31ZV1639 00X31-ZV1-6390 N BF5AK0 2eY1400.2007.
07/01/08 13:02:02 31ZV1630_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. 2006 Honda Motor Co., Ltd.
07/01/08 13:02:09 31ZV1630_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.
07/01/08 13:02:21 31ZV1630_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.
07/01/08 13:02:26 31ZV1630_004 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 CONTROL LOCATIONS ..... 10 CONTROLS ............................................................... 12 Switch Clip and Engine Stop Switch .........
07/01/08 13:02:30 31ZV1630_005 CONTENTS OPERATION ................................................................. 23 SAFE OPERATING PRECAUTIONS ..................... 23 BREAK-IN PROCEDURE........................................ 23 TRANSOM ANGLE ADJUSTMENT ...................... 23 PORTABLE FUEL TANK ........................................ 24 FUEL HOSE CONNECTIONS ................................. 24 FUEL PRIMING ........................................................ 25 STARTING THE ENGINE ............
07/01/08 13:02:34 31ZV1630_006 CONTENTS STORAGE ..................................................................... 56 STORAGE PREPARATION .................................... 56 Cleaning and Flushing ........................................... 56 Fuel ......................................................................... 58 Engine Oil .............................................................. 60 STORAGE PRECAUTIONS .................................... 60 REMOVAL FROM STORAGE .....................
07/01/08 13:02:45 31ZV1630_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 accidents can be prevented if you follow all instructions in this manual and on the outboard motor.
07/01/08 13:02:53 31ZV1630_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. Carbon Monoxide Hazard Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run the engine in a closed garage or confined area. Remove any portable fuel tank from the boat for refueling.
07/01/08 13:03:06 31ZV1630_009 OUTBOARD MOTOR SAFETY SAFETY LABEL LOCATIONS 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.
07/01/08 13:03:18 31ZV1630_010 CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES BF5A Model Type Shaft Length SA LA 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.
07/01/08 13:03:29 31ZV1630_011 CONTROLS AND FEATURES COMPONENT AND CONTROL LOCATIONS GEARSHIFT LEVER ENGINE COVER CHOKE KNOB OIL FILLER CAP/DIPSTICK ENGINE STOP SWITCH TILLER HANDLE SPARK PLUG STARTER GRIP ENGINE COVER LOCK LEVER THROTTLE GRIP TILT LEVER THROTTLE FRICTION KNOB TRANSOM ANGLE ADJUSTING ROD SWITCH CLIP LANYARD FUEL HOSE CONNECTOR (MALE) OIL PRESSURE INDICATOR ENGINE OIL DRAIN BOLT CLAMP SCREW WASH SCREW (FLUSH SCREW) STERN BRACKET ANODE STEERING FRICTION BOLT ANTIVENTILATION P
07/01/08 13:03:34 31ZV1630_012 CONTROLS AND FEATURES Portable Fuel Tank FUEL GAUGE VENT KNOB FUEL TANK FUEL FILLER CAP FUEL HOSE PRIMING BULB FUEL HOSE CONNECTOR (FEMALE) 11
07/01/08 13:03:50 31ZV1630_013 CONTROLS AND FEATURES CONTROLS Switch Clip and Engine Stop Switch ENGINE STOP SWITCH PUSH SWITCH CLIP LANYARD The engine stop switch controls normal engine stopping and emergency engine stopping. The switch clip must be inserted in the engine stop switch in order for the engine to start and run. The lanyard should be attached to the operator’s PFD (Personal Flotation Device) or worn around the wrist.
07/01/08 13:04:09 31ZV1630_014 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. 26 ).
07/01/08 13:04:24 31ZV1630_015 CONTROLS AND FEATURES Starter Grip Engine Cover Lock Lever STARTER GRIP ENGINE COVER LOCK LEVER Transom Angle Adjusting Rod The transom angle adjusting rod adjusts the transom angle of the outboard motor when fully lowered. UNLOCK Pulling the starter grip operates the recoil starter to crank the engine for starting. The motor will start only when the gearshift lever (p. 26 ) is in the N (neutral) position, and the clip is in the engine stop switch.
