Honda BFI15A Owner'S Manual Download

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TAKING CARE OF UNEXPECTED PROBLEMS

Correction

Possible Cause

HARD STARTING OR STALLS

AFTER STARTING

Check control positions.

Fast idle lever raised (side-mount
type).

Leave fast idle lever OFF (p.

Check fuel.

Fuel vent closed (portable fuel
tank).

Open fuel tank vent (p.

Fuel hose not primed.
Fuel pump filter or fuel tank
clogged.

Squeeze priming bulb (p.

Replace fuel filters (p.

Bad fuel; boat stored without
treating or draining gasoline, or
refueled with bad fuel.

Drain fuel tank and vapor
separator (p.

). Refill with fresh

gasoline (p.

Check water separator.

Clean water separator (p.

(The water separator red float has
risen off the bottom of the bowl)

Water separator full of water.

02/10/28 13:57:36 31ZW5601_090

Summary of Contents for BFI15A

Page 1: ......

Page 2: ...Honda Motor Co Ltd reserves the right however to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever No part of this publication may be reproduced without written permission Keep this owner s manual handy so you can refer to it at any time This owner s manual is considered a permanent part of the outboard motor and should remain w...

Page 3: ... is intended to help you avoid damage to your outboard motor other property or the environment We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership The warranty policy is a separate document that should have been given to you by your dealer When your outboard motor needs scheduled maintenance keep in mind that your Honda marine dealer is s...

Page 4: ...ctical or possible to warn you about all the hazards associated with operating or maintaining an outboard motor You must use your own good judgment You will find important safety information in a variety of forms including This entire book is filled with important safety information please read it carefully preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION T...

Page 5: ...ion Switch 18 Switch Clip and Emergency Stop Switch 19 Fast Idle Button 20 Gearshift Throttle Control Lever 20 Top Mount Type Ignition Switch 22 Switch Clip and Emergency Stop Switch 22 Fast Idle Button 23 Gearshift Throttle Control Lever 23 Common Controls Power Trim Tilt Switch 25 Power Tilt Switch 26 Manual Relief Valve 26 Tilt Lock Lever 26 Engine Cover Lock Levers 27 Transom Angle Adjusting R...

Page 6: ...34 IS YOUR OUTBOARD MOTOR READY TO GO 34 OPERATION 36 SAFE OPERATING PRECAUTIONS 36 BREAK IN PROCEDURE 36 TRANSOM ANGLE ADJUSTMENT 37 PORTABLE FUEL TANK optional equipment 38 FUEL HOSE CONNECTIONS 38 FUEL PRIMING 39 STARTING THE ENGINE 39 Side Mount Type 39 Panel Mount Type 42 Top Mount Type 44 STOPPING THE ENGINE 46 Emergency Engine Stopping 46 Normal Engine Stopping 47 GEARSHIFTING AND THROTTLE ...

Page 7: ... Oil Change 64 Oil Filter Change 65 Engine Oil Recommendations 67 Lubrication Points 68 Spark Plug Service 69 REFUELING 71 FUEL RECOMMENDATIONS 72 Fuel Pump Filter Inspection and Replacement 73 Portable Fuel Tank and Filter Cleaning optional equipment 75 Anode Replacement 76 Water Separator Inspection and Service 76 Propeller Replacement 78 STORAGE 79 STORAGE PREPARATION 79 Cleaning and Flushing 7...

Page 8: ...ATOR LIGHT GOES OFF AND ENGINE SPEED IS LIMITED 93 OVERHEATING INDICATOR LIGHT COMES ON AND ENGINE SPEED IS LIMITED 94 SUBMERGED MOTOR 95 TECHNICAL AND CONSUMER INFORMATION 97 TECHNICAL INFORMATION 97 Serial Number Locations 97 Oxygenated Fuels 98 Battery 99 Emission Control System Information 100 Star Label 102 Specifications 104 CONSUMER INFORMATION 107 INDEX 108 WIRING DIAGRAMS Inside Back Cove...

Page 9: ...yone falls overboard and do not run the engine while the boat is near anyone in the water Always stop the engine if you must leave the controls for any reason Always wear a PFD Personal Flotation Device while on the boat Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors Be sure that anyone who operates the outboard motor receives proper instructi...

Page 10: ...in a well ventilated area with the engine stopped Never smoke near gasoline and keep other flames and sparks away Remove any portable fuel tank from the boat for refueling Keep the portable fuel tank away from the battery or other potential spark sources Refuel carefully to avoid spilling fuel Avoid overfilling the fuel tank After refueling tighten the filler cap securely If any fuel is spilled ma...

Page 11: ...n here contain important safety information Please read them carefully These labels are considered permanent parts of your outboard motor If a label comes off or becomes hard to read contact an authorized Honda Marine servicing dealer for a replacement 02 07 23 13 01 33 31ZW5601_010 ...

Page 12: ... LA XA LCA XCA LA XA LCA XCA L X Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications Destination L A C Shaft length TYPE CODE example A America Rotating direction of propeller shaft C Counterrotating propeller shaft None Standard rotating propeller shaft L Long Shaft X Extra Long Shaft 02 07 23 13 01 50 31ZW5601_011 ...

