08/08/04 18:39:44 31ZY9600_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. 2008 Honda Motor Co., Ltd.
08/08/04 18:39:50 31ZY9600_002 INTRODUCTION Congratulations on your selection of a Honda outboard motor. We are certain you will be pleased with your purchase of one of the finest outboard motors on the market. We want to help you get the best results from your new outboard motor and to operate it safely. This manual contains information on how to do that; please read it carefully. As you read this manual you will find information preceded by a symbol.
08/08/04 18:40:00 31ZY9600_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.
08/08/04 18:40:03 31ZY9600_004 CONTENTS OUTBOARD MOTOR SAFETY .................................... 7 IMPORTANT SAFETY INFORMATION ................. 7 SAFETY LABEL LOCATION ................................... 9 CONTROLS AND FEATURES ................................... 10 CONTROL AND FEATURE IDENTIFICATION CODES ................................................................... 10 COMPONENT AND CONTROL LOCATIONS ..... 11 CONTROLS ...............................................................
08/08/04 18:40:07 31ZY9600_005 CONTENTS INDICATORS............................................................ 38 Alternator (ACG) Indicator.................................... 38 Programmed Fuel Injection (PGM-FI) Indicator ... 38 Oil Pressure Indicator ............................................. 39 Overheat Indicator .................................................. 40 Cooling System Indicator ...................................... 41 OTHER FEATURES .................................................
08/08/04 18:40:10 31ZY9600_006 CONTENTS SERVICING YOUR OUTBOARD MOTOR ............... 78 THE IMPORTANCE OF MAINTENANCE ............ 78 MAINTENANCE SAFETY ...................................... 79 TOOL KIT and OWNER’S MANUAL .................... 80 EMERGENCY STARTER ROPE ............................ 80 MAINTENANCE SCHEDULE ................................ 81 TRIM TAB ADJUSTMENT ..................................... 83 MANUAL RELIEF VALVE .....................................
08/08/04 18:40:13 31ZY9600_007 CONTENTS TRANSPORTING ....................................................... 111 WITH OUTBOARD MOTOR INSTALLED ON BOAT ..................................... 111 WITH OUTBOARD MOTOR REMOVED FROM BOAT ................................. 111 TAKING CARE OF UNEXPECTED PROBLEMS... 112 ENGINE WILL NOT START................................. 112 HARD STARTING OR STALLS AFTER STARTING .......................................................... 115 ENGINE OVERHEATS ......................
08/08/04 18:40:21 31ZY9600_008 OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION The Honda BF75D/BF90D 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.
08/08/04 18:40:27 31ZY9600_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. 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.
08/08/04 18:40:37 31ZY9600_010 OUTBOARD MOTOR SAFETY SAFETY LABEL LOCATION FUEL TANK [optional equipment (LHT type)] The label shown here contains important safety information. Please read it carefully. This label is considered a permanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized Honda Marine dealer for a replacement.
08/08/04 18:40:50 31ZY9600_011 CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES Model BF75D Type LHT Transom Height (Shaft Length) BF90D LRT LHT LRT XRT 21.1 in (537 mm) 26.1 in (664 mm) Tiller Handle Remote Control Power Trim/Tilt Trim Meter (optional equipment) Tachometer (optional equipment) Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.
