BF25D/BF30D OwnerÕs Manual 31ZW2600 00X31-ZW2-6000 N 2eY1500.2003.07 Printed in Japan 2004 ©2003 Honda Motor Co., Ltd.
03/07/02 10:12:48 31ZW2600_001 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Keep this owner’s manual handy, so you can refer to it at any time. This owner’s manual is considered a permanent part of the outboard motor and should remain with the outboard motor if resold. The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co.
INTRODUCTION Congratulations on your selection of a Honda outboard motor. We are certain you will be pleased with your purchase of one of the finest outboard motors on the market. We suggest you read the warranty policy to fully understand its We want to help you get the best results from your new outboard motor and to operate it safely. This manual contains the information on how to do that; please read it carefully. As you read this manual you will find information preceded by a symbol.
03/07/02 10:13:09 31ZW2600_003 INTRODUCTION A FEW WORDS ABOUT SAFETY You will find important safety information in a variety of forms, including: Safety Labels − on the outboard motor. Your safety and the safety of others are very important. And using this outboard motor safely is an important responsibility. Safety Messages − preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
03/07/02 10:13:13 31ZW2600_004 CONTENTS OUTBOARD MOTOR SAFETY .................................... 7 IMPORTANT SAFETY INFORMATION ................. 7 SAFETY LABEL LOCATIONS ................................. 9 CONTROLS AND FEATURES ................................... 10 CONTROL AND FEATURE IDENTIFICATION CODES ................................. 10 COMPONENT AND CONTROL LOCATIONS ..... 11 CONTROLS ...............................................................
03/07/02 10:13:17 31ZW2600_005 CONTENTS OTHER FEATURES ................................................. 29 Overrev Limiter ...................................................... 29 Anodes.................................................................... 29 Portable Fuel Tank ................................................. 30 Fuel Cap Vent Knob .............................................. 30 Fuel Priming Bulb .................................................. 31 INSTALLATION .........................
03/07/02 10:13:21 31ZW2600_006 CONTENTS SERVICING YOUR OUTBOARD MOTOR ............... 64 THE IMPORTANCE OF MAINTENANCE ............ 64 MAINTENANCE SAFETY ...................................... 65 TOOL KIT AND EMERGENCY STARTER ROPE ........................ 66 MAINTENANCE SCHEDULE ................................ 67 TRIM TAB ADJUSTMENT ..................................... 69 MANUAL RELIEF VALVE ..................................... 70 ENGINE COVER REMOVAL AND INSTALLATION ..................................
03/07/02 10:13:25 31ZW2600_007 CONTENTS TECHNICAL AND CONSUMER INFORMATION.................................................. 104 TECHNICAL INFORMATION .............................. 104 Serial Number Locations ..................................... 104 Carburetor Modification for High Altitude Operation .......................................................... 105 Battery .................................................................. 105 Oxygenated Fuels.................................................
03/07/02 10:13:37 31ZW2600_008 OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION Honda BF25D and BF30D outboard motors are designed for use with boats that have a suitable manufacturer’s power recommendation. Other uses can result in injury to the operator or damage to the outboard motor and other property. Most accidents can be prevented if you follow all instructions in this manual and on the outboard motor.
03/07/02 10:13:45 31ZW2600_009 OUTBOARD MOTOR SAFETY Refuel With Care Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a wellventilated area, with the engine stopped. Never smoke near gasoline, and keep other flames and sparks away. Remove any portable fuel tank from the boat for refueling. Keep the portable fuel tank away from the battery or other potential spark sources. Refuel carefully to avoid spilling fuel. Avoid overfilling the fuel tank.
03/07/02 10:14:14 31ZW2600_011 CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES Model BF25D Type SH Shaft Length LH SHG LHT SRG BF30D LRG SRT LRT LH SHG LHT S L Long Tiller Handle Remote Control Recoil Starter Electric Starter Mechanical Tilt Gas-assisted Tilt Power Trim/Tilt Tachometer (optional equipment) Trim Meter (optional equipment) Battery charging DC receptacle Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature
03/07/02 10:14:41 31ZW2600_015 CONTROLS AND FEATURES Remote Control box (side-mount type) POWER TRIM/TILT SWITCH (SRT and LRT types) GEARSHIFT/THROTTLE CONTROL LEVER NEUTRAL RELEASE LEVER OIL PRESSURE INDICATOR LIGHT SPARE SWITCH CLIP OVERHEAT INDICATOR LIGHT BUZZER (inside of the box) FAST IDLE LEVER IGNITION SWITCH IGNITION SWITCH KEY LANYARD THROTTLE FRICTION ADJUSTER EMERGENCY STOP SWITCH SWITCH CLIP 14
03/07/02 10:14:50 31ZW2600_016 CONTROLS AND FEATURES Fuel Tank Tachometer (optional equipment) FUEL GAUGE VENT KNOB FUEL TANK FUEL CAP Trim Meter (optional equipment) FUEL HOSE PRIMING BULB FUEL HOSE CONNECTOR (female) 15
03/07/02 10:15:00 31ZW2600_017 CONTROLS AND FEATURES Ignition Switch (SHG and LHT types) CONTROLS SH, LH, SHG and LHT Types (long tiller handle) ON START Recoil Starter Grip (SH and LH types) The ignition switch can be used to operate the starter motor only when the gearshift lever (p. 18 ) is in the N (neutral) position, and the switch clip is in the emergency stop switch. OFF IGNITION SWITCH The ignition switch controls the ignition system and starter motor.
