HONDA 02001 Honda Motor Co., Ltd.
The engine exhaust from this product containschemicals 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., Ltd.
INTRODUCTION Congratulations on your selection of a Honda outboard motor. We are certain you will be pleased with your purchase of one of the finest outboard motors on the market. We want to help you get the best results from your new outboard motor and to operate it safely. This manual contains the information on how to do that; please read it carefully. As you read this manual you will find information preceded by a symbol.
INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this outboard motor safely is an important responsibility. You will find important safety information in a variety of forms, including: Safety Labels - on the outboard motor. A Safety Messages - preceded by a safety alert symbol and one of three signal words, DANGER, WARNING,or CAUTION.
CONTENTS OUTBOARD MOTOR SAFETY.................................... 7 IMPORTANT SAFETY INFORMATION................. 7 ................................. 9 SAFETY LABEL LOCATIONS CONTROLS AND FEATURES ................................... 10 CONTROL AND FEATURE IDENTIFICATION 10 CODES ................................................................... COMPONENT AND CONTROL LOCATIONS..... 11 CONTROLS ............................................................... 15 Side-Mount Type Ignition Switch ...............
CONTENTS OPERATION ................................................................. 34 INDICATORS............................................................ 28 34 SAFE OPERATING PRECAUTIONS..................... Alternator (AGC) Indicator .................................... 28 BREAK-IN PROCEDURE........................................ 34 Programmed Fuel Injection (PGM-FI) Indicator ... 28 FUEL PRIMING........................................................ 35 Oil Pressure Indicator .......................
CONTENTS SERVICING YOUR OUTBOARD MOTOR ............... 52 THE IMPORTANCEOF MAINTENANCE ............ 52 MAINTENANCE SAFETY...................................... 53 TOOL KIT (optional equipment)............................... 54 MAINTENANCE SCHEDULE................................ 55 TRIM TAB ADJUSTMENT..................................... 57 MANUAL RELIEF VALVE..................................... 58 ENGINE COVER REMOVAL AND INSTALLATION................................................... 58 Latch Adjustment.
CONTENTS TRANSPORTING ......................................................... WITH OUTBOARD MOTOR INSTALLED ON BOAT....................................... WITH OUTBOARD MOTOR REMOVED FROM BOAT................................... 81 INDEX .......................................................................... 81 WIRING DIAGRAMS......................... 81 TAKING CAREOF UNEXPECTED PROBLEMS..... 82 BATTERY WILL NOT CHARGE AND ELECTRIC STARTER WILL NOT OPERATE..........................................
OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION Honda BF200NBF225A 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. The most common hazards are discussed below, along with the best way to protect yourself and others.
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. Refuel carefully to avoid spilling fuel. Avoid overfilling the fuel tank. After refueling, tighten the filler cap securely. If any fuel is spilled, make sure the area is dry before starting the engine.
OUTBOARD MOTOR SAFETY SAFETY LABEL LOCATIONS I A WARNING I P L A C ET R A N S M I S S I O NI NN E U T R A LB E F O R ES T A R T I N G . I D 0 NOTOPERATEWITHENGINECOVERREMOVED. I S BELOW THE I B E S U R ET H EA N T I V E N T I L A T I O NP L A T E WATER L I N E . I D 0 N O TS H I F T TO REVERSESUDDENLYATHIGH SPEED. 1 I C H E C KO I LL E V E LB E F O R ES T A R T I N G . I F L U S HT H ES Y S T E MT H O R O U G H L YW I T HF R E S H AFTEREACHUSEINSALTWATER.
CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES Model BFZOOA LA Type XA XCA BF225A XXA XXCA 20.0 in (508 mm) TransomHeight e e e e 30.0 in (762 nun) e e XXA e e e e e e e e e e e e TYPE CODE (example) Destination A: America Rotating direction of propeller shaft C: Counterrotating propeller shaft None: Standard rotating propeller shaft Transom Height L: 20.0 in (508 mm), X: 25.0 in (635 mm), XX: 30.
CONTROLS AND FEATURES COMPONENT AND CONTROL LOCATIONS OIL FILLER CAP (inside engine cover) OIL LEVEL DIPSTICK \ COVER/ENGINE J SPARK PLUG (under coil) COOLING SYSTEM INDICATOR ENGINE COVER : LATCH L TILT LOCK ENGINE OIL DRAIN BOLT...., (inside cover) STERN BRACKET '......