07/01/08 13:04:47 31ZV1630_016 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 steady course while cruising or to prevent the outboard motor from swinging while trailering the boat.
07/01/08 13:05:06 31ZV1630_017 CONTROLS AND FEATURES INDICATORS Cooling System Indicator Oil Pressure Indicator Overrev Limiter OIL PRESSURE INDICATOR The engine is equipped with an overrev 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.
07/01/08 13:05:17 31ZV1630_018 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 ) and has a fuel gauge built into the cap. The cap is provided with a vent knob to seal the portable fuel tank for carrying it to and from the boat.
07/01/08 13:05:23 31ZV1630_019 CONTROLS AND FEATURES Fuel Priming Bulb UP OUTLET END (MOTOR) PRIMING BULB INLET END (TANK) 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.
07/01/08 13:05:37 31ZV1630_020 INSTALLATION Correct and secure installation is essential for safe boating and good performance. Follow the installation instructions provided in this manual. INSTALLATION POSITION 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. Refer to the boat’s certification plate for recommended maximum horsepower.
07/01/08 13:05:49 31ZV1630_021 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.
07/01/08 13:06:01 31ZV1630_022 BEFORE OPERATION ARE YOU READY TO GET UNDER WAY? 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 your PFD or to your wrist. Knowledge Read and understand this manual. Know what the controls do and how to operate them.
07/01/08 13:06:14 31ZV1630_023 BEFORE OPERATION Safety Inspection Look around the outboard motor for signs of oil or gasoline leaks. Maintenance Inspection Check the engine oil level (p. 41 ). Running the engine with a low oil level can cause engine damage. If you are using the portable fuel tank, make sure it is in good condition and properly secured in the boat (p. 24 ). Check to be sure the propeller and shear pin are undamaged (p. 54 ).
07/01/08 13:06:27 31ZV1630_024 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, avoid starting or operating the engine in an enclosed area.
07/01/08 13:06:43 31ZV1630_025 OPERATION PORTABLE FUEL TANK Secure the portable fuel tank in the boat, so 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.
07/01/08 13:06:56 31ZV1630_026 OPERATION FUEL PRIMING STARTING THE ENGINE SWITCH CLIP UP OUTLET END (MOTOR) ENGINE STOP SWITCH The engine will not start or run unless the clip is in the switch. The emergency stop switch clip and lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat. PRIMING BULB Always attach the lanyard to your PFD, or to your wrist, before starting the engine.
07/01/08 13:07:10 31ZV1630_027 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. 26 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.
07/01/08 13:07:25 31ZV1630_028 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.
07/01/08 13:07:37 31ZV1630_029 OPERATION 3. Set the controls the same as for normal starting (see pages 25 − 26 ). Use the choke control if needed. 6 mm CAP NUTS 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.
07/01/08 13:07:47 31ZV1630_030 OPERATION 5. 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. 16 ), and cooling system indicator (p. 16 ). 6. Install the engine cover (p. 41 ), 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.
07/01/08 13:08:05 31ZV1630_031 OPERATION STOPPING THE ENGINE Normal Engine Stopping ENGINE STOP SWITCH Emergency Engine Stopping ENGINE STOP SWITCH LANYARD PUSH THROTTLE GRIP PULL SWITCH CLIP N (neutral) To stop the engine in an emergency, pull the clip out of the engine stop switch by pulling the lanyard. We suggest that you stop the engine this way occasionally to verify that the engine or emergency stop switch is operating properly. 2. Press the engine stop switch until the engine stops. 3.
07/01/08 13:08:20 31ZV1630_032 OPERATION GEARSHIFTING AND THROTTLE OPERATION To shift gears, turn the throttle grip to the SLOW position, then move the gearshift lever to select 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) The throttle grip can be turned to the FAST position only when the gearshift lever is in the F (forward) position.
07/01/08 13:08:36 31ZV1630_033 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.