08/08/04 18:40:57 31ZY9600_012 CONTROLS AND FEATURES COMPONENT AND CONTROL LOCATIONS LHT Type (tiller handle) ENGINE COVER ENGINE COVER LATCH (front) OIL LEVEL DIPSTICK OIL FILLER CAP SPARK PLUG (under coil) ENGINE COVER LATCH (rear) TILLER HANDLE STERN BRACKET MANUAL RELIEF VALVE POWER TILT SWITCH IDLE PORT TILT LOCK LEVER COOLING SYSTEM INDICATOR ANODE (each side) TRIM TAB FLUSH PORT CONNECTOR ENGINE OIL DRAIN BOLT PRODUCT IDENTIFICATION NUMBER GEAR OIL LEVEL SCREW COOLING WATER INTAKE PORT (ea
08/08/04 18:41:01 31ZY9600_013 CONTROLS AND FEATURES INDICATORS (Oil pressure, Overheat, Alternator, PGM-FI) EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP GEARSHIFT LEVER EMERGENCY STOP SWITCH LANYARD POWER TRIM/TILT SWITCH IGNITION SWITCH STEERING FRICTION KNOB 12 THROTTLE FRICTION ADJUSTER THROTTLE GRIP
08/08/04 18:41:04 31ZY9600_014 CONTROLS AND FEATURES Portable Fuel Tank and Fuel Tank Hose Assembly (optional equipment) FUEL FILLER CAP FUEL TANK VENT KNOB FUEL HOSE CONNECTOR FUEL GAUGE FUEL TANK HOSE ASSEMBLY FUEL HOSE JOINT (motor side) FUEL PRIMING BULB 13
08/08/04 18:41:10 31ZY9600_015 CONTROLS AND FEATURES LRT and XRT Types (remote control) ENGINE COVER OIL LEVEL DIPSTICK OIL FILLER CAP ENGINE COVER LATCH (rear) ENGINE COVER LATCH (front) SPARK PLUG (under coil) POWER TILT SWITCH IDLE PORT STERN BRACKET MANUAL RELIEF VALVE TILT LOCK LEVER COOLING SYSTEM INDICATOR ANODE (each side) FLUSH PORT CONNECTOR PRODUCT IDENTIFICATION NUMBER ENGINE OIL DRAIN BOLT GEAR OIL LEVEL SCREW TRIM TAB ANODE EXHAUST PORT/WATER OUTLET PORT PROPELLER (optional equipm
08/08/04 18:41:16 31ZY9600_016 CONTROLS AND FEATURES Remote Controls (optional equipment) (SIDE-MOUNT REMOTE CONTROL) GEARSHIFT/THROTTLE CONTROL LEVER (PANEL-MOUNT REMOTE CONTROL) NEUTRAL RELEASE LEVER GEARSHIFT/THROTTLE CONTROL LEVER NEUTRAL RELEASE LEVER OIL PRESSURE INDICATOR POWER TRIM/TILT SWITCH SPARE SWITCH CLIP OVERHEAT INDICATOR POWER TRIM/TILT SWITCH FAST IDLE LEVER FAST IDLE BUTTON IGNITION SWITCH BUZZER (inside) EMERGENCY STOP SWITCH CONTROL LEVER FRICTION ADJUSTER LANYARD SWITCH C
08/08/04 18:41:22 31ZY9600_017 CONTROLS AND FEATURES (SINGLE TOP-MOUNT REMOTE CONTROL) (DUAL TOP-MOUNT REMOTE CONTROL) GEARSHIFT/THROTTLE CONTROL LEVER GEARSHIFT/THROTTLE CONTROL LEVERS POWER TRIM/TILT SWITCH (RIGHT) POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH (LEFT) FAST IDLE BUTTON CONTROL PANEL (for TOP-MOUNT SINGLE type) BUZZER IGNITION SWITCH EMERGENCY STOP SWITCH CLIP LANYARD 16 FAST IDLE BUTTON (for TOP-MOUNT DUAL type) OIL PRESSURE INDICATOR OVERHEAT INDICATOR EMERGENCY STOP SWITCH
08/08/04 18:41:28 31ZY9600_018 CONTROLS AND FEATURES Indicator Panel (standard equipment) Fuel Hose Assembly (optional equipment) ALTERNATOR (ACG) INDICATOR FUEL HOSE ASSEMBLY FUEL HOSE JOINT (fuel tank side) FUEL PRIMING BULB PROGRAMMED FUEL INJECTION (PGM-FI) INDICATOR FUEL HOSE JOINT (motor side) 17
08/08/04 18:41:36 31ZY9600_019 CONTROLS AND FEATURES Trim Meter (optional equipment) Tachometer (optional equipment) Digital Speedometer (optional equipment) Digital Tachometer (optional equipment) 18
08/08/04 18:41:45 31ZY9600_020 CONTROLS AND FEATURES CONTROLS 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. LHT Type (tiller handle) Ignition Switch ON START OFF Emergency Stop Switch Clip and Emergency Stop Switch EMERGENCY STOP SWITCH The engine will not start unless the gearshift lever is in the N (neutral) position (p.