Page 13: ... GEAR OIL DRAIN BOLT EXHAUST PORT ANTIVENTILATION PLATE ANODE OIL FILLER CAP ENGINE COVER LOCK LEVER ENGINE OIL DRAIN PLUG DRAIN PLUG COVER ANODE TRIM TAB WATER INTAKE COOLING SYSTEM INDICATOR ENGINE COVER LOCK LEVER FUEL HOSE CONNECTOR WASH PLUG Flush plug WASH PLUG Flush plug ANODE OIL LEVEL DIPSTICK 02 07 23 13 01 57 31ZW5601_012 ...

Page 14: ...SE LEVER OVERHEAT INDICATOR LIGHT EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH LANYARD CONTROL LEVER FRICTION ADJUSTER SPARE EMERGENCY STOP SWITCH CLIP NEUTRAL RELEASE LEVER POWER TRIM TILT SWITCH BUZZER inside SIDE MOUNT REMOTE CONTROL PANEL MOUNT REMOTE CONTROL GEARSHIFT THROTTLE CONTROL LEVER FAST IDLE BUTTON GEARSHIFT THROTTLE CONTROL LEVER 02 07 23 13 02 04 31ZW5601_013 ...

Page 15: ...ICATOR LIGHT BUZZER IGNITION SWITCH EMERGENCY STOP SWITCH LANYARD CONTROL PANEL for PANEL TOP MOUNT type SINGLE TOP MOUNT REMOTE CONTROL DUAL TOP MOUNT REMOTE CONTROL EMERGENCY STOP SWITCH CLIP EMERGENCY STOP SWITCH FAST IDLE BUTTON FAST IDLE BUTTON GEARSHIFT THROTTLE CONTROL LEVER GEARSHIFT THROTTLE CONTROL LEVERS 02 07 23 13 02 11 31ZW5601_014 ...

Page 16: ...l equipment Trim Meter optional equipment CONTROLS AND FEATURES FUEL TANK optional equipment FUEL HOSE standard equipment FUEL HOSE CONNECTOR female FUEL GAUGE VENT KNOB FUEL CAP PRIMING BULB 02 07 23 13 02 17 31ZW5601_015 ...

Page 17: ...lly returns to the ON position when released from the START position The ignition switch can be used to operate the starter motor only when the control lever p is in the N neutral position and the switch clip is in the emergency stop switch Turning the ignition switch to the OFF position stops the engine The ignition switch controls the ignition system and starter motor 17 02 07 23 13 02 25 31ZW56...

Page 18: ...run The lanyard must be attached to the operator s PFD Personal Flotation Device or worn around the wrist as shown When used as described the emergency stop switch and lanyard system stops the engine if the operator falls away from the controls A spare switch clip is stored in a slot in the control housing optional equipment The control lever controls gear selection and throttle opening positions ...

Page 19: ...he gear and further movement increases engine speed A friction adjuster near the base of the control lever s adjusts the operating resistance of the control lever s Less friction allows easier control lever movement More friction helps to hold a steady throttle setting while cruising The control lever automatically locks itself in the N neutral position To move the lever out of the N neutral posit...

Page 20: ...F130A models use programmed fuel injection so this lever will not be needed for starting After the engine starts and if the outside temperature is below 41 F 5 C the fast idle lever can be used to accelerate engine warm up The fast idle lever will not move unless the remote control lever is in the N neutral position Conversely the remote control lever will not move unless the fast idle lever is in...

Page 21: ...can be used to operate the starter motor only when the control lever p is in the N neutral position and the switch clip is in the emergency stop switch The switch clip must be inserted in the emergency stop switch in order for the engine to start and run The lanyard must be attached to the operator s PFD Personal Flotation Device or worn around the wrist as shown When used as described the emergen...

Page 22: ...r Fast Idle Button It is necessary to position the control lever in N neutral to push in the fast idle button The gearshift throttle control lever controls engine speed and selects F forward N neutral or R reverse gears By moving the control lever forward or reverse when the fast idle button is pushed in the throttle opening will be increased without engaging the gears 02 07 23 13 03 10 31ZW5601_0...

Page 23: ...he gear and further movement increases engine speed A friction adjuster near the base of the control lever s adjusts the operating resistance of the control lever s Less friction allows easier control lever movement More friction helps to hold a steady throttle setting while cruising The control lever automatically locks itself in the N neutral position To move the lever out of the N neutral posit...

Page 24: ...rates the starter motor The key automatically returns to the ON position when released from the START position Turning the ignition switch to the OFF position stops the engine The ignition switch controls the ignition system and starter motor The ignition switch can be used to operate the starter motor only when the control lever p is in the N neutral position and the switch clip is in the emergen...

Page 25: ...controls engine speed and selects F forward N neutral or R reverse gears The switch clip must be inserted in the emergency stop switch in order for the engine to start and run The lanyard must be attached to the operator s PFD Personal Flotation Device or worn around the wrist as shown By moving the control lever forward or reverse when the fast idle button is pushed in the throttle opening will b...

