Honda Outboard Motor BF40A/50A manual

2000 © HONDA MOTOR CO ., L TD . 1999 31ZW4603 00X31-ZW4-6030 200.2002.08 PRINTED IN U .S.A . BF40A/50A Owner ’s Manual HONDA MOTOR CO., L TD. TOKYO, JAP AN EM CC[...]

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 refer to it at any time. This owner’s manual is considered a permanent part of the outboard motor and should remain with the outboard motor if resold. The [...]

INTRODUCTION Congratulations on your selection of a Honda outboard motor. We are certain you will be pleased with your purchase of one of the finest outboard motors on the market. We want to help you get the best results from your new outboard motor and to operate it safely. This manual contains the information on how to do that; please read it car[...]

INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this outboard motor safely is an important responsibil- ity. To help you make informed decisions about safety, we have provided operat- ing procedures and other information on labels and in this manual. This informa- tion alerts you to potential[...]

TYPES OF HONDA BF40AhOA OUTBOARD MOTORS Model BWOA BFSOA It may be necessary to refer to this chart for reference purposes when reading this manual. TYPE CODE (example) L R T T = Power Trim/l%t R = Remote Control H = Tiller Handle X = Extra Long Shaft L = Long Shaft TTT 3 i[...]

IDENTIFICATION NUMBERS RIGHT STERN BRACKET , /---A PRODUCT IDEilTIFICATION NUMBER Record the Product Identification Number (P.I.N.) and the Engine Serial Number for your reference. Refer to the Product Identification Number when ordering parts, and when making technical or warranty inquiries (see page 107). ENGINE SERIAL NUMBER ‘The Product Ident[...]

CONTENTS 1. OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION.. ......... 7 SAFETY LABEL LOCATIONS .......................... 9 2. COMPONENT IDENTIFICATION ............................ 10 3. CONTROLS TILLER HANDLE TYPE Engine Start Button ............................................... 13 Shift Lever ...............................................[...]

CONTENTS Fuel Line Connection ............................................ 38 STARTING THE ENGINE (TILLER HANDLE TYPE). .. 40 STARTING THE ENGINE (REMOTE CONTROL TYPE) ... 44 Emergency Starting ............................................... 47 Troubleshooting Starting Problems ....................... 52 6. OPERATION Break-in Procedure.. ..........[...]

1. OUTBOARD M;OTOR SAFETY IMPORTANT SAFETY INFORMATION Honda BF4OA and BFSOA outboard motors are designed for use with boats that have a suitable manufacturer’s power recommendation, and other uses can result in injury to the operator or damage to the outboard motor and other property. Most accidents can be prevented if you follow all instruction[...]

1. OUTBOARD MOTOR SAFETY Refuel With Care l Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a well-ventilated area, with the engine stopped. Never smoke near gasoline, and keep other flames and sparks away. l Remove any portable fuel tank from the boat for refueling. Keep the portable fuel tank away from the bat[...]

1. OUTBOARD MOTOR SAFETY SAFETY LABEL LOCATIONS These labels are in the locations shown. They warn you of potential hazards that could seriously injure you. Read these labels carefully. GASOLINE&g: FLAMMABLE DANGEROUS GASOL I NE RHINE fRou WI fOR fllllffi IOlml~lb] INFLAIAMABLE DANGEREUX GAZOL I NE SllllR al Miw fulRmIff lE RElWEIPhU[...]

2. COMPONENT IDENTIFICATION (TILLER HANDLE TYPE) THROTTLE GRIP I FUEL LINE TILLER CONNECT-C I OIL FILLER CAP )R OIL LEVEL HANDLE 1 x / ENGINE COVER I DIPSTICK I GEAR SHIFT LEVER / OIL PRESSURE INDICATOR LIGHT OVERHEAT A NTICA- --- -- VITATION TiLT LEVER W type) WATER INTAKE TRANSOM& ADJUSTING /I / INDICATOR LIGHT t---+1 / ENGINE r FRI[...]

2. COMPONENT IDENTIFICATION (REMOTE CONTROL TYPE) ENGINE COVER FUEL LINE POWER TILT OIL FILLER CAP CONNYCTOR SWITCH (except LR type) KNOB COOLING SYSTEM INDICATOR POWER TRIWILT NEUTRAL SWITCH RELEASE LEVER / OIL PRESSURE INDICATOR ra TILT LEVER a, (LR type) v VERHEAT INDICATOR HT ACCESS COVER SPARE EMERGENCY STOP SWITCH CLIP BUZZER (inside of the[...]

2. COMPONENT IDENTIFICATION FUEL VENT KNOB FUEL GAUGE / FUEL I FtiEL HOSE CONNECTOR PRIMER BULB (FEMALE) POWER TRIM/TILT TYPES TACHOMETER TRIM METER[...]

