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Table Of Contents

PREFACE

CONTENTS

This guide contains set-up and installation

instructions for Honda outboards.

Pre-delivery service must be performed by an

authorized Honda Marine Dealer, OEM or Package

Dealer. These instructions are provided for dealer

use only.

FOLLOW THESE INSTRUCTIONS CAREFULLY

Proper set-up, installation, and pre-delivery service

are esential for safe, reliable operation. Your

customer expects their Honda outbaord motor to be

correctly set-up, installed, adjusted, and ready for

use.

you read this guide, you will find information that

is preceded by a

-1

symbol. The purpose of

this message is to prevent damage to the outboard,

other property, or the environment.

NOT OVERPOWER THE BOAT

Do not install an outboard motor that exceeds the

recommended maximum horsepower for the boat.

refer to the certification plate for the boat's

maximum recommended horsepower. For most

boat applications, the outboard motor should have

a horsepower which provides

80%

of the maximum

recommended horsepower for the boat. If the

certification plate information is not available,

contact the boat manufacturer.

All

information contained in this manual is based on

the latest product information available at the time

of printing. We reserve the right to make changes at

anytime without prior notice.

part of this publication may be reproduced,

stored in a retrieval system, or transmitted, in any

form, by any means, electronic, mechanical,

photocopying, recording, or otherwise, without prior

written permission of the publisher; this includes

text, figures, and tables.

COMMON MODEL INFORMATION

BF8DIBF9.9D

BFI 5DIBF20D

BF25AIB F30A

BF40AIBF50A

BF75AIB F90A

BF115AIBF130A

BFZOOAIBF225A

GAUGES

CONTROL BOXES AND TEMPLATES

PROPELLER APPLICATION CHARTS

INDEX

Date

Issue: June 2003

2001-2003 American Honda Motor

Co.,

Inc.

Summary of content (258 pages)