03/07/02 10:15:11 31ZW2600_018 CONTROLS AND FEATURES Emergency Stop Switch and Switch Clip EMERGENCY STOP SWITCH The switch clip must be inserted in the engine stop switch in order for the engine to start and run. The lanyard should be attached to the operator’s PFD (Personal Flotation Device) or worn around the wrist as shown. When used as described, the emergency stop switch and lanyard system stops the engine if the operator falls away from the controls.
03/07/02 10:15:21 31ZW2600_019 CONTROLS AND FEATURES Throttle Friction Adjuster Gearshif t Lever THROTTLE FRICTION ADJUSTER FIX N (neutral) Steering Friction Adjuster R (reverse) F (forward) (SH and LH types) DECREASE INCREASE GEARSHIFT LEVER RELEASE STEERING FRICTION ADJUSTER BOLT THROTTLE GRIP The throttle friction adjuster adjusts resistance to throttle grip rotation. Turn the adjuster clockwise to increase friction for holding a throttle setting while cruising.
03/07/02 10:15:32 31ZW2600_020 CONTROLS AND FEATURES The steering friction adjuster adjusts steering resistance. Less friction allows the outboard motor to turn more easily. More friction helps to hold steady course while cruising or to prevent the outboard motor from swinging while trailering the boat.
03/07/02 10:15:43 31ZW2600_021 CONTROLS AND FEATURES SRG, LRG, SRT and LRT Types (remote control) For panel-mount or top-mount remote control information, refer to the instructions provided with the remote control equipment. Ignition Switch (side-mount type) ON START OFF Turning the ignition switch key to the START position operates the starter motor. The key automatically returns to the ON position when released from the START position.
03/07/02 10:15:53 31ZW2600_022 CONTROLS AND FEATURES The switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The lanyard must be attached to the operator’s PFD (Personal Flotation Device) or worn around the wrist as shown. Fast Idle Lever (side-mount type) N (neutral) GEARSHIFT/THROTTLE CONTROL LEVER When used as described, the emergency stop switch and lanyard system stops the engine if the operator falls away from the controls.
03/07/02 10:16:02 31ZW2600_023 CONTROLS AND FEATURES Gearshif t/Throttle Control Lever (side-mount type) GEARSHIFT/THROTTLE CONTROL LEVER GEARSHIFT/THROTTLE CONTROL LEVER N (neutral) F (forward) R (reverse) ENGINE SPEED ENGINE SPEED NEUTRAL RELEASE LEVER The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle.
03/07/02 10:16:15 31ZW2600_024 CONTROLS AND FEATURES Common Controls Power Trim/Tilt Switch [SRT and LRT types (side-mount type)] CONTROL LEVER Press UP to trim or tilt the motor up. Press DN to trim or tilt the motor down. POWER TILT SWITCH The power trim/tilt switch is located on the control lever or the tiller handle. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.
03/07/02 10:16:36 31ZW2600_026 CONTROLS AND FEATURES Transom Angle Adjusting Rod (SH and LH types) The transom angle adjusting rod limits the tilt angle of the outboard motor when fully lowered. Trim Tab Proper adjustment prevents the outboard motor from being trimmed too low (p. 56 ). TRIM TAB TIGHTENING BOLT PROPELLER TRANSOM ANGLE ADJUSTING ROD (SHG, LHT, SRG, SRT and LRT types) The trim tab compensates for ‘‘torque steer,’’ which is a reaction of the outboard motor to propeller rotation.
03/07/02 10:16:49 31ZW2600_027 CONTROLS AND FEATURES INSTRUMENTS Tachometer (optional equipment) Fuel Gauge Trim Meter [optional equipment (LHT, SRT and LRT Types)] FUEL GAUGE TACHOMETER TRIM METER The trim meter has a range of 0° to 16° and indicates the trim angle of the outboard motor. Refer to the trim meter when using the power trim/tilt switch to achieve proper boat performance. 26 The tachometer shows engine speed in revolutions per minute.
03/07/02 10:17:09 31ZW2600_029 CONTROLS AND FEATURES Overheating Indicator SRT and LRT Types (side-mount type) If the engine overheats, the red light will come on, and the engine protection system will limit engine speed. SHG and LHT Types (RED) (RED) Remote controls are also equipped with a buzzer that sounds when the red light comes on. Engine overheating may be the result of clogged water intakes.
03/07/02 10:17:19 31ZW2600_030 CONTROLS AND FEATURES Cooling System Indicator OTHER FEATURES Anodes Overrev Limiter The engine is equipped with an overrev limiter to prevent the possibility of mechanical damage from excessive engine speed. COOLING SYSTEM INDICATOR Water should flow from the cooling system indicator while the engine is running. This shows that water is circulating through the cooling system.
03/07/02 10:17:28 31ZW2600_031 CONTROLS AND FEATURES The anodes are made of a sacrificial material that helps to protect the outboard motor from corrosion. Portable Fuel Tank Fuel Cap Vent Knob VENT KNOB There are two anodes on the gear case, one on the stern bracket, and another is the trim tab. OPEN CLOSE FUEL CAP The portable fuel tank has a capacity of 6.6 US gal ( 25 ) and has a fuel gauge built into the cap.