Page 26: ... IN NI IM MU UM M F FORWARD N NEUTRAL R REVERSE Moving the control lever 35 from N neutral selects the gear and further movement increases engine speed A friction adjuster inside the control box adjusts the operating resistance of the control lever s Less friction allows easier control lever movement More friction helps to hold a steady throttle setting while cruising 02 07 23 13 03 46 31ZW5601_02...

Page 27: ...ER TRIM TILT SWITCH SINGLE TYPE The power trim tilt switch is located on the control lever It is a rocker switch with UP and DN down positions for changing the angle of the outboard motor You can use the power trim tilt switch anytime the ignition switch is ON whether the boat is underway or stopped Trim the outboard motor to obtain the best performance and stability p Tilt the outboard motor for ...

Page 28: ...ignition switch ON The power tilt switch is located on the engine pan It is a rocker switch with UP and DN down positions for changing the angle of the outboard motor The outboard motor can be tilted manually after opening the manual relief valve This allows the outboard motor to be tilted when no battery is connected When the boat is to be moored for a long time tilt the outboard motor as far as ...

Page 29: ...EVER LOCK FREE LOCK FRONT ENGINE COVER LOCK LEVER NUT NUT The engine cover lock levers fasten the engine cover to the outboard motor The transom angle adjusting rod limits the tilt angle of the outboard motor when fully lowered Proper adjustment prevents the outboard motor from being trimmed too low p 51 02 07 23 13 04 18 31ZW5601_028 ...

Page 30: ... angle of the outboard motor Refer to the tachometer when using the throttle and power trim tilt controls to achieve the best performance from the boat The tachometer shows engine speed in revolutions per minute When the trim tab is correctly adjusted p steering effort is equal in either direction If uncompensated torque steer would make the outboard motor tend to turn to one side The trim tab com...

Page 31: ...GHT A fuel gauge is built into the cap of the portable fuel tank optional equipment The ACG indicator light turns on and the buzzer sounds when the charging system is faulty The PGM FI indicator light turns on and the buzzer sounds when the engine control system detects a malfunction and momentarily sounds when the ignition key is turned from OFF to ON 02 07 23 13 04 42 31ZW5601_030 ...

Page 32: ...een light is lit oil pressure is OK If oil pressure becomes low the green light will go off and the engine protection system will limit engine speed Remote controls are also equipped with a buzzer that sounds when the green light goes off Low oil pressure indicates that the engine oil level is low or that there is a problem with the engine lubrication system 02 07 23 13 04 52 31ZW5601_031 ...

Page 33: ...y of mechanical damage from excessive engine speed The overrev limiter may be activated during operation limiting engine speed if the outboard motor is tilted excessively or when propeller ventilation occurs during a sharp turn If the overrev limiter is activated check the trim angle of the outboard motor If water stops flowing while the engine is running that indicates a cooling system problem su...

Page 34: ...tor from corrosion There are two anodes on the gear case one on the stern bracket and two small anodes in the water passages of the engine block The portable fuel tank optional equipment has a capacity of US gal and has a fuel gauge built into the cap The cap is provided with a vent knob to seal the portable fuel tank optional equipment for carrying it to and from the boat Open the vent knob 2 or ...

Page 35: ...bulb is built into the fuel hose that connects the fuel tank to the outboard motor Before starting the engine hold the priming bulb up in the direction of the arrow then squeeze the priming bulb until it feels firm This will ensure that fuel is supplied to the engine p 39 02 07 23 13 05 18 31ZW5601_034 ...

Page 36: ...he outboard motor and its operation before you get under way Know what to do in case of emergencies Familiarize yourself with all laws and regulations relating to boating and the use of outboard motors Always wear a PFD Personal Flotation Device while on the boat Attach the emergency stop switch lanyard securely to your PFD or to your wrist For your safety and to maximize the service life of your ...

Page 37: ...Look around the outboard motor for signs of oil or gasoline leaks Check the engine oil level p Running the engine with a low oil level can cause engine damage Check to be sure the propeller is undamaged and the castle nut is secured with the cotter pin p Check that the anodes are securely attached to the gear case p and are not excessively worn The anodes help to protect the outboard motor from co...

Page 38: ...idly in an enclosed area and cause illness or death Proper break in operation allows the moving parts to wear in smoothly for best performance and long service life Run the engine at trolling speed Use the minimum throttle opening necessary to operate the boat at a safe trolling speed Run the engine up to a maximum of 2 000 to 3 000 rpm which is about 10 to 30 of maximum throttle opening Run the e...

Page 39: ...adjusting rod limits the tilt angle of the outboard motor when fully lowered To adjust first tilt the outboard motor so it is not resting on the rod Proper adjustment prevents the outboard motor from being trimmed too low p Remove the nut then remove the rod and insert it in the desired position Reinstall the nut and tighten it securely 51 02 07 23 13 06 08 31ZW5601_038 ...

