Honda Marine BF40A Owner'S Manual Download

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X22ESR-U (DENSO)

DR7EA (NGK)

Spark Plug Service

SERVICING YOUR OUTBOARD MOTOR

SPARK PLUG
WRENCH

SPARK PLUG CAPS

0.024

0.028 in

(0.60

0.70 mm)

SEALING WASHER

Incorrect spark plugs can cause
engine damage.

RECOMMENDED SPARK PLUGS:

Unlatch and remove the engine
cover (p.

Disconnect the spark plug caps
from the spark plugs.

Measure the spark plug electrode
gap with a suitable gauge. The gap
should be 0.024

0.028 inches

(0.60

0.70 mm).

Remove the spark plugs with a
spark plug wrench.

Inspect the spark plugs. Replace
them if the electrodes are worn, or
if the insulators are cracked or
chipped.

03/04/26 19:22:05 31ZW3600_069

Summary of Contents for Marine BF40A

Page 1: ...01 BLACK N HC AH EM3 31ZW3601 00X31 ZW3 6010 1000 2003 07 Printed in Japan C 2003 Honda Motor Co Ltd All Rights Reserved 2004 BF40A 50A AH O M 31ZW3601 BF40A 50A AH O M 31ZW3601 BF40A 50A AH O M 31ZW3...

Page 2: ...onda 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...

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 owne...

Page 4: ...tical 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 varie...

Page 5: ...Ignition Switch side mount type 19 Switch Clip and Emergency Stop Switch side mount type 20 Fast Idle Lever side mount type 21 Gearshift Throttle Control Lever side mount type 21 Common Controls Power...

Page 6: ...onal equipment 36 FUEL HOSE CONNECTIONS 36 FUEL PRIMING 37 STARTING THE ENGINE 37 LH and LHT Types long tiller handle 37 LRT and XRT Types remote control 39 EMERGENCY STARTING 42 STOPPING THE ENGINE 4...

Page 7: ...ction and Replacement 72 Portable Fuel Tank and Filter Cleaning optional equipment 74 Anode Replacement 75 Propeller Replacement 76 STORAGE 77 STORAGE PREPARATION 77 Cleaning and Flushing 77 Fuel 80 E...

Page 8: ...l Number Locations 94 Carburetor Modification for High Altitude Operation 95 Battery 95 Oxygenated Fuels 96 Emission Control System Information 97 Star Label 99 Specifications 101 CONSUMER INFORMATION...

Page 9: ...ne 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...

Page 10: ...n 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 a...

Page 11: ...ain 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...

Page 12: ...Tachometer optional equipment Trim Meter optional equipment Shaft Length Long Tiller Handle L X Refer to this chart for an explanation of the Type Codes used in this manual to identify control and fea...

Page 13: ...WATER INTAKE ENGINE OIL DRAIN PLUG COVER STERN BRACKET WASH PLUG Flush plug POWER TILT SWITCH LHT type ANTIVENTILATION PLATE GEAR OIL DRAIN PLUG FUEL HOSE CONNECTOR TRIM TAB anode PROPELLER optional...

Page 14: ...ER GEAR SHIFT THROTTLE GRIP SWITCH CLIP OIL PRESSURE INDICATOR LIGHT OVERHEAT INDICATOR LIGHT EMERGENCY STOP SWITCH IGNITION SWITCH IGNITION SWITCH KEY STEERING FRICTION ADJUSTER LANYARD POWER TRIM TI...

Page 15: ...NNECTOR TRANSOM ANGLE ADJUSTING ROD TRIM TAB anode STERN BRACKET WASH PLUG Flush plug ENGINE COVER GEAR OIL DRAIN PLUG POWER TILT SWITCH GEAR OIL LEVEL CHECK PLUG PROPELLER optional equipment WATER IN...

Page 16: ...SHIFT THROTTLE CONTROL LEVER NEUTRAL RELEASE LEVER OIL PRESSURE INDICATOR LIGHT POWER TRIM TILT SWITCH SPARE SWITCH CLIP BUZZER inside of the box EMERGENCY STOP SWITCH IGNITION SWITCH IGNITION SWITCH...

Page 17: ...onal equipment Trim Meter optional equipment Tachometer optional equipment CONTROLS AND FEATURES FUEL HOSE CONNECTOR female FUEL GAUGE VENT KNOB FUEL CAP PRIMING BULB FUEL TANK FUEL HOSE 03 04 26 19 1...

Page 18: ...em and starter motor Turning the ignition switch key to the START position operates the starter motor The key automatically returns to the ON position when released from the START position The ignitio...

Page 19: ...lotation 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 swtich clip...