PAGE 1
CONTENTS PREFACE This guide contains set-up and installation instructions for Honda outboards. Pre-delivery service must be performed by an authorized Honda Marine Dealer, OEM or Package Dealer. These instructions are provided for dealer use only. FOLLOW THESE INSTRUCTIONS CAREFULLY Proper set-up, installation, and pre-delivery service are esential for safe, reliable operation. Your customer expects their Honda outbaord motor to be correctly set-up, installed, adjusted, and ready for use.
PAGE 2
IMPORTANCE OF PROPER SET-UP AND PRE-DELIVERY SERVICE For Your Customer’s Safety Proper set-up or pre-delivery service are essential to the customer’s safety and the reliability of the tiller. Any error or oversight made during assembly and servicing of a tiller can result in faulty operation, damage to the tiller or injury to others. For Your Safety Some of the most important general safety precautions are given below.
PAGE 3
1, COMMON MODEL INFORMATION CONVERSION TABLES AND TORQUE VALUES LENGTH CONVERSIONS To Unit From Unit I Centimeters Kilometers From Unit Kilograms Grams Feet .0833 Feet Inches .00328 .394 Meters Feet .0254 5,280 .0328 Miles Yards 1,760 Meters Feet .01 3281 Kilometers Kilometers 1.609 .001 Meters 1000 Meters Miles Miles .621 Millimeters Centimeters 100 I .0006214 1000 3.281 39.371 I To Unit 1 Unit Multiply By1From Unit Multiply By Grams Pounds Ounces IKilograms 453.
PAGE 4
1. COMMON MODEL INFORMATION I TO Unit I km/h From Unit Multiply By]From Unit I 3.6 To Unit Multiply By m/s WS 0.277 I mi/hr I 1.837 I m/s Feet per sec 0.3048 km/h mi/hr (WS) 1.09728 Miles per hr 0.682 (mi/hr) kn 0.592 I m/s Knots (kn) I 1.852 WS 1.688 I ft/S I kn 1.609 1.466 0.869 1.1511I I I km/h I I m/s 0.540 0.447 0.5441 km/h 1 mi/hr kn 0.911 0.621 BATTERY AMPERAGE From Unit To Unit Multiply By From Unit CCA (Cold MCA (Marine Cranking Amps) Cranking Amps) 1.
PAGE 5
1. COMMON MODEL INFORMATION MEASURING HARDWARE AND COMPONENTS INCHES 1 0 0 10 20 2 - 30 50 40 4 3 60 70 80 90 5 6 100 110 120 130 140 150 MILLIMETERS 5/8 in 9/16 in 7/16 in 112 in 3l8 in 5/16 in 114 in 00 0000 00 5mm 6mm 0000 8mm 10mm 12mm 14mm LENGTH L 4 - DIAMETER 16 mrn INSIDE DIAMETER WASHERS ARE BY INSIDE DIAMETER Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 6
1. COMMON MODEL INFORMATION MOTOR SELECTION ANTI-V ENTI LATlON PLATE HEIG HT I Secure and correct outboard motor set-up is essential for safe boating and good performance. Follow the installation instructions provided in this guide. I NOTICE I Do not use an air impact tool to tighten or loosen the transom bolts. Using an air impact tool to tighten or loosen the transom bolts can generate enough heat to damage the bolt threads.
PAGE 7
1. COMMON MODEL INFORMATION DUAL OUTBOARD INSTALLATION TRANSOM CENTER LINE BF200AI225A, BF115A/130A, BF75AI90A Measure across the transom to determine the transom center line and draw a vertical line. On a “ V bottom boat, the vertical line should pass through the keel. Use a pencil and tape measure to locate center line.
PAGE 8
1. COMMON MODEL INFORMATION SINGLE OUTBOARD I-I 1-1 BOAT TRANSOM HEIGHT ! Measure from the top of the transom to the bottom of the boat, not including the keel. DUAL OUTBOARDS t I 3. Measure the distance between the two marks and place a third mark halfway between them. The line connecting the third mark with the keel is the center line. 330mm 330mrn 4. If dual outboards are to be installed, mark transom at a minimum of 330 mm (13 in) [305mm (12 in) for BF40NBF50AI from center line.
PAGE 9
1. COMMON MODEL INFORMATION outboard is the vertical distance from the horizontal contact surface of the transom bracket to the antiventilation plate. If the outboard installation height cannot be achieved, adjust boat transom height. TRANSOM HEIGHT ADJUSTMENT If the transom is too low or too high, or needs to be modified to accommodate the width of the outboard motor(s), contact the boat manufacturer and follow their recommendations for corrective action.
PAGE 10
1. COMMON MODEL INFORMATION TIE BAR INSTALLATION (DUAL MOTORS WITH CABLE STEERING) For BF200NBF225A see DUAL MOTOR INSTALLATION on page 8-11. 1. As described in the applicable model-family chapter, set up steering cable and steering link arm. STEERING WASHER (2) IOX 1.25 mm (2) \' . 2. Install a steering plate on each motor. TORQUE: 34 N*m (25 ft-lb) DESCRIPTION PART NO.
PAGE 11
1. COMMON MODEL INFORMATION h I - 3/8-24 UNF ADJUSTMENT RANGE 4 470-749 rnrn (18.5-29.5 in) I I STEERING PLATES ON ONT OF ENGIN / 3/8-24 UNF HEX HEAD BOLT JAM NUT BUSHING H E A ~ GOES UNDER STEERING PLATE 318 ID FLAT WASHER THREADS MUST BE VISIBLE THROUGH INSPECTION HOLES 4. Be sure that the threaded rods are bottomed out in the rod ends before tightening the jam nuts against the rod ends. 5.
PAGE 12
1. COMMON MODEL INFORMATION HYDRAULIC STEERING RECOMMENDATIONS The following installation instructions (page 1-27 through 1-39) have been reprinted with the permission of Teleflex, Inc. Please contact your local Teleflex distributor with any questions you June have regarding Teleflex hydrauIic steering systems. 1126 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 13
1. COMMON MODEL INFORMATION Teleflex Seastar@ Steering Cylinder Installation I SEASTAR PRO I Horse Power Limitations Single Cylinder, Single Engine Counter Rotating, Splashwell Mount. . . . . . . . . . . 225 HP Counter Rotating, Side/Front Mount. . . . . . . . . . . 300 HP Single Cyllnder, Twln Englne Non Counter Rotating, Side/Splashwell Mount. . . 300 HP Non Counter Rotating, Front Mount . . . . . . . . . . 450 HP Counter Rotating, Splashwell Mount. ..........
PAGE 14
1. COMMON MODEL INFORMATION SINGLE ENGINE 1 *Refer to page 1-39 for torque specifications. I I ENGINE MANUFACTURER YEAR I ' 1992 TO DATE 1996 TO DATE 1998 TO DATE 2001 TO DATE I MODEL CYLINDER NOTE 30-50 HP 75-90 HP 115-1 30 HP 200-225HP HC5345 Requires Spacer Kit H05090 HC5345 (See Fig. A l ) HC5347 (See next page for installation.) HC5345 I I Fully lllling Ihe cn~inemay c a w the steerinn cvlinder to inlerfsre wllh the h s o m and/orsplashkil.
PAGE 15
1. COMMON MODEL INFORMATION For HC5347 Cylinder Installation ONLY I I *Refer to page 1-39 for torque specifications. ENGINE MANUFACTURER YEAR MODEL CYLINDER NOTE 1998 TO DATE 115-130 HP HC5347 (See page 1-35 for twin engine ~~~ applications.) Figure 12 Fully tilting the engine may cause the steering cylinder to Interfere with the transom and/or splashwell. Possible damage to the steerfng system can result. Ensure that the cylinder is tree from interference at all timer.
PAGE 16
1. COMMON MODEL INFORMATION New Tie Bar Installation TWIN ENGINES Installat ion Instructions: New Style Tie Bar following formulas below: The CD dimension must include allowance for engine toe in/out as required, or recommended by the engine manufacturer. Failing to observe toe in/out recommendations may result in harder than normal steering effort. threaded rod must always fully cover inspection hole 1 of the rod end, but never inspection hole 2.
PAGE 17
1. COMMON MODEL INFORMATION TWIN ENGINES H06001-Single Cylinder Tiebar Kit *Refer to Daae 1-39 for toraue sDecifications.
PAGE 18
1. COMMON MODEL INFORMATION I TWIN ENGINES I H06002-Dual Cylinder Tiebar Kit *Refer to page 1-39 for torque specifications. I MODEL MANUFACTURER I 2001 TO DATE I 200-225 HP I HC5345 I H06001 I H06002 I NOTE I See Fig.
PAGE 19
1. COMMON MODEL INFORMATION Old Tie Bar Installation TWIN ENGINES I Insta IIation Instructions: Old Style Tie Bar Cut the tie bar and tie bar tube to length using the following formula. X = CD - 1"(25mm) Y = CD - 4" (10lmm) observe toe in/out recommendations may result in harder than normal steering effort. At the time of Installation and any other time thereafter, the threaded rod must always fully cover lnspectlon hole 1,but never inspection hole 2.
PAGE 20
1. COMMON MODEL INFORMATION I 1 TWIN ENGINES *Refer to page 1-39 for torque specifications. ENGINE MANUFACTURER I I YEAR I MODEL SINGLE CYLINDER 1 ENGNEADAPTERP TES TWIN CEW tie-rod w/o lie rod NOT REQ. H05044A 8 H05009 H05044A I I INOTES I Figure 25 2002 to Date 130HP applications, Cylinder The top cornen of H in- mure betweenbelbow or lea Fully tilting of Independenttilung of the englnelenglnsr may cause the steering cylinder to Inlorfen with the Innsonand/or splarhwsll.
PAGE 21
1. COMMON MODEL INFORMATION For HC5347 Cylinder Installation ONLY *Refer to page 1-39 for torque specifications. MANUFACTURER I ITEM ENGINE ADAPTER PLATES WIN TWIN dw tie-rod w/o tie md YEAR MODEL CYLINDER SINGLE 1998 TO DATE 115-130 HP HC5347 NOT REQ. NOTES - PART# 51 688725 *52 113529 53 113622 54 823673 '55 752930 '56 726825 57 722721 QTY DESCRIPTION 2 2 4 4 4 2 1 Extension Plate Nut3lVNFNylokO Washer 318'dia. Locking Tab Washer Screw M10 x 1.
PAGE 22
1. COMMON MODEL INFORMATION Trolling Motor Tie Bar Installation TWIN ENGINES I H0601O-Single Cylinder Trolling Motor Tiebar Kit *Refer to page 1-39 for torque specifications.
PAGE 23
1. COMMON MODEL INFORMATION Triple Engine Installation I TRIPLEENGINES I H05090 Spacer Kit For Use with Teleflex Hydraulic Steering Cylinder HC5345 & HC5358 *Refer to page 1-39 for torque specifications. 1998 to DATE I 25-50 HP I Fig.
PAGE 24
1. COMMON MODEL INFORMATION I ENGINE MANUFACTURER YEAR MODEL 1992 TO DATE 1996 TO DATE 1998 TO DATE 2001 TO DATE 30-50 HP 75-90 HP 115-1 30 HP 200-225HP CYLINDER TRIPLE ENGINES ENGINE TIE BAR KITS STARBOARD ENG. PORT CYL. TO DRIVE CYL. TO DRWE CYL. ~~~~ 1138 HC5345 H06001 ~ ~ 5 3 4 5 ~06001 HC5347 HC5345 H06001 H06002 ~06002 I NOTE See Fig. 40 Min. Engine Centers-29’ H06002 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 25
1. COMMON MODEL INFORMATION Torque Specifications TECHNICAL INFORMATI0N Bolt Torque Specifications . Values are stated in: inllbs (Nm) These are the recommended maximum torclue values for reusable drv bolts. Bolts should be torqued to this value.+O% -20%.For lubricatedbolts, multiply the dry bolt torque values by .75. Bollske Boll Slm 1116ss 2-56 2-64 2.5 (282) 3.0 1.338) 3.9 (440) 4.4 (497) 5.2 ( 9 7 ) 3-48 3-56 4-40 Brass 2.0 (226) 2.5 1.2821 3 2 (361) 3.6 (.407) 4.3 1.
PAGE 26
1. COMMON MODEL INFORMATION METER WIRE CONNECTIONS Connect wire harnesses properly, as shown in the meter wiring diagram. 1Use Meter Wire Harness A and B for instruments ONLY Do not splice or otherwise add any other electrical appliance to the meter harness. Connect leads and terminals securely. Make sure terminals are waterproof. Use 19-gauge (1.25 mm dia.) wire. Connect the wire harnesses securely.
PAGE 27
1. COMMON MODEL INFORMATION WATER SEPARATORS One of the most effective means of saving a carburetor, or fuel injection system, is installing a water separator. Honda recommends the installation of water separators in situations where condensation or water contamination can be a problem. Given the environment in which boats operate, condensation and water contamination are givens. Racor water separators are available from Honda in three sizes to cover fuel flow from 30 to 60 gph.
PAGE 28
1. COMMON MODEL INFORMATION Keep boat bottom clean of shells, algae growth and dirt. Accumulation causes a significant drop in top speed. Propeller Selection Precautions Propeller Test Reports are available on the iN by clicking on Information Library\Service\PropTests. The outboard motor must be installed vertically in relation to boat bottom. Set moderate trim angle, and adjust power trim angle to lowest setting. Set trim tab so boat will run in a straight line.
PAGE 29
1. COMMON MODEL INFORMATION COTTER PIN 4. Tighten the propeller nut and secure with the cotter pin. If the cotter pin does not align with the hole in the propeller shaft, adjust by turning the nut in the tightening direction. Do not exceed the maximum torque. Refer to the appropriate Honda Marine Shop Manual for torque specifications. After installation, bend the cotter pin ends as shown to secure the propeller nut.
PAGE 30
1. COMMON MODEL INFORMATION TRIM TAB ADJUSTMENT Dual Motors STANDARD ROTATION BFZOONBF225A shown. After engine break-in, run boat at full speed and check to see if boat pulls to the left or right, or an uneven effort is required to turn left or right. Adjust trim tab as required to ensure good, straight running characteristics. BF2OOAl225A shown. L I \ 10 x 32 mm TRIM TAB LOCK BOLT If boat pulls to the left: Loosen trim tab lock bolt and move trim tab trailing edge to the left. 1.
PAGE 31
1. COMMON MODEL INFORMATION RADIO MOUNTlNGlUSAGE BREAK-IN PROCEDURE Observe the following when installing a VHF radio unit: Keep the antenna and radio at least 50 cm (1.6 ft) or more away from the outboard engine, main wire harness, indicator wire harness, switch panel, indicator panel or remote control. Avoid routing the antenna wire too long a distance. The antenna wire should not be routed along the panel wire harness.
PAGE 32
1. COMMON MODEL INFORMATION OPERATIONS CHECK LIST Check all items on the following list. Refer to the applicable Honda Marine Owner‘s Manual or Shop Manual for specifications and detailed procedures. Test every unit to be sure it is functioning properly. ON LAND 0 After completing this check list, complete the Honda Marine Outboard Delivery Check List r M 0 2 3 (see page 1-48)]. Provide the yellow copy to your customer, retain the white copy for your sales file, and submit the pink copy to Honda Marine.