3. CONTROLS (TILLER HANDLE TYPE) Engine Start Button R (reverse) N ENt-bF, START BUTTON Move the gearshift lever to the N (neutra1) position before starting. The engine will not start unless the gearshift lever is in the N (neutral) position. Shift Lever (revtse) N SHIFI- LEVER There are three gearshift lever posi- tions. F (forward): The boat move[...]

,3. CONTROLS (TILLER HANDLE TYPE) Throttle Grip THROTTLE GRIP ‘lItm the grip clockwise or counter- clockwise to adjust the engine speed. Turning the grip in the direction shown by the arrow increases engine speed. Throttle Opening Indicator THRO’ITLE OPENING INDICATOR The label on the grip indicates throttle opening. Throttle Friction Knob THRO[...]

3. CONTROLS (TILLER HANDLE TYPE) Engine Stop Switch ENGINE STOP SVi’ITCH Push the engine stop switch to stop the engine. Emergency Stop Switch Lanyard EMERGENCY STOP SWITCH CLIP The emergency stop switch lanyard is provided to stop the engine immedi- ately in the event the operator should fall overboard or away from the con- trols. The emergency [...]

3. CONTROLS (TILLER HANDLE TYPE) SPARE EMERGENCY ,STOP SWITCH CLIP A spare emergency stop switch clip is provided near the engine stop switch. Oil Pressure Indicator Light I OIL PRESSURE INDICATOR LIGHT The green oil pressure indicator light is normally ON when the outboard motor is running. When the engine oil level is low or the engine lubricatio[...]

3. CONTROLS (REMOTE CONTROL TYPE) Remote Control Lever NEUTRAL RELEASE The remote control lever controls gear selection and throttle opening posi- tions. It is necessary to pull up the neutral release lever to operate the remote control lever. THROTTLE 0 THROTTLE 0 REMOTE CONTROL LEVER ‘ER a-” IEVERSE) F (forward): Moving the lever to the F pos[...]

3. CONTROLS (REMOTE CONTROL TYPE) Neutral Release Lever The neutral release lever is on the The remote control box is equipped remote control lever to prevent an with a key type ignition switch. accidental gear engagement. Key positions: The remote control lever will not engage forward or reverse gear unless the neutral release lever is pulled up. [...]

3. CONTROLS (REMOTE CONTROL TYPE) Emergency Stop Switch Lanyard E S SWITCH LANYARD The emergency stop switch lanyard is provided to stop the engine immedi- ately in the event the operator should fall overboard or away from the con- trols. The emergency stop switch clip must be engaged with the emergency engine stop switch or the engine will not sta[...]

3. CONTROLS (REMOTE CONTROL TYPE) Choke/Fast Idle Lever N (neutral) f-l CHOKE XIMUM FAST IDLE EST IPOSWION CHOKWFAST The choke/fast idle lever provides two functions: 1. Electric choke solenoid activation for easy engine start up. 2. Engine fast idle. The choke/fast idle lever will not move unless the remote control lever is in the N (neutral) posi[...]

3. CONTROLS (REMOTE CONTROL TYPE) Oil Pressure Indicator Light/Buzzer The green oil pressure indicator light turns OFF and the buzzer sounds when the oil level is low and/or the engine lubrication system is faulty. The engine speed slows down gradual- ly- Overheat Indicator Light/Buzzer The red overheat indicator light turns ON and the buzzer sound[...]

3. CONTROLS (POWER TRIM/TILT TYPE) Power Trim/Tilt Switch Power Trim Press the power hn/tilt switch on the remote control lever (remote control type) to adjust the motor trim angle of 00 to 20’ to maintain proper boat mm. The power trim/tilt switch located on the remote control lever (remote control type) can be operated while the boat is under w[...]

3. CONTROLS (POWER TRIM/TILT TYPE) XRTA type outboard Power Trim Do not trim this engine when you are using a large amount of throttle opening. If you do try to tim the engine (for example, wide open throttle), under certain conditions, propeller thrust may override the power trim hydraulics and cause the engine to return to the transom angle adjus[...]

3. CONTROLS (POWER TRIM/TILT TYPE) Tachometer TACHOMETER The tachometer shows the approximate engine speed in revolutions per minute. Refer to the tachometer when using the power trim/tilt switch to achieve proper boat and motor performance. Manual Relief Valve If the power trim/tilt switch will not tilt the outboard motor, the motor can be manuall[...]

(GAS ASSISTED TILT TYPE) 3. CONTROLS (COMMON) Tilt Lever (GAS ASSISTED LEVER Moving the tilt lever to the FREE position allows the motor to be tilted and moving the tilt lever to the LOCK position locks the motor in the desired position. Use the tilt lever to temporarily tilt the motor when the boat is operating in shallow water, or mooring in shal[...]

3. CONTROLS (COMMON) Distribute the load evenly in the boat and run the boat in straight course at full throttle. Slightly turn the steering wheel ?r tiller handle for both right and left turns to determine if an equal amount of effort is required. If adjustment is necessary loosen the tightening bolt and turn the trim tab right or left. Make small[...]