07/01/08 13:08:50 31ZV1630_034 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. 31 ) 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.
07/01/08 13:09:00 31ZV1630_035 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.
07/01/08 13:09:11 31ZV1630_036 OPERATION TILT LEVER MOORING, BEACHING, LAUNCHING ENGINE COVER GRIP 45°, 70° (when mooring) To return the outboard motor to the normal operating position, raise the outboard slightly by pulling on the engine cover grip, then pull the tilt lever to release the outboard, then slowly lower the outboard motor.
07/01/08 13:09:20 31ZV1630_037 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.
07/01/08 13:09:31 31ZV1630_038 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.
07/01/08 13:09:39 31ZV1630_039 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 SWITCH CLIP SPARE SPARK PLUG 8 mm WRENCH 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. Keep these items on the boat, so they will always be available if you need them.
07/01/08 13:09:52 31ZV1630_040 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.
07/01/08 13:10:06 31ZV1630_041 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 Fuel filter Check Replace Fuel line Check Replace Bolts and nuts Check-tightness Crankcase breather tube Check Cooling water passages Clean Water pump Check Each use After use First month or 20 hrs. Every 6 months or 100 hrs. Every year or 200 hrs.
07/01/08 13:10:22 31ZV1630_042 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 OIL FILLER CAP/DIPSTICK The engine cover lock lever fastens the engine cover to the outboard motor. LOWER LIMIT 4.
07/01/08 13:10:36 31ZV1630_043 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.
07/01/08 13:10:47 31ZV1630_044 SERVICING YOUR OUTBOARD MOTOR Engine Oil Recommendations Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. SAE Viscosity Grade The SAE oil viscosity and service category are in the API label on the oil container. Honda recommends that you use API SERVICE category SJ or later oil with the ‘‘starburst’’ certification mark displayed on the container.
07/01/08 13:10:55 31ZV1630_045 SERVICING YOUR OUTBOARD MOTOR If no oil flows from the oil level hole, add the recommended oil (p. 45 ) 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 screw. 44 2.
07/01/08 13:11:04 31ZV1630_046 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 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 screw. GEAR OIL CAPACITY: 0.1 US qt (0.
07/01/08 13:11:26 31ZV1630_047 SERVICING YOUR OUTBOARD MOTOR Lubrication Points Apply marine waterproof grease to the following parts: 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 39 ). To prevent corrosion, apply anticorrosion oil to pivot surf aces where grease cannot penetrate.
07/01/08 13:11:38 31ZV1630_048 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 (0.70 − 0.80 mm) SEALING WASHER Incorrect spark plug can cause engine damage. 1. Unlock and remove the engine cover (p. 41 ). 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.
07/01/08 13:11:55 31ZV1630_049 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. If installing new spark plug, tighten 1/2 turn after the spark plug seats. A loose spark plug can overheat and damage the engine.
07/01/08 13:12:08 31ZV1630_050 SERVICING YOUR OUTBOARD MOTOR FUEL RECOMMENDATIONS parts of the fuel system. 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.
07/01/08 13:12:24 31ZV1630_051 SERVICING YOUR OUTBOARD MOTOR If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda marine dealer. Running the engine with persistent spark knock or pinging can cause engine damage. Running the engine with persistent spark knock or pinging is misuse, and the Distributor’s Limited Warranty (p. 82 ) does not cover parts damaged by misuse.
07/01/08 13:12:38 31ZV1630_052 SERVICING YOUR OUTBOARD MOTOR 3. Disconnect the fuel hose connector from the outboard motor, and place commercially available hose clips on the fuel hoses on each side of the filter to prevent fuel leakage when the fuel hoses are disconnected. FUEL FILTER FUEL HOSE HOSE CLAMPS FUEL HOSE 4. Remove the fuel hoses from the used filter, and discard the filter.