PAGE 33
1. COMMON MODEL INFORMATION ~ ALL NUTS, BOLTS, & OTHER FASTENERS 0 Check security and tighten if necessary. IN THE WATER OUTBOARD MOTOR INSTALLATION 0 Check that there are no water leaks from the motor mounting bolt holes. 0 Check boat for balanced weight distribution. 0 With the outboard perpendicular to the water, check that exhaust ports are a minimum of 125 mm (5 in) above the water. OUTBOARD MOTOR OPERATION 0 Check the chokeheutral switch for proper operation.
PAGE 34
1. COMMON MODEL INFORMATION TERMINAL SERVICE KIT A REFERENCE GUIDE CONNECTORS WITH A SECONDARY LOCK Male Terminal Half n SPECIAL CONNECTORS out of the connector with needle-nose PIN TOOL F w-1 here, and push the lock out. I Hold pin tool firmly by the handle with the pin tool in the down position. Hold connector housing with attachment tab on the top facing toward you. Place the tip of the pin tool toward the front of the release tab on the top of the terminal top.
PAGE 35
1. COMMON MODEL INFORMATION INSTALLING THE NEW TERMINAL Carefully match the old terminal with the new one from the Terminal Service Kit. Choose the correct replacement terminal based on the wire size range the terminal will accommodate. If the replacement terminal quantities are low, reorder by using the terminal part number listed on the inside lid of the Terminal Service Kit.
PAGE 36
1. COMMON MODEL INFORMATION Wire should be visible here Wire crimping on the insulation, not wire 1 Loose strands of wire NO GOOD Wire crimp not crimped evenly GOOD Crimped edges should be even NO GOOD Poor crimping, one side sticks out more Inspect the quality of the wire crimp. If it has any of the following problems, cut it off and start over. Insert the terminal into the connector. Make sure the wire seals are pushed all the way into the connector.
PAGE 37
1.
PAGE 38
1. COMMON MODEL INFORMATION _ _ _ _ ~ WIRE HARNESS FUNCTION/COLOR GUIDE Honda BF8D/9.
PAGE 39
1. COMMON MODEL INFORMATION TILLER LAYOUT REMOTE LAYOUT BF8D/BF9.9D THROUGH BF75NBF90A ALL MODELS Date of Issue: June 2003 0 2001-2003 American Honda Motor Co.,Inc.
PAGE 40
2 . BF8DIBF9.9D SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 INSTALLATI0N HEIGHT RECOMMENDATI0NS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 TRANSOM DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 STEERING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 41
2. BF8DIBF9.9D Model BF8D, BFP8D BF9.9D, BFP9.9D Water cooled 4-strokeI O.H.C., vertical twin 222 cm3 (13.5 cu. in.) 58 x 42 mm (2.3 x 1.7 in) 5.9 kW (8.0 PS)at 4,500-5,000rpm 7.3 kW (9.9 PS) at 5,000-6,000 rpm 12.5 N-m (1.27 kg-m, 9.18 Ib-ft) 13.1 N-m (1.34 kg-m, 9.67 Ib-ft) at 4,000 rpm at 4,500 rpm :iacement Bore x stroke Rated horsepower Maximum torque I Compression ratio 1 377 g (13.3 oz.) / kWh 394 g (13.9 02.
PAGE 42
2. BF8DIBF9.9D Shaft Length Outboard Transom Height S ~ Y P 433 ~ mm (17.0 in) L type 563 mm (22.2 in) XL type 703 mm (27.7 in) Workable Boat Transom Height 383 433 mm (15.1 17.0 in) 513 563 mm (20.2 22.2 in) 653 703 mm (25.7 27.7 in) - - Description Part No. Transom Mount Drill Fixture 07MPZ-ZV301OC The BF8D and BF9.9D outboards motors are designed to be installed on a boat transom with the following transom board thickness: I Boat Transom Board Thickness I 35 - 57 mm (1.3 - 2.
PAGE 43
2. BF8DIBF9.9D TRANSOM DRILL FIXTURE Small Bracket (Types SH, SHS, LH, LHS) 192 mm (7.6 in) r- I 2P (3.7in) / b B Use the upper and lower “B” holes. TRANSOM DRILL FIXTURE I 1. Mark four center marks for the bolt holes on the transom board (two marks on either side of the outboard motor installation lines). The upper bolt holes should be more than 33 mm (1.3 in) from the top of the transom. The lower bolt holes should allow the mounting bolts to contact the upper end of the stern bracket.
PAGE 44
2. BF8DIBF9.9D STEERING CONNECTIONS Do this before final placement of the motor on the transom. Refer to the steering cable manufacturer’s manual for cable handling procedures. PLATE CAP (2) ,(When steering cable is not used.) NU STEERING LINK ROD (marine grease) Tilt-Tube Type STEERING CABLE CAP (2) TILT 1. Remove the left and right caps from the tilt shaft. 218 46i (marine grease) \ / CAP i U T SEALED CAP 2.
PAGE 45
2. BF8DIBF9.9D 3/8-24 UNF SELFLOCKING NUT (2) 118 N-rn (1.8kgf-rn, 13 Ib-ft) I STEERING PLATE SELF-LOCKING NUT (see step 7 below) / 3/8-24 UNF BOLT 4. Install the steering link rod between the steering plate on the motor side and .,,e cable end using the bolt, washers, nuts, and collar as shown. 5. Connect the steering link rod to the inside hole of the steering plate. Do not mount anything in the outer hole of the steering plate. 6.
PAGE 46
2. BF8DIBF9.9D BOLTING MOTOR TO TRANSOM 10 mm SELF-LOCKING NUT (4) I / n WASHER 18) \ \ BOAT Apply marine hull sealant to the mounting holes and hardware. Use Hondabond equivalent silicone sealant for below waterline use. With the motor in place against the transom, verify correct motor height. Motor can be raised by using a lower set of mounting holes. Attach the motor with marine grade hardware. Use washers under all bolts and nuts. Use additional fender washers against the transom.
PAGE 47
2. BF8DIBF9.9D REMOTE CABLE INSTALLATION First, install the remote control box and cables. Remote Control Cables LOCK PLATE (2) . GRO~MET 1. Remove the four (4) screws on each lower case cover and loosen the top-rear screw. 1. Remove the grommet and the control cable plate. 2. Place the grommet over the cables, even with the locking grooves. The shift cable must be on the bottom 2. Pull the covers out from the engine about 20 mm (0.78 in) and allow them to droop. 3.
PAGE 48
2. BF8DIBF9.9D CONTROL SHIFT CONTR 4. Shift the outboard into forward gear by moving the shift link arm forward while turning the propeller. 5. Coat the pivots with marine grease. 6. Set the remote control lever full forward and adjust the shift pivot to be a slip fit in the shift link arm. Slide the lock plate down to secure the pivot. 7.
PAGE 49
2. BF8DIBF9.9D Wire Harness 1. Place the white tie-wrap on the harness near the grommet, and connect the white and the blue harness connectors to their respective plugs on the engine. 2. Slide the connectors onto their tabs on the CDI bracket. Be sure they click into position. 3. With the white tie-wrap inside the grommet, slide the harness into the grommet and into the plastic support. Close the support around the harness. Date of issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 50
2. BF8DIBF9.9D AVAILABLE ACCESSORIES Consult the Honda Marine Accessories Catalog (M0045) for current information on gauges, instrument harnesses, wiring harnesses, switch panels, and control boxes. FUEL SYSTEM CONNECTIONS TUBE CLIP BAND 12 mm (4) MOTOR SIDE FUEL CONNECTOR A 7 TUBE CLIP BAND 20 mm (2) PRIMER BULB FUEL HOSE (LONG) OUTLET VALVE INLET VALVE FUEL TANK FUEL TANK CONNECTOR FUEL TANK FILTER 2 44 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 51
3 . BF15DIBF20D SPECIFICAT1ONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ................................ 3-6 TRANSOM DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 STEERING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 BOLTING MOTOR TO TRANSOM . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 52
3. BF15DIBF20D S PECIFICAT1ONS ENGINE I I I I I BF15D, BFPl5D I BFZOD, BFPZOD Water cooled 4-stroke, overhead valve, vertical twin 350 cm3 (21.5 cu. in.) 59 x 64 mm (2.3 x 2.5 in) 14.7 kW (20 PS) at 5,500 rpm 11 kW (15 PS) at 5,000 rpm 25.2 N-m (2.6 kg-m, 18.8 Ib-ft) 25.8 N-m (2.6 kg-m, 18.8 Ib-ft) at 3,500 rpm at 5,000 rpm I I I I JCompressionratio Fuel consumption Cooling system Ignition system Ignition timing Spark plug Carburetor I 9.
PAGE 53
3. BFlSDIBF20D INSTALLATION HEIGHT RECOMMENDATlONS Shaft Length Outboard Transom Height TRANSOM DRILL FIXTURE Workable Boat Transom Height B 0 TRANSOM DRILLING I Use the upper and lower “B” holes. See also “USING THE TRANSOM MOUNT DRILL FIXTURE” on page 1-23. I I I Description I PartNo. I 07MPZ-ZV3010C I Transom Mount Drill Fixture The BF15D and BF20D outboards motors are designed to be installed on a boat transom with the following transom board thickness: I - 2.
PAGE 54
3. BFlSDIBF20D Small Bracket (Types SHYLH, LHS, XH) 192 mm (7.6 in) r \ 1. Do not use the transom drill fixture for these brackets. 7 ! I i i i i i Power Tilt Bracket (Types SHT, LHT, SRT, LRT, XHT, XRT) 95 mm (3.7 in) 244 mm (9.6 in) l----. 1 8.2 mm (00.3 in) TRANSOM DRILL FIXTURE @B B@ Use the upper “A” holes. 1. Drill two holes with a “Q”drill bit. Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc. 252 mm 19.9 in) 2.
PAGE 55
3. BF15DIBF20D STEERING CONNECTIONS Do this before final placement of the motor on the transom. Refer to the steering cable manufacturer’s manual for cable handling procedures. CAP (2) (When steering cable STEERING CABLE NUT 3.8-24 UNF BOLT RING LINK ROD STEERING CABLE (marine grease) Tilt Tube Type CAP (2) STEERING CABLE I -6a (marine - TILT SHAFT / STEER IN^ CABLE NUT 1. Remove the left and right caps from the tilt tube. CAP ASSEMBLY (marine grease) 2.
PAGE 56
3. BF15DIBF20D INN LOCKING NUT (2) 118 N-rn (1.8 kgf-rn, 13 Ib-fl) STEERING PLATE I NUT 4 (marine grea 310-24 UNF BOLT \\\nl STEERING LINK ROD (marine grease) SELF-LOCKING NUT (see step 7 below) 4. Install the steering link rod between the steering plate on the motor side and the cable end using the bolt, washers, nuts, and collar as shown. 5. Connect the steering link rod to the inside hole of the steering plate. Do not mount anything in the outer hole of the steering plate. 6.
PAGE 57
3. BFlSDIBF20D BOLTING MOTOR TO TRANSOM 10 mm BOLT (4) I 10 mm FENDER WASHER (4) Apply marine hull sealant to the mounting holes and hardware. Use Hondabond HT equivalent silicone sealant for below waterline use. With the motor in place against the transom, verify correct motor height. Motor can be raised by using a lower set of mounting holes. Attach the motor with marine grade hardware. Use washers under all bolts and nuts. Use additional fender washers against the transom.
PAGE 58
3. BF15DIBF20D REMOTE CABLE INSTALLATION First, install the remote control box and cables. Remote Control Cables LOCK PLATE (2) CABLE PLATE 1. Remove the four (4) screws on each lower case cover and loosen the top-rear screw. 1. Remove the grommet and the control cable plate. 2. Place the grommet over the cables, even with the locking grooves. The shift cable must be on the bottom. 2. Pull the covers out from the engine about 20 mm (0.78 in) and allow them to droop. 3.
PAGE 59
3. BFISDIBFZOD 1 , LOaPLATE(2) CONTROL SHIFT C O N T R ~ LCABLE \ 4. Shift the outboard into forward gear by moving the shift link arm forward while turning the propeller. 5. Coat the pivots with marine grease. 6. Set the remote control lever full forward and adjust the shift pivot to be a slip fit in the shift link arm. Slide the lock plate down to secure the Divot. 7.
PAGE 60
3. BF15DIBF20D Wire Harness 1. Place the white tie-wrap on the harness near the grommet. 3. Slide the connectors onto their tabs on the CDI bracket. Be sure they click into position. 4. With the white tie-wrap inside the grommet, slide the harness into the grommet and secure it with the white tie-wrap support. 2. Connect the six-pin and the four-pin harness connectors to their respective plugs on the engine. Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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3. BF15DIBF20D AVAILABLE ACCESSORIES Consult the Honda Marine Accessories Catalog (M0045)for current information on gauges, instrument harnesses, wiring harnesses, switch panels, and control boxes. FUEL SYSTEM CONNECTIONS FUEL CONNECTOR A MOTOR SIDE * TUBE CLIP BAND 12.5 mm (4) --\ PRIMER BULB \ \ TUBE CLIP BAND 12.5 mm (4) I (SHORT) FUEL TANK FUEL TUBE 3-14 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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4 . BF25AIBF30A UNPACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 PARTS LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 INSTALLATI0N HEIGHT REC0MMENDAT I0NS . . . . . . . . . . . . . . . . . . . . . . . . . . .
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PAGE 64
4. BF25AIBF30A 7. Install a chain connedting link or equivalent, with a minimum l i capacity of 500 Ibs. (227 kg), to the engine hanger bracket. A slip hook should not be connected directly to the engine hanger bracket due to insufficient clearance between the engine hanger bracket and the recoil starter or flywheel wver. Use a hoist with a minimum lift capacity of 500 Ibs. (227 kg). Slowly lift the motor just enough so the foam pad can be removed and transferred to the gear case area.
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4. BF25NBF30A Model BF25A 4-stroke, O.H.C., 3-cylinder 499 cm3(30.5 cu. in.) 58 x 63 mm (2.3 x 2.5 in) 18.7 kW (25 PS) at 5,000-6,000 rpm I 22.4 kW (30 PS) at 5,700-6,200 rpm 36.3 N-m (3.7 kg-m, 26.8 Ib-ft) 35.2 N*m (3.59 kg-m, 26.0 Ib-ft) at 4,500 rpm at 4,000 rpm 9.2 : 1 239 g (8.4 oz.) / kWh 291 g (10.3 oz.) / kWh Forced water circulation by impeller pump with thermostat CDI S 2 6 " B.T.D.C. 5-32" B.T.D.C.