3. CONTROLS (COMMON) Cooling System Indicator The cooling system is monitored here to make sure cooling .water is circulating through the engine. Water Intakes WATERINTAKES The engine cooling water is drawn into the water pump through these water intakes. 27[...]

3. CONTROLS (COMMON) ‘hansom Angle Adjusting Rod TRANSOM ANGLEADJUSTINGROD The transom angle adjusting rod is used to adjust the motor angle to achieve the correct boat trim. There are 5 adjustment holes located in the stem bracket. PushQin and turn the transom angle adjusting rod up to remove. To install insert into the proper hole and turn down[...]

3.CONTROLS (COMMON) Fuel Cap/Gauge/Vent Knob VENT KNOB GAUGE FUEL FILLE b I CAP The fuel gauge is part of the fuel cap. The fuel cap vent knob controls air entering and leaving the fuel tank. When refilling the fuel tank, turn the vent knob counterclockwise to the open position and remove the fuel cap. Before transporting, storing or refill- ing th[...]

4. PRE-OPERATION CHECKS Engine Cover Removal/Installation (FRONT) (REAR) ENGINE COVER To remove, release the front and rear engine cover latches and remove the engine cover. To install, position the engine cover over the engine and hook and lock the front and rear latches. . 30[...]

4. PRE-OPERATION CHECKS Engine Oil Engine oil is a major factor affecting engine performance and service life. -1 Running the engine with insuffkient oil can cause serious engine damage. Recommended oil Use high-detergent, premium quality 4-stroke engine oil, certified to meet or exceed U.S. automobile manufac- tures’ requirements for American Pe[...]

4. PRE-OPERATION CHECKS Fuel Level SAFE FILL LEVE Check the fuel gauge and refill the tank to the SAFE FILL level mark if necessary. Fuel tank capacity : 6.6 US gal. (25 lit) B Gasoline is extremely flammable, and gaso- line vapor can explode, causing serious injury or death. Do not smoke or allow flames or sparks in your working area. KEEP OUT OF [...]

4. PRE-OPERATION CHECKS Fuel Recommendations Use unleaded gasoline with a pump octane rating of 86 or higher. These outboard motors are certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life. Never use stale or contaminated gasoline or an oiVgaso- line mixture. Avoi[...]

4. PRE-OPERATION CHECKS Oxygenated Fuels Some conventional gasolines are being blended with alco- hol or an ether compound. These gasolines are collec- tively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure [...]

4. PRE-OPERATION CHECKS Propeller and Cotter Pin blades are thin and sharp. Careless handling of the propeller can result in injury when checking the propeller: l Remove the clip of the emergency stop switch to prevent accidental engine starting. l Wear heavy gloves when handling the propeller. Propeller Check the propeller blades for damage, wear [...]

4. PRE-OPERATION CHECKS Steering Friction Adjustment (common) TO DECREASE Operate the steering wheel or tiller handle right and left and check for the amount of drag felt. Adjust the steering friction adjuster so that a slight amount of drag is felt. The steering should move smoothly and freely. Remote Control Friction Adjustment FHlCTlON . Operate[...]

4. PRE-OPERATION CHECKS Other Checks Check the following items: 1. The fuel hose for kinking, collapsing or loose connections. 2. The stem bracket for damage and mounting bolts for proper torque. 3. The tool kit contents.’ Compare your tool kit contents against the tool kit illustration above. Replace any missing items. 4. The anodes for damage, [...]

5. STARTING THE ENGINE Fuel Tank and Vent Knob VENT KNOB The fuel tank must be properly secured in the boat. This will protect the fuel tank from damage caused by the fuel tank shifting. The fuel tank must be in a well venti- lated area to reduce the chance of a gasoline vapor explosion. Avoid direct sunlight on the fuel tank. Due to the fuel pump [...]

5. STARTING THE ENGINE FUEL HOSE CONNECTOR 2. Connect the fuel hose connector to the outboard motor. Install the outboard end fuel hose connector with the clip toward the outside. Be sure the fuel hose connector is securely snapped in place. NOTICE If the outboard end fuel hose connector is forcibly installed in the reversed direction, the fuel hos[...]

5. STARTING THE ENGINE (TILLER HANDLE TYPE) ENGINE STOP SWITCH SWITCH CLIP 1-1 The water intakes must be lowered into the water. Running the outboard motor out of the water will damage the water pump and overheat the engine. 1. Engage the emergency stop switch clip located at one end of the emer- gency stop switch lanyard with the engine stop swi[...]

5. STARTING THE ENGINE (TILLER HANDLE TYPE) THROlTiE GRIP 3. Align the engine start symbol ” Q, ” on the throttle grip with the pointer ” F ” on the tiller handle. ’ CiIOKE KNOB 4. When the engine is cold or ambient temperature is low pull the choke knob. 5. Press the start button and start the engine. The starter motor con- sumes a large[...]