Page 20: ...e N neutral position only The throttle friction adjuster adjusts resistance to throttle grip rotation Turn the adjuster clockwise to increase friction for holding a throttle setting while cruising Tur...

Page 21: ...rovided with the remote control equipment The ignition switch controls the ignition system and starter motor Moving the tilt lever to the FREE position allows the motor to be tilted and moving the til...

Page 22: ...p 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 Turning the ignition switch...

Page 23: ...d to set idle speed during warm up The lever will not move unless the gearshift throttle control lever is in the N neutral position Conversely the gearshift throttle control lever will not move unless...

Page 24: ...e speed and selects F forward N neutral or R reverse gears Moving the control lever 30 from N neutral selects the gear and further movement increases engine speed A friction adjuster near the base of...

Page 25: ...is a rocker switch with UP and DN down positions for changing the angle of the outboard motor The power tilt switch will operate without turning the ignition switch ON This switch is used with the eng...

Page 26: ...er is used to support the outboard motor in the fully raised position The outboard motor can be tilted manually after opening the manual relief valve This allows the outboard motor to be tilted when n...

Page 27: ...e 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 The trim tab compensates for torque steer whic...

Page 28: ...per minute Refer to the tachometer when using the throttle and power trim tilt controls to achieve the best performance from the boat A fuel gauge is built into the cap of the portable fuel tank optio...

Page 29: ...ure 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 li...

Page 30: ...d XRT Types If the engine overheats the red light will come on and the engine protection system will limit engine speed Remote controls are also equipped with a buzzer that sounds when the red light c...

Page 31: ...ting 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 Wa...

Page 32: ...he outboard motor from corrosion There are two anodes on the gear case one on the stern bracket and another is the trim tab The portable fuel tank has a capacity of US gal and has a fuel gauge built i...

Page 33: ...ulb 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...

Page 34: ...e 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...

Page 35: ...not excessively worn The anodes help to protect the outboard motor from corrosion Check the fuel level in the fuel tank p Check that all fasteners are in place and securely tightened Replace any dama...

Page 36: ...dly 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...

Page 37: ...mits 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 to...

Page 38: ...ound 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 bot...

Page 39: ...et end Squeeze the priming bulb several times until it feels firm indicating that fuel has reached the carburetor The engine will not start or run unless the clip is in the switch The emergency stop s...

Page 40: ...F forward or R reverse position Align the engine start symbol on the tiller handle with the pointer on the throttle grip Turn the ignition switch key to the START position and hold it there until the...

Page 41: ...ufficiently 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 If the indicators show any abnormal c...

Page 42: ...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 To restart a warm engine raise the...

Page 43: ...arts 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 If the fast...

Page 44: ...ure 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 Unlat...

Page 45: ...ope slowly until resistance is felt then pull briskly Keep away from moving parts while pulling the rope If the fast idle control s was used to start the engine return the control s to the normal oper...

Page 46: ...perform the emergency starting procedure be sure the lanyard is attached to your wrist before operating the outboard motor Have your closest authorized Honda marine dealer check your electrical system...

Page 47: ...STOP SWITCH P PU UL LL L LANYARD LRT and XRT Types remote control LH and LHT Types long tiller handle LH and LHT Types long tiller handle To stop the engine in an emergency pull the clip out of the e...

Page 48: ...tiller handle LRT and XRT Types remote control Move the throttle grip to the slowest speed and control gears to N neutral position When the boat is not in use remove and store the ignition key and th...

Page 49: ...ward N neutral or R reverse gears The engine can be started with the gearshift lever in the N neutral position only The throttle grip can be turned to the FAST position only when the gearshift lever i...

Page 50: ...ontrol 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 Moving the control lever beyon...

Page 51: ...friction plate Grease or oil will reduce the friction of the adjuster Steer the boat in the same manner as an automobile Use the steering friction adjuster to help hold a steady course while cruising...

Page 52: ...ect causes boat to plow For best fuel economy limit the throttle opening to 80 Use the throttle friction control p and to help you hold a steady speed It is necessary to trim the angle of the outboard...

Page 53: ...il lt t t th he e m mo ot to or r d do ow wn n POWER TRIM TILT SWITCH LH and LHT Types long tiller handle LRT and XRT Types Excessive trim tilt angle during operation can cause propeller ventilation o...

Page 54: ...se the power trim tilt switch p to tilt the outboard motor so the propeller and gear case won t hit the bottom When operating in shallow water tilt the outboard motor using the tilt lever so the prope...

Page 55: ...d position by pulling on the engine cover grip While the outboard motor is tilted proceed at a low speed and do not operate the outboard motor in reverse The outboard motor will rise suddenly if opera...