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4. BF25NBF30A PARTS LISTING I - I 88 8 DESCRIPTION PART NO. 31ZV7616 17500-ZV5-910 17700-ZW9-010 32161-404-000 91547-SF4-003 50331-ZV5-000 17853-ZV5-000 90302-ZV5-000 90514-ZV4-000 91560-ZV5-000 90105-ZV5-000 90307-ZV5-003 24618-ZV5-000 90504-921-010 90765-ZV5-000 90751-ZV5-000 90015-ZVO-000 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co.,Inc.
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4. BF25AIBF30A STEERING CONNECTIONS Do this before final placement of the motor on the transom. Refer to the steering cable manufacturer’s manual for cable handling procedures. -.- STEERING CABLE \ STEERING LINK P SELF-LOCKING NUT (4) STEERING LINK ARM Tilt-Tube Type - w CAP SEALED 4 STEERING CABLE STEERI~G~TILT TUBE STEERING CABLE NUT 1. Remove the left and right caps from the steeringhlt tube. 2.
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4. BF25NBF30A STEERING LINK ARM INSTALLATION STEERING SELF-LOCKING NUT (see step 3 below) (mari (marine grease) 1. Install bolt, washer, and collar into link arm. Lightly seat the spacer nut against the collar, then thread the bolt into the inside hole on the steering plate. Tighten bolt securely. Hold bolt and tighten self-locking nut. Do not use forward hole. TORQUE: 22 N*m (16 ft-lb) 3/8-24 UNF bolt: 18 N-m (13 ft-lb) 3/8-24 UNF lock nut: 2.
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PAGE 71
4. BF25NBF30A REMOTE CONTROL CABLE INSTALLATION THROTTLE CONTROL PIVOT SHAFT (2) 6 x 28 mm BOLT (2) SEPARATE COVER SHIFT CONTROL CABLE CABLE CLAMP PLATE HARNESS BAND B edgelside against HARNESS I I \ ’WIREBAND I 1. Connect the control cables to the outboard motor with the remote control lever in the neutral position and the choke/fast idle lever in the lowest (idle) position.
PAGE 72
4. BF25NBF30A SEPARATE TOP WASHER PIVOT SHAFT \ LOCK NUT / CONTROL CABLE (marine grease) 6. Thread the lock nuts all the way on the control cables. Thread the pivots shafts onto the control cables. Apply marine grease as shown. 7. Verify that the shift arm on the outboard motor is in the neutral position, or that the control lever at the remote control box is in the neutral position. / SHAFT OCK NUT WASHERS I DO NOT FORGET TO INSTALL.
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4. BF25AIBF30A CONTROL CABLE LENGTH ADJUSTMENT INDEX MARKS PIVOT ROLLER THROTTLE CONTROL CABLE 1. Put the remote control lever in the neutral position. 2. Disconnect the throttle control cable from the throttle arm. THROTTLE ARM I THROTTLE CAM CARBURETOR THROTTLE LEVER THROTTLE ROD 3. Move the throttle arm to the fully-open position until it touches the stopper, and verify that the carburetor throttle lever touches the stopper in the fully-open position. 4.
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PAGE 75
4. BF25NBF30A Top Mount Control/Key Switch Panel Connections 1. Disconnect the main engine harness from the key switch panel harness by unplugging the three Sumitom0 connectors. 2. Plug the mating connectors from the relay box harness into the connectors from the key switch panel harness. 3. Plug the mating connectors from the relay box harness into the connectors on the main engine harness.
PAGE 76
4. BF25NBF30A FUEL SYSTEM CONNECTIONS FUEL CONNECTOR A \ /--3 TUBE CLIP BAND 12.5 mm (4) I FUEL TANK FUEL TUBE 4118 FUEL CONNECTOR Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 77
5 . BF40AIBF50A UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 PARTS LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 INSTALLATI0N HEIGHT REC0MMENDAT I0NS . . . . . . . . . . . . . . . . . . . . . . . . . .
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5. BF40NBF50A 7. Install a chain conneCting link or equivalent, with a minimum lii capacity of 500 Ibs. (227 kg), to the engine hanger bracket. A slip hook should not be connected directly to the engine hanger bracket due to insufficient clearance between the engine hanger bracket and the recoil starter or flywheel cover. Use a hoist with a minimum lift capacity of 500 Ibs. (227 kg). Slowly l ithe motor just enough so the foam padcan be removed and transferredto the gear case area.
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5. BF40NBF50A S PE C IFICAT10 NS ENGINE Model TYPe Displacement Bore x stroke Rated horsepower BF40A I I I I I Oil capacity Recommended oil Starting system Battery system Stopping system Fuel used Fuel tank capacity Fuel pump Exhaust system 4-stro ke, 0.H.C., 3-cylinder 808 cm3 (49.4 cu. in.) 70 x 70 mm (2.8 x 2.8 in) 29.8 kW (40 PS) at 5,000-6,000 rpm I 37.3 kW (50 PS) at 5,500-6,000 rpm 60 N*m (6.05 kg-m, 43.8 Ib-ft) 65 N*m (6.5 kg-m, 47.1 Ib-ft) at 3,500 rDm at 4.500 rDm I 9.2 : 1 276 g (9.74 oz.
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5. BF40NBF50A PARTS LISTING e @ DESCRIPTION Stainless nylon lock nuts 17877-2\/5-000 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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5. BF40NBF50A INSTALLATION HEIGHT RECOMMENDATIONS Shaft Length I Outboard Transom Height TRANSOM DRILL FIXTURE Transom Height Boat @B TRANSOM DRILLING See also “USING THE TRANSOM MOUNT DRILL FIXTURE” on page 1-23. I I I Description Transom Mount Drill Fixture I Part~o. 07MPZ-ZV301OC The BF40A and BF5OA outboards motors are designed to be installed on a boat transom with the following transom board thickness: I Boat Transom Board Thickness 35 57 mm (1.3 2.
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5. BF40AIBFSOA STEERING CONNECTIONS Do this before final placement of the motor on the transom. Refer to the steering cable manufacturer’s manual for cable handling procedures. CAP (2) .. .--.-= 1. Remove the left and right caps from the steering/tilt tube. 2. Apply marine grease to the steering cable and install the steering cable through the steeringhlt tube. Do this before final placement of the motor on the transom. 3. Position the motor on the center line.
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5. BF40NBF50A STEERING LINK ARM INSTALLATION FORWARD 10 mm STAINLESS PLAIN WASHER (3) If the steering cable enters the tiltlsteering tube from the port side, use the forward hole. Otherwise, do not mount anything in the forward hole of the steering plate. This hole is usually used for dual motor installations. 1. Install the steering link arm into the inside hole of the steering plate using the bolt, washer, nuts and collar as shown.
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5. BF40NBF50A ~~~ Motor steering angle is equal when steering wheel is turned full right and full left. If the motor steering angles are not equal: - Major corrections can be made at the steering box (refer to the steering box or steering cable manufacturer’s instructions). - Minor corrections can be made by moving the steeringhilt tube laterally (refer to the BF40NBFSOA Shop Manual). Make the steering angles equal as necessary.
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5. BF40AIBF50A REMOTE CONTROL CABLE INSTALLATION PIVOT SHAFT (2) 6 x 28 mm SELFTAPPING BOLTS (2) SEPARATE TOP CONTROL BOX WIRE HARNESS CONTROL CABLE 6 m m STAINLESS HARNESS CLIP edgekide against 6 mm LOCK PI STAINLESS BOLT (2) 1. Connect the control cables to the outboard motor with the remote control lever in the neutral position and the chokelfast idle lever in the lowest (idle) position. 2. Pass the control box wire harness and control cables through the grommet as shown.
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5. BF40AIBFSOA 6. Apply marine grease to the pins of the pivot shaft. CONTROL BOX WIRE HARNESS \ PIVOT SHAFT WASHERS 6mmLOCKPIN (krg.b P ) 7. Connect the control cables to the shift arm and throttle arm using the 6 mm washers and lock pins as shown. Use the 6 mm washers on both sides of the arm as shown. Tighten the lock nuts securely. SHIFT CONTROL CABLE NOTE DIRECTION I HOLDER 9. Secure the main engine wire harness with the harness clip.
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5. BF40NBF50A CONTROL CABLE LENGTH ADJUSTMENT INDEX MARKS PIVOT ROLLER THROTTLE CONTROL CABLE 1. Put the remote control lever in the neutral position. 2. Disconnect the throttle control cable from the throttle arm. I THROTTLE CAM PEN PIVOT CARBURETOR THROTTLE \ LEVER THROTTLE ROD STOPPER 3. Move the throttle arm to the fully-open position until it touches the stopper, and verify that the carburetor throttle lever touches the stopper in the fully-open position. 4.
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5. BF40NBF50A DETENT ROLLER \A /- SHIFT LINK B 4. If not, loosen the lock nut and adjusting nut connecting shift rod A to shift rod B. 5. Disconnect shift rod A from shift rod B by backing off the adjusting nut. Back off the adjusting nut until it is approximately 3 mm above the top of shift rod B. 6. Turn the lock nut on shift rod B to obtain 0.3 inch (8 mm) between the lock nut and the top of shift rod B as shown. 7.
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5. BF40NBF50A TRIM METER CONNECTIONS IMPORTANT NOTE TO INSTALLER The following illlustrations show 2 versions of the Japan supplied Harness A (9100 and 9110) for trim meter connections. The U.S.A. sourced gauge sets use brand specific gauge harnesses and the connections are not shown. The wire colors and harness configurations are identical to Harness A P/N 32540-ZV5-9100 so the Voltage Conversion Module (VCM) connections are identical.
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5. BF40NBF50A TRIM METER OPERATION The trim control unit, located on the engine, and the throttle switch, located in the remote control, were removed to eliminate the intermittent overtrim buzzer sound on the BF40A3 BF50A3 (2003 models). This is outlined in the BF40A BFSOA Shop Manual Supplement P/N 61ZV3OOV. The 12 Vdc to 5 Vdc trim control unit voltage converter function was moved to the Honda 4 wire trim meter. One of these trim meters is shipped with each BF40A3 BF50A3 trimltilt model outboard.
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COMBINATION TABLE (most common) Side Mount Remote Control Parts n Ln .G = p 0: 0 , , 5. BF40NBF50A Description BF40A3 BF50A3 Part Number Voltage Conversion Module (VCM) Yes No 0 0 Date of issue: June 2003 0 2001-2003 American Honda Motor Co., inc.
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5. BF40NBF50A COMMON PROCEDURES Always make sure all bullet connector boots are properly seated. Four Wire Connector A four wire blue connector was used on all models prior to the BF40A3 BF50A3 and a four wire black connector is used on all BF40A3 BF50A3 models. Refer to page 5-20 for connector location. Combinations 1, la, 3b 1. Use a small piece of safety wire or terminal pin tool F to remove the rubber plug. +RUBBER PLUG Remove and discard. I I 2.
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5. BF40NBFSOA Combination 3b 1. Push the wire into the connector to relieve the tension on the primary lock. Q 2. Insert the tool on top of the terminal and lift the primary lock up, then pull the terminal out of the connector. -----__.- MINIATURE SCREWDRIVER, 1.19 mm 13/64”) wide tip (commercially available) Voltage Conversion Module (VCM) Combinations la, Za, 3a, 4a Position a 2-1/2 inch piece of the corrugated protector between the VCM and harness A. Position seam as shown.
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5. BF40NBF50A CONNECTIONS Components illustrated uninstalled for clarity purposes. Key Switch Panel Combination 1 1. See page 5-18 to prepare the four wire blue male connector to accept the 20 inch optional wire. 2. Connect the color coded wires and refer to the circuit diagram on the following page as needed. 5120 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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5. BF40NBF50A Combination 1 TRIM METER (4 wire) __-__-----_-__ KEY SWITCH PANEL ---------- WIRE CONNECTOR Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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5. BF40NBF50A Combination l a 1. See page 5-18 to prepare the four wire connector and how to secure the VCM. 2. Connect the color coded wires and refer to the circuit diagram on the following page as needed. 5-22 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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5. BF40AIBFSOA Combination l a TRIM METER (3 wire) ggF2 cis METER HARNESS (OW Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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5. BF4ONBF50A Side Mount Remote Control Combination 2 1. Remove the remote control fast idle lever and both rear covers. FAST IDLE ER C IW/ 2. Disconnectthe throttle position switch light greedblack wire. It is not necessary to remove the cable tie. The throttle position switch is no longer needed. 5-24 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 100
PAGE 101
5. BF40NBF50A 6. Connect the color coded wires and refer to the circuit diagram on the following page as needed. Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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5. BF40NBF50A Combination 2 TRIM METER (4 wire) g@E$j Lii$ 81- w BIpl- METER HARNESS (OP) I Date of Issue: June 2003 0 2001-2003 American Honda Motor Co.,Inc.
PAGE 103
PAGE 104