08/08/04 18:41:51 31ZY9600_021 CONTROLS AND FEATURES The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The emergency stop switch lanyard must be attached securely to the operator or to the operator’s PFD (Personal Flotation Device). When used as described, the emergency stop switch and emergency stop switch lanyard system stops the engine if the operator falls away from the controls. A spare switch clip is provided in the tool bag (p.
08/08/04 18:42:01 31ZY9600_022 CONTROLS AND FEATURES Throttle Friction Adjuster Gearshif t Lever THROTTLE FRICTION ADJUSTER FIX N (neutral) Steering Friction Knob R (reverse) F (forward) GEARSHIFT LEVER RELEASE STEERING FRICTION KNOB RELEASE FIX 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.
08/08/04 18:42:10 31ZY9600_023 CONTROLS AND FEATURES LRT and XRT Types (remote control) Side-Mount Type 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. Emergency Stop Switch Clip and Emergency Stop Switch EMERGENCY STOP SWITCH Ignition Switch OFF ON START The ignition switch can be used to start the engine only when the control lever is in the N (neutral) position (p.
08/08/04 18:42:16 31ZY9600_024 CONTROLS AND FEATURES The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The emergency stop switch lanyard must be attached to the operator’s PFD (Personal Flotation Device) or to the operator securely. A spare switch clip is stored in a slot in the control housing and is provided in the tool bag (p. 80 ).
08/08/04 18:42:25 31ZY9600_025 CONTROLS AND FEATURES F (FORWARD) N (NEUTRAL) 30° 30° SHIFT MINIMUM THROTTLE OPENING Fast Idle Lever R (REVERSE) SHIFT FAST IDLE LEVER MINIMUM THROTTLE OPENING MAXIMUM MAXIMUM GEARSHIFT/THROTTLE CONTROL LEVER Moving the control lever 30° from N (neutral) selects the gear, and further movement increases engine speed. The control lever automatically locks itself in the N (neutral) position.
08/08/04 18:42:32 31ZY9600_026 CONTROLS AND FEATURES Panel-Mount Type N (neutral) MAXIMUM FAST IDLE Ignition Switch ON LOWEST POSITION FAST IDLE LEVER The fast idle lever allows you to increase the idle speed only when the control lever is in the N (neutral) position. Place the fast idle lever in its lowest position to cancel the fast idle and return the control lever to normal operation. START OFF IGNITION SWITCH Turning the ignition switch key to the START position operates the starter motor.
08/08/04 18:42:39 31ZY9600_027 CONTROLS AND FEATURES Emergency Stop Switch Clip and Emergency Stop Switch EMERGENCY STOP SWITCH The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The emergency stop switch lanyard must be attached securely to the operator or to the operator’s PFD (Personal Flotation Device).
08/08/04 18:42:47 31ZY9600_028 CONTROLS AND FEATURES Gearshif t/Throttle Control Lever N (NEUTRAL) F (FORWARD) GEARSHIFT/THROTTLE CONTROL LEVER 35° SHIFT 35° R (REVERSE) SHIFT MINIMUM MINIMUM THROTTLE OPENING NEUTRAL RELEASE LEVER THROTTLE OPENING MAXIMUM MAXIMUM GEARSHIFT/THROTTLE CONTROL LEVER The gearshift/throttle control lever controls engine speed and selects F (forward), N (neutral), or R (reverse) gears.
08/08/04 18:42:56 31ZY9600_029 CONTROLS AND FEATURES Fast Idle Button N (neutral) F (forward) R (reverse) It is necessary to position the control lever in N (neutral) to push in the fast idle button. Return the control lever to N position to cancel the fast idle operation. Pull up CONTROL LEVER NEUTRAL RELEASE LEVER Push FAST IDLE BUTTON Use the fast idle button to accelerate engine warm-up after starting the engine. Do not use the fast idle button when starting the engine.
