Honda Outboard Motor BF5A manual

00X31-ZV1-6390 BF5A 31ZV1639 00X31-ZV1-6390 2eY1 400.2007.01 Printed in Japan N BF5AK0 P ANTONE 288 CVC DIC F101 BLA CK[...]

− The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Keep this owner’s manual handy, so you can ref er to it at any time. This owner’s manual is c onsidere d a perm anent pa rt of the outboa rd motor a nd should re main wit h the outboar d motor [...]

1 INTRODUCTION Congratul ations on your sele ction of a Honda outboard mot or. We are cert ain you will be plea sed with your purchas e of one of the f inest outboard m otors on the mar ket. We want to help you ge t the be st resul ts f rom your new outboard motor and to operate it saf ely. This manual conta ins inf ormati on on how to do that; ple[...]

− − − − − − 2 A FEW WORDS ABOUT SAFETY INTRODUCTION Saf ety Mess ages Saf ety Headings Saf ety Labels Saf ety Section Instructions I MPORT AN T SAFET Y I NFORM AT I ON . O UTB O A R D M O TO R S A F E TY. Your saf ety a nd the saf ety of other s are ve ry import ant. And us ing this outboard m otor saf ely i s an impor tant responsibili[...]

3 CONTENTS ................................... OUTBOARD MOTOR SAFETY . 6 ................ IMPORTANT SAFETY INFORMATION . 6 ................................ SAFETY LABEL LOCATIONS . 8 .................................... CONTROLS AND FEATURES . 9 CONTROL AND FEATURE .................................. IDENTIFICATION CODES . 9 .... COMPONENT AND CONTR[...]

4 CONTENTS ................................................................ OPERATION . 23 .................... SAFE OPERATING PRECAUTIONS . 23 ....................................... BREAK-IN PROCEDURE . 23 ..................... TRANSOM ANGLE ADJUSTMENT . 23 ....................................... PORTABLE FUEL TANK . 24 ..........................[...]

5 CONTENTS .................................................................... STORAGE . 56 ................................... STORAGE PREPARATION . 56 .......................................... Cleaning a nd Flushing . 56 ........................................................................ Fuel . 58 ..........................................[...]

6 IMPORTANT SAFETY INFORMATION Operator Responsibility OUTBOARD MOTOR SAFETY It is the operator’s responsibility to provide the ne cess ary saf eguards to prote ct people and prope rty. Know how to stop the e ngine quickly in case of emergency. Underst and the use of all contr ols. Attach the emergency stop switch lanyard securely to the op erato[...]

7 Carbon Monoxide Hazard Ref uel With Care OUTBOARD MOTOR SAFETY Exhaust gas c ontains pois onous carbon m onoxide. Avoi d inhalat ion of exhaust gas . Never run the e ngine in a closed garage or conf ined area. Gasoline is extremely f lammable, and gasol ine vapor can e xplode. Ref uel outdoors, in a well- ventilated area, with the engine stopped.[...]

8 SAFETY LABEL LOCATIONS OUTBOARD MOTOR SAFETY FUEL TA NK The labels sh own here con tain importan t saf ety in f o rmation. Please read th em caref u lly. These labels are co nsidered perma nent part s of your outboard m otor. If a l abel c omes of f or become s hard to r ead, c ontact a n authoriz ed Honda marine dealer f or a rep lacement. 07/01[...]

9 CONTROL AND FEATURE IDENTIFICATION CODES CONTROLS AND FEATURES Shaf t Length Type Model S: Short Shaf t L: Long Sha f t BF5A Ref er to this cha rt f or an expla nation of the Type Code s used in this manua l to identif y control and feature applic ations. BF5A is provided w ith the f ollowing types accord ing to t he shaf t leng th. SA S LA L Sha[...]

10 COMPONENT AND CONTROL LOCATIONS CONTROLS AND FEATURES TILT LEVER ENGI NE COVER TILLER HANDLE ANTIV ENTILATION PLATE ANODE SPARK PLUG THROTTLE GRIP CHOKE KNOB ENGINE STOP SWITCH LANYARD FUEL HOSE CONNECT OR (MA LE) TRANSO M ANGLE ADJUST ING ROD PROP ELLER GEARSHIF T LEVER ENGI NE COVER LOCK LEVER STE RN BRACKET THROTTLE FRIC TION KNOB CLAMP SCRE [...]

11 Portable Fuel Tank CONTROLS AND FEATURES VENT KNO B FUEL TA NK FUEL HOSE PRIM ING BULB FUEL HOSE C ONNEC TOR (FEM ALE) FUEL FILLER C AP FUEL GAUG E 07/01/08 13:03:34 31ZV1630_012[...]