5. BF40NBF50A Combination 2a V COI k 1GE WON TRIM METER (3 wire) HARNESS Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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5. BF40NBF50A Combination 3 1. Run the 12 inch wire as outlined in combination 2. 2. Connect the color coded wires and refer to the circuit diagram on the following page as needed. 5130 Date of issue: June 2003 0 2001-2003 American Honda Motor Co., inc.
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5. BF40NBF50A Combination 3 TRIM METER (4 wire) S E l Q EkS => P9 PP9 -I 6688 98 ---------I REMOTE CONTROL BOX 1 I I I I I II L COLOR COMB :GROUND/MARKING I . 1 . . Date of Issue: June 2003 0 2001-2003 American Honda Motor Co.,Inc.
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5. BF40NBF50A Combination 3a 1. Run the 12 inch wire as outlined in combination 2 and see page 5-18 to secure module. 2. Connect the color coded wires and refer to the circuit diagram on the following page as needed. Connect the VCM greedblack power output wire to harness A light greedblack wire. 532 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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5. BF40NBF50A Combination 3a VOLTAGE CONVERSION MODULE r TRIM METER (3 wire) METER HARNESS (OP) Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 109
5. BF40NBFSOA 5134 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 110
5. BF40AIBFSOA Combination 3b TRIM METER (3 wire) WIRE CONNECTOR I - 7 j 1 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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5. BF40AIBFSOA ~~~ Combination 4 Connect the color coded wires and refer to the circuit diagram on the following page as needed. 5136 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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5. BF40NBF50A Combination 4 (complete wiring diagram page 5-42a) TRIM METER (4 wire) BI ---Do w BN I- METER HARNESS (OP) COLOR COMB :GROUND/MARKING Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 113
5. BF40NBF50A Combination #a 1. See page 5-18 to secure the module. 2. Connect the color coded wires and refer to the circuit diagram on the following page as needed. Connect the VCM greedblack power output wire to harness A light greedblack wire. 5-38 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 114
5. BF40NBF50A Combination 4a COLOR COMB :GROUNDiMARKING Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 115
5. BF40NBF50A Combination 46 Secure the VCM and connect the color coded wires and refer to the circuit diagram on the following page as needed. Depending on the application, it June be necessary to rotate the VCM 180" on main harness and position the VCM closer to remote control. Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 116
5. BF40NBF50A Combination 4b TRIM METER (3 wire) ' HARNESS 10A I I I --- REMOTE CONTROL BOX ------- COLOR COMB :GROUNDIMARKING BW Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 117
5. BF40NBF50A TOOLS AND MATERIALS Each item shown below June not be required for every combination. Terminal pin tool F is included in the Honda Marine Terminal Service Kit A P/N 07VPZ-001000A.
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5. BF40NBF50A AVAILABLE ACCESSORIES Consult the Honda Marine Accessories Catalog (M0045) for current information on gauges, instrument harnesses, wiring harnesses, switch panels, and control boxes. FUEL SYSTEM CONNECTIONS FUEL CONNECTOR A / MOTOR SIDE -TUBE BAND . - - - CLIP - -.. -. ...- 12.5 .-. - .mm ..... 16) ,. I PRIMER BULB \ \ I II / INLET VALVE TUBE CLIP BAND 12.
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6 . BF75AIBF9OA SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 PARTS LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 INSTALLATION HEIGHT RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSOM DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6. BF75NBF90A SPEC1FlCATlONS ENGINE Model TYPe Displacement Bore x stroke Rated horsepower I I I I Maximum torque Compression ratio Fuel consumption Cooling system Ignition svstem Ignition timing Spark plug Carburetor Lubricating system I I I Oil capacity Recommended oil Startina svstem Battery system Stopping system Fuel used Optional fuel tank caDacitv Fuel pump Exhaust system I I I I BF75A 4-stroke, 0.H.C., 4-cylinder 1,590 cm3 (97.0 cu. in.) 75 x 90 mm (3.0 x 3.5 in) 55.
PAGE 121
6. BF75NBF90A PARTS LISTING DESCRIPTION Use with REF. Use with REF. 91560-ZV5-000 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co.. Inc.
PAGE 122
6. BF75NBF90A INSTALLATION HEIGHT RECOMMENDATIONS Shaft Length Outboard Transom Height TRANSOM DRILL FIXTURE Workable Boat Transom Height @B TRA NS0M DRILLING Description Part No. Transom Mount Drill Fixture 07MPZ-ZV301OC Boat Transom Board Thickness 50 70 mm (2 2.75 in) - - D C Use the upper “C” and lower “D” holes.
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6. BF75NBF90A STEERING CONNECTIONS STEERING LINK ARM INSTALLATION Do this before final placement of the motor on the transom. Refer to the steering cable manufacturer’s manual for cable handling procedures. 1. Install bolt, washer, and collar into link arm. Thread bolt into steering arm inside hole. Tighten bolt then tighten lock nut. Do not use forward hole. TORQUE: 3/8-24 UNF bolt: 22 N*m (16 ft-lb) 3/8-24 UNF lock nut: 18 N-m (13 ft-lb) CTFFRINC A R M CAP \ BO UN STEERING LIN Y 1.
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6. BF75NBF90A ~ 5. Directly after completing the steering link arm and steering cable installation, verify the following: Motor turns the proper direction when the steering wheel is turned right and left. If the steering is reversed, correct at the steering box. Motor steering angle is equal when steering wheel is turned full right and full left.
PAGE 125
6. BF75NBF90A TILLER HANDLE ASSEMBLY INSTALLATION SCREW, 5 x 12 rnrn METER WIRE HARNESS A POWER TRlMRlLT MOTOR WIRE TRIM ANGLE SENSOR WIRE 1. Remove right side cap from tilt tube. FRICTION SHAFT FRICTION BLOCK FRICTION BOLT COTTER PIN 2. Apply marine grease to the friction shaft and install friction shaft into tilt tube. Apply marine grease to O-ring then install 0ring into friction block. Install friction block over friction shaft and onto tilt tube.
PAGE 126
PAGE 127
6. BF75NBF90A POWER TRlMlTlLT FOOT SWITCH When mounting a tiller handle type outboard, an optional power trimhilt foot switch can be installed. It will be necessary to perform wiring connections. Connect the terminals and terminal covers to the wire harness that comes from the power trim/tilt foot switch. Be sure to use water resistant terminal covers. If terminals are added, always use a wire crimper and securely stake terminals to wires.
PAGE 128
6. BF75NBF90A REMOTE CONTROL CABLE INSTALLATION AND ADJUSTMENT CONTROL CABLE Route and connect cables to the remote control before connecting them to the motor. PIVOT SHAFT THROTTLE SHIFT CABLE CONNECTOR 3 mm (0.12 in) minimum .(J 3. Thread pivot shaft onto threaded portion of the throttle and shift cable as shown. 4. Do not tighten lock nuts at this time. The lock nuts will be tightened after cables are connected. CABLE CLAMP PLATE \ '/ 'HARNESS GROMMET TIE-WRAP BAND 1.
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6. BF75NBF9OA THROTTLE CAM 6. Throttle cable connection: Apply marine grease to the throttle cable pivot shaft. Rotate the throttle cam until marks line up with roller. The “V” mark on the shift link bracket will be aligned with the “A” mark on the shift link. 8. Grease pivot shaft with marine grease. Fkl (marine grease) & ,PIVOT SHAFT LOCK NUT . 0 Adjust pivot shaft until it will easily attach to the throttle arm top hole. Install pivot shaft from the engine side.
PAGE 130
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6. BF75NBF90A AVAILABLE ACCESSORIES Consult the Honda Marine Accessories Catalog for current information on gauges, instrument harnesses, wiring harnesses, switch panels, and control boxes. FUEL SYSTEM CONNECTIONS FUEL CONNECTOR A MOTOR SIDE * TUBE CLIP BAND 12.5 mm (4) PRIMER BULB \ TUBE CLIP BAND AND12.5 12.5 mm (4) '\ 'i OUTLET VALVE FUEL TUBE (SHORT) FUEL TANK FUEL TUBE 6114 I I nNC\ Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
PAGE 132
7. BF115AIBF130A Rigging Reminders To ensure proper operation. you must install a PGM-FI panel indicator or a key switch panel with PGM-FI lights. See the Honda Marine Accessories Catalog (M0045). UNPACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 INSTALLATION HEIGHT RECOMMENDATIONS . . . .
PAGE 133
PAGE 134
7. BFI 1SAIBFI30A 5. Slide off the corrugated cardboard engine cover protector. 7. Remove the two nuts and remove the steel band from the outboard motor. STEEL BAND (mglnr cow protector) 6. Remove the plastic cover from the outboard motor. PLASnCCOVER / NUf (2) 8. Connect a hoist to the engine hanger. Carefully lif! the outboard motor with the lower crate frame attached. Use a suitable hoist with a capacity rating of 550 Ib (250 kg) or more.
PAGE 135
PAGE 136
7. BFI 1SAIBFI 30A S PEC IFICAT10 NS ENGINE Model BF115A TY Pe Displacement I Bore x stroke IRated horsepower IMaximum torque lcompression ratio Fuel consumption Cooling system Ignition system Ignition timing Spark ~ l u a I Fuel SUDD~Vsvstem I Fuel injection system /Fuel injection nozzle /Fuel pipe Lubricating system I I I I 4-stroke, O.H.C., 4-cylinder 2,254 cm3 (137.5 cu. in.) 86 x 97 mm (3.4 x 3.8 in) 84.6 kW (115 PS) at 5,000-6,000 rpm I 95.6 kW (130 PS) at 5,000-6,000 rpm 169 N*m (17.
PAGE 137
7. BF115AIBF130A INSTALLATION HEIGHT RECOMMENDATIONS Shaft Length I I Outboard I Transom Height I TRANSOM DRILL FIXTURE WorkableBoat Transom Height I I @B TRANSOM DRILLING See also ‘USING THE TRANSOM MOUNT DRILL FIXTURE” on page 1-23. I Description I Transom Mount Drill Fixture I PartNo. I I 07MPZ-ZV3010C I The BF115A and BF130A outboards motors are designed to be installed on a boat transom with the following transom board thickness: Boat Transom Board Thickness 50 70 mm (2 2.
PAGE 138
7. BFI 1SAIBFI30A STEERING CONNECTIONS STEERING LINK ARM INSTALLATION Do this before final placement of the motor on the transom. Refer to the steering cable manufacturer's manual for cable handling procedures. 1. Install bolt, washer, and collar into link arm. Remove access grommet from inside engine cover area and thread bolt into steering arm inside hole. Tighten bolt then tighten lock nut. Do not use forward hole.
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7. BFIISNBF130A steering is reversed, correct at the steering box. Motor steering angle is equal when steering wheel is turned full right and full left. If the motor steering angles are not equal: - Major corrections can be made at the steering box (refer to the steering box or steering cable manufacturer’s instructions). - Minor corrections can be made by moving the steeringltilt tube laterally (refer to the BFll5A/BFl30A Shop Manual). Make the steering angles equal as necessary.
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7. BF115AIBF130A REMOTE CONTROL CABLE INSTALLATION AND ADJUSTMENT SEPARATE COVER FLANGE BOLT, Route and connect cables to the remote control before connecting them to the motor. THROTTLE SHIFT CABLE WIRE HARNES BATTERY CABLE viewed from outside GROMMET HEX. BOLT, 6 x 40 mm edgekide against Dainted surface. I -E TIE WHITE MARK 1. Pass the main wire harness, indicator wire harness, battery cable and control cables through grommet. 2.
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7. BFIlSA/BF130A THROTTLE CABLE CONNECTION 1. Put the remote control lever in the NEUTRAL position. 2. Thread the pivot shaft onto the threaded portion of the throttle cable. Apply marine grease to the pivot pin. 3. Adjust the pivot shaft until it slips into the throttle arm. Install the pivot shaft from the engine side. Install washers on both sides of the arm and secure with a lock pin. Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc. THROTTLE CABLES CLOSE OPEN 4.
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7. BFI 15AIBF130A SHIFT CABLE CONNECTION 1. Center remote control lever: a. Move remote control lever to full forward position. b. Slowly return control lever to the NEUTRAL position. c. Move control lever to full REVERSE position. d. Slowly return control lever to the NEUTRAL position. NEUTRAL SWITCH II - \ DETENT ROLLER I I \ e SHIFT ARM 2.
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8. BF2OOA/BF225A i Rigging To ensure proper operation. you must install a PGM-FI panel indicator or a key switch panel with PGM-FI lights. See the Honda Marine Accessories Catalog (M0045). UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 PARTS LISTING . . . . . . . . . . . . . . . . . .
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8. BF2OONBF225A 6. Attach a three point engine chain sling to the three engine hangers. As necessary, use clean protective pads between the anchors and the engine bell cover or other related parts. Use an overhead gantry type crane with a lift capacity of at least 2oooSbs. Do not use an automotive type telescoping hydraulic crane. This type of crane may tend to Up whenlhe boom is extended and the engine is l i e d to the Installation height.