CONTROLS AND FEATURES Remote Controls (optional equipment) (SIDE-MOUNT REMOTE CONTROL) GEARSHIFTmHROTTLE CONTROL LEVER (PANEL-MOUNT REMOTE CONTROL) NEUTRAL RELEASE GEARSHIFTiTHROTTLE CONTROL LEVER NEUTRAL OIL PRESSURE DICATOR LIGHT SPARE SWITCH CLI CONTROL LEVER FRICTION ADJUSTER LANYARD EMERGENCY STOP SWITCH SWITCH CLIP 12
CONTROLS AND FEATURES (DUAL TOP-MOUNT REMOTE CONTROL) (SINGLE TOP-MOUNT REMOTE CONTROL) GEARSHIFTRHROTTLE CONTROL LEVER GEARSHIFTRHROTTLE CONTROL LEVERS POWER TRIM/TILT SWITCH (RIGHT) POWER TRIM/TILT SWITCH (LEFT) FAST IDLE BUTTON CONTROL PANEL (for PANELD'OP-MOUNT type) OIL PRESSURE INDICATOR LIGHT INDICATOR LIGlI T SWITCH CLIP EMERGENCY STOP SWITCH 13
CONTROLS AND FEATURES Trim Meter (optional equipment) 14
CONTROLS AND FEATURES CONTROLS Side-Mount Type Ignition Switch 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. The ignition switch can be used to operate the starter motor only when the control lever (p. 17 ) is in the N (neutral) position, and the switch clip is in the emergency stop switch. Turning the ignition switch to the OFF position stops the engine.
CONTROLS AND FEATURES Switch Clip and Emergency Stop Switch EMERGENCY STOP SWITCH \ The switch clip must be inserted in the emergency stop switch in order for the engineto start and run. The lanyard must be attached to the operator’s PFD (Personal Flotation Device) or worn around the wrist as shown. Gearshift/Throttle Control Lever CONTROL LEVER When used as described, the emergency stop switch and lanyard system stops the engineif the operator falls away from the controls.
CONTROLS AND FEATURES Moving the control lever 30" from N (neutral) selects the gear, and further movement increases engine speed. N (NEUTRAL) 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. A friction adjuster near the base of the control lever(s) adjusts the operating resistance of the control lever(s).
CONTROLS AND FEATURES Fast Idle Lever Panel-Mount Type N (neutral) MAXIMUM FAST IDLE Ignition Switch START ON OFF ' IGNITION SWITCH KEY The fast idle lever is only needed for starting carbureted outboard models. The BF200A and BF225A models use programmed fuel injection so, this lever will not be needed for starting. The fast idle lever will not move unless the remote control lever is in the N (neutral) position.
CONTROLS AND FEATURES 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. Switch Clip and Emergency Stop Switch EMERGENCY STOP SWITCH The ignition switch can be used to operate the starter motor only when the control lever (p. 21 ) is in the N (neutral) position, and the switch clip is in the emergency stop switch. Turning the ignition switch to the OFF position stops the engine.
CONTROLS AND FEATURES Fast Idle Button N (neutral) It is necessary to position the control lever in N (neutral) to push in the fast idle button. Gearshift/Throttle Control Lever CONTROL LEVER LEVER FAST IDLE BUTTON By moving the control lever forward or reverse when the fast idle button is pushed in, the throttle opening will be increased without engaging the gears. 20 The gearshifdthrottle control lever controls engine speed and selects F (forward), N (neutral), or R (reverse) gears.
CONTROLS AND FEATURES Moving the control lever 35" from N (neutral) selects the gear, and further movement increases engine speed. N (NEUTRAL) 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. A friction adjuster near the base of the control lever adjusts the operating resistance of the control lever. Less friction allows easier control lever movement.
CONTROLS AND FEATURES Top-Mount Type Ignition Switch ON START I Switch Clip and Emergency Stop Switch EMERGENCY STOP SWITCH The ignition switch can be used to operate the starter motor only when the control lever (p. 24 ) is in the N (neutral) position, and the switch clip is in the emergency stop switch. OFF IGNITION SWITCH KEY 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.
CONTROLS AND FEATURES The switch clip must be inserted in the emergency stop switch in order for the engineto 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 Button N (neutral) Gearshift/Throttle Control Lever .e-,:) F (forward) When used as described, the emergency stop switch and lanyard system stops the engineif the operator falls away from the controls.
CONTROLS AND FEATURES Moving the control lever 35" from N (neutral) selects the gear, and further movement increases engine speed. A friction adjuster inside the control box adjusts the operating resistance of the control lever(s). Less friction allows easier control lever movement. More friction helps to hold a steady throttle setting while cruising.
CONTROLS AND FEATURES Common Controls The power tridtilt switch is located on the control lever. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor.
CONTROLS AND FEATURES Power Tilt Switch POWER TILT SWITCH Manual Relief Valve Tilt Lock Lever MANUAL RELIEF VALVE TILT LOCK ,NUAL release) The power tilt switch is located on the enginepan. It is a rocker switch with UP and DN (down) positions for changing the angle of the outboard motor. The power tilt switch will operate without turning the ignition switch ON. This switch is used with the engine stopped to raise the outboard motor for mooring, trailering or maintenance.