Page 56: ...ng on the engine cover grip To lower the outboard motor tilt up move the tilt lock lever to the FREE position then lower the outboard motor to the desired position Use the tilt lever to raise and lowe...

Page 57: ...not closed the outboard motor will tilt up when operated in reverse The outboard motor can also be tilted manually after opening the manual relief valve This feature enables the outboard motor to be t...

Page 58: ...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...

Page 59: ...ould 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...

Page 60: ...H CLIP LH and LHT Types Always carry the spare emergency stop switch clip and the emergency starter rope onboard The spare clip may either be stored in the optional tool bag or in an easily accessible...

Page 61: ...adjust Replace Check Check Grease Clean Each 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 After use 3 Emission related items Lubricate more freque...

Page 62: ...f necessary 2 Check Check Replace Check Replace Checklevel tightness Check tightness Check Clean 3 Emission related items Lubricate more frequently when used in salt water These items should be servic...

Page 63: ...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...

Page 64: ...es then lift the engine cover off the outboard motor To install the engine cover place the cover on the outboard motor then latch both front and rear latches securely The outboard motor can be tilted...

Page 65: ...ertical position Remove the dipstick and wipe it clean Insert the dipstick all the way in then remove it and check the oil level shown on the dipstick If the oil level is low remove the oil filler cap...

Page 66: ...plug cover Place the drain plug cover as shown to use it as an oil drain guide Place a suitable container under the guide An engine oil evacuation device may be used to remove the engine oil Drain the...

Page 67: ...ground Remove the engine oil drain bolt and washer Allow the used oil to drain completely then install a new sealing washer on the engine oil drain bolt and tighten it securely Reinstall the drain plu...

Page 68: ...d service life Use 4 stroke automotive detergent oil SAE 5W 30 is recommended for general use The SAE oil viscosity and service classification are in the API label on the oil container Honda recommend...

Page 69: ...ot penetrate Apply Honda Marine Corrosion 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 anticorros...

Page 70: ...SPARK PLUGS Unlatch and remove the engine cover p Disconnect the spark plug caps from the spark plugs Measure the spark plug electrode gap with a suitable gauge The gap should be 0 024 0 028 inches 0...

Page 71: ...refully by hand to avoid 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 spa...

Page 72: ...unscrew the fuel tank cap Remove the fuel tank from the boat for refueling Check the fuel gauge and refill the tank when necessary After refueling install the cap and tighten it securely Turn the ven...

Page 73: ...em 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...

Page 74: ...and Replacement SERVICING YOUR OUTBOARD MOTOR PUSH P PU UL LL L FUEL HOSE CONNECTOR The fuel pump filter is located under the engine cover between the fuel coupling and the fuel pump Water or sedimen...

Page 75: ...ed Pull the spring retainer toward you and raise the fuel filter Inspect the filter for water and or sediment accumulation If the filter is OK reinstall it If water and or sediment are present replace...

Page 76: ...nnector O ring Replace them if damaged Reinstall the filter and hose connector in the fuel tank Tighten the hose connector securely 3 1 2 Securely connect the fuel hose connector to the outboard motor...

Page 77: ...he outboard motor The anodes must be exposed to the water in order to protect the outboard motor The anodes are located on the trim tab and the stern bracket They are made of a sacrificial material th...

Page 78: ...ibility of the engine being started while you are working with the propeller The propeller blades may have sharp edges so wear heavy gloves to protect your hands Remove the cotter pin unscrew the cast...

Page 79: ...ush 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 cont...

Page 80: ...pter Move the gearshift lever or control lever to the N neutral position Flush the outboard motor in the neutral position only Turn on the fresh water supply to the flush kit coupler Damage caused by...

Page 81: ...on the wash plug If tape was used to cover the three water intakes in step 6 remove the tape now Install the wash plug into the gear case securely Allow the engine to run at idle for at least 5 minute...

Page 82: ...t 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 tan...

Page 83: ...plugs p and remove the clip from the emergency stop switch Pour a tablespoon 5 10 cm of clean engine oil into each cylinder Using the emergency starter rope p rotate the flywheel a few revolutions to...

Page 84: ...the boat for storage we recommend storing it vertically by mounting it on a stand Cover the outboard motor to keep out dust Do not use sheet plastic as a dust cover A nonporous cover will trap moistu...

Page 85: ...mal running position if possible Tighten the steering friction adjuster to prevent the outboard motor from moving while trailering the boat Use a motor support bar to prevent the outboard motor from m...

Page 86: ...r or refer to the shop manual Battery connections loose or corroded Starter malfunction switch malfunction or electrical problem in the starting circuit Clean and tighten battery connections Replace o...

Page 87: ...d in stop switch Gearshift lever or control lever not in neutral position Insert clip in stop switch Shift to neutral p and Fast idle lever not raised side mount type Turn throttle grip to START posit...

