel valve lever to the appropriate position page 15 Primer bulb not squeezed When using the portable fuel tank Squeeze primer bulb to supply fuel page 42 Engine flooded Clean and dry spark plug page 78 No sparks across spark plug Install plug cap securely page 79 Fuel does not reach the carburetor Loosen the carburet...

Page 54: ... 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 outboard motor at full throttle for more than 5 minutes at a time The shift lever has three positions FORWARD NEUTRAL and REVERSE An indicator at the base of the shift lever aligns with th...

Page 55: ...ion in which it is to turn To turn to the right swing the tiller handle to the left To turn to the left swing the tiller handle to the right For smooth steering adjust the steering friction bolt so that a slight drag is felt when turning SLOW THROTTLE GRIP SLOW STEERING FRICTION BOLT TO DECREASE FRICTION TO INCREASE FRICTION 32ZVC6000 book Page 55 Thursday April 28 2016 10 51 AM ...

Page 56: ...ip for manual speed control turn the throttle friction knob counterclockwise Do not operate without the engine cover Exposed moving parts could cause injury water may damage the engine Confirm that the tilt lever is in the RUN position For best performance passengers and equipment should be distributed evenly to balance the boat Cruising SHIFT LEVER FAST THROTTLE GRIP FORWARD THROTTLE FRICTION KNO...

Page 57: ...e the internal and portable fuel tank vents by turning the vent knob clockwise all the way see page 22 23 disconnect the fuel line connector from the outboard motor and install the fuel inlet cap see page 23 5 Move the tilt lever to the TILT position Hold the engine cover grip and raise the outboard motor Do not use the tiller handle to tilt the outboard motor Before tilting up leave the outboard ...

Page 58: ... stops tilt the outboard motor slightly then lower the outboard motor slowly Make sure water comes out from the cooling water check hole When the outboard motor is tilted up cruise at low speed Never operate in reverse when the outboard motor is tilted up The outboard motor will rise up causing an accident 18 when cruising in shallow water TILT LEVER 58 when mooring 34 32ZVC6000 book Page 58 Thurs...

Page 59: ...tes when the engine speed increases excessively The over rev limiter can be activated while cruising tilting up the outboard motor or when ventilation occurs during a sharp turn When the over rev limiter is activated 1 Reduce the throttle opening immediately and check the trim angle 2 If the trim angle is correct but the over rev limiter stays activated stop the engine check the condition of the o...

Page 60: ...you always operate the outboard motor at altitudes higher than 1 500 m 5 000 feet above sea level have your authorized Honda dealer perform these carburetor modifications Even with suitable carburetor jetting engine horsepower will decrease approximately 3 5 for each 300 m 1 000 feet increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification i...

Page 61: ...engine with the emergency stop switch lanyard from time to time to be sure that the emergency stop switch is operating properly In normal use 1 Turn the throttle grip to SLOW position and move the shift lever to NEUTRAL PULL EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD EMERGENCY STOP SWITCH THROTTLE GRIP NEUTRAL SHIFT LEVER SLOW SLOW NEUTRAL 32ZVC6000 book Page 61 Thursday April 28 201...

Page 62: ...re using the internal fuel tank turn the fuel valve lever to the OFF position BF4A or portable fuel tank position BF5D and BF6A see page 15 and close the internal fuel tank vent by turning the vent knob clockwise all the way see page 23 If you will be storing tilting or transporting the outboard motor If you are using a portable fuel tank close the internal and portable fuel tank vents by turning ...

Page 63: ...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 or stored In cold weather to prevent ice from forming inside the water pump raise the outboard motor out of th...

Page 64: ...vent by turning the vent knob clockwise all the way or drain the gasoline If you will be transporting the outboard motor Do not carry the outboard motor by the engine cover The engine cover can be unlatched and outboard motor can drop resulting in an accidental injury and damage To avoid damaging the outboard motor never use it as a handle for lifting or moving the boat CARRYING HANDLE Transportin...

Page 65: ...1 Attach the stern brackets to a motor stand and mount the outboard motor to the brackets Vertical transport 2 Move the shift lever to the REVERSE position and lock the tilt lever 3 Transport the outboard motor with the tiller handle raised STERN BRACKET MOTOR STAND 32ZVC6000 book Page 65 Thursday April 28 2016 10 51 AM ...