12 CONTROLS Choke Knob Switch Clip and Engine Stop Switch CONTROLS AND FEATURES ENGINE STOP SWITCH LANYARD SWI TCH CLIP LANYARD CHOKE KNOB PUSH SWITCH CLIP O O F F F F O O N N The engine st op switch contr ols normal e ngine stopping and emer gency engine s topping. The switch clip must be inserted in the engi ne stop s witch in or der f or the eng[...]

13 Throttle Grip Throttle Friction Knob Gearshif t Lever CONTROLS AND FEATURES THROTTLE GRIP R (reverse) N( n e u t r a l ) F( f o r w a r d ) INDEX MARK THROTTLE FRIC TION KNOB T T O O D D E E C C R R E E A A S S E E F F R R I I C C T T I I O O N N T T O O I I N N C C R R E E A A S S E E F F R R I I C C T T I I O O N N GEARSHIF T LEVER The gearsh [...]

14 Engine Cover Lock Lever Transom An gle Adjust ing Rod Starter Grip CONTROLS AND FEATURES UNLOCK TRANSO M ANGLE ADJ USTING ROD ENGINE COV ER LOCK LEVER STARTER GR IP The engine cove r lock lever f aste ns the engine c over to the outboar d motor. The motor will s tart only whe n the gearshif t lever (p . ) is in the N (neutral) positio n, and the[...]

15 INSTRUMENTS Steering Friction Bolt Tilt Lever Fuel Gauge CONTROLS AND FEATURES TILT LEVER FUEL GAUG E STEERING FR ICTION BOLT T T O O D D E E C C R R E E A A S S E E F F R R I I C C T T I I O O N N T T O O I I N N C C R R E E A A S S E E F F R R I I C C T T I I O O N N ENGI NE COVER G RIP FUEL FILLER C AP Less f rictio n allows the outb oard mot[...]

16 INDICATORS Oil Pressure Indicator Cooling System Indicator OTHER FEATURES Overrev Limiter CONTROLS AND FEATURES COOL ING SYS TEM INDI CATOR OIL PRE SSURE INDI CATOR TA KIN G CARE OF U NEX PECT ED PROBLEMS Wate r should f low f rom the cooli ng syste m indicat or while the engine i s running. This shows t hat wate r is circ ulating t hrough the c[...]

17 Portable Fuel Tank Anode Fuel Filler Cap Vent Knob CONTROLS AND FEATURES VENT KNO B O O P P E E N N CLOS E ANODE FUEL FILLER C AP The po rtable f uel tank has a capacity of US gal ( ) and has a f uel gauge bu ilt into the cap. The anode is ma de of a sacrif icia l material that helps to p rotect the outboard mot or f rom corrosion. There is a n [...]

18 Fuel Priming Bulb CONTROLS AND FEATURES INLET END (TANK) UP OUTLET END (MOTOR ) PRIM ING BULB A priming bulb is built into th e f uel hose that c onnects the f uel ta nk to the outboard m otor. Bef ore start ing the engine, hold the priming bu lb up in the direction of the arrow, then squeeze the priming bulb un til it f eels f irm. Th is will e[...]

− − − − 17.1 in (434 mm) 22.1 in (561 mm) 19 POWER REQUIREMENTS INSTALLATION POSITI ON INSTALLATION CENTER LIN E IDLE POR T M M O O T T O O R R T T R R A A N N S S O O M M H H E E I I G G H H T T 02 i n (0 50 mm) B B O O A A T T T T R R A A N N S S O O M M H H E E I I G G H H T T ANTIV ENTILATION P LATE WATER SURFACE 5.9 in (150 mm) Correct[...]

20 ATTACHMENT TRANSOM ANGLE ADJUSTMENT INSTALLATION STERN BRACKE T SAFET Y ROPE CL AMP SCREWS Attach the stern bracket to the boat transom by tigh tening the clamp screws. Attac h a rope f rom the boat to the hole in t he stern bracket. T his will help to pr event accidental lo ss of the outboard m otor. Use the tra nsom angle adj ustment rod (p. )[...]

Improperly maintaining this outboard motor, or failing to correct a problem before operation, can cause a malfunction in which you could be seriously hurt or killed. Always perform a pre- operation inspection before each operation, and correct any problem. 21 ARE YOU READY TO GET UNDER WAY? Saf ety Knowledge IS YOUR OUTBOARD MOTOR READY TO GO? BEFO[...]