5. STARTING THE ENGINE (TILLER HANDLE TYPE) 6. If it was necessary to use the choke knob to start the engine, slowly return it to its initial position. Turn the throttle grip in the SLOW direction lo a position where the engine does not stall. (each side) 7. After the engine starts, verify water is flowing through the cooling system by monitoring t[...]

5. STARTING THE ENGINE (TILLER HANDLE TYPE) OIL PRESSURE in INDICATOR LIGHT 0 I . w NORMAL: GREEN LI:HT ON ABNORMAL: GREEN LIGHT BLINKING OR OFF 8. With the engine running, check to see if the green engine oil pressure indicator light turns ON. Stop the engine if the oil pressure indicator light does not turn ON. Check the engine oil level (see [...]

5. STARTING THE ENGINE (REMOTE CONTROL TYPE) EMERGENCY RtRRGENCY STOP EMERGENCY STOP SWITCH CLIP SWITCH LANYARD 1 NOTICE 1 The water intakes must be lowered into the water. Running the outboard motor out of the water will damage the water pump and overheat the engine. 1. Engage the emergency stop switch clip located at one end of the emer- gency st[...]

5. STARTING THE ENGINE (REMOTE CONTROL TYPE) CHORhAST IDLE LEVER ‘U’ FAST 3. When the engine is cold or the ambient temperature is low, lift the choke/fast idle lever up fully. This will provide a rich fuel mixture. When the engine is warm, it may be necessary to raise the choke/fast idle lever slightly. Hold it in this position. The choke/fast[...]

5. STARTING THE ENGINE (REMOTE CONTROL TYPE) COOLING SYSTEM _-_.-.-. INDICATOR f--l WATER INTAKE -2fY--- (each side) 6. After the engine starts, verify water is flowing through the cooling system by monitoring the cooling system indica- tor. The amount of water coming out of the cooling sys- tem indicator will vary due to thermostat operation. Sto[...]

5. STARTING THE ENGINE (EMERGENCY STARTING) Emergency Starting (FRONT) ENGINE COVER LATCHES If the electric starting system will not start the engine the engine can be started by using the pull emergency rope from the tool kit. 1. Release the front and rear engine cover latches then remove the engine cover. 2. Remove the four 6 x 25 mm bolts and th[...]

5. STARTING THE ENGINE (EMERGENCY STARTING) SHIl+ LEVER (TILLER HANDLE TYPE) 3. Depending on what type of out- board motor you have, move the shift lever or the control lever to the N (neutral) position. (REMOTE CONTROL TYPE) ENGINE STOP SWITCH SPARE EMERGENCY SOP SWITCH STOP SWITCH CLIP 4. If your outboard motor is a tiller .handle type, engage th[...]

5. STARTING THE ENGINE (EMERGENCY STARTING) EMERGENCY SPARE EM~ENCY STOP SWITCH CLIP 5. If your outboard motor is a remote control type, turn the ignition key to the ON position. Engage the emer- gency stop switch clip, locatedat one end of the emergency stop switch lanyard, with the emergency engine stop switch. A spare emergency stop switch clip [...]

5. STARTING THE ENGINE (EMERGENCY STARTING) (REMOTE CONTROL TYPE) It should only be necessary to pull the engine 1 or 2 limes with the choke knob out. ENGINE START,SYMBOL POIN?ER I TIIROTnE GRIP (TILLER HANDLE TYPE) 7. On the tiller handle type align the engine start symbol ” Q, ” on the throttle grip with the painter ” b ” on the tiller ha[...]

5. STARTING THE ENGINE (EMERGENCY STARTING) FLYWHEEL EMERGENCY 8. Set the emergency starter rope knot in the notch in the flywheel and wind the emergency starter rope counterclockwise around the fly- wheel. 9. Pull the emergency starter rope lightly until resistance is felt, then pull briskly. If the engine fails to start refer to Troubleshooting o[...]

5. STARTING THE ENGINE ‘Ikoubleshooting Starting Problems L 5 SYMPTOM Starter motor doesn’t turn over. Starter motor turns over but engine will not start. i2 POSSIBLE CAUSE 1. Shift lever not in neutral position. 2. Blown fuse. 3. Weak battery. 1. Emergency stop switch clip is not engaged. 2. Out of fuel 3. Vent knob not open. 4. Primer bulb ha[...]

6. OPERATION Break-in Procedure Break-in period 10 hours Break-in operation allows the moving parts to wear-in evenly and thus ensures proper performance and longer outboard motor life. Break-in your new outboard motor as follows: First 15 minutes: Run the outboard motor at trolling speed. Use the minimum amount of throttle opening necessary to ope[...]

6. OPERATION (TILLER HANDLE TYPE) Gear Shifting N (neutrd) R (reverse) POINTER Gearshift lever has 3 positions: FORWARD, NEUTRAL, and REVERSE. An indicator at the base of the gearshift lever aligns with the letters F, N. and R on the motor pan. 1. Align the pointer on the tiller han- dle with the SLOW position on the throttle grip to decrease engin[...]