03/07/02 10:17:34 31ZW2600_032 CONTROLS AND FEATURES Fuel Priming Bulb UP OUTLET END (MOTOR) PRIMING BULB INLET END (TANK) A priming bulb is built into the fuel hose that connects the fuel tank to the outboard motor. Before starting the engine, hold the priming bulb up in the direction of the arrow, then squeeze the priming bulb until it feels firm. This will ensure that fuel is supplied to the engine (p. 43 ).
03/07/02 10:17:46 31ZW2600_033 INSTALLATION Correct and secure installation is essential for safe boating and good performance. Follow the installation instructions provided in this manual. POWER REQUIREMENTS Before installation, check to be sure that the outboard motor does not exceed the recommended maximum horsepower for the boat on which it is to be installed. Refer to the boat’s certification plate for recommended maximum horsepower.
03/07/02 10:17:56 31ZW2600_034 INSTALLATION When the outboard motor is installed extremely low, the idle port may be immersed and the engine may become hard to start or may run poorly. Check that the idle port is high enough from the water level when the engine is stopped with the boat fully loaded. ATTACHMENT Attach the stern bracket to the boat transom by tightening the clamp screws. Attach a rope from the boat to the hole in the stern bracket.
03/07/02 10:18:18 31ZW2600_036 INSTALLATION Plug and Receptacle (types with recoil starter) Battery Terminals DC RECEPTACLE ( ＋ ) TERMINAL ( − ) TERMINAL − TO BATTERY RED BATTERY To prepare the outboard motor for connection to a battery, pull the cover out of the DC receptacle, connect your battery charging wires to the receptacle. Attach the connected DC receptacle on the holder on the tiller arm.
03/07/02 10:18:21 31ZW2600_037 INSTALLATION Be caref ul to avoid connecting the battery in reverse polarity, as that will damage the battery-charging system in the outboard motor.
03/07/02 10:18:33 31ZW2600_038 BEFORE OPERATION ARE YOU READY TO GET UNDER WAY？ Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury. Safety Always wear a PFD (Personal Flotation Device) while on the boat. Attach the emergency stop switch lanyard securely to your PFD or to your wrist. Knowledge Read and understand this manual. Know what the controls do and how to operate them.
03/07/02 10:18:47 31ZW2600_039 BEFORE OPERATION Safety Inspection Look around the outboard motor for signs of oil or gasoline leaks. If you are using the portable fuel tank, make sure it is in good condition and properly secured in the boat (p. 42 ). Check that the fuel hose is undamaged and properly connected (p. 42 ). Wipe up any spills before starting the engine. Check that all fasteners are in place and securely tightened. Maintenance Inspection Check the engine oil level (p. 71 ).
03/07/02 10:19:01 31ZW2600_040 OPERATION SAFE OPERATING PRECAUTIONS BREAK-IN PROCEDURE Break-in period: 10 hours Next 60 minutes: Run the engine up to a maximum of 4,000 to 5,000 rpm, which is about 50% to 80% of maximum throttle opening. To safely realize the full potential of this outboard motor, you need a complete understanding of its operation and a certain amount of practice with its controls.
03/07/02 10:19:12 31ZW2600_041 OPERATION TRANSOM ANGLE ADJUSTMENT The transom angle adjusting rod limits the tilt angle of the outboard motor when fully lowered. Proper adjustment prevents the outboard motor from being trimmed too low (p. 56 ). TURN UP PUSH TRANSOM ANGLE ADJUSTING ROD TRANSOM ANGLE ADJUSTING ROD TO CHANGE UNLOCKED POSITION LOCKED POSITION 40 TO LOCK Do not allow water to enter the idle exhaust port or the engine can be damaged.
03/07/02 10:19:21 31ZW2600_042 OPERATION Motor Angle Inspection (Cruising) INCORRECT CAUSES BOAT TO ‘‘PLOW’’ INCORRECT CAUSES BOAT TO ‘‘SQUAT’’ O. K CORRECT GIVES MAXIMUM PERFORMANCE Install the outboard motor at the best trim angle for stable cruising and maximum power. Trim angle too large: Incorrect causes boat to ‘‘squat’’. Trim angle too small: Incorrect causes boat to ‘‘plow’’.
03/07/02 10:19:34 31ZW2600_043 OPERATION PORTABLE FUEL TANK Secure the portable fuel tank in the boat, so it won’t move around and become damaged. FUEL HOSE CONNECTIONS FUEL HOSE CONNECTOR Before use, open the fuel tank vent by turning the vent knob at least 2 or 3 turns counterclockwise. FUEL HOSE Place the portable fuel tank in a wellventilated location, away from direct sunlight, to reduce the possibility of a gasoline vapor explosion.
03/07/02 10:19:44 31ZW2600_044 OPERATION FUEL PRIMING STARTING THE ENGINE UP OUTLET END (MOTOR) SH, LH, SHG and LHT Types (long tiller handle) EMERGENCY STOP SWITCH PRIMING BULB Check to be sure there are no fuel leaks before starting the engine. Do not squeeze the priming bulb when the engine is running because that could flood the carburetors. The emergency stop switch clip and lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat.