Engine Cover Latch ENGINE COVER LATCH * CONTROLS AND FEATURES Trim Tab TIGHTENING YLT INSTRUMENTS Trim Meter (optional equipment) TRIM TAB The engine cover latch fastens the engine cover to the outboard motor. The trim tab compensates for "torque steer," which is a reaction of the outboard motor to propeller rotation. If uncompensated, torque steer would make the outboard motor tend to turn to one side.
CONTROLS AND FEATURES Tachometer (optional equipment) INDICATORS Alternator (ACG) Indicator ACG INDICATOR LIGHT Programmed Fuel Injection (PGM-FI) Indicator PGM-FI INDICATOR LIGHT t TACHOMETER The tachometer shows engine speed in revolutions per minute. Refer to the tachometer when using the throttle and power tridtilt controls to achieve the best performance from the boat. 28 The ACG indicator light turns on and the buzzer sounds when the charging system is faulty.
CONTROLS AND FEATURES Oil Pressure Indicator When the green light is lit, oil pressure is OK. (side-mount type) Overheating Indicator (side-mount type) If oil pressure becomes low, the green light will go off, and the engine protection system will limit engine speed. Remote controls are also equipped with a buzzer that sounds when the green light goes off.
CONTROLS AND FEATURES If the engine overheats, the red light will come on, and the enginewill stop in 20 seconds after the engine protection system will limit engine speed, Cooling System Indicator COOLING SYSTEM INDICATOR Water Contamination Buzzer The water contamination buzzer sounds when water has accumulated in the water separator. 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.
CONTROLS AND FEATURES Overrev Limiter Anodes The engine is equipped with an overrev limiter to prevent the possibility of mechanical damage from excessive engine speed. OUTLET END (MOTOR) The overrev limiter may be activated during operation, limiting engine speed, if the outboard motor is tilted excessively, or when ventilation occurs during a sharpturn. If the overrev limiter is activated, check the trim angle of the outboard motor. Check to see if the correct propeler is installed.
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 doand how to operate them. Familiarize yourself with the outboard motor and its operation before you get under way.
BEFORE OPERATION Safety Inspection Look around the outboard motor for signs of oil or gasoline leaks. Check that the fuel hose is undamaged and properly connected. Wipe up any spills before starting the engine. Maintenance Inspection Check the engine oil level (p. 60 ). Running the engine with a low oil level can cause engine damage. Check to be sure the propeller is undamaged, and the castle nut is secured with the cotter pin (p. 74 ).
OPERATION SAFE OPERATING PRECAUTIONS BREAK-IN PROCEDURE Break-in period: 10 hours Next 64) minutes: Run the engineup 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. Proper break-in operation allows the moving parts to wear in smoothly for best performance and long service life.
OPERATION FUEL PRIMING OUTLET END (MOTOR) PRIMING BULB INLET END (TANK) Hold the priming bulb up in the direction of the arrow, then squeeze the priming bulb several times until it feels firm, indicating that fuel has reached the engine. Gasoline is highly flammable andexplosive. You can be burnedor seriously injured when handling fuel. Stop the engine andkeep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.
OPERATION STARTING THE ENGINE The engine will not start or run, unless the clip is in the switch. Side-Mount Type 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. EMERGENCY STOP ?WITCH N (neutral) Always attach the lanyard to your PFD, or to your wrist, before starting the engine. CLIP SWITCH \ LANYARD 1.
OPERATION ON Using the electric starter for 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 damagethe starter motor and flywheel. FAST IDLE RANGE 3. Leave the fast idle lever in the OFF (fully lowered) position. IGNITION SWITCH KEY 4.Turn the ignition switch key to the START position and hold it there until the engine starts.
OPERATION MAXIMUM FAST IDLE I - - @) 5. 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 OF (5OC), warm up the engine for at least 10 minutes at 2,000 rpm. Raise the fast idle lever to achieve approximately 2,000 rpm. 38 During the warm-up period, check the oil pressure indicator (p. 29 ), overheating indicator (p. 29 ), and cooling system indicator (p. 30 ).
OPERATION Panel-Mount Type The enginewill not start or run, unless the clip is in the switch. EMERGENCY STOP SWITCH SWITCH CLIP N (neutral) The emergency stop switch clip and lanyard system is a safety device that will stop the engineif you fall away from the controls while operating the boat. \ Always attach the lanyard to your PFD, or to your wrist, before starting the engine. C L LANYARD 1.
OPERATION START N (neutral) Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it. SWITCH KEY \ Turning the ignition switch key to the START positionwhile the engine is running can damage the starter motor and flywheel. CONTROL FAST IDLE BUTTON 3. Turn the ignition switch key to the START position and hold it there until the engine starts. When the engine starts, release the key, allowing it to return to the ON position.