22 Saf ety Inspection Maintenance Inspection BEFORE OPERATION Look around the outboar d motor f or signs of oil or gasoline lea ks. If you are using the port able f uel tank, make s ure it is in good conditio n and properly secured in the boat (p. ). Check that the f uel hose is undamage d and proper ly connected (p . ). Wipe up an y spills bef ore[...]

23 SAFE OPERATING PRECAUTIONS BREAK-IN PROCEDURE TRANSOM ANGLE ADJUSTMENT OPERATION TRANSO M ANGLE ADJUST ING ROD TO CHANG E TO LOCK UNLOC KED POSI TION LOCKED POSITION I MPORT AN T SAFET Y I NFORM AT I ON BEFORE OPERAT I ON . To saf ely realize the f ull potential of this out board motor , you need a comple te underst anding of its operat ion and [...]

Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Wipe up spills immediately. Handle fuel only outdoors. Stop the engine and keep heat, sparks, and flame away. 24 PORTABLE FUEL TANK FUEL HOSE CONNECTIONS OPERATION FUEL HOSE C ONNEC TOR (OUTBOA RD MOTOR SID E) FUEL HOSE C ONNEC TOR (FUEL TANK S ID[...]

25 FUEL PRIMING STARTING THE ENGINE OPERATION OUTLET END (MOTOR ) INLET END (TANK) PRIM ING BULB ENGINE STOP SWITCH LANYARD UP SWI TCH CLIP The engine wil l not start or r un unless the clip is in the switch. The emergency stop switch clip and lanyard sy stem is a saf ety device t hat will stop the e ngine if you f all away f rom the control s whil[...]

26 OPERATION CHOKE KNOB THROTTLE GRIP N (neut ral) GEARSHIF T LEVER MARK O O F F F F O O N N Check the p osition of the gearshif t lever. It must b e in the N (neutral) position f o r starting. The engine wil l not start i f the gearshif t lever is in the F (f o rward) or R (reve rse) posi tion. Align the START position with the mar k f or start in[...]

27 EMERGENCY STARTING OPERATION ENGINE COV ER LOCK LEVER UNLOCK STARTER GR IP Directio n to pull T AK I N G CARE OF U NEX PECT ED PROBLEM S If the rec oil star ter is inope rative , you can sta rt the engine m anually usi ng the emergency starter rope supplied with the tool kit. Unlock and remove t he engine cover. Pull the starter grip lightly unt[...]

− 28 OPERATION START ER ROPE 6 mm CAP NUTS FLYWH EEL COVE R 6 mm FLANG E BOLTS T AK I N G CARE OF U NEX PECT ED PROBLEM S, Pull the emergen cy starter rope slowly un til resistance is f elt, then pull bris kly. Keep aw ay f rom moving part s while pulling the rope. If necessary , rewind the ro pe and pull agai n. If the engine does not start af t[...]

Exposed moving parts can cause injury. Do not operate the outboard motor without the engine cover. Use extreme c are when installing the engine cover. 29 OPERATION If it was necessary to remove the emer gency stop s witch la nyard f rom your wrist to perf orm the emer gency st arting pr ocedure , be sure t he lanya rd is at tache d to your wrist be[...]

30 STOPPING THE ENGINE Emergency Engine Sto pping Normal Eng ine Stopping OPERATION THROTTLE GRIP N (neut ral) PULL ENGINE STOP SWITCH LANYARD SWI TCH CLIP GEARSHIF T LEVER ENGINE STOP SWITCH PUSH To stop the engine i n an eme rgency, pull the cli p out of the engine stop switch by pulling t he lanyard. We sugges t that you stop the engi ne this wa[...]

31 GEARSHIFTING AND THROTTLE OPERATION OPERATION THROTTLE GRIP R (reverse) N (neutral) F( f o r w a r d ) T T O O D D E E C C R R E E A A S S E E F F R R I I C C T T I I O O N N T T O O I I N N C C R R E E A A S S E E F F R R I I C C T T I I O O N N THROTTLE FRIC TION KNOB GEARSHIF T LEVER To shif t gears, turn the throttle grip to the SLOW positio[...]

32 STEERING OPERATION STEERING FR ICTION BOLT T T O O D D E E C C R R E E A A S S E E F F R R I I C C T T I I O O N N T T O O I I N N C C R R E E A A S S E E F F R R I I C C T T I I O O N N Steer by mov ing the tiller hand le opposite the di recti on you want the boat to turn. Use the steering f rictio n bolt to help hold a stea dy course while c r[...]

