31ZV1650 00X31-ZV1-6500 N BF5AK0 2eY1100.2009.
09/06/15 14:42:56 31ZV1650_001 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. 2009 Honda Motor Co., Ltd.
09/06/15 14:43:03 31ZV1650_002 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 information on how to do that; please read it carefully. As you read this manual you will find information preceded by a symbol.
09/06/15 14:43:16 31ZV1650_003 INTRODUCTION A FEW WORDS ABOUT SAFETY You will find important safety information in a variety of forms, including: Safety Labels − on the outboard motor. Your safety and the safety of others are very important. And using this outboard motor safely is an important responsibility. Safety Messages − preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
09/06/15 14:43:20 31ZV1650_004 CONTENTS OUTBOARD MOTOR SAFETY .................................... 6 IMPORTANT SAFETY INFORMATION ................. 6 SAFETY LABEL LOCATIONS ................................. 8 CONTROLS AND FEATURES ................................... 11 CONTROL AND FEATURE IDENTIFICATION CODES ................................. 11 COMPONENT AND CONTROL LOCATIONS ..... 12 CONTROLS ...............................................................
09/06/15 14:43:24 31ZV1650_005 CONTENTS OPERATION ................................................................. 25 SAFE OPERATING PRECAUTIONS ..................... 25 BREAK-IN PROCEDURE........................................ 25 TRANSOM ANGLE ADJUSTMENT ...................... 25 PORTABLE FUEL TANK ........................................ 26 FUEL HOSE CONNECTIONS ................................. 26 FUEL PRIMING ........................................................ 27 STARTING THE ENGINE ............
09/06/15 14:43:28 31ZV1650_006 CONTENTS STORAGE ..................................................................... 58 STORAGE PREPARATION .................................... 58 Cleaning and Flushing ........................................... 58 Fuel ......................................................................... 60 Engine Oil .............................................................. 62 STORAGE PRECAUTIONS .................................... 62 REMOVAL FROM STORAGE .....................
09/06/15 14:43:38 31ZV1650_007 OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION The Honda BF5A outboard motor is designed for use with boats that have a suitable manufacturer’s power recommendation. Other uses can result in injury to the operator or damage to the outboard motor and other property. Most injuries or property damage can be prevented if you follow all instructions in this manual and on the outboard motor.
09/06/15 14:43:46 31ZV1650_008 OUTBOARD MOTOR SAFETY Refuel With Care Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a wellventilated area, with the engine stopped. Never smoke near gasoline, and keep other flames and sparks away. Remove any portable fuel tank from the boat for refueling. Keep the portable fuel tank away from the battery or other potential spark sources. Carbon Monoxide Hazard Exhaust contains poisonous carbon monoxide, a colorless, odorless gas.
09/06/15 14:43:55 31ZV1650_009 OUTBOARD MOTOR SAFETY SAFETY LABEL LOCATIONS US, Puerto Rico, and US Virgin Islands Types FUEL TANK The labels shown here contain important safety information. Please read them carefully. These labels are considered permanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized Honda Marine dealer for a replacement.
09/06/15 14:44:04 31ZV1650_010 OUTBOARD MOTOR SAFETY Canadian Types FUEL CAUTION GASOLINE FLAMMABLE DANGER GAZOLINE INFLAMMABLE DANGEREUX CAUTION READ OWNER’S MANUAL KEEP TOTALLY CLOSED WHEN NOT IN USE. KEEP AWAY FROM HEAT, SPARKS, AND OPEN FLAME. ‘‘SECURE ABOVE DECK IN WELL VENTILATED AREA.’’ ‘‘DO NOT USE FOR LONG TERM FUEL STORAGE.’’ DANGER HARMFUL OR FATAL IF SWALLOWED. KEEP OUT OF REACH OF CHILDREN. IF SWALLOWED, DO NOT INDUCE VOMITING. CALL A PHYSICIAN IMMEDIATELY.
09/06/15 14:44:12 31ZV1650_011 OUTBOARD MOTOR SAFETY Canadian Types Honda outboard motor is designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the outboard motor. Failure to do so could result in personal injury or equipment damage. 10 Gasoline is harmful or fatal if swallowed. Keep the fuel tank out of reach of children. Gasoline is extremely flammable and is explosive under certain conditions.
09/06/15 14:44:23 31ZV1650_012 CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES BF5A Model SA SC Type Shaft Length LA LC S L Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications. BF5A is provided with the following types according to the shaft length.