OPERATION ~~ During the warm-up period, check the oil pressure indicator (p. 29 ), overheating indicator (p. 29 ), and cooling system indicator (p. 30 ). The engine will not start or run, unless the clip is in the switch. Top-Mount Type EMERGENCY STOP SWITCH The emergency stop switch clip and lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat.
OPERATION START N (neutral) Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it. , IGNITION SWITCH KEY 2. Set the control lever in the N (neutral) position. The engine will not start if the F (forward) or R (reverse) gears are engaged. . \ 3. Turn the ignition switch key to the START position and hold it there until the engine starts. When the engine starts, release the key, allowing it to return to the ON position.
OPERATION N (neutral) During the warm-up period, check the oil pressure indicator (p. 29 ), overheating indicator (p. 29 ), and cooling system indicator (p. 30). If the indicators show any abnormal condition, immediately stop the engine and determine the cause of the problem. Refer to TAKING CAREOF UNEXPECTED PROBLEMS, p. 82. FAST IDLE BUTTON 4. Before getting under way, allow the engineto warm up sufficiently to ensure good performance.
OPERATION To stop the engine in an emergency, pull the clip out of the emergency stop switch by pulling the lanyard. We suggest that you stop the engine this way occasionally to verify that the engine and emergency stop switch is operating properly. Normal Engine Stopping Top-Mount Type Side-Mount Type N (neutral) N (neutral) I LEVER Panel-Mount Type N (neutral) W 44 1. Move thecontrol lever(s) to the N (neutral) position.
OPERATION 3. When the boat is not in use, remove and store the ignition key and the emergency stop switch clip and lanyard. Side-Mount Type GEARSHIFTING AND THROTTLE OPERATION Side-Mount Type GUL CONTROL LEVER RELEASE LEVER Panel-Mount/Top-Mount Types N (neutral) n OFF F (forward) IGNITION KEY \ 2. Turn the ignition switch key to the OFF position.
OPERATION To shift gears, move the control lever to select F (forward), N (neutral) and R (reverse) gears. Panel-Mount Type Side-Mount Type N (neutral) &$$t \, I ,/'. Moving the control lever beyond the gear selection range increases engine speed. LEVER TO INCREASE .
OPERATION Top-Mount Type 0 FRICTION STEERING Steer the boat in the same manner as an automobile. I CONTROL LEVER FRICTION ADJUSTER Adjust the throttle friction adjuster so the control lever will hold a constant throttle setting while cruising.
OPERATION CRUISING motor. Engine Speed Trim For best fuel economy, limit the throttle opening to 80%. Use the throttle friction control (p. 46 ) to help you hold a steady speed. Use the power trimhilt switch to trim the outboard motor for the best performance and stability. 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 enginespeed.
OPERATION Side-Mount Type Top-Mount Type (single type) MOTOR TRIMMED TOO LOW MOTOR TRIMMED TOO HIGH POWER TRIM/TILT SWITCH MOTOR TRIMMED CORRECTLY Panel-Mount Type POWER TRIM/TILT SWITCH (dual type) BOW TOO LOW DUE TO 1. LOAD IN THE FRONT 2. MOTOR TRIMMED TOO LOW POWER TRIM/TILT SWITCH (RIGHT) BOW TOO HIGH DUE TO 1. LOAD IN THE REAR 2.
OPERATION If steering effort is not equal in both directions, adjust the trim tab to compensate for “torque steer,” which is the reaction of the outboard motor to propeller rotation. TIGHTENING BOLT SHALLOW WATER OPERATION MOORING, BEACHING, LAUNCHING When operating in shallow water, use the power trimhilt switch (p. 49 ) to tilt the outboard motor, so the propeller and gear case won’t hit the bottom.
OPERATION pimi- POWER TILT SWITCH \ Do not attempt touse the power tilt switch to tilt theoutboard motor down while the tilt lock lever is in the lock position. Damageto the power tilt system mayoccur. MANUAL RELIEF VALVE \ For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns. Close thevalve firmly after positioning the engine. Be sure the valve is closed before operating the outboard motor.
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 followthe inspection and maintenance recommendations and schedules in thisowner‘s manual.
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. Safety Precautions Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards: - Carbon monoxide poisoning from engine exhaust.
SERVICING YOUR OUTBOARD MOTOR -- -- TOOL KIT (optional equipment) The following tools are supplied by your dealer for simple maintenance procedures and emergency repairs. Keep these items on the boat, so they will always be available if you need them. r l l4 x l7 WRENCH s==s \ - lo x l2 m m WRENCH \.
eck SERVICING YOUR OUTBOARD MOTOR MAINTENANCE SCHEDULE r\ I\ \\ 1 REGULARSERVICEPERIOD (3) Perform at every indicated monthor operating hour interval. whichever comes first. .ITEM I I Each use I I After use I I First month Every 6 months or ... 20 hrs. or 100 hrs. or 200 hrs. Every 2 years Every year or 400 hrs. * oil0 Engine 0 0 0( 2 ) Emission related items. ( I ) Lubricate more frequently when used in salt water.