03/07/02 10:19:53 31ZW2600_045 OPERATION N (neutral) RECOIL STARTER GRIP START POSITION POINTER THROTTLE GRIP SHIFT LEVER 2. Check the position of the gearshift lever. It must be in the N (neutral) position for starting. The engine will not start if the gearshift lever is in the F (forward) or R (reverse) position. 3. Align the engine start symbol ‘‘ ’’ on the tiller handle with the pointer ‘‘ ’’ on the throttle grip.
03/07/02 10:20:06 31ZW2600_046 OPERATION 4. Recoil starter type: Pull the recoil starter grip slowly until you feel resistance, then pull briskly. Return the starter grip gently. Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can damage it. Electric starter type: Turn the ignition switch key to the START position and hold it there until the engine starts.
03/07/02 10:20:16 31ZW2600_047 OPERATION SRG, LRG, SRT and LRT Types (remote control) The engine will not start or run, unless the clip is in the switch. For panel-mount or top-mount remote control information, refer to the instructions provided with the remote control equipment. The emergency stop switch clip and lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat.
03/07/02 10:20:27 31ZW2600_048 OPERATION ON FAST IDLE OFF START START Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can damage it. Turning the ignition switch key to the START position while the engine is running can damage the starter motor and f lywheel. FAST IDLE LEVER IGNITION SWITCH KEY 3. To start a cold engine, leave the fast idle lever in the START (fully lowered) position. 4.
03/07/02 10:20:40 31ZW2600_049 OPERATION FAST IDLE LEVER 6. Before getting under way, allow the engine to warm up sufficiently to ensure good performance. Above 41°F (5°C), warm up the engine for 2 or 3 minutes. Below 41°F (5°C), warm up the engine for at least 10 minutes at 2,000 rpm. 5. If the fast idle lever was used to start the engine, gradually lower the lever as the engine warms up. When the fast idle lever is fully lowered, the control lever can be moved away from the N (neutral) position.
03/07/02 10:20:53 31ZW2600_050 OPERATION 6 × 22 mm BOLT RECOIL STARTER ASSEMBLY 6 × 22 mm BOLT KNOT FLYWHEEL NEUTRAL START CABLE EMERGENCY STARTER ROPE FLYWHEEL COVER (Recoil starter type) 2. Recoil starter type: Loosen the neutral start cable lock nut and disconnect the neutral start cable. Remove the recoil starter assembly by unscrewing the four starter assembly bolts. (Electric starter type) Electric starter type: Remove the flywheel cover by unscrewing the four cover bolts. 3.
03/07/02 10:21:04 31ZW2600_051 OPERATION EMERGENCY STARTER ROPE 6. If the fast idle control(s) was used to start the engine, return the control(s) to the normal operating position as the engine warms up. During the warm-up period, check the oil pressure indicator (p. 27 ), overheating indicator (p. 28 ), and cooling system indicator (p. 29 ). 7. Leave the recoil starter assembly off, but install the engine cover (p. 70 ), and lock it in place by latching the engine cover latch. 5.
03/07/02 10:21:17 31ZW2600_052 OPERATION STOPPING THE ENGINE Emergency Engine Stopping SH, LH, SHG and LHT Types (long tiller handle) EMERGENCY STOP SWITCH To stop the engine in an emergency, pull the clip out of the emergency stop switch by pulling the lanyard. Normal Engine Stopping SH, LH, SHG and LHT Types (long tiller handle) We suggest that you stop the engine this way occasionally to verify that the emergency stop switch is operating properly.
03/07/02 10:21:28 31ZW2600_053 OPERATION SRG, LRG, SRT and LRT Types (remote control) N (neutral) SH and LH Types (long tiller handle) SRG, LRG, SRT and LRT Types (remote control) EMERGENCY STOP SWITCH PRESS CONTROL LEVER OFF IGNITION SWITCH KEY 1. Move the throttle grip to the slowest speed and control gears to N (neutral) position. SHG and LHT Types (long tiller handle) 3. When the boat is not in use, remove and store the ignition key and the emergency stop switch clip and lanyard.
03/07/02 10:21:47 31ZW2600_055 OPERATION SRG, LRG, SRT and LRT Types (remote control) To shift gears, move the control lever to select F (forward), N (neutral) and R (reverse) gears. Side-Mount Type CONTROL LEVER Moving the control lever beyond the gear selection range increases engine speed. NEUTRAL RELEASE LEVER 54 TO INCREASE FRICTION The control lever cannot be moved from the N (neutral) position unless the neutral release lever is squeezed.
03/07/02 10:22:00 31ZW2600_056 OPERATION STEERING Steering Friction Adjuster SH, LH, SHG and LHT Types (long tiller handle) SH and LH Types STEERING FRICTION ADJUSTER BOLT TO DECREASE FRICTION (FREE) TO INCREASE FRICTION (LOCK) Steer by moving the tiller handle opposite the direction you want the boat to turn. Use the steering friction adjuster to help hold a steady course while cruising. Move the adjuster to the LOCK direction to increase steering friction for holding a steady course.
03/07/02 10:22:16 31ZW2600_057 OPERATION CRUISING Engine Speed For best fuel economy, limit the throttle opening to 80%. Use the throttle friction control (p. 53 and 54 ) to help you hold a steady speed. For rough water conditions or large waves, slow down to prevent the propeller from rising out of the water. The engine is equipped with an overrev limiter to prevent the possibility of mechanical damage from excessive engine speed.