Page 66: ...tboard motor upward Always rest the outboard motor on a protector and be sure to protect it from impact and damage Any other transport or storage position may cause damage or oil leakage Horizontal transport CASE PROTECTORS INCORRECT PROTECTOR 32ZVC6000 book Page 66 Thursday April 28 2016 10 51 AM ...

Page 67: ...tboard motor should be trailed in the normal running position If there is insufficient road clearance in this position then trailer the outboard motor in the tilted position using a motor support device such as a transom saver bar or remove the outboard motor from the boat Tilt lever should be in the tilted position Close the internal fuel tank vent by turning the vent knob clockwise all the way o...

Page 68: ...g water check hole while the engine is running If not stop the engine and determine the cause of the problem With Water Hose Joint Optional equipment 1 Tilt down the outboard motor 2 Wash the outside of the outboard motor with clean fresh water 3 Remove the wash plug 4 Flush the cooling system using the water hose joint a Attach a hose from a fresh water faucet to the water hose joint b Remove the...

Page 69: ...utboard motor 2 Wash the outside of the outboard motor with clean fresh water 3 Remove the propeller see page 87 4 Stand the outboard motor in a suitable container of water The water level must be at least 100 mm 4 in above the antiventilation plate 5 Start the engine and run slowly for at least 5 minutes 6 After flushing stop the engine If you are using the internal fuel tank turn the fuel valve ...

Page 70: ...re to reinstall the engine cover if it was removed before starting the engine Lock it securely by pulling up the lock lever If the engine must be run make sure there is water at least 100 mm 4 in above the antiventilation plate otherwise the water pump may not receive sufficient cooling water and the engine will overheat Use only Honda Genuine parts or their equivalents for maintenance or repair T...

Page 71: ...ergency repairs Spare shear pin and cotter pin are located inside the engine compartment above the engine under cover EMERGENCY STOP SWITCH CLIP TOOL KIT PLIERS FLAT SCREWDRIVER GRIP SPARK PLUG WRENCH Spare Parts TOOL BAG EMERGENCY STARTER ROPE SPARE SHEAR PIN SPARE COTTER PIN 10 12 mm WRENCH 32ZVC6000 book Page 71 Thursday April 28 2016 10 51 AM ...

Page 72: ... Every 6 months or 100 hrs Every year or 200 hrs Refer to page Engine oil Check level o 32 Change o o 74 Gear case oil Change o o 76 Starter rope Check o 77 Carburetor linkage Check adjust o 2 o 2 Valve clearance Check adjust o 2 o 2 Spark plug Check adjust o 78 Replace o 78 Propeller and Cotter pin Check o 38 Anode Check o 8 38 Idling speed Check adjust o 2 o 2 Lubrication Grease o 1 o 1 82 Fuel ...

Page 73: ...e for leaks cracks or damage Replace the fuel line if there are signs of leaks cracks or damage 7 Upon starting check for unusual engine sounds and cooling water flowing freely from the check hole Each use After use First month or 20 hrs Every 6 months or 100 hrs Every year or 200 hrs Refer to page Fuel filter Check o 83 Replace o 83 Fuel line Check o 5 38 41 Replace Every 2 years If necessary 2 6...

Page 74: ...itial replacement then every 100 operating hours or 6 months Oil capacity 0 55 L 0 58 US qt 0 48 Imp qt Recommended oil SAE 10W 30 engine oil or equivalent API Service category SG SH or SJ 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 31 Remove the oil filler ca...

Page 75: ...vel shown on the dipstick 4 Reinstall the oil filler cap securely 5 Install the engine cover and lock it securely by push down the engine cover latch see page 31 Please dispose of used outboard 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...

Page 76: ...n plug and washers 2 Allow the used oil to drain completely then install an oil pump adapter in the oil drain hole If water or contaminated milky colored oil flows out the drain hole when the plug is removed have the outboard motor checked by authorized Honda Marine dealer 3 Add oil through the oil drain hole until it flows out the oil level hole then install the oil level plug oil drain plug and ...

Page 77: ...MAINTENANCE Starter Rope Check Check the starter rope every 6 months or after every 100 operating hours Replace the rope if it is frayed STARTER ROPE 32ZVC6000 book Page 77 Thursday April 28 2016 10 51 AM ...