09/06/15 14:44:35 31ZV1650_013 CONTROLS AND FEATURES COMPONENT AND CONTROL LOCATIONS GEARSHIFT LEVER ENGINE COVER OIL FILLER CAP/DIPSTICK CHOKE KNOB EMERGENCY STOP SWITCH TILLER HANDLE SPARK PLUG STARTER GRIP ENGINE COVER LOCK LEVER THROTTLE GRIP TILT LEVER THROTTLE FRICTION KNOB TRANSOM ANGLE ADJUSTING ROD COOLING SYSTEM INDICATOR EMERGENCY STOP SWITCH CLIP OIL PRESSURE INDICATOR EMERGENCY STOP SWITCH LANYARD ENGINE OIL DRAIN BOLT CLAMP SCREW WASH SCREW (FLUSH SCREW) STERN BRACKET ANTIVENTILA
09/06/15 14:44:40 31ZV1650_014 CONTROLS AND FEATURES Portable Fuel Tank FUEL GAUGE VENT KNOB FUEL TANK FUEL FILLER CAP FUEL HOSE PRIMING BULB FUEL HOSE CONNECTOR (FEMALE) 13
09/06/15 14:44:52 31ZV1650_015 CONTROLS AND FEATURES CONTROLS EMERGENCY STOP SWITCH The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The emergency stop switch lanyard must be attached securely to the operator or to the operator’s PFD (Personal Flotation Device). PUSH When used as described, the emergency stop switch and emergency stop switch lanyard system stops the engine if the operator falls away from the controls.
09/06/15 14:45:09 31ZV1650_016 CONTROLS AND FEATURES Throttle Grip Throttle Friction Knob Gearshift Lever INDEX MARK TO DECREASE FRICTION R (reverse) N (neutral) F (forward) TO INCREASE FRICTION THROTTLE GRIP THROTTLE FRICTION KNOB The throttle grip controls engine speed. The throttle friction knob adjusts resistance to throttle grip rotation. An index mark on the tiller handle shows throttle position and is helpful for setting the throttle correctly when starting (p. 28 ).
09/06/15 14:45:22 31ZV1650_017 CONTROLS AND FEATURES Starter Grip Engine Cover Lock Lever ENGINE COVER LOCK LEVER Direction to pull Transom Angle Adjusting Rod The transom angle adjusting rod adjusts the transom angle of the outboard motor when fully lowered. UNLOCK STARTER GRIP Pulling the starter grip operates the recoil starter to crank the engine for starting. The motor will start only when the gearshift lever (p.
09/06/15 14:45:41 31ZV1650_018 CONTROLS AND FEATURES Steering Friction Bolt STEERING FRICTION BOLT TO DECREASE FRICTION Tilt Lever INSTRUMENTS ENGINE COVER GRIP TILT LEVER Fuel Gauge FUEL FILLER CAP TO INCREASE FRICTION FUEL GAUGE The steering friction bolt adjusts steering resistance. Less friction allows the outboard motor to turn more easily. More friction helps to hold a steady course while cruising or to prevent the outboard motor from swinging while trailering the boat.
09/06/15 14:45:56 31ZV1650_019 CONTROLS AND FEATURES INDICATORS Cooling System Indicator Oil Pressure Indicator Rev Limiter OIL PRESSURE INDICATOR The engine is equipped with an rev limiter to prevent the possibility of mechanical damage from excessive engine speed. COOLING SYSTEM INDICATOR When the oil pressure indicator is lit, oil pressure is OK. If oil pressure becomes low, the oil pressure indicator will go off, and the engine protection system will limit engine speed.
09/06/15 14:46:05 31ZV1650_020 CONTROLS AND FEATURES Anode Portable Fuel Tank ANODE Fuel Filler Cap Vent Knob VENT KNOB CLOSE OPEN FUEL FILLER CAP The anode is made of a sacrificial material that helps to protect the outboard motor from corrosion. There is an anode on the antiventilation plate. The portable fuel tank has a capacity of 3.2 US gal (12 L) and has a fuel gauge built into the cap.
09/06/15 14:46:11 31ZV1650_021 CONTROLS AND FEATURES Fuel Priming Bulb UP OUTLET END (motor side) PRIMING BULB INLET END (tank side) A priming bulb is built into the fuel hose that connects the fuel tank to the outboard motor. Before starting the engine, hold the priming bulb up in the direction of the arrow, then squeeze the priming bulb until it feels firm. This will ensure that fuel is supplied to the engine.
09/06/15 14:46:23 31ZV1650_022 INSTALLATION Correct and secure installation is essential for safe boating and good performance. Follow the installation instructions provided in this manual. INSTALLATION POSITION CENTER LINE IDLE PORT MOTOR TRANSOM HEIGHT BOAT TRANSOM HEIGHT POWER REQUIREMENTS Before installation, check to be sure that the outboard motor does not exceed the recommended maximum horsepower for the boat on which it is to be installed.
09/06/15 14:46:37 31ZV1650_023 INSTALLATION If the outboard motor is installed too low, the boat will squat and be hard to plane, and the motor will spray water that may enter the boat. It will tend to porpoise, and high-speed stability will be reduced. If the outboard motor is installed too high, that will cause propeller ventilation. Optimum installation height varies with boat type and bottom shape.
09/06/15 14:46:48 31ZV1650_024 BEFORE OPERATION ARE YOU READY TO GET UNDERWAY? Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury. Safety Always wear a PFD (Personal Flotation Device) while on the boat. Attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD. Knowledge Read and understand this manual. Know what the controls do and how to operate them.
09/06/15 14:47:02 31ZV1650_025 BEFORE OPERATION Safety Inspection Look around the outboard motor for signs of oil or gasoline leaks. If you are using the portable fuel tank, make sure it is in good condition and properly secured in the boat (p. 26 ). Check that the fuel hose is undamaged and properly connected (p. 26 ). Wipe up any spills before starting the engine. Check the stern bracket to be sure the outboard motor is securely installed. Check that all controls are operating properly.