6. OPERATION (TILLER HANDLE TYPE) Steering RIGHT TURN LEFT TURN Move the tiller Move the tiller handle to the left. handle to the right. The tiller handle is moved in the oppo- site direction in which you want the boat to turn. On the Power trim/tilt type, press the DN portion of the power trim/tilt switch (optional part) and tilt the motor to the [...]

6. OPERATION (TILLER HANDLE TYPE) F (forward) RELEASE With the gearshift lever in the F (for- To set the throttle at a steady speed, turn ward) position, turn the throttle grip the throttle friction knob clockwise. To toward the FAST mark to increase release the throttle grip for manual speed speed. For optimum fuel economy, limit control, turn the[...]

6. OPERATION (REMOTE CONTROL TYPE) NEUTRAL RELEASE LEVER 1 Ill PULL UP While pulling up the neutral release lever, move the control lever 30 toward F (forward) or 30” toward R (reverse) to engage the desired gear. F (forward) OPENING Moving the control lever further from 30” will increase throttle opening and boat speed. MAXIMUM The control lev[...]

6. OPERATION (REMOTE CONTROL TYPE) Cruising POWER TRIM/TILT SWITCH 1. On the Power trim/tilt type, press the DN portion of the power trim/tilt switch and tilt the motor to the lowest position. N (fokrd) (neutral) I 2. Move the control lever from N (neutral) 30’ toward F (forward) to engage the P (forward) gear. Moving the control lever further fr[...]

6. OPERATION (GAS ASSISTED TILT TYPE) Tilt Lever Tilt the motor up to prevent the pro- peller and gear case from hitting the bottom when beaching or stopping in shallow water. 1. Move the gearshift lever to the N ( neutral) position and stop the engine. ‘d PUSH SWITCH ENGINE COVER GRIP TILT LEVER 2. To tilt the motor up, move the tilt lever to[...]

6. OPERATION (GAS ASSISTED TILT TYPE) 3. With the outboard motor tilted up to the desired position, move the tilt lever to the LOCK position to lock the motor. 4. To lower the motor back down, move the till lever to the FREE position, while holding the engine cover grip, then lower the motor gently. Move the tilt lever to LOCK position. The tilt le[...]

6. OPERATION (GAS ASSISTED TILT TYPE) ,CVF TILT LOCK ,v LEVER (lock Dosition) Use the tilt lock lever to hold the motor in the highest tilt position when the boat is moored for a long time. 1. Move the tilt lever to the FREE position (refer to page 60), then pull the engine cover grip and tilt the motor all the way up. 2. Move the tilt lock lever [...]

6. OPERATION (POWER TRIM/TILT TYPE) XRTA type outboard (refer to page 23) The power trim/tilt system can adjust the motor angle while cruising, or the motor tilt angle while mooring. Motor trim angle adjustment is necessary to com- pensate for boat load or weight distribu- tion, water conditions, propeller or engine condition. The motor trim angle [...]

6. OPERATION (POWER TRIM/TILT TYPE) 60’ T ANGLE ‘200 TRIM ANGLE Decrease the trim angle on high speed turns to reduce the possibility of propel- ler ventilation. Improper motor trim angle can result in an unstable steering condition. The power trim/tilt warning system will be activated and an intermittent buzzer sounds when the motor is trimmed[...]

6. OPERATION (POWER TRIM/TILT TYPE) Trim Meter The trim meter indicates the trim angle of the motor. Refer to the trim meter, and press the Up or DN portion of the power trim/tilt switch to adjust ths motor trim angle to achieve boat performance and stability. BOW TOO LOW DUE TO 1. LOAD IN THE FRONT 2. MOTOR TRIMMED TOO LOW With the motor trimmed l[...]

6. OPERATION (POWER TRIM/TILT TYPE) Power Tilt Switch (Motor Pan) POtiR TILT SWITCH The power tilt switch located on the motor pan is a convenience switch for tilting the motor for trailering, or per- forming outboard motor maintenance. This power tilt switch should only be operated when the boat is stopped and the motor is off. Manual Relief Valve[...]

6. OPERATION (POWER TRIM/TILT TYPE) LEVER Tilt Lock Lever Use the tilt lock lever when the boat is moored. 1. Tilt the motor up as far as it will go using the power trim/tilt switch. 2. Move the tilt lock lever to the LOCK position and lower the outboard motor until the lock lever contacts the stem bracket (refer to page 25). It may be necessary to[...]

6. OPERATION Tkim Tab Adjustment TIGHTENING B The trim tab is provided to adjust for “torque steer” which is a reaction of the propeller rotation or propeller torque. If during a high speed mm an unequal amount of effort is required to turn the boat right or left, adjust the trim tab so that an equal amount of effort is required. Distribute the[...]