33 CRUISING Engine Speed Transom Angle OPERATION CORRECT GIVE S MAXIMUM PERFO RMANCE Transom Angle ( Cruising) ROUGH WAVES MOTOR AN GLE ADJUST ED TOO LOW MOTOR AN GLE ADJUST ED TOO HIGH MOTOR AN GLE ADJUST ED CORRECT LY Exces sive trans om angle during operation ca n cause prope ller venti lation, ove rheating, and water pump d amage. T his type of[...]

34 SHALLOW WATER OPERATION OPERATION 30° ENGI NE COVER G RIP Do not use t he tiller hand le as a lever to raise the outboard motor. Applying excessive f orce t o the t iller handle can d amage it. An excess ive til t angle d uring operation ca n cause prope ller venti lation, ove rheating, and water pump d amage. T his type of damage is not cover [...]

35 MOORING, BEACHING, LAUNCHING OPERATION TILT LEVER 45°, 70° (when m ooring) ENGI NE COVER G RIP To raise the out board motor out of the water while the b oat is moored, or f o r maximum clearance wh en beaching or laun ching, tilt the outboard mot or to the 45° or 70° positi on. Stop the eng ine bef o re tilting the outboard motor . The 45° [...]

Improperly maintaining this outboard motor, or failure to c orrect a proble m before operation, can cause a malfunction in which you could be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. 36 THE IMPORTANCE OF MAINTENANCE Maintena nce, replacement, or repair of the emis[...]

− − − Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in the owner’s manual. 37 MAINTENANCE SAFETY Saf ety Precautions Burns f rom ho t parts. Injury f rom movi ng parts. Carbon monoxide poisoni ng f rom engine exhaust. SERVICING Y[...]

× 38 TOOL KIT AND EMERGENCY STARTER ROPE SERVICING YOUR O UTBOARD MOTOR EMERGEN CY STARTER R OPE FLUSH K IT 10 12 mm WRENCH PLIERS TOOL BAG FLAT SCREWDRIVER PHILIPS SCREWDRIVER 8 mm WRENCH SPARE SPARK PLUG COTTER PINS SHEAR PINS WATER MOUTH NUT SPARK PLUG WRENCH WATER MOUTH SEAT WATER HOSE CONNECTOR SPARE SWITCH CLIP The f ollowing tools are supp [...]

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 39 MAINTENANCE SCHEDULE SERVICING YOUR O UTBOARD MOTOR Distributor’s Li mited W arranty Lubrica te more frequently when used in sa lt wate r. These items should be service d by an authorize d Honda ma rine deale r, unless you ha ve the proper tools a nd are me chanica lly prof ic[...]

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 40 SERVICING YOUR O UTBOARD MOTOR Perform at every indicated month or operating hour inter val, whichever comes f irst. REGULAR SERVICE PERIOD First month or 20 hrs. (2) Each use Af ter use (4) Every 6 months or 100 hrs. (2) Every 2 years (If necessary) (2) ITEM Clean Check Check Replace Check Replace Check-t[...]

41 ENGINE COVER REMOVAL AND INSTALLATION Engine Oil Level Check SERVICING YOUR O UTBOARD MOTOR UPPER LIMIT LOWER LIMIT ENGINE COV ER LOCK LEVER UNLOCK OIL FILLER C AP/DIP STICK OIL FILLER CAP /DIPSTIC K Running the engi ne with a low oi l level can ca use engine d ama ge. Check the engine oi l level with the engine st opped and the outboard motor i[...]

42 Engine Oil Chan ge SERVICING YOUR O UTBOARD MOTOR DRAIN BO LT Improper d isposal of engi ne oil can be harmf ul to the environment. If you change y our own oil, ple ase dispose of the used oil properly. Put it in a seal ed container, and tak e it to a recycling cen ter. Do not discard it in a trash bin, dump it on the ground or pour it d own a d[...]

SAE Visco sity Grade AMBIENT TEMPERATURE 4.8 lbf·ft (6.5 N·m , 0.66 kgf·m) 43 Engine Oil Recomm endations Gear Case Oil Level Check SERVICING YOUR O UTBOARD MOTOR GEAR OIL LEVEL SCR EW GEAR OIL DRAIN/FI LL SCREW Oil is a major f actor af f ecting perf ormance a nd service li f e. Use 4-str oke automoti ve deterge nt oil. SAE 10W-30 is rec ommend[...]

44 Gear Case Oil Chan ge SERVICING YOUR O UTBOARD MOTOR If no oil f lows f rom the oil leve l hole, add the recommend ed oil (p. ) f o llowing the p rocedure describ ed in Gear Case Oi l Change. Change th e gear case oil with the engine st opped and the outboard motor in the ver tical pos ition. Place a s uitable c ontainer be low the oil drain hol[...]