Page 40: ...round and become damaged Before use open the fuel tank vent by turning the vent knob at least 2 or 3 turns counterclockwise Connect the fuel hose to the tank and the outboard motor as shown Be sure both connectors snap securely into place Place the portable fuel tank optional equipment in a well ventilated location away from direct sunlight to reduce the possibility of a gasoline vapor explosion T...

Page 41: ...efore starting the engine Check to be sure there are no fuel leaks before starting the engine Do not squeeze the priming bulb when the engine is running The engine will not start or run unless the clip is in the switch Put the emergency stop switch clip in the emergency stop switch and attach the lanyard to your PFD Personal Flotation Device or to your wrist as shown Hold the priming bulb up in th...

Page 42: ...ithin 5 seconds release the key and wait at least 10 seconds before operating the starter again Leave the fast idle lever in the OFF fully lowered position Fast idle lever cannot be raised unless the control lever is in the N neutral position The control lever cannot be moved away from the N neutral position unless the fast idle lever is lowered Set the control lever in the N neutral position The ...

Page 43: ...cators show any abnormal condition immediately stop the engine and determine the cause of the problem Refer to p Before getting under way allow the engine to warm up sufficiently to ensure good performance Above 41 F 5 C warm up the engine for 2 or 3 minutes Below 41 F 5 C warm up the engine for at least 10 minutes at 2 000 rpm Raise the fast idle lever to achieve approximately 2 000 rpm If the fa...

Page 44: ...gine if you fall away from the controls while operating the boat Always attach the lanyard to your PFD or to your wrist before starting the engine Set the control lever in the N neutral position The engine will not start if the F forward or R reverse gears are engaged Put the emergency stop switch clip in the emergency stop switch and attach the lanyard to your PFD Personal Flotation Device or to ...

Page 45: ... engine starts When the engine starts release the key allowing it to return to the ON position If the engine fails to start within 5 seconds release the key and wait at least 10 seconds before operating the starter again Before getting under way allow the engine to warm up sufficiently to ensure good performance Above 41 F 5 C warm up the engine for 2 or 3 minutes Below 41 F 5 C warm up the engine...

Page 46: ...p is in the switch The emergency stop switch clip and lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat Always attach the lanyard to your PFD or to your wrist before starting the engine Put the emergency stop switch clip in the emergency stop switch and attach the lanyard to your PFD Personal Flotation Device or to your wrist as...

Page 47: ...tarter motor and flywheel Set the control lever in the N neutral position The engine will not start if the F forward or R reverse gears are engaged Turn the ignition switch key to the START position and hold it there until the engine starts When the engine starts release the key allowing it to return to the ON position If the engine fails to start within 5 seconds release the key and wait at least...

Page 48: ...tes During the warm up period check the oil pressure indicator p overheating indicator p and cooling system indicator p If the indicators show any abnormal condition immediately stop the engine and determine the cause of the problem Refer to p Below 41 F 5 C warm up the engine for at least 10 minutes at 2 000 rpm Push the fast idle button then move the control lever forward or reverse to open the ...

Page 49: ...pe Side Mount Type Move the control lever s to the N neutral position To stop the engine in an emergency pull the clip out of the emergency stop switch by pulling the lanyard We suggest that you stop the engine this way occasionally to verify that the engine and emergency stop switch is operating properly 1 02 07 23 13 08 01 31ZW5601_048 ...

Page 50: ...verse CONTROL LEVER NEUTRAL RELEASE LEVER O OF FF F Side Mount Type Panel Mount Top Mount Types Side Mount Type When the boat is not in use remove and store the ignition key and the emergency stop switch clip and lanyard Turn the ignition switch key to the OFF position 3 2 02 07 23 13 08 13 31ZW5601_049 ...

Page 51: ...ADJUSTER CONTROL LEVER Panel Mount Type Side Mount Type Top Mount Type Panel Mount Type To shift gears move the control lever to select F forward N neutral and R reverse gears The control lever cannot be moved from the N neutral position unless the neutral release lever is squeezed side mount panel mount types Moving the control lever beyond the gear selection range increases engine speed 02 07 23...

Page 52: ...ASE FRICTION CONTROL LEVER FRICTION ADJUSTER Top Mount Type Adjust the throttle friction adjuster so the control lever will hold a constant throttle setting while cruising Steer the boat in the same manner as an automobile 02 07 23 13 08 32 31ZW5601_051 ...

Page 53: ...o activation of the overrev limiter reduce speed and check the trim angle of the outboard motor Use the power trim tilt switch to trim the outboard motor for the best performance and stability You can use the power trim tilt switch at any time whether the boat is under way or stopped Press the UP or DN down side of the switch to adjust the angle of the outboard motor Refer to the trim meter p for ...

Page 54: ...TCH POWER TRIM TILT SWITCH BOW TOO LOW DUE TO 1 LOAD IN THE FRONT 2 MOTOR TRIMMED TOO LOW BOW TOO HIGH DUE TO 1 LOAD IN THE REAR 2 MOTOR TRIMMED TOO HIGH MOTOR TRIMMED TOO LOW MOTOR TRIMMED TOO HIGH MOTOR TRIMMED CORRECTLY ROUGH WAVES Top Mount Type Side Mount Type Panel Mount Type 02 07 23 13 08 57 31ZW5601_053 ...