Page 78: ...ent Spark plug which have an improper heat range may cause engine damage 1 Remove the engine cover see page 31 2 Remove the spark plug cap 3 Use the wrench and screwdriver to remove the spark plug 4 Inspect the spark plug 1 If the electrode is 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 w...

Page 79: ...e washer SPARK PLUG TORQUE 18 N m 1 8 kgf m 13 lbf ft If installing new spark plug tighten 1 2 turn after the spark plug seats to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer The spark plug must be securely tightened An improperly tightened plug can become very hot and may cause engine damage 8 Reinstall the spark plug...

Page 80: ...ICAL 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 minutes and call a physician immediately POISON Electrolyte is poison ANTIDOTE Ext...

Page 81: ...red terminal cover to the battery positive terminal then the battery negative cable black terminal cover to the battery negative terminal Tighten the bolts and nuts securely Coat the battery terminals with grease When disconnecting the battery cable be sure to disconnect at the battery negative terminal first To connect connect at the positive terminal first then at the negative terminal Never dis...

Page 82: ...erval 20 operating hours or a month after the date of purchase for initial lubrication then every 100 operating hours or 6 months Apply anticorrosion oil to pivot surfaces where grease cannot penetrate CLAMP SCREWS TILT LINKAGE SWIVEL CASE HANDLE PIVOT PROPELLER SHAFT TILT LEVER REVERSE LOCK LEVER SHIFT SHAFT 32ZVC6000 book Page 82 Thursday April 28 2016 10 51 AM ...

Page 83: ... explode causing serious injury or death Do not smoke or allow flames or sparks in your working area KEEP OUT OF REACH OF CHILDREN Always work in a well ventilated area Be sure that any fuel drained from the outboard motor is stored in a safe container Be careful not to spill fuel when replacing the filter Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry befor...

Page 84: ... arrow mark on the fuel filter is toward the fuel pump side Fuel flow will be impeded if the filter is installed backward 6 Connect the fuel tubes to the fuel filter securely with the tube clamps 7 Remove the clamps used to close the fuel tubes 8 Prime fuel to the fuel filter When using the internal fuel tank Pull the starter grip to prime the carburetor with gasoline see page 39 and check for lea...

Page 85: ...lean the fuel tank and tank filter every year or after every 200 operating hours Fuel Tank Cleaning 1 Disconnect the fuel line connector from fuel tank 2 Empty the tank pour in a small quantity of gasoline and clean the tank thoroughly by shaking it Drain and dispose of the gasoline properly 32ZVC6000 book Page 85 Thursday April 28 2016 10 51 AM ...

Page 86: ...e are no abnormalities How to replace the fuse 1 Stop the engine 2 Remove the fuse case lid and pull the blown fuse out of the clip with your finger 3 Push the spare fuse into the clips Designated fuse 15A Never use a fuse with a different rating from that specified Serious damage to the electrical system or a fire may result If the fuse is blown check the cause then replace the fuse with a spare ...

Page 87: ...ands wear the heavy gloves during replacement Replacement 1 Remove the cotter pin the propeller cap and the propeller 2 Remove the broken shear pin and replace it with a new one 3 Install the propeller or install a new propeller if the propeller is damaged then install the propeller cap finger tight 4 Install a new cotter pin and spread the ends of it as shown Use a Honda Genuine shear pin and cot...

Page 88: ... of the carburetor into a suitable container then retighten the drain screw see page 90 4 Remove the spark plug Disengage the emergency stop switch clip from the emergency stop switch and pull the starter grip several times to completely expel water from the cylinder When cranking the engine with an open ignition circuit spark plug removed from the ignition circuit disengage the emergency stop swi...

Page 89: ...top switch 7 Attempt to start the engine Exposed moving parts can cause injury Use extreme care when installing the engine cover Do not operate the outboard motor without the engine cover If the engine fails to start remove the spark plug clean and dry the electrode then reinstall the spark plug and attempt to start the engine again If the engine starts and no mechanical damage is evident continue...

Page 90: ...le and gasoline vapor can explode causing serious injury or death Do not smoke or allow flames or sparks in your working area KEEP OUT OF REACH OF CHILDREN 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 or stored Close t...