09/06/15 14:47:15 31ZV1650_026 OPERATION SAFE OPERATING PRECAUTIONS To safely realize the full potential of this outboard motor, you need a complete understanding of its operation and a certain amount of practice with its controls. Before operating the outboard motor for the first time, please review the IMPORTANT SAFETY INFORMATION on page 6 and the chapter titled BEFORE OPERATION. For your safety, do not start or run the engine in a confined or partly enclosed area.
09/06/15 14:47:28 31ZV1650_027 OPERATION PORTABLE FUEL TANK Secure the portable fuel tank in the boat so that it won’t move around and become damaged. FUEL HOSE CONNECTIONS FUEL HOSE CONNECTOR Before use, open the fuel tank vent by turning the vent knob at least 2 or 3 turns counterclockwise. Gasoline is highly flammable and explosive. Place the portable fuel tank in a wellventilated location, away from direct sunlight, to reduce the possibility of a gasoline vapor explosion.
09/06/15 14:47:39 31ZV1650_028 OPERATION FUEL PRIMING STARTING THE ENGINE EMERGENCY STOP SWITCH CLIP UP OUTLET END (motor side) EMERGENCY STOP SWITCH PRIMING BULB INLET END (tank side) Hold the priming bulb up in the direction of the arrow; then squeeze the priming bulb several times until it feels firm, indicating that fuel has reached the engine. Check to be sure there are no fuel leaks before starting the engine.
09/06/15 14:47:50 31ZV1650_029 OPERATION CHOKE KNOB N (neutral) MARK OFF ON THROTTLE GRIP GEARSHIFT LEVER 2. Check the position of the gearshift lever. It must be in the N (neutral) position for starting. The engine will not start if the gearshift lever is in the F (forward) or R (reverse) position. 28 3. To start a cold engine, pull the choke knob to the ON position. To restart a warm engine, leave the choke knob in the OFF position. 4.
09/06/15 14:48:03 31ZV1650_030 OPERATION 6. If the choke knob was pulled to the ON position to start the engine, gradually push it to the OFF position as the engine warms up. Direction to pull Also, as the engine warms up, the throttle grip can be turned to the SLOW position without stalling. EMERGENCY STARTING If the recoil starter is inoperative, you can start the engine manually using the emergency starter rope supplied with the tool kit. ENGINE COVER LOCK LEVER 7.
09/06/15 14:48:14 31ZV1650_031 OPERATION 3. Set the controls the same as for normal starting (see pages 27 − 28 ). Use the choke control if needed. 6 mm CAP NUTS EMERGENCY STARTER ROPE 4. Set the knotted end of the emergency starter rope in the notch in the flywheel. Wind the rope clockwise around the flywheel. 6 mm FLANGE BOLTS FLYWHEEL COVER 2. Remove the two 6 mm cap nuts and 6 mm flange bolts, and remove the flywheel cover. 5.
09/06/17 20:34:29 31ZV1650_032 OPERATION 6. If the choke control was used to start the engine, return the control to the normal operating position as the engine warms up. During the warm-up period, check the oil pressure indicator (p. 18 ), and cooling system indicator (p. 18 ). 7. Install the engine cover (p. 43 ), and lock it in place by locking the engine cover lock lever. Exposed moving parts can cause injury. Do not operate the outboard motor without the engine cover.
09/06/15 14:48:39 31ZV1650_033 OPERATION STOPPING THE ENGINE Normal Engine Stopping EMERGENCY STOP SWITCH Emergency Engine Stopping EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH LANYARD PUSH THROTTLE GRIP PULL EMERGENCY STOP SWITCH CLIP N (neutral) To stop the engine in an emergency, pull the emergency stop switch clip out of the emergency stop switch by pulling the emergency stop switch lanyard.
09/06/15 14:48:53 31ZV1650_034 OPERATION GEARSHIFTING AND THROTTLE OPERATION To shift gears, turn the throttle grip to the SLOW position; then move the gearshift lever to select the F (forward), N (neutral), or R (reverse) gears. The engine can be started with the gearshift lever in the N (neutral) position only. THROTTLE GRIP R (reverse) N (neutral) F (forward) The throttle grip can be turned to the FAST position only when the gearshift lever is in the F (forward) position.
09/06/15 14:49:06 31ZV1650_035 OPERATION STEERING STEERING FRICTION BOLT TO DECREASE FRICTION TO INCREASE FRICTION Steer by moving the tiller handle opposite the direction you want the boat to turn. Use the steering friction bolt to help hold a steady course while cruising. Turn the bolt clockwise to increase steering friction for holding a steady course. Turn the bolt counterclockwise to decrease friction for easy turning.
09/06/15 14:49:20 31ZV1650_036 OPERATION CRUISING Transom Angle Engine Speed Install the outboard motor at the best transom angle for stable cruising and maximum power. For best fuel economy, limit the throttle opening to 80%. Use the throttle friction control (p. 33 ) to help you hold a steady speed. For rough water conditions or large waves, slow down to prevent the propeller from rising out of the water. Transom angle too large: Incorrect causes boat to ‘‘squat.