SERVICING YOUR OUTBOARD MOTOR \ REGULAR SERVICE PERIOD(3) Perform at every indicated month or operating hour interval, whichever comes first. First month Each use After usc or 20 hrs. 100 hrs. ITEM @ I Fuel filter Fuel filter line 1 I I 20006rs. 2 years 40rhrs.
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. TIGHTENING BOLT TIGHTENING BOLT LEFT I I RIGHT I I If uncompensated, torque steer would make the outboard motor tend to turn to one side. 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.
SERVICING YOUR OUTBOARD MOTOR MANUAL RELIEF VALVE MANUAL RELIEF VALVE ENGINE COVER REMOVAL AND INSTALLATION k ENGINE COVER NUAL release) The outboard motor can be tilted manually after opening themanual relief valve. This featureenables the outboard motor to be tilted or lowered when no battery is connected. For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns. Close the valve firmly after positioning the outboard motor.
SERVICING YOUR OUTBOARD MOTOR Latch Adjustment REAR I A loose engine cover may rattle or allow water to enter. Check whether the engine cover fitsproperly and adjust if necessary. Q i 5.8'mm) in (4.8 - Cover Lock Bolt Adjustment 1. Remove the engine cover. I I NUT Engine Cover Clearance Inspection FRONT P INSPECTION POINT With the engine cover in place, measure the clearance between the engine cover and the engine undercase at the latch. 2.
SERVICING YOUR OUTBOARD MOTOR Engine Oil Level Check OIL FILLER CAP Engine Oil Change Check the engine oil level with the engine stopped and the outboard motor in the vertical position. An engine oil evacuation/filling device may be used to remove/add the engineoil. 1. Unlock and remove the engine cover (p. 58 ). Drain the used oil while the engine is warm. Warm oil drains quickly and completely. 2. Remove the dipstick and wipe it clean. 1. Unlock and remove the engine cover (p. 58 ). 4.
SERVICING YOUR OUTBOARD MOTOR DRAIN PLUG Improper disposal of engine oil can beharmful to the environment. I f you change yourown 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. 5. Install the oil drain plug cover and secure it with the screw. 3. Place a suitable container below the oil drain guide to catch the used oil, then remove the oil filler cap and the drain plug. 4.
SERVICING YOUR OUTBOARD MOTOR Engine Oil Recommendations Oil is amajor factor affecting performance and service life. Use 4-stroke automotive detergent oil. SAE Viscosity Grades l-FR++l -30 -20 -10 0 10 20 30 40°C AMBIENT TEMPERATURE SAE 1 OW-30 is recommended for general use. 62 The SAE oil viscosity and service classification are in the API label on the oil container.
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 55 ). 6 THROTTLE A M S H I F T ENGINE COVER ARM SHAFT Apply anticorrosionoil to pivotsurf aces where greas cannot penetrate.
SERVICING YOUR OUTBOARD MOTOR Spark Plug Service SPECIAL SCREWS RECOMMENDED SPARK PLUGS: IZFRGFll (NGK) VKJ20RZ-M11 (DENSO) WIRE CONNECTOR IGNITION COIL \ p E l Incorrect spark plugs can cause engine damage. 1. Disconnect the battery negative (-) terminal. 2. Unlock and remove the engine cover (p. 58 ). L.ENGINE UNDER COVER 3. Remove the twenty special bolts, and remove the R. and L. engine under covers. 4.
SERVICING YOUR OUTBOARD MOTOR 9. Install the spark plugs carefully, by hand, to avoid cross-threading. SPARK PLUG WRENCH 10. After each spark plug seats, tighten with a spark plug wrench supplied in the tool kit to compress the sealing washer. If reinstalling the used spark plugs, tighten 1/8 - 1/4 turn after the spark plugs seat. 6. Remove the spark plugs with a spark plug wrench and 17 mm wrench. 7. Inspect the sparkplugs.
SERVICING YOUR OUTBOARD MOTOR 11. Install the ignition coil. Reinstall the bolt. 12. Push the wire connector onto the ignition coil. Make sure it locks in place. 13.Repeat this procedure for the other five spark plugs. 14. Reinstall the covers. When reinstalling the covers, make sure not to jam the wire harnesses in between the covers and engine case.
SERVICING YOUR OUTBOARD MOTOR REFUELING Check the fuellevel and refill if neccessary. Do not fill the fueltank above the UPPER LIMIT. Refer to Gasoline is highly flammable andexplosive. You can be burned or seriously injured when handling fuel. Stop the engine andkeep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. Never refill the fueltank inside a building where gasoline fumes may reach flames or sparks.