6. OPERATION (MOTOR PROTECTION SYSTEM) Engine Oil Pressure and Overheat If the engine oil pressure drops and/or the engine overheats, either or both warning systems could be activated. When activated the engine speed will decrease gradually and the green oil pressure indicator light will turn OFF and the red overheat indicator light will turn ON. A[...]

6. OPERATION (MOTOR PROTECTION SYSTEM) When the oil pressure warning sys- tems is activated: 1. Stop the engine immediately and check the engine oil level (refer to page 31). 2. If the oil is up to the recommended level, restart the engine. If the oil pressure warning system stops after 30 seconds, the system is normal. If the throttle was closed s[...]

6. OPERATION (MOTOR PROTECTION SYSTEM) Over-Rev Limiter This’ outboard motor is equipped with an engine over-rev limiter which acti- vates when the engine speed increases excessively. The over-rev limiter can be activated while cruising, tilting up the motor, or when ventilation occurs during a sharp turn. When the over-rev limiter is activated: [...]

6. OPERATION (MOTOR PROTECTION SYSTEM) When the power trim warning system is activated: 1. Immediately decrease the trim angle by pressing the DN portion of the power trim/tilt switch. 2. Immediately reduce the throttle opening to SLOW and operate the engine at low speed. There are also 2 small sacrificial anodes in the water passages of the engine[...]

6. OPERATION Shallow Water Operation LNOflCElExcessive trim/tilt angle during operation can cause the pro- peller to raise out of the water and cause propeller ventilation and engine over-revving. Excessive trim/tilt angle can also damage the water pump and overheat the engine. When operating in shallow water, tilt the motor up to prevent the prope[...]

6. OPERATION High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel con- sumption will increase. A very rich mixture will also foul the spark plugs and cause hard starting. High altitude performance can be improved by specific modifi- cations to the carburetors. If yo[...]

7. STOPPING THE ENGINE (THLLE:R HANDLE TYPE) ’ Emergency Engine Stop ENGINE STOP SWITCH EMERGENCY STOP MERGENCY STOP bWlTCH CLIP Disengage the emergency stop switch clip from the engine stop switch by pulling the emergency stop switch lan- yard. It is a good idea to stop the engine with the emergency stop switch lanyard from time to time to be su[...]

7. STOPPING THE ENGINE (TILLER HANDLE TYPE) 2. Push the engine stop switch until the engine stops. 75[...]

: 7, STOPPING THE ENGINE (REMOTE CONTROL TYPE) Emergency Engine Stop Normal Engitw Stop EMERGENCY iY (neutral) STOP SWITCH EMERGENCY STOP SWITCH LANYARD EMERGENCY STOP SWITCH CLIP Disengage the emergency stop switch clip from the emergency engine stop switch by pulling the emergency stop switch lanyard. It is a good idea to stop the engine with the[...]

8. TRANSPORTING Trailering STEERING FRICTION When trailering or transporting the boat with the motor attached, it is recommended that the motor remain in the normal run position. Tighten the steering friction adjuster se- curely to stop the motor’s side to side movement. If there is insufficient road clearance with the motor in the normal run po-[...]

9. CLEANING AND FLUSHING . w WASH PLUG (flush plug) Thoroughly clean and flush the out- board motor with fresh water after operating in dirty or salty water. Flush Kit (optional part) 1. Wash the outside of the outboard motor with clean, fresh water. 2. Remove the wash plug and sealing washer from the WASH plug hole in the gear case. Be sure not to[...]

9. CLEANING AND FLUSHING i INDICATOR 7. Start the engine. Monitor the cool- ing system indicator. Stop the engine if water does not come out’ of the cooling system indicator and check the fresh water supply. If the fresh water supply is insufficient it may be necessary to temporarily cover the three water intakes with duct tape. WATER INTAKES 8. [...]

10. MAINTENANCE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce pollution. m improper mainte- nance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow the inspection and maintenan[...]

10. MAINTENANCE Safety Precautions l Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards: -Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventila- tion whenever you operate the engine. -Bums from hot parts. Let the engine cool before touch- ing. - Injury fr[...]

10. MAINTENANCE The U.S. Clean Air Acts EPA regulations require all manufactur- ers to furnish written instructions describing the operation and mainte- nance of emission control systems. The following instructions and proce- dures must be followed in order to keep the emissions from your Honda engine within the emission standards. Tampering and Al[...]

10. MAINTENANCE Replacement Parts The emission control systems on your Honda engine were designed, built, and certified to conform with EPA emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you[...]

10. MAINTENANCE Tool Kit and Spare Parts The following tools and spare parts are supplied with the outboard motor for maintenance, adjustment, and emergency repairs. TOOL KIT 10 x 12 mm WRENCH s= 8 mm WRENCH E-=II FLAT SCREWDRIVER -_71 PHILLIPS SCREWDRIVER -== OIL CHECK SCREWDRIVER PLIERS C 0 3 SCREWDRIVER HANDLE 18x 19mm SOCKET WRENCH TOOL BAG[...]