Page 88: ...tion fuel pump failure ignition malfunction stuck valves etc Refuel p Squeeze priming bulb p Replace or repair faulty components as necessary Open fuel tank vent p Take outboard motor to an authorized...

Page 89: ...hout treating or draining gasoline or refueled with bad fuel Check fuel Fuel hose not primed Fuel pump filter or fuel tank filter clogged Squeeze priming bulb p Replace fuel filters p Fast idle lever...

Page 90: ...ns Water intake screens clogged Clean water intake screens ENGINE OVERHEATS Possible Cause Correction Carburetor malfunction fuel pump failure ignition malfunction etc Replace or repair faulty compone...

Page 91: ...electric starter relay circuit are protected by the 15 ampere fuse If the fuse burns out the engine will not charge the battery and the electric starter will not operate The engine can be started usin...

Page 92: ...t should come on within 30 seconds and the engine will respond normally to throttle grip or control lever operation If the engine protection system remains activated after 30 seconds return to the nea...

Page 93: ...th a buzzer that sounds when the red indicator light comes on If overheating activates the engine protection system idle the engine in neutral and check the cooling system indicator Engine overheating...

Page 94: ...ns of water contamination then a second engine oil change should be performed after running the engine for half an hour If there is a Honda marine dealer nearby take the motor to the dealer immediatel...

Page 95: ...ngine was running when it submerged there may be mechanical damage such as bent connecting rods If the engine binds when cranked do not attempt to run the engine until it has been repaired If the engi...

Page 96: ...he space provided on this page You will need these numbers when ordering parts and when making technical or warranty inquiries p Engine serial number The engine serial number is stamped on the cylinde...

Page 97: ...carburetor air fuel mixture will be too rich Performance will decrease and fuel consumption will increase A very rich mixture will also foul the spark plugs and cause hard starting High altitude perf...

Page 98: ...line containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol Methyl Tertiary Butyl Ether 15 by volume You may use gasoline containing up to 15 MTBE by...

Page 99: ...stems 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 ac...

Page 100: ...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...

Page 101: ...ine 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...

Page 102: ...ndards 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 Personal Watercraft and Ou...

Page 103: ...15 0 02 mm 0 23 0 02 mm See page 68 See shop manual See shop manual No other adjustment is needed 950 50 rpm Gear case Engine Exhaust Intake L L L Gear case Engine 210 5 lbs 95 5 kg 214 9 lbs 97 5 kg...

Page 104: ...60 0 70 mm See page 68 See shop manual See shop manual 950 50 rpm 0 15 0 02 mm 0 23 0 02 mm No other adjustment is needed Gear case Engine Engine Gear case Exhaust Intake L X L X L X 214 9 lbs 97 5 k...

Page 105: ...omer 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 info...

Page 106: ...ND FEATURE IDENTIFICATION CODES 10 CONTROLS AND FEATURES 10 Cooling System Indicator 29 CRUISING 50 EMERGENCY STARTING 42 Emission Control System Information 97 Emergency Stop Switch and Switch Clip 1...

Page 107: ...READY TO GO 32 Lubrication Points 67 MAINTENANCE SAFETY 57 MAINTENANCE SCHEDULE 59 MANUAL RELIEF VALVE 24 62 MOORING BEACHING LAUNCHING 54 Oil Pressue Indicator 27 OIL PRESSURE INDICATOR LIGHT GOES OF...

Page 108: ...Emergency Engine Stopping 45 Normal Engine Stopping 45 STORAGE 77 STORAGE PRECAUTIONS 82 STORAGE PREPARATION 77 Cleaning and Flushing 77 Engine oil 81 Fuel 80 SUBMERGED MOTOR 92 Switch Clip and Emerge...

Page 109: ...83 WITH OUTBOARD MOTOR INSTALLED ON BOAT 83 WITH OUTBOARD MOTOR REMOVED FROM BOAT 83 Trim Meter optional equipment 26 Trim Tab 25 52 TRIM TAB ADJUSTMENT 61 WIRING DIAGRAMS Inside Back Cover 03 04 26...

Page 110: ...A3yoko 03 7 30 4 07 PM 1...

Page 111: ...A3yoko 03 7 30 4 07 PM 2...

Page 112: ...A3yoko 03 7 30 4 07 PM 3...

Page 113: ...01 BLACK N HC AH EM3 31ZW3601 00X31 ZW3 6010 1000 2003 07 Printed in Japan C 2003 Honda Motor Co Ltd All Rights Reserved 2004 BF40A 50A AH O M 31ZW3601 BF40A 50A AH O M 31ZW3601 BF40A 50A AH O M 31ZW3...

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