07/01/08 13:12:49 31ZV1630_053 SERVICING YOUR OUTBOARD MOTOR 7. Securely connect the fuel hose connector to the outboard motor (refer to page 24 ). 8. Prime the engine using the priming bulb (p. 25 ). Check for fuel leaks. Repair any fuel leaks if necessary. 9. Install and lock the engine cover. If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fuel tank. Clean the fuel tank and tank filter if necessary.
07/01/08 13:13:04 31ZV1630_054 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.
07/01/08 13:13:16 31ZV1630_055 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. Before replacing the propeller or the shear pin, remove the clip from the engine stop switch to prevent any possibility of the engine being started while you are working with the propeller.
07/01/08 13:13:24 31ZV1630_056 SERVICING YOUR OUTBOARD MOTOR Installation COTTER PIN Spare shear pins and cotter pins are provided in the engine compartment (p. 38 ). 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 genuine Honda stainless steel cotter pin or equivalent cotter pin and bend the pin ends as shown.
07/01/08 13:13:38 31ZV1630_057 STORAGE STORAGE PREPARATION remaining in the water pump. WATER HOSE CONNECTOR 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.
07/01/08 13:13:48 31ZV1630_058 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. 54 ). 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. 81 ). 2.
07/01/08 13:13:57 31ZV1630_059 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 carburetors 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.
07/01/08 13:14:13 31ZV1630_060 STORAGE The Distributor’s Limited Warranty (p. 81 ) does not cover fuel system damage or engine performance problems resulting from neglected storage preparation. Draining the Fuel System 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. Loosen the drain screw to drain fuel from the carburetor.
07/01/08 13:14:27 31ZV1630_061 STORAGE Engine Oil STORAGE PRECAUTIONS 1. Change the engine oil (p. 42 ). Select a well-ventilated storage area. If possible, avoid storage areas with high humidity. 2. Remove the spark plug (p. 47 ), and remove the clip from the engine stop switch. 3. Pour a tablespoon (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. 48 ).
07/01/08 13:14:40 31ZV1630_062 STORAGE Cover the outboard motor to keep out dust. Do not use sheet plastic 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.
07/01/08 13:14:52 31ZV1630_063 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. 32 ). Remove the outboard motor from the boat and secure the outboard motor in either the vertical or horizontal position shown on p. 61 .
07/01/08 13:15:03 31ZV1630_064 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction 1. Check emergency stop switch clip. Clip not inserted in stop switch. Insert clip in stop switch. 2. Check control positions. Gearshift lever not in neutral position. Shift to neutral (p. 26 ). Choke OFF. Pull choke knob to ON position, unless engine is warm (p. 26 ). Throttle grip not in START position. Turn throttle grip to START position (p. 26 ).
07/01/08 13:15:20 31ZV1630_065 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. 64 Possible Cause Correction Out of fuel. Refuel (p. 48 ). Fuel vent closed (portable fuel tank). Open fuel tank vent (p. 24 ). Fuel hose not primed. Squeeze priming bulb (p. 25 ). Fuel filter or fuel tank filter restricted. Replace restricted filters (p.
07/01/08 13:15:35 31ZV1630_066 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. 26 ). Throttle grip not in START position. Turn throttle grip to START (p. 26 ). Fuel vent closed (portable fuel tank). Open fuel tank vent (p. 24 ). Fuel hose not primed. Squeeze priming bulb (p. 25 ). Fuel filter or fuel tank filter restricted.
07/01/08 13:15:51 31ZV1630_067 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. 47 ). 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.
07/01/08 13:15:57 31ZV1630_068 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. 54 ). 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.
07/01/08 13:16:09 31ZV1630_069 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.
07/01/08 13:16:19 31ZV1630_070 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 dealer 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. 59 . 3.
07/01/08 13:16:28 31ZV1630_071 TAKING CARE OF UNEXPECTED PROBLEMS 7. Attempt to start the engine. When cranking the engine with an open ignition circuit (spark plug removed f rom the ignition circuit), remove the clip f rom the engine stop switch to prevent possible damage to the ignition system. If the engine fails to start, remove the spark plug, clean and dry it, then reinstall the spark plug and attempt to start the engine again. 5.