10. MAINTENANCE MAINTENANCE SCHEDULE Use only genuine HONDA parts or their equivalent for maintenance or repair. Replacement parts which are not of equivalent quality may damage the motor. RBGULAR SERVICE PERIOD (3) Perform at every indicated month or operating hour intervals, whichever comes first. ITEM 0 Engine oil Check level Change PIRST EVERY [...]

10. MAINTENANCE Perform at every indicated month or operating hour intervals, whichever comes first. a ‘1 0 Emission-related items (I) Lubricate more frequently when used in salt water. (2) These items should be serviced by an authorized Honda Marine dealer, unless the owner has the proper tools and is mechanically proficient. See the Honda Shop [...]

10. MAINTENANCE Engine Oil Engine oil is a major factor affecting engine performance and service life. Oil check interval: Each use. Oil change interval: After the first 20 hours, then every 100 hours. (Refer to the maintenance schedule page 85). OIL CAPACITY: 2.1 US qt (2.0 lit)...When oil filter is not replaced 2.5 US qt (2.4 lit)....When oil fil[...]

10. MAINTENANCE 2. Loosen the drain plug cover screw using a flat blade screwdriver and remove the drain plug cover. 3. Place the drain plug cover as shown to use it as an oil drain guide. Place a suitable container under the guide. L / 4. Remove the engine oil drain bolt and washer using a 12 mm wrench and drain the engine oil. 5. Install a new se[...]

10. MAINTENANCE 7. Refill to the upper limit mark on the oil level dipstick with the recom- mended oil. NOTE: To avoid incorrect gauging of the engine oil level, inspect the oil level when the engine has cooled. The outboard motor needs to be in the vertical position, 8. Reinstall the oil filler cap. Always wash your hands after handling used oil. [...]

10. MAINTENANCE LEVEL PLUG DRAIN PLUG Gear Oil Level/Check 1. Position the outboard motor verti- cally. 2. Remove the level plug and see if oil flows out. If no oil flows out, fill through the drain plug hole until the oil starts to flow out through the level plug hole. If there is water in the oil, the water will flow out first when the drain plug[...]

10. MAINTENANCE Spark Plugs To ensure proper engine operation, the spark plugs must be properly gapped and free of deposits. Check-replace interval: After the first 20 hours, then every 200 hours. (Refer to the maintenance schedule page 85). Recommended spark plug: DR7EA (NGK), X22ESR-U (DENSO) Use only the recommended spark plugs or equivalent. -1[...]

10. MAINTENANCE 7. Thread the plugs in by hand to pre- vent cross threading. 8. After the spark plugs are seated, tighten with a spark plug wrench to compress the washers. If installing new spark plugs, tighten l/2 turn after the spark plugs seat to com- press the washers. If reinstalling used spark plugs, tighten l/8-1/4 turn after the spark plugs[...]

10. MAINTENANCE To protect the battery from mechani- cal damage and to prevent the bat- tery from falling or tipping over, the battery must be: l Installed in the correct size corro- sion-resistant battery box. l Properly secured in the boat. l Secured in a location free from di- rect sunlight and water spray. l Secured away from the fuel tank to a[...]

10. MAINTENANCE Engine Fuel Filter FUEL PUMP ARBURETOR FUEL FILTER The engine fuel filter is located under the engine cover between the fuel cou- pling and the fuel pump. Water or sediment accumulated in the fuel filter can cause loss of power or hard start- ing. Check interval: Every 100 hours (Refer to the mainte- nance schedule page 86.) Change [...]

10. MAINTENANCE ’ v FUEL FILTER 3. Pull the spring retainer toward you, and raise the fuel filter. 4. Check the fuel filter for water accu- mulation or .sediment. If no water or sediment are found, reinstall the fuel filter properly. FUEL HOSES Change 1. Remove the fuel filter. Before removing the fuel filter, to prevent fuel leakage, place fuel [...]

10. MAINTENANCE 4. Securely connect the fuel hose connector to the outboard motor (refer to page 38). 5. Prime the engine using the primer bulb (refer to page 39). Check for fuel leaks. Repair any fuel leaks if necessary. If loss of power or hard starting are found IO be caused by excessive water or sediment accumulation in the fuel filter, inspect[...]

10. MAINTENANCE FUEL TANK HOSE CONNECTOR I& FUEL TANK FILTER Fuel Tank Filter Cleaning/Replacement 1. Turn the fuel tank hose connector counterclockwise to remove the fuel tank filter. 2. Clean the fuel tank filter with non- flammable cleaner or solvent. Replace the fuel tank filter if neces- sary. 3. After cleaning or replacement, rein- stall [...]

10. MAINTENANCE : Propeller COTTER PIN (stainless] I CkSTLE NUT PLAIN WASHER SPECIAL SPLINE WASHER OI’ELLER If the propeller is damaged, replace it as follows: l Before replacing the propeller, remove the emergency stop switch clip to prevent acciden- tal engine starting. l The propeller is thin and sharp. To protect your hands, wear the heavy [...]