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8. BF200NBF225A SPEC IFICATIONS Model TY Pe Displacement Bore x stroke Rated horsepower (full throttle ranael \Maximumtoraue I ComDression ratio Fuel consumption ratio Cooling system Ignition system lanition timina I BF2OOA I 4-stroke, O.H.C., 6-cylinder 3,471 cm3 (211.7 cu in) 89 x 93 mm (3.5 x 3.7 in) 147.1 kW (200 HP) at 5,000-5,700 rpm 165.5 kW (225 HP) at 5,500-6,000 rpm 295 N-m (30.1 ka-m. 217.7 Ib-ft) 9.
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8. BF200AIBF225A PARTS LISTING I I I 1 Ilndicatorwire harness 2 ]Indicator panel assembly Pan-head screw I(5 x 40mm) Flange nut (5mm) 3 4 BF2OOA DESCRIPTION 5 Plain washer (5mm) 6 I Lock washer (5mm) I I 1 1 I I 1 1 I I IUndercasegrommet A 4 Ii1 BF225A I I PARTNO.
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8. BF200NBF225A BFSOOA REF. NO. BF225A DESCRIPTION PART NO. 25 Instruction (CARB) 1 1 1 1 1 1 1 1 1 1 NIA 26 Owner’s Manual 1 1 1 1 1 1 1 1 1 1 3 1ZY 2601 8-6 REMARKS Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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8. BF200NBF225A 1' 7 314" 6' 6 314" Engine Side e barb) Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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8. BF200NBF225A INSTALLATION HEIGHT RECOMMENDATIONS Shaft Length Outboard Transom Height TRANSOM DRILL FIXTURE Workable Boat Transom Height 1 -- 610 635 mm (24 25 in) 737 762 mm (29 3o in) 635 mm (25 in) XX type 762 mm (30 in) TRANSOM DRILLING Use the upper “C” and lower “D” holes. See also “USING THE TRANSOM MOUNT DRILL FIXTURE” on page 1-23. I Description Transom mount drill fixture I Part~o. 07MPZ-ZV301OC 85 mm (3.35 in) 1.
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8. BF2OONBF225A STEERING STEERING LINK ARM INSTALLATION BOLT (discard) SELECTION A single cable steering system is not recommended for either the BF200A or BF225A. The steering system selection is determined by the particular application. Consult the boat manufacturer or steering manufacturer for recommendations. Hydraulic steering would be the best choice to improve boat stability, minimize lost motion in the steering system, and reduce boat chine walk on high-performance boats.
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8. BF200NBF225A BOLTING MOTOR TO TRANSOM Apply zealant. BOLT, 12 x 119 mm (4) FENDER WASHER, SELF NUT, 12 mm (4) \ n - . boat manufacturer)] PLAIN WASHER, 12 mm (8) edgelside against Dainted surface. I BOAT Apply marine hull sealant to the mounting holes and hardware. Use Hondabond HT (P/N 08718-0001) or equivalent silicone sealant for below waterline use. With the motor in place against the transom, verify correct motor height. Motor can be raised by using a lower set of mounting holes.
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8. BF200AIBF225A REMOTE CONTROL CABLE INSTALLATION AND ADJUSTMENT REMOTE CONTROL CABLE PLATE Route the electrical harnesses and cables through the boat. Connect the cables to remote control before connecting them to the motor. WHITE TAPE / CABLE FRONT COVER BRACKET 1. Route the battery cable to the front cover bracket. Position the battery cable white tape mark so it aligns with the edge of the front cover bracket. 2. Spray the grommet with silicone spray. REMOTE CONTROL CABLE 5.
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8. BF200NBF225A ENGINE ELECTRICAL LOOP MAIN WIRE HARNESS 6. Connect the indicator panel 3 pin and main 14 pin connectors to the engine electrical bracket. Secure the connectors to the locking tabs on the bracket. Route the wires through the locking plastic loop and follow the path to the grommet. Route the two individual portions of the harness through the grommet as indicated. UNDERCASE GROMMET A 8. Install the control cables with the throttle cable inside and the shift cable outside.
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8. BF200NBF225A SHIFT CABLE CONNECTION 1. Centering remote control lever: a. Move remote control lever to full FORWARD position. b. Slowly return control lever to NEUTRAL position. c. Move control lever to full REVERSE position. d. Slowly return control lever to NEUTRAL position. I DETENT SPRING\ GROOVE 2. With the outboard motor in the NEUTRAL position, make sure the detent spring roller is set in the center of the shift arm neutral position groove. If not, move the detent spring LEFT or RIGHT.
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8. BF200NBF225A THROTTLE CABLE CONNECTION 1. Put the remote control lever in the neutral position. THROTTLE ARM THROTTLE ARM STOPPER CABLE END 2. Apply a light coat of marine grease to the pivot pin and sliding surface. 3. Adjust the cable end until it will just slip onto the throttle arm. Slide the locking plate forward into the locked position. Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc. 4. Move the remote control lever to the full throttle position.
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AVAILABLE ACCESSORIES Consult the Honda Marine Accessories Catalog (M0045) for current information on gauges, instrument harnesses, wiring harnesses, switch panels, and control boxes. FUEL HOSE CONNECTION BOAT SIDE Do not use unlined, worm-type fuel hose clamps because they will shred the outside of the fuel hose. During operation, check for any fuel or air leaks and repair immediately. If these connections suck air, the engine fuel pump will malfunction.
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9 . GAUGES Rigging Reminders Do not splice or otherwise cut into any wire harness. Always pull power from the battery via an electrical buss. 1 INSTALLATION INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9-3 SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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9. GAUGES WATER PRESSURE GAUGE RUBBER HOSE INSTALLATION . . . . . . . . . . . . . . . . . . 9-40 Date of issue: June 2003 0 2001-2003 American Honda Motor Co.. inc.
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9. GAUGES INSTALLATION INFORMATION SAFETY INFORMATION Disconnect the battery before starting the installation of any electrical gauge. Use the appropriate size fuse to protect electrical circuits. Be careful to avoid touching wrenches or other tools to the metal frames because short circuits June be caused, resulting in sparks, fire damage or electrical component damage. If electrical wire is added, make sure it is the proper gauge and color for the circuit.
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9. GAUGES GENERAL INFORMATION BLACK REDWHITE 1. Wires of the same color are connected together. When wires of differing colors are connected, a color tube of the same color is attached near the connector. When couplers are used, those of the same color are connected together. When two-color wires are used, the main base color is noted first, and the subordinate marking color last. WHITE BLUE 2.
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9. GAUGES 8. When a fuse is burned out, investigate and repair the cause of the short before replacing the fuse. Be sure to replace the fuse with the specified capacity. Check / I 9. If a terminal is oxidized or corroded, remove the oxidation or corrosion with a nonconductive plastic scrub pad and contact cleaner before reconnecting it. Oxidation or corrosion 10. When disconnecting locking couplers, be sure to disconnect the locking device carefully. 11.
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9. GAUGES 12. Be sure to reconnect couplers by inserting them fully into their receptacles. Check locking couplers to be sure locking devices are reconnected securely. 13. When reconnecting wire harnesses, be sure nothing has been left unconnected. -UNLOCKED LOCKED 14. Be sure the coupler covers are not stretched or rolled back but surround their couplers completely. CORRECT INCORRECT CONNECTED 15.
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9. GAUGES 17. Before reconnecting wire connectors, check them to make sure the covers are not torn or broken, and the gaps of female terminals are not overly expanded or loose. CORRECT INCORRECT 18. Do not break the coverings of wire harnesses. If the covering of a wire harness is broken, either repair it with electrician’s tape or replace it. OK REPAIR OR REPLACE 19. Connect wire fixing bands securely to frames in their designated locations.
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9. GAUGES 22. Clamped wires or wire harnesses should not touch or rest on rotating or moving parts. CORRECT -xk).. .. .. .... - - . _.. INCORREC’I Do not touch! 23. Be sure all wires and wire harnesses are routed away from hot surfaces. -._ 24. Wires should not lay or rest on sharp body edges or parts. .. Wires should be routed clear of bolts and screw heads or ends. 25.
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9. GAUGES FARIA@ PARTS LISTING Open the gauge carton and check all loose parts against the following list.
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9. GAUGES Water Pressure Gauge (not included in 5 gauge set) Qty. Ref 1 2 3 1 1 I 1 2 l 2 1 14I I I 5 Description I I 1 I1 I 1711 I 2 8 9 1 Water Pressure Gauge Mounting Bracket RubberHose BrassNut P Splitwasher .
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9. GAUGES Speedometer Fuel Gauge m MOUNTING BRACKET \ MOUNTING BRACKET BRASS NUT (2) I BRASS NUT (3) diameter hole SPLIT WASHER (2) SPLIT WASHER (2) Tachometer Water Pressure Gauge ‘ELECTOR SWITCH (see below) MOUNTING BRACKET diameter hole SPLIT WASHER (2) SPLIT WASHER (2) Trim Meter Hour Meter MOUNTING BRACKET DASH 52.4 mm (2-1116”) liameter hole diameter hole SPLIT WASHER (2) Volt Meter MOUNTING BRACKET l - DASH 52.
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9. GAUGES ELECTRICAL CONNECTIONS 1. Disconnect the battery. 2. Connect the Faria Instrument Harness to the Honda control panel as shown. SPEEDOMETER To light post BLACK To light post €3-REDlWHlTE To control panel wire harness. FUEL GAUGE “I” POST 6U2- BLACWELLOW “B+” POST @tD BLACWEL - BOAT LIGHT SWITCH GRAY -GRAY LACK- BLACK TACHOMETER “SIG” POST -GRAY “B+” POST CUa- BLACWEL “GND” POST BLACK To light post -REDWHITE B L A C W E L L O W a I D E = BLACWELLOW Replaceable 10 amp fuse.
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9. GAUGES 4. Connect the other end of the Faria Instrument harness to the instruments as shown. 5. Secure the wire terminals with the hardware as shown. SPEEDOMETER (-) TERMINAL / 4 !S3- BLACK =REDWHITE RUBBERHOSE / CONNECTION (page 9-18) FUEL GAUGE A “I” POST BLACWELLOW 6ff3BLACWELLOW 4 BLACK p-L-REDWHITE TRIM METER LIGHT TERMINALS “BAT” POST \ BLACK YELLOW/BLUE BLACWELLOW \ P BLACK D REDWHITE YELLOWlBLUE 9 44 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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9. GAUGES TACHOMETER LIGHT TERMINAL “GND” POST GfU BLACWELLOW REDWHITE POST YELLOW / BLACK VOLT METER / “+” POST LIGHT REDYITE BLACK/ YELLOW WBLACWELLOW “G” REDWHITE BRASS NUT ( 2 r - WATER PRESSURE CK CONNECTION RUBBER HOSE (page 9-18) MQ -BLACK 3 REDWHITE 6. Connect the rubber hose for the speedometer (page 9-16) and water pressure gauge (page 9-18). 7. Before connecting the battery, recheck all electrical connections and ensure mounting hardware is secure. 8.
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9. GAUGES ANALOG HOUR METER INSTALLATION ITEM Female Spade Connector Eyelet Terminal 9 46 PART NUMBER 07VPZ-001050A 07VPZ-001060A Date of Issue: June 2003 0 2001-2003 American Honda Motor Co.. Inc.
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9. GAUGES 3. Fasten the rubber hose at regular intervals with small plastic wire ties (be careful not to pinch tubing). - \ 4. Starting at the top of the swivel case, route the rubber hose over the top of the steering arm, down through the inside of the swivel case along side the shift rod, and out the bottom of the swivel case to the pitot tube. SWIVEL CASE \ PITOT TUBE 5. Cut approximately 3 mm (1/8”) off the nipple end. Clean the pitot tube if it is clogged with salt or any other foreign material.
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9. GAUGES WATER PRESSURE GAUGE RUBBER HOSE INSTALLATION 1. After installing the speedometer in the dash, connect the rubber hose to the back of the speedometer and secure with a cable tie. 2. Route the rubber hose back to the motor alongside the control cables. A slight downward slope from bow to stern will help avoid trapping water. Avoid sharp turns, crimping, kinking, or other forces that June reduce the inside diameter of the hose. Do not coil any excess rubber hose.
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9. GAUGES 6. Apply a sealing compound to a BF75190 CABLE TIE 118’’ NPT NIPPLE 1 / 8 x 28 BSPT brass hose fitting and install the fitting securely. 7. Secure the rubber tubing with a plastic cable tie. CABLE TIE BF1151130 RUBBER TUBING / 1/8” NPTNIPPLE Date of Issue: June 2003 0 2001-2003 American Honda Motor Co.,Inc.
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9. GAUGES Faria Instrument Speedometer Tachometer Fuel Gauge Trim Meter Volt Meter Water Pressure Gauge Hour Meter Replacement Bulb GE No.158 GE No.1948 GE No.194 GE No.161 GE No.194 GE No.161 NA Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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9. GAUGES BEEDE PARTS LISTING Open the gauge carton and check all loose parts against the following list.