0.1 US qt (0.1 ) 4.8 lbf·ft (6.5 N·m, 0.66 kgf·m) 4.8 lbf·ft (6.5 N·m, 0.66 kgf·m) 45 SERVICING YOUR O UTBOARD MOTOR GEAR OIL BOTTLE Add oil through t he oil dra in hole until it f lows out the oil le vel hole, then install th e oil level screw. Remove the pump ada pter and instal l the oil drain sc rew. GEAR OIL CAPACITY: OIL LEVEL SCREW TOR[...]

46 Lubrication Points SERVICING YOUR O UTBOARD MOTOR PROPELLER SHAFT CLAMP SCREWS SWIVEL CASE THROTTLE CABLE AND PIVOT SHIFT SHAFT AND PIVOT TILLER HANDLE PIVOT TILT RELEASE LEVER AND REVERSE LOCK ROD TRANSOM ANGLE ADJUSTING ROD ENGINE COVER LOCK LEVER T o prevent corr osion, apply anticorrosion oil to pivot surf ace s where grease c annot penetrat[...]

− − − − W16EPR-U (DENSO) BPR5ES (NGK) 0.028 0.031 in (0.70 0.80 mm) 47 Spark Plug Service SERVICING YOUR O UTBOARD MOTOR 0.028 0.031 in (0.70 0. 80 mm) SPARK PLUG W RENCH SEAL ING WASH ER SIDE ELECTR ODE Incorrect spark plug can caus e engine damage. RECOMMENDED SPARK PLUGS: Unlock and remove t he engine cover (p. ). Disconne ct the s park [...]

− 3.2 US gal (12 ) 48 REFUELING Portable Fuel Tank SERVICING YOUR O UTBOARD MOTOR VENT KNO B CLOS E O O P P E E N N FUEL GAUG E SAFE F ILL LEVEL FUEL F ILLER CAP A loose s park plug can overhe at and damage the engine. Overtighte ning the spark plug c an dam a ge t he t h re a ds in t he c y l i nde r head. Install the spark plug caref u lly, by [...]

Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. 49 FUEL RECOMMENDATIONS SERVICING YOUR O UTBOARD MOTOR Use unleaded gasoline with a pump octane rati ng of 86 or higher. Never ref ill th[...]

Wipe up spills immediately. Handle fuel only outdoors. Stop the engine and keep heat, sparks, and flame away. You can be burned or seriously injured when handling fuel. Gasoline is highly flammable and explosive. 50 Fuel Filter Inspection and Replacement SERVICING YOUR O UTBOARD MOTOR UNLOCK ENGINE COV ER LOCK LEVER Running the engine with pers ist[...]

51 SERVICING YOUR O UTBOARD MOTOR ARROW (Fuel Fl ow Directio n) FUEL F ILTER FUEL F ILTER FUEL HOSE HOSE CLAM PS FUEL HOSE HOSE CLAM PS Remove the f uel hoses f rom the used f ilter, and discard the f ilter. To ease ho se removal, release the hose clamps by squeezin g the clamp ends together with pliers while pulling of f th e hoses. Install the ne[...]

Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. 52 Portable Fuel Tank and Tan k Filter Cleaning SERVICING YOUR O UTBOARD MOTOR FUEL HOSE Fuel Tank Insta ll and lock the engine c over. E[...]

53 Anode Replacement Recoil Starter Rope Inspection SERVICING YOUR O UTBOARD MOTOR RECOI L START ER ROPE ANODE BOLT FILTER O-RING TANK FILTER JOIN T (Fue l Hose Connect or) Fuel T ank Fil t er Painting or coati ng the anodes will def eat thei r purpose and will lead to rust and corrosion damage to the outboard motor. T he anod es must be expose d t[...]

54 Propeller and Shear Pin Replacement SERVICING YOUR O UTBOARD MOTOR COTTER PIN PROP ELLER CAP SHEAR PIN Removal Remove the cotter p in, the propell er cap, and the pr opeller . Remove the broke n shear pin and repla ce it with a new one. Operat ing the outboa rd motor at higher altitud es will reduce available power. T his may requi re decreasing[...]

55 SERVICING YOUR O UTBOARD MOTOR COTTER PIN In s ta lla ti on Spare shear pins and cotter pin s are provided in the engi ne compar tment (p. ). Insta ll the s hear pi n and the propell er, then inst all the prope ller cap f inger tight. Use a genuine Honda s tainles s steel cotter pin o r equivalent co tter pin and bend t he pin ends as shown. Be [...]