07/01/08 13:16:40 31ZV1630_072 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. 79 ). PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER The product identification number is stamped on the swivel case.
07/01/08 13:16:46 31ZV1630_073 TECHNICAL AND CONSUMER INFORMATION Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. High altitude performance can be improved by specific modifications to the carburetor.
07/01/08 13:16:56 31ZV1630_074 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.
07/01/08 13:17:07 31ZV1630_075 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.
07/01/08 13:17:21 31ZV1630_076 TECHNICAL AND CONSUMER INFORMATION Star Label The Star Label means Cleaner Marine Engine A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board. This engine has been certified as a: The Symbol for Cleaner Marine Engines: Cleaner Air and Water - for healthier lifestyle and environment.
07/01/08 13:17:33 31ZV1630_077 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.
07/01/08 13:18:11 31ZV1630_078 TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description Code Type Overall length Overall width Overall height Transom height 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 SA LA 20.7 in (525 mm) 13.8 in (350 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.
07/01/08 13:18:24 31ZV1630_079 TECHNICAL AND CONSUMER INFORMATION CONSUMER INFORMATION Customer Service Information Honda Publications Contacting Honda These publications will give you additional information for maintaining and repairing your outboard motor. 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.
07/01/08 13:18:37 31ZV1630_080 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 Warranty Pleas
07/01/08 13:18:43 31ZV1630_081 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.
07/01/08 13:18:57 31ZV1630_082 TECHNICAL AND CONSUMER INFORMATION Distributor’s Limited Warranty This warranty is limited to Honda Outboard Motors distributed by American Honda Motor Co., Inc., Power Equipment Division, 4900 Marconi Drive, Alpharetta, Georgia 30005-8847.
07/01/08 13:19:11 31ZV1630_083 TECHNICAL AND CONSUMER INFORMATION If you are unable to obtain warranty service, or are dissatisfied with the warranty service you receive, take the following steps: First, contact the owner of the dealership involved; normally this should resolve the problem. However, if you should require further assistance, write or call the Honda Marine Customer Relations. Please see Contacting Honda page 79 .
07/01/08 13:19:23 31ZV1630_084 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.
07/01/08 13:19:30 31ZV1630_085 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.
07/01/08 13:19:40 31ZV1630_086 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. YOUR WARRANTY RIGHTS AND OBLIGATION California The California Air Resources Board and American Honda Motor Co., Inc.
07/01/08 13:19:46 31ZV1630_087 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.
07/01/08 13:19:54 31ZV1630_088 TECHNICAL AND CONSUMER INFORMATION 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. to sell and service that Honda marine product during his normal business hours.
07/01/08 13:20:04 31ZV1630_089 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
07/01/08 13:20:13 31ZV1630_090 WIRING DIAGRAM 89
07/01/08 13:20:17 31ZV1630_091 INDEX Anode ............................................................................. 17 Replacement ............................................................... 53 ARE YOU READY TO GET UNDER WAY?............. 21 ATTACHMENT ............................................................ 20 BEFORE OPERATION................................................. 21 BREAK-IN PROCEDURE ............................................
07/01/08 13:20:21 31ZV1630_092 INDEX Gear Case Oil Change ........................................................................ 44 Level Check................................................................ 43 GEARSHIFTING AND THROTTLE OPERATION ... 31 Gearshift Lever............................................................... 13 HARD STARTING OR STALLS AFTER STARTING ................................................................ 65 Honda Publications ...............................................
07/01/08 13:20:26 31ZV1630_093 INDEX SAFE OPERATING PRECAUTIONS ......................... 23 SAFETY LABEL LOCATIONS ..................................... 8 Serial Number Locations................................................ 71 SERVICING YOUR OUTBOARD MOTOR ............... 36 SHALLOW WATER OPERATION ............................. 34 Spark Plug Service ......................................................... 47 Specifications .................................................................
31ZV1639 00X31-ZV1-6390 N BF5AK0 2eY1400.2007.