09/06/15 14:49:29 31ZV1650_037 OPERATION SHALLOW WATER OPERATION When operating in shallow water, tilt the outboard motor, using the tilt lever, so the propeller and gear case won’t hit the bottom. ENGINE COVER GRIP To tilt the outboard motor, raise the outboard motor to the 30° position by pulling on the engine cover grip. Do not use the tiller handle as a lever to raise the outboard motor. Applying excessive f orce to the tiller handle can damage it.
09/06/15 14:49:39 31ZV1650_038 OPERATION TILT LEVER MOORING, BEACHING, LAUNCHING Before tilting up, leave the outboard motor in the running position for one minute after stopping the engine to drain the water from inside the engine. Stop the engine before tilting the outboard motor. The 38° or 58° position is not an operating position. Raise and lower the outboard motor as described on p. 36 .
09/06/15 14:49:47 31ZV1650_039 SERVICING YOUR OUTBOARD MOTOR THE IMPORTANCE OF MAINTENANCE Proper maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. Improperly maintaining this outboard motor or failure to correct a problem 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.
09/06/15 14:49:57 31ZV1650_040 SERVICING YOUR OUTBOARD MOTOR MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. 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.
09/06/15 14:50:07 31ZV1650_041 SERVICING YOUR OUTBOARD MOTOR TOOL KIT AND EMERGENCY STARTER ROPE FLAT SCREWDRIVER 10 × 12 mm WRENCH PLIERS TOOL BAG PHILIPS SCREWDRIVER SPARK PLUG WRENCH SPARE EMERGENCY STOP SWITCH CLIP 8 mm WRENCH SPARE SPARK PLUG EMERGENCY STARTER ROPE The following tools are supplied with the outboard motor for simple maintenance procedures and emergency repairs. An emergency starter rope is also supplied.
09/06/15 14:50:20 31ZV1650_042 SERVICING YOUR OUTBOARD MOTOR MAINTENANCE SCHEDULE Follow the MAINTENANCE SCHEDULE table and service your outboard motor accordingly. Please note, a claim for warranty coverage will not be denied simply because the maintenance schedule for your outboard was not followed. However, any part(s) that fails specifically due to lack of maintenance, or improperly performed maintenance, would not be covered under the Distributor’s Limited Warranty.
09/06/15 14:50:32 31ZV1650_043 SERVICING YOUR OUTBOARD MOTOR REGULAR SERVICE PERIOD (3) Perform at every indicated month or operating hour interval, whichever comes first. ITEM Fuel tank and tank filter Clean Thermostat Check Check Fuel filter Replace Check Fuel line Replace Check-tightness Bolts and nuts Check Crankcase breather tube Clean Cooling water passages Check Water pump Emergency stop switch Check Each use After use First month or 20 hrs. Every 6 months or 100 hrs. Every year or 200 hrs.
09/06/15 14:50:48 31ZV1650_044 SERVICING YOUR OUTBOARD MOTOR ENGINE COVER REMOVAL AND INSTALLATION ENGINE COVER LOCK LEVER Engine Oil Level Check OIL FILLER CAP/DIPSTICK Check the engine oil level with the engine stopped and the outboard motor in the vertical position. 1. Unlock and remove the engine cover. 2. Remove the oil filler cap/dipstick and wipe it clean. UNLOCK LOWER LIMIT OIL FILLER CAP/DIPSTICK The engine cover lock lever fastens the engine cover to the outboard motor. 4.
09/06/15 14:51:01 31ZV1650_045 SERVICING YOUR OUTBOARD MOTOR Engine Oil Change Improper disposal of engine oil can be harmf ul to the environment. If you change your own oil, please dispose of the used oil properly. Put it in a sealed container, and take it to a recycling center. Do not discard it in a trash bin, dump it on the ground, or pour it down a drain. An engine oil evacuation device may be used to remove the engine oil. Drain the used oil into a suitable container while the engine is warm.
09/06/15 14:51:11 31ZV1650_046 SERVICING YOUR OUTBOARD MOTOR Engine Oil Recommendations Oil is a major factor affecting performance and service life. Use 4-stroke detergent oil. If Honda 10W-30 FC-W oil is not available, Honda recommends that you use API service category SG, SH or SJ oil. The SAE oil viscosity and service category are in the API label on the oil container. Gear Case Oil Level Check Check the gear case oil level with the engine stopped and the outboard motor in the vertical position.
09/06/15 14:51:18 31ZV1650_047 SERVICING YOUR OUTBOARD MOTOR If no oil flows from the oil level hole, add the recommended oil (p. 47 ) following the procedure described in Gear Case Oil Change. Gear Case Oil Change Change the gear case oil with the engine stopped and the outboard motor in the vertical position. 1. Place a suitable container below the oil drain hole to catch the used oil, then remove the oil level screw and oil drain/fill screw. 46 2.
09/06/15 14:51:27 31ZV1650_048 SERVICING YOUR OUTBOARD MOTOR OIL LEVEL SCREW TORQUE: 4.8 lbf·ft (6.5 N·m, 0.66 kgf·m) Avoid losing more than 1 fl oz (30 cm3) while reinstalling the drain/ fill screw. OIL DRAIN SCREW TORQUE: 4.8 lbf·ft (6.5 N·m, 0.66 kgf·m) GEAR OIL BOTTLE 3. Add oil through the oil drain hole until it flows out the oil level hole, then install the oil level screw. Remove the pump adapter and install the oil drain/fill screw. GEAR OIL CAPACITY: 0.11 US qt (0.