03/07/02 10:22:52 31ZW2600_060 OPERATION SHG, SRG and LRG Types ENGINE COVER GRIP When operating in shallow water, tilt the outboard motor, using the tilt lever, so the propeller and gear case won’t hit the bottom. TILT While the outboard motor is tilted, proceed at a low speed, and do not operate the outboard motor in reverse. The outboard motor will rise suddenly if operated in reverse. Monitor water flow from the cooling system indicator (p.
03/07/02 10:23:15 31ZW2600_062 OPERATION MOORING, BEACHING, LAUNCHING An excessive tilt angle during operation can cause propeller ventilation, overheating, and water pump damage. SH and LH Types SHG, SRG and LRG Types Use the tilt lever to raise and lower the outboard motor as described on p. 59 .
03/07/02 10:23:24 31ZW2600_063 OPERATION If more clearance is needed to swing the tilt lock lever into the LOCK position, rock the outboard motor back slightly by pulling on the engine cover grip. RIGHT STERN BRACKET MANUAL RELIEF VALVE LOCK FREE To lower the outboard motor, tilt up, move the tilt lock lever to the FREE position, then lower the outboard motor to the desired position.
03/07/02 10:23:27 31ZW2600_064 OPERATION Be sure the valve is closed before operating the outboard motor. If the valve is not closed, the outboard motor will tilt up when operated in reverse.
03/07/02 10:23:37 31ZW2600_065 SERVICING YOUR OUTBOARD MOTOR THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. Improperly maintaining this outboard motor, or failure to correct a problem before operation, can cause a malfunction in which you could be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.
03/07/02 10:23:48 31ZW2600_066 SERVICING YOUR OUTBOARD MOTOR MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in the owner’s manual.
03/07/02 10:23:56 31ZW2600_067 SERVICING YOUR OUTBOARD MOTOR SPARE EMERGENCY STOP SWITCH CLIP (long tiller handle type) AND EMERGENCY STARTER ROPE TOOL KIT 10 × 12 mm WRENCH PLIERS OIL CHECK SCREWDRIVER SPARE EMERGENCY STOP SWITCH CLIP (long tiller handle type) 18×19 mm SOCKET WRENCH FLAT SCREWDRIVER PHILLIPS SCREWDRIVER 8 mm WRENCH TOOL BAG SCREWDRIVER HANDLE EMERGENCY STARTER ROPE Always carry the spare emergency stop switch clip and the emergency starter rope onboard.
03/07/02 10:24:10 31ZW2600_068 SERVICING YOUR OUTBOARD MOTOR MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (3) Perform at every indicated month or operating hour interval, whichever comes first.
03/07/02 10:24:24 31ZW2600_069 SERVICING YOUR OUTBOARD MOTOR REGULAR SERVICE PERIOD (3) Perform at every indicated month or operating hour interval, whichever comes first. ITEM Thermostat Fuel filter Fuel line Battery and cable connection Bolts and nuts Crankcase breather tube Cooling water passages Each use Check Check Replace Check Replace Check level-tightness Check-tightness Check Clean After use First month or 20 hrs. Every 6 months or 100 hrs. Every year or 200 hrs. Every 2 years or 400 hrs.
03/07/02 10:24:38 31ZW2600_070 SERVICING YOUR OUTBOARD MOTOR TRIM TAB ADJUSTMENT The trim tab compensates for ‘‘torque steer’’ which is a reaction of the outboard motor to propeller rotation. LEFT If uncompensated, torque steer would make the outboard motor tend to turn to one side. RIGHT When the trim tab is correctly adjusted, steering effort is equal in either direction. If steering effort is unequal, loosen the trim tab bolt and adjust the angle of the trim tab. Retighten the trim tab bolt securely.
03/07/02 10:25:01 31ZW2600_072 SERVICING YOUR OUTBOARD MOTOR Engine Oil Level Check OIL FILLER CAP Check the engine oil level with the engine stopped and the outboard motor in the vertical position. Running the engine with a low oil level can cause engine damage. 5. Install the oil filler cap and tighten it securely. 1. Unlatch and remove the engine cover. 6. Install and lock the engine cover. 2. Remove the dipstick and wipe it clean. (P.70) OIL LEVEL DIPSTICK UPPER LIMIT 4.
03/07/02 10:25:09 31ZW2600_073 SERVICING YOUR OUTBOARD MOTOR Engine Oil Change SEALING WASHER Improper disposal of engine oil can be harmf ul to the environment. If you change your own oil, please dispose of the used oil properly. Put it in a sealed container, and take it to a recycling center. Do not discard it in a trash bin or dump it on the ground. An engine oil evacuation device may be used to remove the engine oil. Drain the used oil while the engine is warm.
03/07/02 10:25:29 31ZW2600_075 SERVICING YOUR OUTBOARD MOTOR Lubrication Points Wipe the outside of the engine with a cloth dipped in oil. Apply marine anticorrosion grease to the following parts: Lubrication interval: After the first 20 hours or 1 month, then every 100 hours or 6 months. (Refer to the maintenance schedule page 67 ). TILLER HANDLE TILT SHAFT MOUNT FRAME CLAMP SCREWS To prevent corrosion, apply anticorrosion oil to pivot surf aces where grease cannot penetrate.