56 STORAGE PREPARATION Cleaning and Flushing STORAGE WATER HOSE WATER HOSE CONN ECTOR Cl eaning Fl ushing W it h t he H ond a Wa ter H ose Connector Proper stor age prepa ration is esse ntial f or keeping your outboa rd motor tr ouble-f ree a nd looking good. The f o llowing steps will help to keep rust and corro sion f rom impairing your outboar d[...]

57 STORAG E ANTIV ENTILATION P LATE Fl ushing W it hout t he Hond a Wa ter H ose Connector Running the engine without good water circ ulation c an cause overheati ng and water pump damage. Distributor’s Li mited W arranty It is nece ssar y to run the e ngine during the f lushing proce dure. For saf ety, rem ove the propell er f rom the outboard m[...]

58 Fuel STORAG E Ad d ing a Fuel St abil izer Depending on the region where you operate your outboard , f uel f ormulations may deteriorate and oxidize rapidly. Fuel deteriorati on and oxid ation can oc cur in as littl e as 15 d ays and may cause damage to the carburetors and f uel system. Please check wit h your servicing dealer f or local s torag[...]

Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. 59 STORAG E DRAIN SCREW DRAIN TUBE AIR GUI DE CARBURET OR DRAIN PORT Dr aining t he Fuel Syste m Distributor’s Li mited W arranty Af te[...]

− 60 Engine Oil STORAGE PRECAUTIONS STORAG E CARRYING HANDL E Lif ting the outboard motor by the engine co ver, or using the instal led outboard motor as a hand le or lever to move the boat, can damage the outboard motor. Select a well-ventilated storage area. If possible , avoid stora ge areas wi th high humidit y. If your portable f uel ta nk c[...]

61 REMOVAL FROM STORAGE STORAG E CASE PROT ECTORS BEFORE OPERAT I ON Any other horizontal storage posi tion may cause damage to the outboard motor or oil le akage. Cover the outboa rd motor to keep out dust. Do not use shee t plastic a s a dust cover . A nonporous cover wil l trap moisture, promo ting rust and corrosion . Check your outboar d motor[...]

62 WITH OUTBOARD MOTOR INSTALLED ON BOAT WITH OUTBOARD MOTOR REMOVED FROM BOAT TRANSPORTING CARRYING HANDL E MOTOR SUP PORT BAR (commercia lly available) Lif ting the outboard motor by the engine cov er, or using the install ed outboard motor as a handle or lever t o move the boat, can damage the outboard motor. If there is i nsuf f icient road cle[...]

63 TAKING CARE OF UNEXPECTED PROBLEMS Check emergency stop switch clip. Check contr ol positions . Clip not inserted in stop switch . Insert clip in stop switch. Shif t to neutral (p . ). ENGINE WILL NOT START Possible Cause Correction Gears hif t lever not in neutra l positi on. Choke OFF. Pull choke knob to ON position, unless e ngine is warm (p.[...]

64 TAKING CARE OF UNEXPECTED PROBLEMS Correction Possible C ause ENGINE WILL NOT START (conti nued) Check f uel. Out of f uel. Fuel hose not pri med. Bad f uel; boat store d without treating or drainin g gasoline, or ref u eled with bad gasoline. Carbure tor malf unction, f uel pump f ailu re, ignition malf un ction, stuck valves, etc. Ref u el (p.[...]

65 TAKING CARE OF UNEXPECTED PROBLEMS Correction Possible C ause HARD STARTING OR STALLS AFTER STARTING Check control positions. Choke OFF. Pull choke knob to ON position, unless e ngine is warm (p. ). Check f uel. Throttle grip not in START positi on. Turn throttle grip to START (p. ). Open f uel tank vent (p. ). Fuel vent cl osed (port able f uel[...]

66 TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS AFTER STARTING (conti nued) Take outboa rd motor to a n authoriz ed Honda marine de aler , or ref er to the shop ma nual. Faulty ther mostat or wa ter pump. Replac e or repair f aulty components as necessary. ENGINE OVERHEATS Possible Cause Correction Carbure tor malf unction, f uel pump[...]

67 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT DRIVE THE PROPELLER Possible Cau se Correction Broken shea r pin. Damaged gearsh if t mechan ism. Replace shear p in (p. ). Replac e or repair f aulty components as necessary. Check shear p in. Take outboa rd motor to a n authoriz ed Honda marine de aler , or ref er to the shop ma nual. 2. 1. 54[...]

68 OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMI TED TAKING CARE OF UNEXPECTED PROBLEMS OIL PRE SSURE INDI CATOR If the throttle is closed suddenly af ter f u ll throttle operatio n, engine sp eed may drop belo w the specif ied idle rpm, a nd that coul d activa te the engine prot ection sys tem momentarily. If low oil pressu re activates[...]