09/06/15 14:51:45 31ZV1650_049 SERVICING YOUR OUTBOARD MOTOR Lubrication Points Apply Honda Marine waterproof grease to the parts shown below: Lubrication interval: 20 operating hours or one month after the date of purchase or the initial use, then every 100 hours or 6 months (refer to the maintenance schedule on page 41 ). To prevent corrosion, apply anticorrosion oil to pivot surf aces where grease cannot penetrate.
09/06/15 14:51:58 31ZV1650_050 SERVICING YOUR OUTBOARD MOTOR Spark Plug Service SPARK PLUG WRENCH RECOMMENDED SPARK PLUGS: BPR5ES (NGK) W16EPR-U (DENSO) SIDE ELECTRODE 0.028 − 0.031 in (0.7 − 0.8 mm) SEALING WASHER Incorrect spark plug can cause engine damage. 1. Unlock and remove the engine cover (p. 43 ). 2. Disconnect the spark plug cap from the spark plug. 3. Remove the spark plug with a spark plug wrench and screwdriver supplied in the tool kit. 4. Inspect the spark plug.
09/06/15 14:52:15 31ZV1650_051 SERVICING YOUR OUTBOARD MOTOR 6. Install the spark plug carefully, by hand, to avoid cross-threading. REFUELING Portable Fuel Tank 7. After the spark plug seats, tighten with a spark plug wrench supplied in the tool kit to compress the sealing washer. If reinstalling the used spark plug, tighten 1/8−1/4 turn after the spark plug seats. FUEL TANK CAPACITY: 3.2 US gal (12 L) Check the fuel gauge and refill the tank when necessary.
09/06/15 14:52:27 31ZV1650_052 SERVICING YOUR OUTBOARD MOTOR FUEL RECOMMENDATIONS Gasoline is highly flammable and explosive. Use unleaded gasoline with a pump octane rating of 86 or higher. You can be burned or seriously injured when handling fuel. Your outboard motor is certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors.
09/06/15 14:52:41 31ZV1650_053 SERVICING YOUR OUTBOARD MOTOR Fuel Filter Inspection and Replacement ENGINE COVER LOCK LEVER The fuel filter is located under the engine cover, on the right side of the engine. Water or sediment accumulation in the filter can cause loss of power or hard starting. To prevent engine malfunction, inspect the filter and replace when necessary. UNLOCK Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
09/06/15 14:52:55 31ZV1650_054 SERVICING YOUR OUTBOARD MOTOR FUEL FILTER FUEL HOSE FUEL FILTER ARROW (Fuel Flow Direction) 7. Securely connect the fuel hose connector to the outboard motor (refer to page 26 ). 8. Prime the engine using the priming bulb (p. 27 ). Check for fuel leaks. Repair any fuel leaks if necessary. 9. Install and lock the engine cover. HOSE CLAMPS FUEL HOSE 4. Remove the fuel hoses from the used filter, and discard the filter.
09/06/15 14:53:03 31ZV1650_055 SERVICING YOUR OUTBOARD MOTOR Portable Fuel Tank and Tank Filter Cleaning Fuel Tank 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. 54 FUEL HOSE Empty the portable fuel tank into an approved gasoline container. Use a funnel to avoid spilling fuel.
09/06/15 14:53:17 31ZV1650_056 SERVICING YOUR OUTBOARD MOTOR Recoil Starter Rope Inspection Fuel Tank Filter Anode Replacement ANODE TANK FILTER JOINT (Fuel Hose Connector) O-RING BOLT FILTER Inspect the recoil starter rope, and replace it if it becomes frayed. The anode is located on the antiventilation plate. It is made of a sacrificial material that helps to protect the outboard motor from corrosion. Always keep the emergency starter rope on the boat in case the recoil starter rope fails.
09/06/15 14:53:28 31ZV1650_057 SERVICING YOUR OUTBOARD MOTOR Propeller and Shear Pin Replacement Removal PROPELLER CAP 2. Remove the broken shear pin and replace it with a new one. A shear pin is used to protect the propeller and drive mechanism from damage when the propeller strikes an obstruction.
09/06/15 14:53:35 31ZV1650_058 SERVICING YOUR OUTBOARD MOTOR Installation COTTER PIN Spare shear pins and cotter pins are provided in the engine compartment (p. 40 ). 1. Install the shear pin and the propeller, then install the propeller cap finger tight. 2. Be sure to replace the cotter pin with a new one. Use a Honda Genuine stainless steel cotter pin or equivalent cotter pin and bend the pin ends as shown.
09/06/15 14:53:53 31ZV1650_059 STORAGE STORAGE PREPARATION the water pump. Proper storage preparation is essential for keeping your outboard motor trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your outboard motor’s function and appearance, and will make the engine easier to start when you use the outboard motor again. Touch up any damaged paint, and coat areas that may rust with Honda Corrosion Inhibitor, or equivalent.