03/07/02 10:25:41 31ZW2600_076 SERVICING YOUR OUTBOARD MOTOR Spark Plug Service 0.024 − 0.028 in (0.60 − 0.70 mm) RECOMMENDED SPARK PLUGS: DR7EA (NGK) X22ESR-U (DENSO) Incorrect spark plugs can cause engine damage. 1. Unlatch and remove the engine cover (p. 70 ). 2. Disconnect the spark plug caps from the spark plugs. 3. Remove the spark plugs with a spark plug wrench. SEALING WASHER SPARK PLUG CAPS SPARK PLUG WRENCH 4. Inspect the spark plugs.
03/07/02 10:25:50 31ZW2600_077 SERVICING YOUR OUTBOARD MOTOR 7. After each spark plug seats, tighten with a spark plug wrench to compress the sealing washer. If reinstalling used spark plugs, tighten 1/8 - 1/4 turn after the spark plugs seat. If installing new spark plugs, tighten 1/2 turn after the spark plugs seat. 6. Install the spark plugs carefully, by hand, to avoid cross-threading. Loose spark plugs can overheat and damage the engine.
03/07/02 10:26:04 31ZW2600_078 SERVICING YOUR OUTBOARD MOTOR REFUELING Portable Fuel Tank Gasoline is highly flammable and explosive. FUEL TANK CAPACITY: 6.6 US gal (25 ) Check the fuel gauge and refill the tank when necessary. FUEL GAUGE SAFE FILL LEVEL Remove the fuel tank from the boat for refueling. VENT KNOB CLOSE You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.
03/07/02 10:26:12 31ZW2600_079 SERVICING YOUR OUTBOARD MOTOR FUEL RECOMMENDATIONS Use unleaded gasoline with a pump octane rating of 86 or higher. Your outboard motor is certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.
03/07/02 10:26:39 31ZW2600_082 SERVICING YOUR OUTBOARD MOTOR FUEL HOSE CLIPS FUEL PUMP 7. Securely connect the fuel hose connector to the outboard motor (refer to page 42 ). Portable Fuel Tank and Filter Cleaning Fuel Tank 8. Prime the engine using the priming bulb (p. 43 ). Check for fuel leaks. Repair any fuel leaks if necessary. FUEL HOSE If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fuel tank.
03/07/02 10:26:49 31ZW2600_083 SERVICING YOUR OUTBOARD MOTOR Anode Replacement Fuel Tank Filter TANK FILTER JOINT (Fuel Connector) The anodes are located on the trim tab and the stern bracket. They are made of a sacrificial material that helps to protect the outboard motor from corrosion. Replace the anodes when they have been reduced to about half their original size, or if they are crumbling. FILTER 1.
03/07/02 10:26:59 31ZW2600_084 SERVICING YOUR OUTBOARD MOTOR Propeller Replacement Removal Installation Before replacing the propeller, remove the clip from the engine stop switch to prevent any possibility of the engine being started while you are working with the propeller. Remove the cotter pin, unscrew the castle nut, remove the washer, then remove the propeller and thrust washer. Install the propeller in the reverse order of removal.
03/07/02 10:27:10 31ZW2600_085 STORAGE STORAGE PREPARATION Cleaning Proper storage preparation is essential for keeping your outboard motor troublefree and looking good. The following steps will help to keep rust and corrosion from impairing your outboard motor’s function and appearance, and will make the engine easier to start when you use the outboard motor again. Wash the outside of the outboard motor with clean, fresh water, and flush the cooling system as described.
03/07/02 10:27:18 31ZW2600_086 STORAGE GARDEN HOSE ADAPTER (FLUSH KIT COUPLER) 4. Move the gearshift lever or control lever to the N (neutral) position. Flush the outboard motor in the neutral position only. 5. Turn on the fresh water supply to the flush kit coupler. Running the engine without good water circulation can cause overheating and water pump damage. 2. Remove the sealing washer from the wash plug and install the sealing washer on the flush kit coupler. 3.
03/07/02 10:27:26 31ZW2600_087 STORAGE WATER INTAKES 9. Remove the sealing washer from the garden hose adapter and install the sealing washer on the wash plug. If tape was used to cover the three water intakes in step 6, remove the tape now. Flushing Without the Honda Garden Hose Adapter It is necessary to run the engine during the flushing procedure. For safety, remove the propeller from the outboard motor (p. 83 ). 10. Install the wash plug into the gear case securely. 7.
03/07/02 10:27:38 31ZW2600_088 STORAGE Fuel Running the engine without good water circulation can cause overheating and water pump damage. Damage caused by running the outboard motor without sufficient cooling water is not covered by the Distributor’s Limited Warranty. 2. Start the engine and run in the N (neutral) position at low speed for at least 10 minutes. 3. After flushing, stop the engine, remove the water container, and reinstall the propeller (p. 83 ).
03/07/02 10:28:07 31ZW2600_090 STORAGE 5. Repeat this procedure to drain ＃3 carburetor. 6. After all three carburetors are drained, reinstall the drain tube on ＃1 carburetor. 7. Drain the fuel tank into an approved gasoline container, or if you need to store fuel in the fuel tank, you can extend fuel storage life by filling the fuel tank with fresh gasoline and adding a fuel stabilizer that is formulated for that purpose. If using the portable fuel tank, firmly close the fuel tank vent knob.
03/07/02 10:28:15 31ZW2600_091 STORAGE If the outboard motor will be removed from the boat for storage, we recommend storing it vertically by mounting it on a stand. Cover the outboard motor to keep out dust. Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture, promoting rust and corrosion. REMOVAL FROM STORAGE Check your outboard motor as described in the BEFORE OPERATION chapter of this manual.