Page 55: ... outboard motor so the propeller and gear case won t hit the bottom Proceed at low speed and monitor water flow from the cooling system indicator p to be sure the outboard motor is not tilted so high that the water intakes are out of the water To raise the outboard motor out of the water while the engine is stopped and the boat is moored or for maximum clearance when beaching or launching use the ...

Page 56: ...o the power tilt system may occur The outboard motor can also be tilted manually after opening the manual relief valve This feature enables the outboard motor to be tilted when no battery is connected For manual tilting use a screwdriver to turn the valve counterclockwise 1 or 2 turns Close the valve firmly after positioning the engine Be sure the valve is closed before operating the outboard moto...

Page 57: ... care for your outboard motor the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating...

Page 58: ...hould perform a given task Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes ...

Page 59: ...RIVER TOOL BAG The following tool kit can be purchased from an authorized Honda marine dealer and may be used for simple maintenance procedures and emergency repairs Keep this tool kit or an equivalent onboard so they will always be available if you need them Always carry a spare emergency stop switch clip onboard The spare clip may either be stored in the optional tool bag or in an easily accessi...

Page 60: ...st Check adjust Check adjust Replace Check Check Grease After use First month or 20 hrs 2 2 2 2 1 Every 6 months or 100 hrs 2 2 2 1 Every year or 200 hrs 2 2 2 2 2 3 Emission related items Lubricate more frequently when used in salt water These items should be serviced by an authorized Honda marine dealer unless you have the proper tools and are mechanically proficient Refer to the Honda shop manu...

Page 61: ...y when used in salt water Emission related items 1 2 3 4 Each use After use 4 First month or 20 hrs 2 Every 6 months or 100 hrs 2 Every year or 200 hrs 2 2 Every 2 years or 400 hrs 2 Check Clean Check Replace Replace Check Check Replace Check level tightness Check tightness Check Clean Water separator Fuel tank and tank filter Fuel filter Fuel filter High pressure type Thermostat Fuel line Battery...

Page 62: ... tab is correctly adjusted steering effort is equal in either direction If steering effort is unequal loosen the trim tab bolt and adjust the angle of the trim tab Retighten the trim tab bolt securely If less effort is required to make left turns move the back of the trim tab left Adjust the trim tab in small increments and retest steering effort with the boat evenly loaded and running at cruising...

Page 63: ...ng use a screwdriver to turn the valve counterclockwise 1 or 2 turns Close the valve firmly after positioning the outboard motor The outboard motor can be tilted manually after opening the manual relief valve This feature enables the outboard motor to be tilted when no battery is connected To remove the engine cover turn both front and side levers to the unlocked position then lift the engine cove...

Page 64: ...ance is outside the specified range adjust the lock lever brackets Remove the engine cover Loosen the retaining bolts on the front and or side lock lever brackets and move the bracket s as necessary to obtain the specified engine cover clearance After adjustment tighten the retaining bolts securely and install the engine cover Recheck the engine cover clearance and readjust if necessary Specified ...

Page 65: ...rtical position Unlock and remove the engine cover p Remove the dipstick and wipe it clean If the oil level is low remove the oil filler cap and add oil to reach the upper limit mark shown on the dipstick Use the oil recommended on p Install the oil filler cap and tighten it securely Install and lock the engine cover Insert the dipstick all the way in then remove it and check the oil level shown o...

Page 66: ...ick p with the recommended oil Engine oil refill capacity Without oil filter change With oil filter change Install the oil filler cap and tighten it securely Install and lock the engine cover Place a suitable container below the oil drain guide to catch the used oil then remove the oil filler cap and the drain plug Allow the used oil to drain completely then reinstall the engine oil drain plug and...

Page 67: ... and coat the gasket of the new oil filter with clean engine oil Screw on the new filter by hand until it contacts the engine then use a suitable tool to tighten the filter an additional 7 8 turn OIL FILTER TIGHTENING TORQUE Drain the engine oil and reinstall the drain plug and oil drain cover see Engine Oil Change on p Tilt the outboard motor and place a suitable container below the oil drain gui...

Page 68: ...adapter optional part and a hose to supply water Return the outboard motor to the vertical position and fill the crankcase with the specified amount p of the recommended oil Start the engine and check for leaks Stop the engine and check the oil level as described on page If necessary add oil to bring the oil level to the upper limit mark on the dipstick 6 7 8 64 63 02 07 23 13 11 29 31ZW5601_067 ...

Page 69: ...and service life Use 4 stroke automotive detergent oil The SAE oil viscosity and service classification are in the API label on the oil container Honda recommends that you use API SERVICE category SG or SH oil with the starburst certification mark displayed on the container SAE 10W 30 is recommended for general use 02 07 23 13 11 35 31ZW5601_068 ...