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9. GAUGES Water Pressure Gauge (not included in 5 gauge set) Ref 1 2 3 4 5 6 7 8 2 2 1 1 2 Description Water Pressure Gauge Mounting Bracket RubberHose BrassNut Star Washer 1/8" NPT Fitting RedSleeve CableTie 9 1 AdaDtor 1/8" NPTF To BSPT Qty.
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9. GAUGES Speedometer Fuel Gauge MOUNTING BRACKET MOUNTING BRACKET \ BRASS NUT (2) I DASH 86 mm (3-3/8”) diameter hole) STAR WASHER (2) STAR WASHER (2)/ Tachometer Water Pressure Gauge A MOUNTINGIBRACKET light wire and strip the diameter hole STAR WASHE STAR WASHER (2) Trim Meter Analog Hour Meter MOUNTING BRACKET DASH, 52.4 mm (2416”) diameter hole STAR WASHER (2 STAR WASHER (2) Volt Meter A MOUNTING BRACKET I BRASS DASH, 52.
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9. GAUGES #1 #2 Instrument lights operate when Honda key switch is ON. Instrument lights operate when light switch is ON. Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc. Connect redlwhite wire to the blacklyellow wire. Connect red/white wire and blacklyellow wires to the boat light switch.
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9. GAUGES 4. Connect the other end of the Beede instrument harness to the instruments as shown. 5. Secure the wire terminals with the hardware as shown. SPEEDOMETER (+) TERMINAL \ I BEEDE INSTUMENT I HARNESS BLACK \ I I CONNECTION (page 9-28) FUEL GAUGE %k WASHER (3) ‘%“POST// “I” POST PINK (from boat sender unit) G ~ X BLACKNELLOW I ~ BLACK REDWHITE TRIM METER YELLOWlBLUE tSU- BLACKNELLOW YE LLOWlBLUE BLACKNELLOW STAR WASHER (3) P BLACK REDWHITE Date of Issue: June 2003 0 2001-2003 Ameri
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9. GAUGES TACHOMETER harness wire to STAR WASHER (3) BIACWELLOW / GRAY VOLT METER “L” POST A “G” POST WBLACWELLOW REDNVHITE BLACW E L L O W REDNVHITE WATER PRESSURE RUBBER HOSE CONNECTION (page 9-30) \ __ - -BLACK 3 B- REDWHITE 6. Connect the rubber hose for the speedometer (page 9-28) and water pressure gauge (page 9-30). 7. Before connecting the battery, recheck all electrical connections and ensure mounting hardware is secure. 8.
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9. GAUGES 3. Fasten the rubber hose at regular intervals with small plastic wire ties (be careful not to pinch tubing). 4. Starting at the top of the swivel case, route the rubber hose over the top of the steering arm, down through the inside of the swivel case alongside the shift rod, and out the bottom of the swivel case to the pitot tube. 5. Cut approximately 3 mm (1/8”) off the nipple end. Clean the pitot tube if it is clogged with salt or any other foreign material. 6.
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9. GAUGES WATER PRESSURE GAUGE TUBING INSTALLATION 1. After installing the water pressure gauge in the dash, connect the rubber hose to the back of the water pressure gauge and secure with a cable tie. 2. Route the rubber hose back to the motor alongside the control cables. Avoid sharp turns, crimping, kinking, or other forces that June reduce the inside diameter of the hose. Do not coil any excess hose. Cut hose to the desired length. 3.
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9. GAUGES BF2001225 1. Use a 5 mm hex wrench and remove the water pressure access plug (located above the starboard exhaust manifold). ADAPTOR 118" NPTF TO BSPT* I 2. Apply sealing compound to the adaptor 1 / 8 NPTF to BSPT (supplied with kit*) and install the adaptor securely where the access plug was removed. 3. Apply sealing compound to the 1 / 8 NPT brass hose fitting (supplied with kit) and install the fitting securely in the adaptor. 4.
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9. GAUGES TE LEFLEX@ PARTS LISTING Open the gauge carton and check all loose parts against the following list.
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9. GAUGES Water Pressure Gauge* Ref 1 Qty. 1 Description Water Pressure Gauge Mounting Bracket Rubber Hose 1/8" NPT Fitting I 7 I 1 I Adaptor1/8"NPTFToBSPT I @ 0 I& 1/8" BSPT (British Pipe Thread- male) Ac 1/8" NPTF (National Pipe Thread- female) * The water pressure gauge is not included in the 5 gauge set. It must be ordered separately. Use the Teleflex Instrument Harness (PIN 32200-ZW7-000AH) to connect Teleflex gauges to the Honda main harness (refer to 9-36). GAUGE INSTALLATION 1.
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9. GAUGES Speedometer Fuel Gauge MOUNTING BRACKET 1 MOUNTING BRACKET 8 LOCK NUT 52.4 mm (2-1116") diameter hole Volt Meter Water Pressure Gauge 6MOUNTING BRACKET DASH 52.4 mm (2-1116") diameter hole LOCK WASHER (2) Tachometer Trim Meter MOUNTING BRACKET \ MOUNTING )ASH i2.4 mm (2-1116") liameter hole \Y Tachometer Ranging Switch Setting: Using a small screwdriver, turn the dial to the appropriate setting.
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9. GAUGES ELECTRICAL CONNECTIONS 1. Disconnect the battery. 2. Connect the Teleflex instrument harness to the Honda switch panel or control box as shown. To light post To light post -REDMIHI To control panel wire harness. “I”POST “G” POST BLACKNE BLACK --b LIGHT SWITCH “G” POST - BLA e TELEFLEX INSTUMENT 21 +..---.
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9. GAUGES -BLACK REDWHITE BLACWELLOW GRkY VOLT METER A f < LIGHT POST / BLACK/ “I” POST \ BLACWELLOW WATER PRESSURE LIGHT POST REDWHITE RUBBER HOSE CONNECTION (page 9-39) B-- BLACK W I 3 REDWHITE 6. Connect the rubber hose for the speedometer (page 9-39) and water pressure gauge (page 9-40). 7. Before connecting the battery, recheck all electrical connections and ensure mounting hardware is secure. 8. Reconnect the battery and check the operation of each gauge.
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9. GAUGES ~~ SPEEDOMETER RUBBER HOSE INSTALLATION CABLE TIE 1. After installing the speedometer in the dash, connect the rubber hose to the back of the speedometer and secure with a cable tie. 2. Route the rubber hose back to the motor alongside the control cables. A slight downward slope from bow to stern will help avoid trapping water. Avoid sharp turns, crimping, kinking, or other forces that June reduce the inside diameter of the hose. Do not coil any excess rubber hose.
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9. GAUGES Speedometer Water Tube Maintenance The pitot tube should be flushed with fresh water before storing the boat for prolonged periods. Any remaining water in the rubber hose should also be removed before storing the boat for prolonged periods. If the pitot tube or rubber hose should become clogged: 1. Disconnect the rubber hose from the speedometer and the pitot tube. 2. Clean the rubber hose with a stiff wire or blow air through it.
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BF200/225 1. Use a 5 mrn hex wrench and remove the water pressure access plug (located above the starboard exhaust manifold). ADAPTOR 1/8" NPTF TO BSPT* I 2. Apply sealing compound to the adaptor 1/8" NPTF to BSPT (supplied with kit*) and install the adaptor securely where the access plug was removed. 3. Apply sealing compound to the 1/8" NPT brass hose fitting (supplied with kit) and install the fitting securely in the adaptor. 4. Use a 7/32" drill bit and open the hole through the grommet membrane.
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I 0. CONTROL BOXES AND TEMPLATES Rigging Reminders Use only TFXTREME cables for all rigging procedures. Place tie wraps no closer than 3 ft . to the control box. with a minimum 8 in. distance between tie wraps . REMOTE CONTROL BOX LOCATION AND SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 PREMIUM SlNGLElDUAL TOP-MOUNT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 PREMIUM SIDE-MOUNT REMOTE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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10. CONTROL BOXES AND TEMPLATES REMOTE CONTROL BOX LOCATION AND SELECTION LOCATION Select a mounting location which allows easy access and unobstructed, comfortable operation of the remote control lever. Make sure there are no cable obstructing components between the remote control box and the outboard motor. The remote control box is normally mounted on the starboard side of the gunnel. The control lever can be reversed to accommodate port side or starboard helmkonsole installation.
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10. CONTROL BOXES AND TEMPLATES ~ _ _ _ _ PREMIUM SlNGLElDUAL TOP-MOUNT CONTROL PARTS LISTING (Remote Control Kit) Take out all parts from the kit and check them against the parts list shown below. Be sure all parts listed are contained in the package. Q 1 1 I I I I RT. HD I LT. HD 1 RT. HD I LT. HD I Ref. No. Description Single Single Lever Lever I Dual Lever Dual Lever Part No.
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10. CONTROL BOXES AND TEMPLATES PARTS LISTING (Single Lever Type) Right-Hand Type ii & RED CONNECTOR RED CONNECTOR 8 Left-Hand Type I Quantity Ref. No. Description 1 Left inner housing assy. 2 Right inner housing assy. 3 Remote control housing grip 4 I Right grip cover 5 6 /Gripcover Remote control handle I Part No. 1 24810-ZW5-UO1 1 I I I 1 1 7 Grip cap 1 8 Power tilt/trim switch assy. A 1 9 Power tilt/trim switch assy.
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10. CONTROL BOXES AND TEMPLATES PARTS LISTING (Single Lever Type) (continued) vy Right-Hand Type i RE^ CONNECTOR BLUE CONNECTOR RED CONNECTOR B Left-Hand Type I Quantity Ref. No. Description Right-Hand Handle Type I Left-Hand Handle Type Part No.
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10. CONTROL BOXES AND TEMPLATES PARTS LISTING (Dual Lever, Right-Hand Handle Type) 9 BLUE CONNECTOR 1016 Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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10. CONTROL BOXES AND TEMPLATES PARTS LISTING (Dual Lever, Right-Hand Handle Type) 9 20 21 5 x 20 mm pan-head screw 5 mm lock washer Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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10. CONTROL BOXES AND TEMPLATES PARTS LISTING (Dual Lever, Left-Hand Handle Type) 9 I Ref. No. I I I I Description I Quantity I Part No. 1 Left inner housing assy. 1 24810-ZW5-UO1 2 Right inner housing assy. 1 24810-ZW5-UlI 3 Remote control housing grip 2 24813-ZW5-UOl 4 Right grip cover 1 24812-ZW5-UlI 5 6 7 8 I Grip cover I Remote control handle I Grip cap I I I 1 2 I I I 24813-ZW5-U21 24811-ZW5-UO1 Power tilt/trim switch assy. A 2 1 9 Power tilt/trim switch assy.
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10. CONTROL BOXES AND TEMPLATES PARTS LISTING (Dual Lever, Left-Hand Handle Type) 0 Ref. No. I I I Quantity Part No. 12 Remote control box housing 1 2482O-ZW5-U21 13 Remote control box mark 1 87703-ZW5U21 14 15 (Housing lead lSub harnessA 16 17 \Sub harness B 4 x 10 mm pan-head screw 18 5 x 10 mm pan-head screw 5 x 16 mm pan-head screw 5 x 20 mm pan-head screw 19 20 I Description 21 15 mm lock washer Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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10. CONTROL BOXES AND TEMPLATES COMPONENT IDENTIFICATION This section shows the right-hand handle type only. The right-hand remote control is designed to perform the throttle operation and the tilt angle adjustment with the right hand. Note the name and operation of each part of the left-hand handle type are identical with those of the right-hand handle type.
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10. CONTROL BOXES AND TEMPLATES ~~~ SHIFT OPERATION Move the remote control lever to the NEUTRAL position. Push the fast idle button, and move the remote control lever a little forward to start the engine. The fast idle button can only be pushed when the remote control lever is in the neutral position. After starting the engine, warm up the engine.
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10. CONTROL BOXES AND TEMPLATES INSTALLATION POSITION Select the remote control installation position on the boat. LEFT-HAND HANDLE SINGLE LEVER TYPE RIGHT-HAND HANDLE SINGLE LEVER TYPE 50 mm (1.97 in) minimum Both the single and the dual lever type remote controls are available in the right-hand handle type and the left-hand handle type respectively. Select the correct type for the boat.
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10. CONTROL BOXES AND TEMPLATES HOUSING LEA I1 CONTROL CUSHIONSCREWS BACK PLATE 11. Connect the throttle control cable to the throttle arm, in the same manner as the gearshift control cable, with an E-ring. 12. Install the back plate and the housing bracket in the reverse order of removal. /-----7 INNER HOUSIN 6. Remove the screws and remove the back plate from the inner housing. 7. Apply marine grease to both the shift and throttle pins at the end of each arm.