Page 91: ... the engine cover see page 31 When using the internal fuel tank When starting the engine after draining the gasoline prime the carburetor with gasoline see page 39 Before storing the outboard motor for a prolonged period we recommend that you remove the fuel line connector and operate the engine at 2 000 to 3 000 min 1 rpm until it stops Outboard Motor Storage 1 Tilt the outboard motor remove the ...

Page 92: ... according to the type of the battery Refer to the battery manufacturer s instructions 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 Ke...

Page 93: ... care not to get the solution of water in the battery cells Dry the battery thoroughly 3 Fill the battery with distilled water to the upper level line Never overfill the battery 4 Store the battery on a level surface in a cool dry well ventilated place out of direct sunlight 5 Once a month check the specific gravity of the electrolyte and recharge as required to prolong battery life TERMINAL TERMI...

Page 94: ...o a motor stand and mount the outboard motor to the brackets page 27 2 Store the outboard motor with the tiller handle raised Horizontal storage Rest the outboard motor on the case protectors With tiller handle side of the outboard motor upward Any other transport or storage position may cause damage or oil leakage CASE PROTECTORS INCORRECT 32ZVC6000 book Page 94 Thursday April 28 2016 10 51 AM ...

Page 95: ...vironment 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 32ZVC6000 book Page 95 Thursday April 28 2016 10 51 AM ...

Page 96: ...o supply fuel page 42 8 Fuel is not reaching the carburetor Loosen the carburetor drain screw to see if there is fuel in the carburetor float bowl page 90 9 Engine is flooded Clean and dry the spark plug page 78 10 Plug cap is not installed properly Install plug cap securely page 79 11 Fuel valve lever is not turned to the appropriate position Turn the fuel valve lever to the appropriate position ...

Page 97: ...roper position page 25 to 28 1 Water intake and or water check tube are is clogged Clean water intake and or water check tube 2 Engine is overloaded because of unequally distributed passengers or excessive load on the boat Distribute the passengers equally Do not load on the boat excessively 3 Thermostat is faulty Consult with an authorized Honda outboard motor dealer 4 Cavitation Install the outb...

Page 98: ...SH SJ SAE 10W 30 Gear case API standard GL 4 SAE 90 Hypoid gear oil Oil capacity Engine 0 55 L 0 58 US qt 0 48 Imp qt Gear case 0 10 L 0 11 US qt 0 09 Imp qt D C output 2 12V 6A Cooling system Water cooling with thermostat Exhaust system Underwater exhaust Spark plug BKR6E E NGK Fuel pump Mechanical type Fuel Unleaded gasoline 91 research octane 86 pump octane or higher Tank capacity Internal fuel...

Page 99: ... Engine API standard SG SH SJ SAE 10W 30 Gear case API standard GL 4 SAE 90 Hypoid gear oil Oil capacity Engine 0 55 L 0 58 US qt 0 48 Imp qt Gear case 0 10 L 0 11 US qt 0 09 Imp qt D C output 2 12V 6A Cooling system Water cooling with thermostat Exhaust system Underwater exhaust Spark plug BKR6E E NGK Fuel pump Mechanical type Fuel Unleaded gasoline 91 research octane 86 pump octane or higher Tan...

Page 100: ... API standard SG SH SJ SAE 10W 30 Gear case API standard GL 4 SAE 90 Hypoid gear oil Oil capacity Engine 0 55 L 0 58 US qt 0 48 Imp qt Gear case 0 10 L 0 11 US qt 0 09 Imp qt D C output 2 12V 6A Cooling system Water cooling with thermostat Exhaust system Underwater exhaust Spark plug BKR6E E NGK Fuel pump Mechanical type Fuel Unleaded gasoline 91 research octane 86 pump octane or higher Tank capac...

Page 101: ...le Sound Pressure level at operator s ears 2006 42 EC ICOMIA 39 94 75 dB A 77 dB A 79 dB A Uncertainty 2006 42 EC ICOMIA 39 94 2 dB A 2 dB A 3 dB A Measured sound power level Reference to EN ISO3744 Uncertainty Reference to EN ISO3744 Vibration level at hand arm 2006 42 EC ICOMIA 38 94 2 8 m s2 3 0 m s2 3 1 m s2 Uncertainty 2006 42 EC ICOMIA 38 94 0 4 m s2 0 5 m s2 0 4 m s2 32ZVC6000 book Page 101...