69 SUBMERGED MOTOR TAKING CARE OF UNEXPECTED PROBLEMS STARTER GR IP A subme rged outboar d motor mus t be serviced immediately af ter it is recovered f rom th e water in order to minimize corrosion . Remove the e ngine cover, and rinse t he outboard motor wi th f resh w ater to remove salt water, sand, mud, e tc. Drain the ca rburetor a s descri be[...]

70 TAKING CARE OF UNEXPECTED PROBLEMS W hen cranking the engine with an open igniti on circui t (spark plug removed f rom the ignition circ uit), remov e the clip f rom the engine s top switch to preven t possib le da mage to th e ignition s ystem . Attempt to start the engin e. Reinsta ll the s park plug, a nd put the emergency stop switch clip in[...]

71 TECHNICAL INFORMATION Serial Number Locations TECHNICAL AND CONSUMER INFORMATION ENGI NE SERIAL NUMB ER PRODUCT IDE NTIFICAT ION NUMBER Engine ser ial numbe r: Product ide ntif ication numbe r: The product ide ntif ication numbe r is stamped on the swivel case. The engine se rial numbe r is stam ped on the right side of the motor. Record the pro[...]

72 Carburetor Modif ication f or High Altitude Operation TECHNICAL AND CONSUMER INFO RMATION W hen the carburetor has been modif ied f or high altitude operation, the air -f uel mixt ure will be t oo lean f or low altitude use. Operation at altitudes below 5,000 f eet (1,500 meters ) with a modif ied carburetor may cause the engi ne to overheat and[...]

73 Emission C ontrol Syst em Inf ormation TECHNICAL AND CONSUMER INFO RMATION Source of Emissions Tamper ing and Al t er ing The U.S. and Cal if or nia Cl ean Air Act s The combust ion process pr oduces carbon monoxi de, oxides of nitrogen, and hydroca rbons. Control of hydrocar bons and oxides of nitrogen is very important because, under certain c[...]

74 TECHNICAL AND CONSUMER INFO RMATION Maint ena nce Repl acement Par ts Probl ems That May Af f ect Emissions A manuf actur er of an af termarket part assumes the responsibility that the part will no t adversely af f ect emis sion perf ormanc e. The manuf actur er or rebuil der of the part must certif y that use o f the part will not result in a f[...]

75 Star Label The Symbol f or Cleaner Marine Engi nes: Cleaner Air and Wate r - Better Fuel Economy - Longer Emissio n Warranty - TECHNICAL AND CONSUMER INFO RMATION The St ar Label means Cl eaner Mar ine Engine A Star label was applied to this outbo ard motor in accordance with the requir ements of the Calif ornia Air Resources Board . f o r healt[...]

76 Two Stars Very Low Emission One Star Low Emission Three Stars Ultra Low Emission Four Stars Super Ultra Low Emission TECHNICAL AND CONSUMER INFO RMATION The one-st ar label ide ntif ies engines t hat meet t he Air Resourc es Board’s Persona l Wate rcraf t and Outboar d marine e ngine 2001 exhaust e missi on standa rds. Engines m eeting thes e [...]

− −− × ×× − − ± ± ± BF5A BADS 13.8 in (350 mm) LA SA 20.7 in (525 mm) 39.6 in (1,005 mm) 44.7 in (1,135 mm) 17.1 in (434 mm) 22.1 in (561 mm) 59.5 lbs (27.0 kg) 60.6 lbs (27.5 kg) 3.7 kW (5.0 HP) 4,500 5,000 rpm 4 stroke OHV 1 cylinder, water-cooled 7.7 cu-in (127 cm ) 0.028 0.031 in (0.70 0.80 mm) Recoil starte r Digital Igniti on [...]

− 78 CONSUMER INFORMATION Honda Publications Custom er Service Inf ormation American Hon da Motor Co ., Inc. TECHNICAL AND CONSUMER INFO RMATION Cont act ing H ond a Shop M anual Part s Cat al og Your own er’s manual was written to cover mos t of the questions you might as k about your Honda. Any questi ons not answ ered in t he owner’s manua[...]

79 TECHNICAL AND CONSUMER INFO RMATION Warra n ty C ov erag e Pleas e include the f ollowing inf ormation i n your communi cation: Model and c omplete s eria l number Date of purchase Name and location of selling dealer Name and location of servicing dealer (if d if f erent) A deta iled des cript ion of your concerns Your new Honda is c overed by t[...]