08/08/04 18:43:04 31ZY9600_030 CONTROLS AND FEATURES Top-Mount Type Ignition Switch 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. Emergency Stop Switch Clip and Emergency Stop Switch EMERGENCY STOP SWITCH The ignition switch can be used to start the engine only when the control lever is in the N (neutral) position (p.
08/08/04 18:43:11 31ZY9600_031 CONTROLS AND FEATURES The emergency stop switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The emergency stop switch lanyard must be attached securely to the operator or to the operator’s PFD (Personal Flotation Device). When used as described, the emergency stop switch clip and emergency stop switch lanyard system stops the engine if the operator falls away from the controls.
08/08/04 18:43:17 31ZY9600_032 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). Refer to p. 71 . N (NEUTRAL) F (FORWARD) 35° SHIFT 35° MINIMUM Less friction allows easier control lever movement. More friction helps to hold a steady throttle setting while cruising.
08/08/04 18:43:24 31ZY9600_033 CONTROLS AND FEATURES Fast Idle Button N (neutral) F (forward) R (reverse) It is necessary to position the control lever in N (neutral) to push in the fast idle button. Return the control lever to N position to cancel the fast idle operation. CONTROL LEVER FAST IDLE BUTTON Use the fast idle button to accelerate engine warm-up after starting the engine. Do not use the fast idle button when starting the engine. See page 62 for engine warm-up instructions.
08/08/04 18:43:33 31ZY9600_034 CONTROLS AND FEATURES Common Controls Power Trim/Tilt Switch (tiller handle/control lever side) LRT and XRT Types (side-mount type) (top-mount type) LHT Type SINGLE TYPE POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH POWER TRIM/ TILT SWITCH CONTROL LEVER CONTROL LEVER (panel-mount type) DUAL TYPE POWER TRIM/TILT SWITCH CONTROL LEVER POWER TRIM/TILT SWITCH (LEFT) (RIGHT) CONTROL LEVERS 33
08/08/04 18:43:43 31ZY9600_035 CONTROLS AND FEATURES The power trim/tilt 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. You can use the power trim/tilt switch anytime whether the boat is underway, stopped, or the ignition switch is in the OFF position. It is necessary for the ignition switch to be in the ON position for the trim meter to indicate the motor angle.
08/08/04 18:43:53 31ZY9600_036 CONTROLS AND FEATURES Tilt Lock Lever Engine Cover Latch (front/rear) Trim Tab GEAR CASE GROMMET FREE ENGINE COVER LATCHES (front/rear) LOCK UNLATCH STERN BRACKET TILT LOCK LEVER The tilt lock lever is used to support the outboard motor in the fully-raised position. When the boat is to be moored for a long time, tilt the outboard motor up as far as it will go.
08/08/04 18:44:07 31ZY9600_037 CONTROLS AND FEATURES INSTRUMENTS Tachometer (optional equipment) Digital Tachometer (optional equipment) Trim Meter (optional equipment) TACHOMETER TRIM METER The trim meter indicates the relative trim angle of the outboard motor. Refer to the trim meter when using the power trim/tilt switch to achieve the best performance from the boat. 36 The tachometer shows engine speed in revolutions per minute.
08/08/04 18:44:19 31ZY9600_038 CONTROLS AND FEATURES Digital Speedometer (optional equipment) Fuel Gauge [optional equipment (LHT type)] FUEL GAUGE Digital Speedometer includes the following functions. Speedometer Fuel Level Meter Voltmeter Tripmeter Fuel Integration Meter Fuel Economy Meter Fuel Flow Meter Water Separator Indicator Refer to the Operation Guide included with the Digital Speedometer for operation information.
08/08/04 18:44:28 31ZY9600_039 CONTROLS AND FEATURES INDICATORS Alternator (ACG) Indicator The ACG indicator turns on and the buzzer sounds in one-second intervals when the charging system is faulty.