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10. CONTROL BOXES AND TEMPLATES 6. While holding the stopper bolt, tighten the lock nut. TORQUE: 5-8 N*m ( 3.6-5.8 ft-lb) 7. With the control lever in the full throttle position, recheck at the outboard motor that the throttle arm is against the full throttle stop. THROTTLE FRICTION ADJUSTMENT The operating load of the remote control lever can be adjusted by turning the adjusting screw. Adjust the load according to your preference as described below. COVER \ Y 1. Remove the cover as shown. 2.
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10. CONTROL BOXES AND TEMPLATES WIRE HARNESS CONNECTIONS When using optional harnesses: Check whether wire harnesses are connected as shown on the wiring diagrams on the following pages. Connect leads and terminals securely, and waterproof to prevent moisture from entering and corroding the connector terminals. Observe the following wire harness connector instructions: If the standard 16.
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10. CONTROL BOXES AND TEMPLATES WIRING DIAGRAM (Top Mount Single-Lever Type) I POWER TRIM/TILT SWITCH INDICATOR LIGHTS EMERGENCY STOP SWITCH To METER WIRE HARNESS A Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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10. CONTROL BOXES AND TEMPLATES WIRING DIAGRAM (Top Mount Single-Dual Type) To METER WIRE EMERGENCY STOP SWITCH HARNESS A SWITCH PANEL / LEVER SIDE POWER TRlMlTlLT SWITCH To METER WlRF HARNESS A SWITCH PANEL TOP SWITCH 3P CONNECTOR (RED) RIGHT SWITCH PANEL RE HARNESS connection point with vinyl approximately 5 timer around. 104 8 tape Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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10. CONTROL BOXES AND TEMPLATES PREMIUM SIDE-MOUNT REMOTE CONTROL PARTS LISTING Take out all parts from the kit and check them against the parts list shown below. Be sure all parts listed in the parts list are contained in the package. 1b' Ka I Ref. No.
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10. CONTROL BOXES AND TEMPLATES COMPONENT IDENTIFICATION NEUTRAL RELEASE LEVER POWER TRlM/TlLT SWITCH CONTROL LEVER OIL PRESSURE INDICATOR LIGHT CHOKElFAST IDLE LEVER OVERHEAT INDICATOR LIGHT IGNITION SWITCH EMERGENCY ENGINE STOP SWITCH ‘FRICTION Neutral Release Lever Power Trimmilt Switch Control Lever Indicator Lights Choke/Fast Idle Lever Ignition Switch Emergency Engine Stop Switch Friction Adjuster ADJUSTER Must be raised to move the control lever into forward or reverse gears.
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10. CONTROL BOXES AND TEMPLATES 6. Before installing the 8 x 35 mm control lever bolt, install the control cables into the control box (see page 10-23). CONTROL LEVER SCREW(2) POWER TRlMFlLT SWITCH WIRE \ \ \ a I 9. Install cover C and tighten the screws securely. TORQUE: 2 N.m (0.2 kg-m, 1.4 ft-lb) INOTICE I HOLD-DOWN Overtightening the mounting screws can damage or distort the control box. SWITCH WIRE CONNECTOR (3) Route the power trimhilt switch wire harness as shown.
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10. CONTROL BOXES AND TEMPLATES REMOTE CONTROL CABLE INSTALLATION / COVER C LOCK PIN, 6 mm (2) THROTTLE CONTROL CABLE CABLE EYE END (2) CABLE CLAMP SPACER SHIFT CONTROL CABLE More than 8 mm (0.3 in) (marine grease) CABLE EYE END v SCREW (2) 2. Screw the lock nuts and cable eye ends onto the threads of the remote control cables at least 8 mm (0.3 in). Apply marine grease to the holes in the eye ends. 1. Remove the two screws and cover C.
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10. CONTROL BOXES AND TEMPLATES REMOTE CONTROL INSTALLATION After the control cable installation and adjustment, install the remote control. SHIFT CABLE REMOTE CONTROL \ SPACER PLATE \ V WASHER (6) 3. Install the shift cable by aligning the cable groove with the cable guide plate. Then connect the eye end to the short arm pin using the washer and 6 mm lock pin. Install the washer on the lock pin side. COVER C SCREW(2) .. I \ NUT (3) 1. Put the control lever in the neutral position. 2.
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10. CONTROL BOXES AND TEMPLATES OPERATIONAL CHECKS Before operating the boat, make sure the cables are correctly adjusted and that there are no kinks or sharp bends in the cables. Operate the remote control lever and verify the control cables move smoothly. p7E-l 3. Loosen the lock nut and turn the stopper bolt until it touches the throttle lever. The carburetor and control lever must be in the full throttle position. 4.
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10. CONTROL BOXES AND TEMPLATES WIRE HARNESS CONNECTIONS When using optional harnesses: Check whether wire harnesses are connected as shown on the wiring diagram on the following page. Connect leads and terminals securely. If necessary, wrap connections with vinyl tape to waterproof connections. The BF130 requires a 17 wire main wire harness or a 14 wire main wire harness and the 3 wire PGM-FI panel wire harness. If the standard 16.
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10. CONTROL BOXES AND TEMPLATES WIRING DIAGRAM (AW models to A2 models, excluding A3*) (*See Outboard Motor Service Bulletin #38 and Chapter 5 of this guide for information specific to BF40A3/BF50A3 models) W I 0 ss To METER WIRE HARNESS A -REMOTE CONTROL EMERGENCY ENGINE STOP SWITCH IGNITION SWITCH b .
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10. CONTROL BOXES AND TEMPLATES PREMIUM FLUSH-MOUNT REMOTE CONTROL PARTS LISTING (Single Lever Type) i- Quantity Ref. No.
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10. CONTROL BOXES AND TEMPLATES PARTS LISTING (Single Lever Type) (continued) :- Quantity Ref. No. I I I I I Description Mark, handle flush mount Right-Hand Handle Type Left-Hand Handle Type Part No. 1 1 87701-ZW7-U00 Mark, flush mount remote control box I 1 I 1 I 87703-ZW7-UOO 15 Holder, neutral lock I 1 I 1 I 24832-ZW7-UO1 16 Cover assy. 1 1 24830-ZW7-UO1 Base 1 1 24833-ZW7-UO1 Plate, dual 1 1 24826-ZW5-UO1 Housing assy., inner (FL M/T.
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10. CONTROL BOXES AND TEMPLATES COMPONENT IDENTIFICATION The right-hand remote control is designed to perform the throttle operation and the tilt angle adjustment with the right hand. The name and operation of each part of the left-hand handle type are identical with those of the right-hand handle type. Flush Mount Remote Control POWER TRIM AND TILT Remote Control Lever The remote control lever controls gear selection and throttle opening positions.
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10. CONTROL BOXES AND TEMPLATES CHANGE IN THE CONTROL LEVER POSITION 2. Remove the four screws and remove the dwell plate retainer. CAM PLATE RIGHT-HAND REMOTE CONTROL BOX I CIRCLIP LEFT-HAND REMOTE CONTROL BOX THROTTLE ARM ASSY. 3. Remove the circlip, then remove the plate. PLAIN BRAKE SHOE The remote control box permits you to change the control lever position from the right-hand side to the left-hand side or vice versa. BACK PLATE \ SCREW \ DWELL PLATE RETAINER THROTTLEARM ASSEMBLY 4.
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10. CONTROL BOXES AND TEMPLATES ~ HEX HEAD,BOLT /SHIFT ARM ASSEMBLY 7. Loosen the hex head bolt, and install the shift arm assembly, while holding it in an inverted position. TORQUE: 5-8 N*m (0.5-0.8 kgf-m, 3.6-5.8 Ibf-ft) 8. Install the throttle shaft on the opposite side to the original position, with the two hex head bolts. TORQUE: 5-8 N*m (0.5-0.8 kgf-m, 3.6-5.8 Ibf-ft) 10 mm (0.4 10. Set the brake disk and brake shoe assembly on the throttle arm asembly, and install the throttle shaft.
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10. CONTROL BOXES AND TEMPLATES THROTTLE OPENING ADJUSTMENT With this remote control box, the throttle opening can be adjusted by using the following procedure: Control Lever Tension Adjustment M \1 LOCK NUT \ THROTTLE FULL STOPPER BOLT\ THROTTLE STOPPER BOLT \ \\ LOCK NUT T LESS THAN 1Omm (0.4 in) By turning in or out the throttle friction screw at the rear of the remote control box, the stiffness of the control lever can be adjusted.
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10. CONTROL BOXES AND TEMPLATES FLUSH MOUNT REMOTE CONTROL INSTALLATION (right-hand handle) This section explains the installation procedure of the right-hand handle remote control. The left-hand handle remote control can be installed in the same manner. When the mounting plate (hull) is more than 30 mm (1.18 in), the installation of the remote control box is impossible. TEMPLATE CABLE CLAMP 5 . MOUNTI~G SURFACE 1. Attach the drilling template to the remote control mounting surface using adhesive tape.
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10. Install the back plate in the reverse order of removal. Y SCREWS \WAVE WASHERS \L1LARGE PlplN WASHER SCREW 11. Remove the screws, wave washers and set washer. Set the remote control box so that the mounting holes align with the mounting holes in the base. 12. Tightly screw the base to the remote control box. TORQUE: 3-45 N*m (0.3-0.5 kg-m, 2.2-3.6 ft-lb) Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc. 13. Install the base to the mounting plate (hull) with the screws and nuts.
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10. CONTROL BOXES AND TEMPLATES ADJUSTING SCREW HOLE 18. Install the control lever on the remote control box. i' '\ ----__ POWER TRIM AND TILT SWITCH WIRE 14. Install the cover on the base by aligning the adjusting screw holes in the cover and the base. 19. Place the set washer in the boss of the control lever, and fasten it with the screws and wave washers. TORQUE: 3-4 N*m (0.3-0.4 kg-m, 2.2-2.9 ft-lb) POWER TRIM AND TILT SWITCH WIRE \ \ FAST IDLE BUTTON 20.
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10. CONTROL BOXES AND TEMPLATES REMOTE CONTROL CABLE CONNECTION N NEUTRAL FORWARD pi%q Check that the cables are not sharply bent (less than 406 mm (16 in) in radius) or unnecessarily bent. (The number of bends should be minimized.) Also, check that no portions of the cables are clamped so hard as to deform the cable outers. 4. After connecting the cables to the engine, move the control lever through all functions several times and check for smooth operation at the engine and remote control box.
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10. CONTROL BOXES AND TEMPLATES CONTROL LEVER LIMIT ADJUSTMENT (BF25/30/40/50 models only) The forward and reverse throttle limit stop screws on the premium remote controls are pre-set for the BF75/90/115/130 outboard motors. If these remote controls are to be used on the BF25/30/40/50, it is necessary to perform the following adjustment procedure. 1. Remove the cover by removing the two screws. 2.
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10. CONTROL BOXES AND TEMPLATES , Side Flush-Mount EMERGENCY STOP SWrrCH ?MOTE CONTROL I I To ENGINE WIRE HARNESS INDICATOR LIGHTS To METER WIRE HARNESS A I I SWITCH PANEL CONNECTION FOR ENGINE WIRE HARNESS CONTROL PANEL WIRE HARNESS To METER WIRE EXTENSION HARNESS Refer to .page _ 1058 for harness usage. Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc. Connect coupler inside engine cover.
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10. CONTROL BOXES AND TEMPLATES Single Top-Mount Control I POWER TRlM/TlLT SWITCH INDICATOR LIGHTS To METER WIRE HARNESS A SWITCH PANEL R SS CONNECTION Brown neutral SWITCH To METER WIRE / Refer to page 1068 for harness usage. inside engine cover. EMERGENCY STOP SWITCH Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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10. CONTROL BOXES AND TEMPLATES Dual Top-Mount Control EMERGENCY STOP SWITCH \ PORT I'OWER TRlM/TlLT SWITCH STARBOARD POWER TRlM/TlLT SWITCH To METER WIRE EMERGENCY STOP ri CHOKE SWITCH i 1. IGNITION SWITCH IGNITION SWITCH INDICATOR LIGHTS INDICATOR LIGHTS PORT SWITCH PANEL SWITCH PANEL To PORT MOTOR WIRE HARNESS To STARBOARD MOTOR WIRE HARNESS Connect couplers inside engine cover. Use separate batteriesfor the two outboard motors.
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10. CONTROL BOXES AND TEMPLATES PREMIUM SINGLE TOP-MOUNT CONTROL TEMPLATE Prior to using the template, use calipers or ruler to be sure template dimensions are correct. Dimensions can change due to photocopying or reprinting. HAND LEVER y SIDE 57 mm (2.24 in) C Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc. 75 mm (2.95 in) K 46mm > (.
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10. CONTROL BOXES AND TEMPLATES PREMIUM DUAL TOP-MOUNT CONTROL TEMPLATE Prior to using the template, use calipers or ruler to be sure template dimensions are correct. Dimensions car FRONT SIDE I ! I I i I c c P r .-- Y t t T r T I ‘I I - . c Date of Issue: June 2003 0 2001-2003 American Honda Motor Co., Inc.
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10. CONTROL BOXES AND TEMPLATES PREMIUM FLUSH-MOUNT REMOTE CONTROL TEMPLATE Prior to using the template, use calipers or ruler to be sure template dimensions are correct. Dimensions can change due to photocopying or reprinting. . I 33mm (1 3 0 in) left hand model 1 .- i 33mm (1.30 in) . c Qight hand model -x.\ Cut out the shaded area. When using bolthut [for hull thickness of less than 20 mm (0.78 in)]: 7 mm diameter (0.28 in) through hole, 3 places.
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Common Model Information BF8D - BF9.