09/06/15 14:54:04 31ZV1650_060 STORAGE Flushing Without the Honda Water Hose Connector It is necessary to run the engine during the flushing procedure. For safety, remove the propeller from the outboard motor (p. 56 ). Running the engine without good water circulation can cause overheating and water pump damage. Damage caused by running the outboard motor without sufficient cooling water is not covered by the Distributor’s Limited Warranty (p. 83 ). 3.
09/06/15 14:54:15 31ZV1650_061 STORAGE Fuel Depending on the region where you operate your outboard, f uel f ormulations may deteriorate and oxidize rapidly. Fuel deterioration and oxidation can occur in as little as 15 days and may cause damage to the carburetor and f uel system. Please check with your servicing dealer f or local storage recommendations. Gasoline will oxidize and deteriorate in storage. Old gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system.
09/06/15 14:54:29 31ZV1650_062 STORAGE Draining the Fuel System You can avoid fuel deterioration problems by draining the fuel tank and carburetor. 1. Disconnect the fuel hose from the outboard motor. 2. Disconnect the drain tube from the air guide, then connect it to the carburetor drain port as shown. CARBURETOR DRAIN PORT DRAIN SCREW AIR GUIDE 3. With the outboard motor in a vertical position, place an approved gasoline container below the fuel drain outlet, and use a funnel to avoid spilling fuel.
09/06/15 14:54:41 31ZV1650_063 STORAGE Engine Oil STORAGE PRECAUTIONS 1. Change the engine oil (p. 44 ). Select a well-ventilated storage area. If possible, avoid storage areas with high humidity. 2. Remove the spark plug (p. 49 ), and remove the emergency stop switch clip from the emergency stop switch. 3. Pour 1−2 teaspoons (5 − 10 cm3) of clean engine oil into the cylinder. 4. Pull the starter grip several times to distribute the oil in the cylinder. 5. Reinstall the spark plug (p. 50 ).
09/06/15 14:54:52 31ZV1650_064 STORAGE Cover the outboard motor to keep out dust. Do not use plastic sheet as a dust cover. A nonporous cover will trap moisture, promoting rust and corrosion. REMOVAL FROM STORAGE CASE PROTECTORS Store the outboard motor either vertically or horizontally with the tiller handle side up. If storing horizontally, be sure to fold the tiller handle, and rest the outboard motor on its case protectors.
09/06/15 14:55:02 31ZV1650_065 TRANSPORTING WITH OUTBOARD MOTOR INSTALLED ON BOAT WITH OUTBOARD MOTOR REMOVED FROM BOAT When trailering a boat with the outboard motor attached, leave the engine in the normal running position, if possible, and tighten the steering friction bolt securely (p. 34 ). Remove the outboard motor from the boat and secure the outboard motor in either the vertical or horizontal position shown on p. 63 .
09/06/15 14:55:14 31ZV1650_066 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction 1. Check emergency stop switch clip. Clip not inserted in emergency stop switch. Insert clip in emergency stop switch. 2. Check control positions. Gearshift lever not in neutral position. Shift to neutral (p. 28 ). Choke OFF. Pull choke knob to ON position, unless engine is warm (p. 28 ). Throttle grip not in START position. Turn throttle grip to START position (p. 28 ).
09/06/15 14:55:32 31ZV1650_067 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START (continued) 3. Check fuel. 4. Remove and inspect spark plug. 5. Take outboard motor to an authorized Honda Marine dealer, or refer to the shop manual. 66 Possible Cause Correction Out of fuel. Refuel (p. 50 ). Fuel vent closed (portable fuel tank). Open fuel filler cap vent knob (p. 26 ). Fuel hose not primed. Squeeze priming bulb (p. 27 ). Fuel filter or fuel tank filter restricted.
09/06/15 14:55:46 31ZV1650_068 TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS AFTER STARTING 1. Check control positions. 2. Check fuel. Possible Cause Correction Choke OFF. Pull choke knob to ON position, unless engine is warm (p. 28 ). Throttle grip not in START position. Turn throttle grip to START position (p. 28 ). Fuel vent closed (portable fuel tank). Open fuel filler cap vent knob (p. 26 ). Fuel hose not primed. Squeeze priming bulb (p. 27 ).
09/06/15 14:56:01 31ZV1650_069 TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS AFTER STARTING (continued) Possible Cause Correction 3. Remove and inspect spark plug. Spark plug faulty, fouled, or improperly gapped. Gap or replace spark plug (p. 49 ). 4. Take outboard motor to an authorized Honda Marine dealer, or refer to the shop manual. Carburetor malfunction, fuel pump failure, ignition malfunction, etc. Replace or repair faulty components as necessary.
09/06/15 14:56:10 31ZV1650_070 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT DRIVE THE PROPELLER Possible Cause Correction 1. Check shear pin. Broken shear pin. Replace shear pin (p. 56 ). 2. Take outboard motor to an authorized Honda Marine dealer, or refer to the shop manual. Damaged gearshift mechanism. Replace or repair faulty components as necessary.
09/06/15 14:56:18 31ZV1650_071 TAKING CARE OF UNEXPECTED PROBLEMS OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMITED If oil pressure becomes low, the green indicator will go off. If you are at cruising speed, engine speed will decrease gradually. OIL PRESSURE INDICATOR Low oil pressure may be the result of a low engine oil level, or there may be a problem with the engine lubrication system.