80 TECHNICAL AND CONSUMER INFO RMATION W arr ant y Ser vice As the owner of a Honda product, your ser vicing de aler m ay ask you t o authori ze an inspec tion. If the problem is c overed under w arrant y, your deale r will perf orm any warranty repairs f or you at no co st. However, you may be res ponsible f or additiona l non-warra nty charge s. [...]

−− 81 Distributor’s L imited Warr anty To Qualif y f o r This Warranty: What Americ an Honda Will Repair or Replace Unde r Warranty: To Obtain Warra nty Service: TECHNICAL AND CONSUMER INFO RMATION This warranty is limited to Honda Outboard Motors distributed by American Honda Motor Co., Inc., Power Equipment Division, 4900 Ma rconi Drive , A[...]

82 Exclusions: Disclaimer of consequential damag e and limitation of implied warranties: TECHNICAL AND CONSUMER INFO RMATION Contacting Honda Operation with f uels, oils, add itives and lubricants which are not sui table f or use in the product Conditions ca used by the use of propeller (s) t hat do not all ow the outboa rd motor to r un in its rec[...]

83 Accessories and Replacemen t Parts To Qualif y f or This Warranty: What American Honda Will Repai r or Replace Under Warranty: TECHNICAL AND CONSUMER INFO RMATION This warranty is limited to Honda Power Equipment parts,accessories and apparel when distributed by American Honda Motor Co., Inc ., 1919 Torrance Bl vd., Torrance , Calif ornia 90501-[...]

84 Exclusions: To Obtain Warra nty Service: Disclaimer of consequential damag e and limitation o f implied warranties: TECHNICAL AND CONSUMER INFO RMATION You must take the Honda Outboa rd Motor product accessory or rep lacement part or the o utboard mo tor or boat on which the accessory or replacemen t part is insta lled, and pr oof of purchase, a[...]

85 Emission C ontrol System Warran ty YOUR WARRANTY RIGHTS AND OBLIGATION Calif ornia Other States All States MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE: TECHNICAL AND CONSUMER INFO RMATION The Calif orn ia Air Resources Board an d American Honda Motor Co., Inc. are pleas ed to expl ain the emis sion contr ol syst em war ranty on yo[...]

86 OWNER’S WARRANTY RESPONSIBILITY: WARRANTY COVERAGE: TECHNICAL AND CONSUMER INFO RMATION Contacting Honda As the outboard engi ne owner, you are res ponsible f or the perf orman ce of the req uired mainten ance listed in your owner’s ma nual. Amer ican Honda Motor Co., I nc. recommends th at you retain all receipts cov ering mainte nance on y[...]

87 TO OBTAIN WARRANTY SERVICE: EXCLUSIONS: DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATION OF IMPLIED WARRANTIES: TECHNICAL AND CONSUMER INFO RMATION You must ta ke your Honda out board engine , along wit h your sale s regis trati on card or other pr oof of original purchas e date, a t your expense, to any Honda M arine deale r who is aut horized[...]

＊ ＊ 88 EMISSION CONTROL SYSTEM WARRANTY PARTS: TECHNICAL AND CONSUMER INFO RMATION Air intake duct, Crankcase breather tub e, Positive crankcase ven tilation valve, Vap or separator, Intake m anif old tuning valve (Intake air bypas s control valve) Carburetor assembly, Throttle body, Fuel injector, Fuel pump, Fuel pressure regulator, T hrottle [...]

89 WIRING DIAGRAM 07/01/08 13:20:13 31ZV1630_090[...]

90 INDEX ............................................................................ Anode . 17 .............................................................. Replacement . 53 ............ ARE YOU READY TO GET UNDER WAY? . 21 ........................................................... ATTACHMENT . 20 ...............................................[...]

91 INDEX Gear Case Oil ....................................................................... Change . 44 ............................................................... Level Che ck . 43 .. GEARSHIFTING AND THROTTLE OPERATION . 31 .............................................................. Gearshif t Lever . 13 HARD STARTING OR STALLS AFTER ..[...]

92 INDEX ........................ SAFE OPERATING PRECAUTIONS . 23 .................................... SAFETY LABEL LOCATIONS . 8 ............................................... Serial Number Lo cations . 71 .............. SERVICING YOUR OUTBOARD MOTOR . 36 ............................ SHALLOW WATER OPERATION . 34 ..................................[...]

00X31-ZV1-6390 BF5A 31ZV1639 00X31-ZV1-6390 2eY1 400.2007.01 Printed in Japan N BF5AK0 P ANTONE 288 CVC DIC F101 BLA CK[...]