Page 70: ... Inhibitor or equivalent to all areas under the engine cover except the belts Wipe the outside of the engine with a cloth dipped in oil Apply marine anticorrosion grease to the following parts Lubrication interval After the first 20 hours or 1 month then every 100 hours or 6 months Refer to the maintenance schedule page Apply anticorrosion oil to pivot surfaces where grease cannot penetrate 58 02 ...

Page 71: ...aps from the spark plugs Inspect the spark plugs Replace them if the electrodes are worn or if the insulators are cracked or chipped Clean the spark plugs with a wire brush if you are going to reuse them Unlock and remove the engine cover p Measure the spark plug electrode gap with a suitable gauge The gap should be 0 028 0 031 inches 0 70 0 80 mm Remove the spark plugs with a spark plug wrench 1 ...

Page 72: ...oid cross threading After each spark plug seats tighten with a spark plug wrench to compress the sealing washer If reinstalling used spark plugs tighten 1 8 1 4 turn after the spark plugs seat If installing new spark plugs tighten 1 2 turn after the spark plugs seat Attach the spark plug caps Each cord is marked with a number near the spark plug cap Match the cord numbers with the cylinder numbers...

Page 73: ...L line After refueling install the cap and tighten it securely Turn the vent knob clockwise to the CLOSED position and return the fuel tank to the boat To refuel turn the vent knob counterclockwise to the OPEN position and unscrew the fuel tank cap Spilled fuel is not only a fire hazard it causes environmental damage Wipe up spills immediately Never refill the fuel tank inside a building where gas...

Page 74: ...tem life Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in the fuel tank Occasionally you may hear a light spark knock or pinging metallic rapping noise while operating under heavy loads This is no cause for concern If spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline If spark knock or pinging persist...

Page 75: ... Replacement SERVICING YOUR OUTBOARD MOTOR FUEL HOSE CONNECTOR The fuel pump filter is located under the engine cover between the fuel coupling and the fuel pump Water or sediment accumulated in the filter can cause loss of power or hard starting To prevent engine malfunction inspect the filter and replace when necessary Remove the engine cover and disconnect the fuel hose connector from the outbo...

Page 76: ...all the fuel filter properly Remove the fuel filter Before removing the fuel filter to prevent fuel leakage place fuel hose clamps on the fuel hoses at the each side of the fuel filter Install the new fuel filter so the arrow on the fuel filter points toward the fuel pump Fuel flow will be reduced if the fuel filter is installed backward Connect the fuel hoses to the fuel filter securely with the ...

Page 77: ...nonflammable solvent Inspect the fuel tank filter and the connector O ring Replace them if damaged Reinstall the filter and hose connector in the fuel tank Tighten the hose connector securely 3 7 1 2 Securely connect the fuel hose connector to the outboard motor refer to page 8 If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter i...

Page 78: ...e located on each side of the gearcase They are made of a sacrificial material and help protect the outboard motor from corrosion Replace the anodes when they are reduced to about half their original size or if they are crumbling A water separator is located below the engine oil filter If water gets past the water separator the water can cause loss of power hard starting and or possible fuel injec...

Page 79: ... fuel tube clamps Remove the suspension strap three screws and bowl Reattach the water separator to the water separator bracket Install suspension strap and align the I mark with screw see page Thoroughly clean the bowl Replace the O ring and reassemble the water separator TIGHTENING TORQUE If excessive water or sediment was found in the water separator inspect the fuel tank Clean the fuel tank an...

Page 80: ...e sharp edges so wear heavy gloves to protect your hands Remove the cotter pin unscrew the castle nut remove the washer then remove the propeller and thrust washer Inspect the propeller shaft for any fishing line or debris Apply marine grade grease to the propeller shaft and beveled surface of the thrust washer Install the propeller in the reverse order of removal Install the thrust washer with th...

Page 81: ...and appearance and will make the engine easier to start when you use the outboard motor again Thoroughly clean and flush the outboard motor with fresh water after operation in dirty water or salt water Touch up any damaged paint and coat areas that may rust with Honda Corrosion Inhibitor or equivalent Lubricate controls with a silicone spray lubricant Remove the flush port cap Wash the outside of ...

Page 82: ...supply and flush the outboard motor for at least 10 minutes After flushing remove the garden hose adapter and install the flush port cap Attach a garden hose from a fresh water faucet to the garden hose adapter Screw the garden hose adapter into the flushing connector 4 5 2 3 02 07 23 13 13 59 31ZW5601_081 ...

Page 83: ...stem components serviced or replaced The length of time that gasoline can be left in your fuel tank and vapor separator without causing functional problems will vary with such factors as gasoline blend your storage temperatures and whether the fuel tank is partially or completely filled The air in a partially filled fuel tank promotes fuel deterioration Very warm storage temperatures accelerate fu...

Page 84: ...y Install the drain hose to the silencer case Drain the fuel tank into an approved gasoline container or if you need to store fuel in the fuel tank you can extend fuel storage life by filling the fuel tank with fresh gasoline and adding a fuel stabilizer that is formulated for that purpose If using the portable fuel tank optional equipment firmly close the fuel tank vent knob Rotate the engine a f...