09/06/15 14:56:27 31ZV1650_072 TAKING CARE OF UNEXPECTED PROBLEMS SUBMERGED MOTOR A submerged outboard motor must be serviced immediately after it is recovered from the water in order to minimize corrosion. If there is a Honda Marine dealership nearby, take the motor to the dealer immediately. If you are far from a dealer, proceed as follows: 1. Remove the engine cover, and rinse the outboard motor with fresh water to remove salt water, sand, mud, etc. 2. Drain the carburetor as described on p. 61 . 3.
09/06/17 20:34:36 31ZV1650_073 TAKING CARE OF UNEXPECTED PROBLEMS 7. Attempt to start the engine. Be sure the water level is at least 2 inches (5 cm) above the antiventilation plate. When cranking the engine with an open ignition circuit (spark plug removed f rom the ignition circuit), remove the emergency stop switch clip f rom the emergency stop switch to prevent possible damage to the ignition system.
09/06/15 14:56:46 31ZV1650_074 TECHNICAL AND CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Locations Record the product identification number, the engine serial number, and the date of purchase in the space provided on this page. You will need these numbers when ordering parts, and when making technical or warranty inquiries (p. 81 ). PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER The product identification number is stamped on the swivel case.
09/06/15 14:56:53 31ZV1650_075 TECHNICAL AND CONSUMER INFORMATION Carburetor Modification for High Altitude Operation At altitudes above 2,000 ft (600 meters), the standard carburetor airfuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.
09/06/15 14:57:03 31ZV1650_076 TECHNICAL AND CONSUMER INFORMATION Emission Control System Information The U.S. and Calif ornia Clean Air Acts Source of Emissions EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems. The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons.
09/06/15 14:57:13 31ZV1650_077 TECHNICAL AND CONSUMER INFORMATION Problems That May Af f ect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption.
09/06/15 14:57:26 31ZV1650_078 TECHNICAL AND CONSUMER INFORMATION Star Label The Star Label means Cleaner Marine Engine US, Puerto Rico, and US Virgin Islands This engine has been certified as a: A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board. The Symbol for Cleaner Marine Engines: Cleaner Air and Water - for healthier lifestyle and environment.
09/06/15 14:57:36 31ZV1650_079 TECHNICAL AND CONSUMER INFORMATION One Star Low Emission The one-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.
09/06/15 14:58:22 31ZV1650_080 TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description code Type Overall length Overall width Overall height Transom height (when transom angle at 12°) Dry mass [weight] Rated power Full throttle range Engine type Displacement Spark plug gap Starter system Ignition system Lubrication system Specified oil Oil capacity CARB star label Cooling system Exhaust system BF5A BADS S L 20.7 in (525 mm) 13.8 in (350 mm) 39.6 in (1,005 mm) 44.7 in (1,135 mm) 17.
09/06/15 14:58:39 31ZV1650_081 TECHNICAL AND CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications (United States, Puerto Rico, and U.S.Virgin Islands) These publications will give you additional information for maintaining and repairing your outboard motor. Accessory Catalog Your authorized Honda Marine dealer offers a wide selection of accessories (optional equipment, oils, and lubricants) to enhance your boating experience. Visit www.honda-marine.
09/06/15 14:58:51 31ZV1650_082 TECHNICAL AND CONSUMER INFORMATION Please include the following information in your communication: Your name, address and telephone number (complete with area code) Model and complete serial number Date of purchase Name and location of selling dealer Name and location of servicing dealer (if different) A detailed description of your concerns Warranty Coverage Your new Honda is covered by the following warranties: Distributor’s Limited Warranty Emission Control System Warrant
09/06/15 14:58:57 31ZV1650_083 TECHNICAL AND CONSUMER INFORMATION Warranty Service Please remember that recommended maintenance interval servicing is not included in your warranty coverage. Additionally, your warranty does not apply to the normal wear of items (such as spark plug(s), water pump, etc.). As the owner of a Honda product, your servicing dealer may ask you to authorize an inspection. If the problem is covered under warranty, your dealer will perform any warranty repairs for you at no cost.
09/06/15 14:59:11 31ZV1650_084 TECHNICAL AND CONSUMER INFORMATION Warranty Statements The American Honda Distributor’s Limited Warranty applies to outboards purchased in the United States, Puerto Rico, or the U.S. Virgin Islands. The Honda Canada Distributor’s Warranty applies to outboards purchased in Canada. The product warranty is only valid in the country where the product was purchased.
09/06/15 14:59:25 31ZV1650_085 TECHNICAL AND CONSUMER INFORMATION All parts replaced under warranty will be considered as part of the original product and any warranty on those parts will expire coincidentally with the original product warranty. To Obtain Warranty Service: You must take your Honda Outboard Motor and proof of the original purchase date, at your expense, to any dealer who is authorized to service Honda Outboard Motors in the United States, Puerto Rico, or the U.S.