10. MAINTENANCE Submerged Motor A submerged motor must be serviced immediately after it is recovered from the water in order to minimize corrosion. Immediately take the outboard motor to the closest authorized Honda Marine dealer or if you are far from a dealership, proceed as follows: 1. Remove the engine cover, and rinse the motor with fresh wate[...]

I 10. MAINTENANCE : 8. Engage the emergency stop switch clip with the emergency stop switch and attempt IO start the engine (be sure the watet level is at least 2 inches above the anti-ventilation plate). l If the engine fails to start, re- move the spark plugs, clean and dry the electrodes. then re- install the spark plugs and at- tempt to start t[...]

11. STORAGE For longer service life of the outboard motor, have your outboard motor ser- viced by an authorized Honda Marine dealer before storage. If you are unable to take the motor to your dealer, proceed as follows: Draining the Carburetors Be careful not to spill gasoline. Spilled gasoline or gasoline vapor may ignite. If any gasoline is spill[...]

11. STORAGE Fuel Tank VENT KNOB FUEL CAP 1. Close the fuel cap vent knob. 2. Disconnect the fuel coupling from the outboard motor (refer to page 38). Outboard Motor Position Transport and store the motor either vertically or horizontally, as shown above. Store th: outboard motor in a well-ventilated area free from direct sunlight and humidity. Vert[...]

12. TROUBLESHOOTING (1) Engine does not start. Fuel l Fuel is not fed to carburetor. There is no gasoline in fuel tank. Vent knob is not open or vent clogged. Fuel filter is clogged. Fuel line is kinked. Fuel line is connected improperly. Fuel pump is faulty. Primer bulb is faulty. Check valve in connector is faulty Electrical l Sparks across spark[...]

12. TROUBLESHOOTING (2) Engine starts but immediately stops. Engine some times stops while cruising. Fuel l No gasoline in fuel tank. l There is gasoline - in fuel tank. 104 E E Water is mixed with gasoline. Vent knob is not open or vent is clogged. Fuel filter is clogged. - Air screw is open too wide. ILIdlingspeedistooslow. Carburetor vent is clo[...]

13. SPECIFICATIONS MODEL BWOA Description Code BAYS Type Overall length H R H-r RT 28.6 in 27.0 in 28.6 in 27.0 in (725 mm) (685 mm) (725 mm) (685 mm) Overall width 1 14.6 in (370 mm) I Overall height L 1 53.6 in (1.360 mm) Xl 57.5 in (1.460 mm) Transom height L 1 XI 20.5 in (520 mm) 24.5 in (622 mm) Full throttle range Engine type Disolacement 5,0[...]

13. SPECIFICATIONS MODEL BFSOA Description Code BAZS Type R 1 HT RT Overall length Overall width 27.0 in 28.6 in 27.0 in (685 mm) (725 mm) (685 mm) 14.6 in (370 mm) Overall height L 53.6 in (I ,360 mm) X 57.5 in (1,460 mm) Transom height L 20.5 in (520 mm) X 24.5 in (622 mm) Weight L 198 lb 205 lb 203 lb (90 W (93 kg) (92 kg) X 212 Ib (96 kg) Rated[...]

14. WARRANTY SERVICE Warranty Service Information Servicing dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management. The Service Manager or General Manager can heip. A[...]

Current customer service contact information: Your owner's manual was written to cover most of the questions you might ask about your Honda. Any questions not answered in the owner's manual can be answered by your Honda dealer. If your dealer doesn't have an immediate answer, they should be able to get it for you. If you have a diffe[...]

15. WIRING DIAGRAM TILLER HA 108[...]

15. WIRING DIAGRAM REMOTE CONTROL TYPE io9[...]

15. WIRING DIAGRAM REMOTE CONTROL, POWER TRIM/TILT TYPE .- -- r _-^----- -------_ I XRTA typeoutbonrd I 1 I 1- I I I I I I I I I I I I -l 110[...]

16. INDEX Anode Metal ........................................................................................ 26 PRE-OPERATION CHECK ......................................................... 37 MOTOR PROTECTION SYSTEM .............................................. 71 Battery (not included). .........................................................[...]

16. INDEX Neutral Release Lever ......................................................................... 18 Oil Pressure Indicator Light ................................................................ 16 Oil Pressure Indicator Light/Buzzer .................................................... 2.1 Other Checks ......................................[...]

16.INDEX Trim Tab Adjustment ......................................................................... .67 TROUBLESHOOTING .................................................................... 103 Starting Problems ......................................................................... .52 . WARRANTY SERVICE .......................................[...]

[...]

[...]

2000 © HONDA MOTOR CO ., L TD . 1999 31ZW4603 00X31-ZW4-6030 200.2002.08 PRINTED IN U .S.A . BF40A/50A Owner ’s Manual HONDA MOTOR CO., L TD. TOKYO, JAP AN EM CC[...]