03/07/02 10:28:32 31ZW2600_093 TRANSPORTING WITH OUTBOARD MOTOR REMOVED FROM BOAT To carry, hold the outboard motor by the carrying handle, or hold by the carrying handle and the lug beneath engine cover lock lever, as shown. Secure the outboard motor in either the vertical or horizontal position shown on p. 90 . Lif ting the outboard motor by the engine cover, or using the installed outboard motor as a handle or lever to move the boat, can damage the outboard motor.
03/07/02 10:28:42 31ZW2600_094 TRANSPORTING HOIST HOOK LIFTING EYE When transporting the outboard motor on a vehicle, perform the following. 1. Remove the engine cover, lift the outboard motor using the engine lifting eye, and place on the outboard motor stand. 2. Secure the outboard motor with the bolts and nuts. 3. Reinstall the engine cover.
03/07/02 10:28:56 31ZW2600_095 TAKING CARE OF UNEXPECTED PROBLEMS ELECTRIC STARTER WILL NOT OPERATE 1. Check battery. Possible Cause Correction Battery connections loose or corroded. Clean and tighten battery connections. Battery discharged. Recharge battery. 2. Check fuse. Fuse burnt out. Replace fuse (p. 97 ). 3. Use emergency starting procedure (p. 48 ), then take outboard motor to an authorized Honda Marine dealer, or refer to the shop manual.
03/07/02 10:29:07 31ZW2600_096 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction 1. Check emergency stop switch clip. Clip not inserted in stop switch. Insert clip in stop switch. 2. Check control positions. Gearshift lever or control lever not in neutral position. Shift to neutral (p. 44 and 46 ). Throttle grip not in START position (long tiller-handle type). Turn throttle grip to START position (p. 44 ). Fast idle lever not raised (sidemount type).
03/07/02 10:29:22 31ZW2600_097 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START (continued) 3. Check fuel. 4. Remove and inspect spark plugs. 5. Take outboard motor to an authorized Honda marine dealer, or refer to the shop manual. 96 Possible Cause Correction Out of fuel. Refuel (p. 77 ). Fuel vent closed (portable fuel tank). Open fuel tank vent (p. 30 ). Fuel hose not primed. Squeeze priming bulb (p. 31 ). Fuel pump filter or fuel tank filter clogged. Replace fuel filters (p.
03/07/02 10:29:35 31ZW2600_098 TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS AFTER STARTING 1. Check control positions. 2. Check fuel. Possible Cause Correction Throttle grip not in START position (long tiller-handle type). Turn throttle grip to START position (p. 44 ). Fast idle lever not raised (sidemount type). Raise fast idle lever, unless engine is warm (p. 46 ). Fuel vent closed (portable fuel tank). Open fuel tank vent (p. 30 ). Fuel hose not primed.
03/07/02 10:29:52 31ZW2600_099 TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS AFTER STARTING (continued) Possible Cause Correction 3. Remove and inspect spark plugs. Spark plugs faulty, fouled or improperly gapped. Gap or replace spark plugs (p. 75 ). 4. Take outboard motor to an authorized Honda marine dealer, or refer to the shop manual. Carburetor malfunction, fuel pump failure, ignition malfunction, etc. Replace or repair faulty components as necessary.
TAKING CARE OF UNEXPECTED PROBLEMS BATTERY WILL NOT CHARGE AND ELECTRIC STARTER WILL NOT OPERATE 10A FUSE FUSE COVER 15A, 10A Never use a f use with a rating greater than specif ied. Serious damage to the electrical system could result.
03/07/02 10:30:15 31ZW2600_101 TAKING CARE OF UNEXPECTED PROBLEMS OIL PRESSURE INDICATOR LIGHT GOES OFF AND ENGINE SPEED IS LIMITED (GREEN) (GREEN) BUZZER (remote control type) (long tiller handle/SH and LH types) (GREEN) (long tiller handle/SHG and LHT types) 100 If oil pressure becomes low, the green indicator light will go off, and the engine protection system will limit engine speed. If you are at cruising speed, engine speed will decrease gradually.
03/07/02 10:30:25 31ZW2600_102 TAKING CARE OF UNEXPECTED PROBLEMS OVERHEATING INDICATOR LIGHT COMES ON AND ENGINE SPEED IS LIMITED (RED) If the engine overheats, the red indicator light will come on, and the engine protection system will limit engine speed. If you are at cruising speed, engine speed will decrease gradually. Remote-control types are equipped with a buzzer that sounds when the red indicator light comes on.
03/07/02 10:30:35 31ZW2600_103 TAKING CARE OF UNEXPECTED PROBLEMS If there is no water flowing from the cooling system indicator, stop the engine, and tilt the outboard motor to inspect the water intake screens. If restricted, clean the water intake screens, return the outboard motor to the running position, restart the engine, and check the cooling system indicator again.
03/07/02 10:30:54 31ZW2600_105 TECHNICAL AND CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Locations PRODUCT IDENTIFICATION NUMBER STARTER MOTOR Record the product identification number and engine serial number in the space provided on this page. You will need these numbers when ordering parts, and when making technical or warranty inquiries (p. 113 ). SWIVEL CASE 104 ENGINE SERIAL NUMBER The product identification number is stamped on a plate attached on top of the swivel case.