SERVICING YOUR OUTBOARD MOTOR FUEL RECOMMENDATIONS Use unleaded gasoline with apump octane ratingof 86 or higher. These outboard motors are certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt orwater in the fuel tank.
SERVICING YOUR OUTBOARD MOTOR Fuel Pump Filter Inspection and Replacement The fuel pump filter (inside the strainer cup) is located below the engine oil filter. Water or sediment accumulated in the filter can cause loss of power or hard starting. To prevent engine malfunction, inspect the filter and replace when necessary. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop theengine and keep heat, sparks, and flame away. Handle fuel only outdoors.
SERVICING YOUR OUTBOARD MOTOR SCREW (3) 4. Remove the three screws and separate the fuel strainer cup from the strainer body. 5. Thoroughly clean the strainer cup, and replace with a new fuel filter. Id FUEL HOSES \ FUEL FILTER (inside strainercup) SUSPENSION STRAP 2. Looking through the translucent strainer cup, check the fuel filter for water accumulation or sediment. 3. Remove the suspension strap from the strainer bracket, then remove the strainer assembly from the strap.
SERVICING YOUR OUTBOARDMOTOR 8. Prime the engineusing the priming bulb (refer to page 35). Check for fuel leaks. Repair any fuel leaks if necessary. Water Separator Inspection and Service Gasoline is highly flammable and explosive. If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fuel tank. Clean the fueltank and tank filter if necessary. It may be necessary to drain the fueltank completely and refill with fresh gasoline.
SERVICING YOUR OUTBOARD MOTOR SUSPENSION STRAP I FUELTUBES 5. Remove the three screws and separate the water separator cup from the body. 9. Squeeze and release the priming bulb to fill the vapor separator, and check for leaks. 6. Thoroughly clean the water separator cup. If the buzzer sounds or water or sediment accumulation are found to be caused by excessive water or sediment accumulation in the fuel filter, inspect the fueltank. 7. Reassemble the water separator body and the cup.
SERVICING YOUR OUTBOARD MOTOR Anode Replacement p q i ANODE (stern bracket) Painting or coating the anodes will defeat their purpose and will lead to rust and corrosion damageto the outboard motor. The anodes must be exposed to the water in order to protect the outboard motor. ANODE (each side) The anodes are located on each side of the gearcase. They are made of a sacrificial material that helps to protect the outboard motor from corrosion.
SERVICING YOUR OUTBOARD MOTOR Propeller Replacement 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. 1. Apply marine-grade grease to the propeller shaft and beveled surface of the thrust washer. 1- 2. Install the propeller in the reverse order of removal. Install the thrust washer with the grooved side toward the gearcase.
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 functionand 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 on p. 30.
STORAGE WATER HOSE (Commercially available) FLUSH PLUG CONNECTOR 2. Screw the water hose into the flush plug connector. 3. Turn on the fresh water supply and flush the outboard motor for at least 10 minutes. 4.After flushing, remove the garden hose adapter, and install the flush plug cap.
STORAGE Fuel Gasoline will oxidize and deteriorate in storage. Old gasoline will cause hard starting, and it leaves gum deposits that clog the fuelsystem. If the gasoline in your fuel tank and vapor separetor deteriorates during storage, you may need to have the vapor separetor and other fuel system components serviced or replaced.
STORAGE 4.Tilt up the outboard motor. Engine Oil 5. Tilt down the outboard motor, and 1. Change the engine oil (p.60 61 ). drain the vapor separator. 6. After draining thoroughly, tighten the drain bolt securely. 7. Clip the drain hose on the head cover. 8. Drain the fuel tank into an approved gasoline container, or if you need to store fuel in the fuel tank, you can extendfuel storage life by filling the fuel tank with fresh gasoline and adding a fuel stabilizer that is formulated for that purpose.
STORAGE STORAGE PRECAUTIONS S Select a well-ventilated storage area. If possible, avoid storage areas with high humidity. If storing a container of gasoline, store it away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a sparkproducing electric motor, or where power tools are operated. 2. Attach the hoist hooks to the lifting eyes. 3.
STORAGE Cover the outboard motorto keep out dust. Do not use sheet plastic as a dust cover. A nonporous coverwill trap moisture, promoting rust and corrosion. REMOVAL FROM STORAGE Check your outboard motoras described in the BEFORE OPERATION chapter of this manual. If the cylinders were coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal. PROTECTOR If it is necessary to store the outboard motor horizontally, drain the vapor separator (p.
TRANSPORTING WITH OUTBOARD MOTOR INSTALLED ON BOAT WITH OUTBOARD MOTOR REMOVED FROM BOAT When trailering a boat with the outboard motor attached, leave the engine in the normal running position, if possible. Secure the outboard motor in either the vertical or horizontal position shown on p. 79 - 80. Use a motor support bar to prevent the outboard motor from moving while trailering the boat. Refer to the manufacturer's instructions for using a motor support bar.
TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction 1. Check emergency stopswitch clip. Clip not inserted in stop switch. Insert clip in stop switch. 2. Check control positions. Control lever not in neutral position. Shift to neutral. Fast idle lever raised (side-mount Leave fast type). 82 idle lever OFF (p. 18 ).
TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START (continued) 3. Check fuel. Possible Cause Correction Out of fuel. Refuel (p. 67 ), Fuel hose not primed. Squeeze priming bulb(p. 31 ). Fuel pumpfilter or fueltank filter clogged. Replace fuel filters (p. 69 ). Bad fuel; boat stored without treating or draining gasoline, or refueled with bad gasoline. Drain fuel tank and vapor separator (p. 77 ). Refill with fresh gasoline (p. 67 ).
TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START (continued) Possible Cause 4.Check battery. ~~~ ~ ~ ~~~~~~~ 5. Check fuses. 6. Remove and inspect spark plugs. 7. Use starting procedure (p. 36 ), then take outboard motor toan authorized Honda Marinedealer, or referto the shop manual. 84 1 Correction Battery connections loose or corroded. Clean andtighten battery connections. Battery discharged. Recharge battery. Fuse(s) burnt out. Spark plugs faulty, fouledor improperly gapped.
TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS AFTER STARTING Possible Cause Correction 1. Check control positions. Fast idle lever raised (side-mount type). Leave fast idle lever OFF (p. 18 ). 2. Check fuel. Fuel hose not primed. Fuel pump filter or fuel tank clogged. Squeeze priming bulb (p. 31 ). Replace fuel filters (p. 69 ). Bad fuel; boat stored without treating or draining gasoline, or refueled with bad fuel. Drain fuel tank and vapor separator (p. 77).
TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS AFTER STARTING (continued) Correction Possible Cause Clean, gap orreplace spark plugs (P. 64 >. Spark plugs faulty, fouled or improperly gapped. 3. Remove and inspect spark plugs. ~ . ENGINEOVERHEATS 1. Check water intake screens. 2. Take outboard motor to an authorized Honda Marinedealer, or refer to the shop manual. 86 Replace or repair faulty components as necessary. Fuel system malfunction, fuel pump failure, ignition malfunction, etc.
TAKING CARE OF UNEXPECTED PROBLEMS BATTERY WILL NOT CHARGE AND ELECTRIC STARTER WILL NOT OPERATE The battery-charging (ACG) circuit and the electric starter relay circuit are protected by the 10, 15 and 30ampere main fuses and 150-ampere ACG fuse. If the fuse burns out, the engine will not charge the battery, and the electric starter will not operate. The ignition switch is protected by the 10-ampere main fuse.
TAKING CARE OF UNEXPECTED PROBLEMS Fuse FUSE (150A) FUSE CASE LID / 3 . Remove the fuse case lid. 4. Remove the old fuse by removing two 5 mm screws. 5. Install a new fuse with the “150 A” mark downward. ACG FUSE: 150 A SPARE FUSE Disconnect the battery cable at the battery negative (-) terminal before replacing the f use. Failure to do so may causeA short circuit. Replacement 1 . Stop the engine. 2. Remove the engine cover. 88 6.
TAKING CARE OF UNEXPECTED PROBLEMS OIL PRESSURE INDICATOR LIGHT GOES OFF AND ENGINE SPEED IS LIMITED Panel-Mount/Top-Mount Types Side-Mount Type If the throttle is closed suddenly after full throttle operation, engine speed may drop below the specified idle rpm, and that could activate the engine protection system momentarily. If low oil pressure activates the engine protection system, stop the engine, check the engine oil level (p. 60 ), and add oil if needed.
TAKING CARE OF UNEXPECTED PROBLEMS OVERHEATING INDICATOR LIGHT COMES ON AND ENGINE SPEED IS LIMITED Side-Mount Type If the engine overheats, the red indicator light will come on,and the engine will stop in 20 seconds after the engine protection system will limit engine speed. If you are at cruising speed, engine speed will decrease gradually. COOLING SYSTEM INDICATOR / Remote-control types are equipped with a buzzer that sounds whenthe red indicator light comes on.
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 clogged, clean the water intake screens, return the outboard motor to the running position, restart the engine, and check the cooling system indicator again.
TAKING CARE OF UNEXPECTED PROBLEMS 3. Change the engine oil as described on p. 60 - 61 . If there was water in the engine crankcase, or if the used engine oil showed signs of water contamination, then a second engine oil change should be performed after running the engine for half an hour. 4.Remove the spark plugs (p. 64). Operate the starter to expel1 water from the engine’scylinder. 5. Put a teaspoon of engine oil into each spark plug hole to lubricate the inside of the cylinders.