09/06/15 14:59:38 31ZV1650_086 TECHNICAL AND CONSUMER INFORMATION Accessories and Replacement Parts This warranty is limited to Honda Power Equipment parts,accessories and apparel when distributed by American Honda Motor Co., Inc., 1919 Torrance Blvd., Torrance, California 90501-2746.
09/06/15 14:59:44 31ZV1650_087 TECHNICAL AND CONSUMER INFORMATION To Obtain Warranty Service: You must take the Honda Outboard Motor product accessory or replacement part or the outboard motor or boat on which the accessory or replacement part is installed, and proof of purchase, at your expense, to any Honda Marine authorized service facility or dealer in the United States, Puerto Rico, or the U.S. Virgin Islands, during normal business hours.
09/06/15 14:59:53 31ZV1650_088 TECHNICAL AND CONSUMER INFORMATION Emission Control System Warranty Your new Honda outboard engine complies with both the U.S. EPA and State of California emission regulations. American Honda provides the same emission warranty coverage for outboard engines sold in all 50 states. outboard engine at no cost to you including diagnosis, parts and labor. Your emission control system may include such parts as the carburetor or fuel injection system and catalytic converter.
09/06/15 14:59:58 31ZV1650_089 TECHNICAL AND CONSUMER INFORMATION OWNER’S WARRANTY RESPONSIBILITY: As the outboard engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. American Honda Motor Co., Inc. recommends that you retain all receipts covering maintenance on your outboard engine, but American Honda Motor Co., Inc. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
09/06/15 15:00:06 31ZV1650_090 TECHNICAL AND CONSUMER INFORMATION may be denied. If the part in question is not related to the reason that your engine requires repair, your claim will not be denied. TO OBTAIN WARRANTY SERVICE: You must take your Honda outboard engine, along with your sales registration card or other proof of original purchase date, at your expense, to any Honda Marine dealer who is authorized by American Honda Motor Co., Inc.
09/06/15 15:00:17 31ZV1650_091 TECHNICAL AND CONSUMER INFORMATION EMISSION CONTROL SYSTEM WARRANTY PARTS: SYSTEMS COVERED BY THIS WARRANTY: Fuel Metering PARTS DESCRIPTION Carburetor assembly, Throttle body, Fuel injector, Fuel pump, Fuel pressure regulator, Throttle position sensor, Intake air temperature sensor, Engine temperature sensor, Manifold absolute pressure sensor, Idle air control valve, Barometric pressure sensor, Fuel line solenoid valve, Intake manifold, Intake valves, and Oxygen sensor or
09/06/15 15:00:28 31ZV1650_092 TECHNICAL AND CONSUMER INFORMATION Canada WARRANTY PERIOD RETAILED ON OR AFTER APRIL 1, 2005: Distributor’s Warranty HONDA CANADA INC., for and on behalf of Honda Motor Co. Ltd., Tokyo, Japan, gives the following written warranty on each new marine product manufactured by Honda Motor Co. Ltd., Japan, distributed in Canada by Honda Canada Inc. and sold by authorized Honda Marine dealers. Whenever used herein, the word ‘‘Honda’’ refers to Honda Canada Inc.
09/06/15 15:00:40 31ZV1650_093 TECHNICAL AND CONSUMER INFORMATION THIS WARRANTY DOES NOT COVER THE OWNER’S OBLIGATION a) Any repairs required as a result of collision, accident, striking any object, misuse or lack of required maintenance; b) Any repairs required as a result of any attachments, parts or devices installed by or repairs done by a party other than an authorized Honda dealer; c) Any outboard that has been operated out of water, (Run Dry) damaging the water pump and or engine components due to
09/06/15 15:00:49 31ZV1650_094 TECHNICAL AND CONSUMER INFORMATION REPLACEMENT PARTS AND ACCESSORY WARRANTY New genuine Honda replacement parts or accessories sold to a consumer or installed by an authorized Honda Marine dealer which are not covered by the DISTRIBUTORS WARRANTY are warranted for a period of one year from date of purchase, provided, however, that this Replacement Parts and Accessory Warranty does not apply to any replacement parts modified, used with, or installed on a marine product for whi
09/06/15 15:00:55 31ZV1650_095 INDEX Anode ............................................................................. 19 Replacement ............................................................... 55 ARE YOU READY TO GET UNDERWAY?.............. 23 ATTACHMENT ............................................................ 22 BEFORE OPERATION................................................. 23 BREAK-IN PROCEDURE ............................................
09/06/15 15:01:03 31ZV1650_096 INDEX Gear Case Oil Change ........................................................................ 46 Level Check................................................................ 45 GEARSHIFTING AND THROTTLE OPERATION ... 33 Gearshift Lever............................................................... 15 HARD STARTING OR STALLS AFTER STARTING ................................................................ 67 Honda Publications ...............................................
09/06/15 15:01:07 31ZV1650_097 INDEX SAFE OPERATING PRECAUTIONS ......................... 25 SAFETY LABEL LOCATIONS ..................................... 8 Serial Number Locations................................................ 73 SERVICING YOUR OUTBOARD MOTOR ............... 38 SHALLOW WATER OPERATION ............................. 36 Spark Plug Service ......................................................... 49 Specifications .................................................................
31ZV1650 00X31-ZV1-6500 N BF5AK0 2eY1100.2009.