03/07/02 10:31:02 31ZW2600_106 TECHNICAL AND CONSUMER INFORMATION Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plugs and cause hard starting. High altitude performance can be improved by specific modifications to the carburetors.
03/07/02 10:31:13 31ZW2600_107 TECHNICAL AND CONSUMER INFORMATION Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.
03/07/02 10:31:23 31ZW2600_108 TECHNICAL AND CONSUMER INFORMATION Emission Control System Information The U.S. and Calif ornia Clean Air Acts Source of Emissions EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems. The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons.
03/07/02 10:31:33 31ZW2600_109 TECHNICAL AND CONSUMER INFORMATION Problems That May Af f ect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption.
03/07/02 10:31:58 31ZW2600_111 TECHNICAL AND CONSUMER INFORMATION One Star Low Emission The one-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S.EPA’s 2006 standards for marine engines.
03/07/02 10:32:39 31ZW2600_112 TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description Code Type Overall length Overall width Overall height Transom height Weight Rated power Full throttle range Engine type Displacement Starter system Ignition system Lubrication system Specified oil H BF25D BATJ HG 28.3 in (720 mm) 14.8 in (375 mm) 47.0 in (1,195 mm) 52.0 in (1,320 mm) 17.0 in (431 mm) 21.7 in (552 mm) Oil capacity HT S L S L S 155.4 lbs (70.5 kg) 179.7 lbs (81.5 kg) 188.5 lbs (85.
03/07/02 10:33:17 31ZW2600_113 TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description Code Type Overall length Overall width Overall height Transom height Weight Rated power Full throttle range Engine type Displacement Starter system Ignition system Lubrication system Specified oil BF25D BATJ RG S L S L S L RT 25.2 in (640 mm) 14.8 in (375 mm) 47.0 in (1,195 mm) 52.0 in (1,320 mm) 17.0 in (431 mm) 21.7 in (552 mm) 169.8 lbs (77.0 kg) 174.2 lbs (79.0 kg) 174.2 lbs (79.0 kg) 178.6 lbs (81.
03/07/02 10:33:58 31ZW2600_114 TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description Code Type Overall length Overall width Overall height Transom height Weight Rated power Full throttle range Engine type Displacement Starter system Ignition system Lubrication system Specified oil H BF30D BAUJ HG 28.3 in (720 mm) 14.8 in (375 mm) 47.0 in (1,195 mm) 52.0 in (1,320 mm) 17.0 in (431 mm) 21.7 in (552 mm) Oil capacity HT S L S L 179.7 lbs (81.5 kg) S 188.5 lbs (85.5 kg) L 159.8 lbs (72.
03/07/02 10:34:35 31ZW2600_115 TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description Code Type Overall length Overall width Overall height Transom height Weight Rated power Full throttle range Engine type Displacement Starter system Ignition system Lubrication system Specified oil BF30D BAUJ RG S L S L S L RT 25.2 in (640 mm) 14.8 in (375 mm) 47.0 in (1,195 mm) 52.0 in (1,320 mm) 17.0 in (431 mm) 21.7 in (552 mm) 174.2 lbs (79.0 kg) 174.2 lbs (79.0 kg) 178.6 lbs (81.0 kg) 22.
03/07/02 10:34:51 31ZW2600_116 TECHNICAL AND CONSUMER INFORMATION CONSUMER INFORMATION Warranty Service Information Or telephone: (770) 497-6400 Honda Publications Honda Marine dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management. The Service Manager or General Manager can help. Almost all problems are solved in this way.
03/07/02 10:34:56 31ZW2600_117 INDEX Anodes ............................................................................ 29 Replacement ............................................................... 82 ARE YOU READY TO GET UNDER WAY？ .......... 37 ATTACHMENT ............................................................ 33 Battery .......................................................................... 105 Connections ................................................................
03/07/02 10:35:00 31ZW2600_118 INDEX Gearshift Lever............................................................... 18 Gearshift/Trottle Control Lever SRG, LRG, SRT and LRT Types (remote control) Side-Mount Type ................................................... 22 GEARSHIFTING AND THROTTLE OPERATION ... 53 SH, LH, SHG and LHT Types (long tiller handle).... 53 SRG, LRG, SRT and LRT Types (remote control) ... 54 Honda Publications ......................................................
03/07/02 10:35:04 31ZW2600_119 INDEX Recoil Starter Grip (SH and LH types) .......................... 16 REFUELING.................................................................. 77 REMOVAL FROM STORAGE .................................... 90 SAFE OPERATING PRECAUTIONS ......................... 39 SAFETY LABEL LOCATIONS ..................................... 9 Serial Number Locations.............................................. 104 SERVICING YOUR OUTBOARD MOTOR ...............
03/07/02 10:35:07 31ZW2600_120 INDEX TRANSPORTING ......................................................... 91 WITH OUTBOARD MOTOR INSTALLED ON BOAT .............................................................. 91 WITH OUTBOARD MOTOR REMOVED FROM BOAT ........................................................ 92 Trim Meter (optional equipment) .................................. 26 Trim Tab ................................................................... 25, 58 TRIM TAB ADJUSTMENT ........................
BF25D/BF30D OwnerÕs Manual 31ZW2600 00X31-ZW2-6000 N 2eY1500.2003.07 Printed in Japan 2004 ©2003 Honda Motor Co., Ltd.