Page 85: ...ch as the portable fuel tank optional equipment store it away from any appliance that operates with a flame such as a furnace water heater or clothes dryer Also avoid any area with a sparkproducing electric motor or where power tools are operated Attach the hoist hook to the lifting eye Disconnect the outboard motor from the boat hoist the outboard motor and move it to the storage area After the o...

Page 86: ...oard motor as described in the chapter of this manual If the cylinders were coated with oil during storage preparation the engine may smoke briefly at startup This is normal If it is necessary to store the outboard motor horizontally drain the vapor separator p and drain the engine oil p before removing the outboard motor from the boat Rest the motor on a cushion of protective material 64 81 02 07...

Page 87: ...ther the vertical or horizontal position shown on p When trailering a boat with the outboard motor attached leave the engine in the normal running position if possible Use a motor support bar to prevent the outboard motor from moving while trailering the boat Refer to the manufacturer s instructions for using a motor support bar 83 84 02 07 23 13 14 53 31ZW5601_086 ...

Page 88: ...h malfunction or electrical problem in the starting circuit Clean and tighten battery connections Replace fuse s p Replace or repair faulty components as necessary ELECTRIC STARTER WILL NOT OPERATE Possible Cause Correction Use starting procedure p then take outboard motor to an authorized Honda Marine dealer or refer to the shop manual 1 2 3 39 91 02 07 23 13 15 06 31ZW5601_087 ...

Page 89: ...Fast idle lever raised side mount type Out of fuel Fuel vent closed portable fuel tank Fuel hose not primed Fuel pump filter or fuel tank filter clogged Bad fuel boat stored without treating or draining gasoline or refueled with bad gasoline Leave fast idle lever OFF p Refuel p Open fuel tank vent p Squeeze priming bulb p Replace fuel filters p Drain fuel tank and vapor separator p Refill with fre...

Page 90: ...nction stuck valves etc Replace or repair faulty components as necessary Dry and install the spark plugs Start the engine with the throttle open using the fast idle lever or fast idle button Spark plugs wet with fuel flooded engine Spark plugs faulty fouled or improperly gapped Clean gap or replace spark plugs p The water separator red float has risen off the bottom of the bowl Water separator ful...

Page 91: ...t p Fuel hose not primed Fuel pump filter or fuel tank clogged Squeeze priming bulb p Replace fuel filters p Bad fuel boat stored without treating or draining gasoline or refueled with bad fuel Drain fuel tank and vapor separator p Refill with fresh gasoline p Check water separator Clean water separator p The water separator red float has risen off the bottom of the bowl Water separator full of wa...

Page 92: ... Water intake screens clogged Clean water intake screens ENGINE OVERHEATS Possible Cause Correction Replace or repair faulty components as necessary Take outboard motor to an authorized Honda Marine dealer or refer to the shop manual Spark plugs faulty fouled or improperly gapped Clean gap or replace spark plugs p Remove and inspect spark plugs Possible Cause Correction Fuel system malfunction fue...

Page 93: ...starter will not operate MAIN FUSES Remove and inspect the fuses If a fuse is burnt out install a replacement fuse of the specified rating The outboard motor is supplied with spare fuses in the fuse holders Remove the fuse covers With the engine stopped remove the engine cover Before further operation try to determine and correct the electrical problem that caused the fuse to burn out An uncorrect...

Page 94: ... downward ACG FUSE After finishing replacement install the fuse case lid with its hook toward the engine side Be sure to check the fuse case lid is securely locked Remove the old fuse by removing two 5 mm screws A spare fuse is located on the reverse side of the fuse case lid and tightened with two 3 mm screws When the new fuse is set as a spare fuse on the reverse side of the fuse case lid set th...

Page 95: ...ine speed If you are at cruising speed engine speed will decrease gradually With the engine oil at the recommended level restart the engine If the lubrication system is OK the green indicator light should come on within 30 seconds and the engine will respond normally to throttle control lever operation If the engine protection system remains activated after 30 seconds return to the nearest boat la...

Page 96: ...gradually Remote control types are equipped with a buzzer that sounds when the red indicator light comes on Engine overheating may be the result of clogged water intake screens or there may be a problem with the cooling system thermostat or water pump If the engine is stopped after running at full throttle and then restarted soon afterward that could activate the engine protection system momentari...

Page 97: ...Drain the vapor separator as described on p If there is no water flowing from the cooling system indicator stop the engine and tilt the outboard motor to inspect the water intake screens If clogged clean the water intake screens return the outboard motor to the running position restart the engine and check the cooling system indicator again If there is still no water flowing from the cooling syste...

Page 98: ...remove the spark plugs clean and dry them then reinstall the spark plugs and attempt to start the engine again If the engine starts and no mechanical damage is evident continue to run the engine for a half hour or longer Be sure the water level is at least two inches above the antiventilation plate to avoid overheating and water pump damage As soon as possible take the outboard motor to an authori...

Page 99: ...serial numbers in the space provided on this page You will need these numbers when ordering parts and when making technical or warranty inquiries p The product identification number is stamped on a plate attached on the left stern bracket Product identification number The engine serial number is stamped on the cylinder head on the back of the engine Engine serial number 107 02 07 23 13 17 28 31ZW5...