Page 102: ...ia Honda Motor Europe Ltd Tulika 15 17 10613 Tallinn Tel 372 6801 300 Fax 372 6801 301 honda baltic honda eu com CROATIA Fred Bobek d o o Honda Marine Croatia Trg lnd zona bb 22211 Vodice Tel 385 22 44 33 00 33 10 Fax 385 22 44 05 00 www honda marine hr DENMARK TIMA A S Tårnfalkevej 16 2650 Hvidovre Tel 45 36 34 25 50 Fax 45 36 77 16 30 http www hondapower dk GERMANY Honda Deutschland GmbH Sprendl...

Page 103: ...M17 Tel 356 21 498 561 Fax 356 21 480 150 POLAND Aries Power Equipment Sp z o o ul Wroclawska 25 01 493 Warszawa Tel 48 22 861 43 01 Fax 48 22 861 43 02 www ariespower pl www mojahonda pl info ariespower pl ROMANIA Hit Power Motor Srl str Vasile Stroescu nr 12 Camera 6 Sector 2 021374 Bucuresti Tel 40 21 637 04 58 Fax 40 21 637 04 78 http www honda ro hit_power honda ro IRELAND Two Wheels ltd M50 ...

Page 104: ...omocion Canarias S A Carretera General del Sur KM 8 8 38107 Santa Cruz de Tenerife Tél 34 922 620 617 Fax 34 922 618 042 www aucasa com ventas aucasa com taller aucasa com TURKEY Anadolu Motor Uretim ve Pazarlama AS Esentepe mah Anadolu cad No 5 Kartal 34870 Istanbul Tel 90 216 389 59 60 Fax 90 216 353 31 98 www anadolumotor com tr antor antor com tr AUSTRALIA Honda Australia Motorcycle and Power ...

Page 105: ...105 18 EC DECLARATION OF CONFORMITY CONTENT OUTLINE 32ZVC6000 book Page 105 Thursday April 28 2016 10 51 AM ...

Page 106: ...106 EC DECLARATION OF CONFORMITY CONTENT OUTLINE 32ZVC6000 book Page 106 Thursday April 28 2016 10 51 AM ...

Page 107: ...107 EC DECLARATION OF CONFORMITY CONTENT OUTLINE 32ZVC6000 book Page 107 Thursday April 28 2016 10 51 AM ...

Page 108: ...108 EC DECLARATION OF CONFORMITY CONTENT OUTLINE 32ZVC6000 book Page 108 Thursday April 28 2016 10 51 AM ...

Page 109: ...109 EC DECLARATION OF CONFORMITY CONTENT OUTLINE 32ZVC6000 book Page 109 Thursday April 28 2016 10 51 AM ...

Page 110: ...ter Intake Port 21 Cruising in Shallows 60 D Disposal 95 Draining the Gasoline 90 E EC DECLARATION OF CONFORMITY CONTENT OUTLINE 105 Emergency Starting 48 Stop Switch 18 Stop Switch Lanyard Clip 18 Engine Cover Lock Latch 21 Oil Change 74 Oil Level 32 F Filling the Carburetor with Gasoline 39 Fuel Filler Cap Vent Knob 23 Filler Cap Vent Knob Fuel Gauge 22 Filter Check Replacement 85 Fuel Valve Lev...

Page 111: ...er Checks 38 Outboard Motor Angle 27 Attachment 27 Storage 91 Over rev Limiter 59 P Pre Operation Checks 31 Priming the Carburetor with Gasoline 39 R Removing Installing Engine Cover 31 Replacing the Fuse 86 S Safety 6 Information 6 Safety Label Locations 9 Servicing a Submerged Outboard Motor 88 Shear Pin Change 87 Shift Lever 14 Spark Plug Service 78 Specifications 98 Starter Grip 14 Starter Rop...

Page 112: ...iction Knob 17 Grip 17 Tilt Lever 20 Tilting the Outboard Motor 57 Tool Kit and Spare Parts 71 Trailering 67 Transom Height 25 Transporting 63 Troubleshooting 96 Starting Problems 53 W With Water Hose Joint 68 Without Water Hose Joint 69 32ZVC6000 book Page 112 Thursday April 28 2016 10 51 AM ...

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