47 TECHNICAL AND CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Locations Record the product identification number and engine serial numbers in the space provided on this page. You will need these numbers when ordering parts, and when making technical or warranty inquiries (p. 103 >. PRODUCT IDENTIFICATION NUMBER STERN BRACKET ENGINE SERIAL NUMBER The product identification number is stamped on a plate attached on the right stern bracket.
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. Before using an oxygenated fuel, try to confirm the fuel’s contents.
TECHNICAL AND CONSUMER INFORMATION You may use gasoline containing up to 5% methanol by volume, as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5 % methanol by volume may cause starting and/or performance problems. It may also damage.meta1, rubber, and plastic parts of your fuel system. If you notice any undesirable operating symptoms, try another service station, or switch to another brand of gasoline.
TECHNICAL AND CONSUMER INFORMATION Emission Control System Information The US.and California 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.
TECHNICAL AND CONSUMER INFORMATION Problems That MayAffect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. 0 Hard starting or stalling after starting. 0 Rough idle. 0 Misfiring or backfiring under load. 0 Afterburning (backfiring). Black exhaust smoke or high fuel consumption.
TECHNICAL AND CONSUMER INFORMATION Star Label The StarLabel means Cleaner Marine Engine This engine has been certified as a:1- A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board. t 0 0 The Symbolfor Cleaner Marine Engines: Cleaner Air and Water- for healthier lifestyle and environment. - Better Fuel Economy burns up to 30 - 40 percent less gas and oil than conventional carbureted two-stroke engines, saving money and resources.
TECHNICAL AND CONSUMER INFORMATION One Star Low Emission Two Stars Very Low Emission Three Stars Ultra Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 exhaust emissionstandards. Engines meetingthese standards have 75% lower emissionsthan conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.
TECHNICAL AND CONSUMER INFORMATION Specifications I Mnnm Description Code Type Overall length Overall width Overall height Transom height I Rc')nnA "I L V U m BAEJ LA 1 1 1 system Ignition system Lubrication system Specified oil Starter I BAEJ 1 BAFJ I BAEJ 1 BAFJ XA 1 XCA 1 XXA I XXCA 36.2 i n (920 mm) 24.6 in (625 mm) 70.9 i n 75.8 in (1,800 mm) (1,925 mm) 65.7 in (1,670 mm) 20.0i n 25.0 in (635 mm) 30.
TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description Code Type Overall length Overall width Overall height (1,670 (1,800 rnrn) (1,925 rnrn) Transom height 20.0 in 25.0 in (635 rnrn) 30.0 in (762 rnrn) Weight mrn) 589 Ibs 600 Ibs (272 kg) 611 Ibs (277 kg) (267 kn) Gear case: 1.OO US qt (0.95 !2,0.84Imp Rated power Full throttle range Engine type Displacement Spark plug gap Honda outboards are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.
TECHNICAL AND CONSUMER INFORMATION BF200A & BF225A Tune up Spark plug gap Idle speed Valve clearance (cold) Other specifications 102 0.039-0.043in (1.00-1.10mm) See page 65 650 50 rpm See shop manual 0.22 k 0.02 mm Intake: See shop manual Exhaust: 0.30 0.02 mm No other adjustments needed.
TECHNICAL AND CONSUMER INFORMATION CONSUMER INFORMATION Customer 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.
INDEX Alternator (ACG) Indicator ............................................ 28 Anodes ............................................................................ 31 Replacement ............................................................... 73 ? .......... 32 AREYOUREADYTOGETUNDERWAY Battery ............................................................................ 95 BATTERY WILL NOT CHARGE AND ELECTRIC STARTER WILL NOT OPERATE ...... 87 32 BEFORE OPERATION.............................................
INDEX Fast Idle Lever ................................................................ 18 Fuel PRIMING ................................................................... 35 Priming Bulb.............................................................. 3 1 RECOMMENDATIONS ........................................... 68 Pump Filter Inspection and Replacement.................. 69 Gear Oil Level Check..................................................... 63 GearshifdTrottle Control Lever Panel-Mount Type............
INDEX Oil Pressue Indicator...................................................... 29 OIL PRESSURE INDICATOR LIGHT GOES OFF AND ENGINE SPEEDIS LIMITED ............... 89 OPERATION ................................................................. 34 OTHER FEATURES..................................................... 3 1 OUTBOARD MOTOR SAFETY .................................... 7 29 Overheating Indicator.....................................................
Tachometer (optional equipment) .................................. 28 TAKING CAREOF UNEXPECTED PROBLEMS..... 82 TECHNICAL AND CONSUMER INFORMATION ... 93 TECHNICAL INFORMATION.................................... 93 THE IMPORTANCEOF MAINTENANCE ................ 52 Throttle Button Panel-Mount Type...................................................... 20 Top-Mount Type........................................................ 23 Tilt Lock Lever...............................................................
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