Page 100: ...s unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed un...

Page 101: ...d or performance problems It may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty Fo...

Page 102: ...ystems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons Tampering with or altering the emission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems Alterations that would cause the engine to operate outside its design parameters The following...

Page 103: ...nt service If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring under load Afterburning backfiring Black exhaust smoke or high fuel consumption The emission control systems on your Honda engine were designed built and certified to conform with EPA and California...

Page 104: ...gine A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board for healthier lifestyle and environment burns up to 30 40 percent less gas and oil than conventional carbureted two stroke engines saving money and resources protects consumer for worry free operation This engine has been certified as a 02 07 23 13 18 22 31ZW5601_103 ...

Page 105: ...quivalent to the U S EPA s 2006 standards for marine engines The two star label identifies engines that meet the Air Resources Board s 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines The three star label identifies engines that meet the Air Resources Board s 2008 exhaust emission standards Engines meeting these standards ha...

Page 106: ... L8 DENSO ZFR7F 8 NGK Diaphragm type Automotive unleaded gasoline 86 pump octane or higher Forward Neutral Reverse dog type 30 right and left 5 stages 8 12 16 20 24 Engine Gear case Engine Gear case L X L X without oil filter change 104 Specifications TECHNICAL AND CONSUMER INFORMATION MODEL Description Code Type Overall length Overall width Overall height Transom height Weight Rated power Full th...

Page 107: ... L8 DENSO ZFR7F 8 NGK Diaphragm type Automotive unleaded gasoline 86 pump octane or higher Forward Neutral Reverse dog type 30 right and left 5 stages 8 12 16 20 24 Engine Gear case Engine Gear case L X L X without oil filter change 105 Specifications TECHNICAL AND CONSUMER INFORMATION MODEL Description Code Type Overall length Overall width Overall height Transom height Weight Rated power Full th...

Page 108: ...djustments needed 0 028 0 031 in 0 70 0 80 mm 750 50 rpm 0 26 0 02 mm 0 30 0 02 mm Exhaust Intake 106 TECHNICAL AND CONSUMER INFORMATION BF115A BF130A Tune up Spark plug gap Idle speed Valve clearance cold Other specifications 02 07 23 13 19 53 31ZW5601_107 ...

Page 109: ...ustomer Relations Office You can write Marine Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia 30005 8847 Or telephone 770 497 6400 When you write or call please give us this information Model and serial numbers p Name of the dealer who sold the outboard motor to you Name and address of the dealer who services your outboard motor Date of purchase Your name address and telep...

Page 110: ...CONTROL LOCATIONS 11 CONSUMER INFORMATION 107 Warranty Service Information 107 CONTROLS 15 CONTROLS AND FEATURE IDENTIFICATION CODES 10 CONTROLS AND FEATURES 10 Cooling System Indicator 31 CRUISING 51 Emission Control System Information 100 Engine Cover Lock Levers 27 Lock Lever Adjustment 62 Lock Lever Bracket Adjustment 62 REMOVAL AND INSTALLATION 61 Oil Change 64 Filter Change 65 Level Check 63...

Page 111: ...Panel Mount Type 20 Side Mount Type 16 Top Mount Type 23 GEARSHIFTING AND THROTTLE OPERATION 48 Panel Mount Type 49 Side Mount Type 49 Top Mount Type 50 HOISTING THE OUTBOARD MOTOR 82 Ignition Switch Panel Mount Type 18 Side Mount Type 15 Top Mount Type 22 IMPORTANT SAFETY INFORMATION 7 INDICATORS 29 INSTRUMENTS 28 IS YOUR OUTBOARD MOTOR READY TO GO 34 Lubrication Points 68 MAINTENANCE SAFETY 56 M...

Page 112: ...tor 29 Propeller Replacement 78 REFUELING 71 REMOVAL FROM STORAGE 84 SAFE OPERATING PRECAUTIONS 36 SAFETY LABEL LOCATIONS 9 Serial Number Locations 97 SERVICING YOUR OUTBOARD MOTOR 55 SHALLOW WATER OPERATIONS 53 Spark Plug Service 69 Specifications 104 Star Label 102 STARTING THE ENGINE 39 Panel Mount Type 42 Side Mount Type 39 Top Mount Type 44 STEERING 50 STOPPING THE ENGINE 46 Emergency Engine ...

Page 113: ...e Button Panel Mount Type 20 Top Mount Type 23 Tilt Lock Lever 26 TOOL KIT optional equipment 57 TRANSOM ANGLE ADJUSTMENT 37 Transom Angle Adjusting Rod 27 TRANSPORTING 85 WITH OUTBOARD MOTOR INSTALLED ON BOAT 85 WITH OUTBOARD MOTOR REMOVED FROM BOAT 85 Trim Meter optional equipment 28 Trim Tab 28 TRIM TAB ADJUSTMENT 60 WIRING DIAGRAMS Inside Back Cover 02 07 23 13 20 25 31ZW5601_112 ...

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