08/08/04 18:44:39 31ZY9600_040 CONTROLS AND FEATURES When the engine control system detects a PGM-FI malfunction, the PGM-FI indicator turns on and the buzzer sounds at one-second intervals. Under normal conditions, when the ignition key is turned on the following will occur: 1. Both the PGM-FI indicator and ACG indicator will turn on. 2. The buzzer will beep twice. 3. The PGM-FI indicator will turn off shortly after the second beep. 4. The ACG indicator will turn off after the engine starts.
08/08/04 18:44:49 31ZY9600_041 CONTROLS AND FEATURES When the oil pressure indicator is lit, oil pressure is OK. Overheat Indicator LRT and XRT Types LHT Type (side-mount type) If oil pressure becomes low, the indicator will go off, and the engine protection system will limit engine speed. Refer to TAKING CARE OF UNEXPECTED PROBLEMS, on p. 119 . All models are equipped with a buzzer that sounds continuously when the oil pressure indicator goes off.
08/08/04 18:44:55 31ZY9600_042 CONTROLS AND FEATURES When the alert triggers, the overheat indicator comes on and the buzzer sounds a steady tone as the engine speed is reduced to 1,800 rpm. If the condition persists for another 20 seconds, the engine shuts off. Refer to TAKING CARE OF UNEXPECTED PROBLEMS, on p. 120 . All models are equipped with a buzzer that sounds continuously when the red light comes on. Engine overheating may be the result of clogged water intakes.
08/08/04 18:45:05 31ZY9600_043 CONTROLS AND FEATURES OTHER FEATURES Overrev Limiter Water Separator Buzzer The engine is equipped with an overrev limiter to prevent the possibility of mechanical damage from excessive engine speed. The water separator buzzer sounds a rapid, repeating signal when water has accumulated in the water separator. Check to see if the correct propeller is installed.
08/08/04 18:45:13 31ZY9600_044 CONTROLS AND FEATURES Fuel Filler Cap Vent Knob [optional equipment (LHT type)] VENT KNOB Fuel Priming Bulb (optional equipment) UP OUTLET END (motor side) CLOSE OPEN PRIMING BULB FUEL FILLER CAP The fuel filler cap is provided with a vent knob to seal the portable fuel tank for carrying it to and from the boat. Open the vent knob 2 or 3 turns before starting the engine.
08/08/04 18:45:18 31ZY9600_045 CONTROLS AND FEATURES Anodes ANODE (each side) The anodes are made of a sacrificial material that helps to protect the outboard motor from corrosion. There are two anodes on the gear case, one on the stern bracket and two small anodes in the water passages of the engine block.
08/08/04 18:45:28 31ZY9600_046 BEFORE OPERATION ARE YOU READY TO GET UNDERWAY? Your safety is your responsibility. A little time spent in preparation will significantly reduce your risk of injury. Knowledge Read and understand this manual. Know what the controls do and how to operate them. Familiarize yourself with the outboard motor and its operation before you get underway. Know what to do in case of an emergency.
08/08/04 18:45:40 31ZY9600_047 BEFORE OPERATION Safety Inspection Look around the outboard motor for signs of oil or gasoline leaks. If you are using the portable fuel tank (optional equipment), make sure it is in good condition and properly secured in the boat (p. 49 ). Check that the fuel hose is undamaged and properly connected. Wipe up any spills before starting the engine. Check the stern bracket to be sure the outboard motor is securely installed. Check that all controls are operating properly.
08/08/04 18:45:50 31ZY9600_048 BEFORE OPERATION Tiller Handle Height/Angle Adjustment (LHT type) Install the height adjustment block so that the selected angle of the tiller handle is in this position. The tiller handle height and angle can be adjusted to three positions by changing the installation direction of the height adjustment block. Select a suitable height and angle for the operator and secure the block. 1.
08/08/04 18:46:01 31ZY9600_049 OPERATION SAFE OPERATING PRECAUTIONS BREAK-IN PROCEDURE Break-in period: 10 hours 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.
08/08/04 18:46:10 31ZY9600_050 OPERATION PORTABLE FUEL TANK [optional equipment (LHT type)] Secure the portable fuel tank in the boat so that it won’t move around and become damaged. Before use, open the fuel tank vent by turning the vent knob at least 2 or 3 turns counterclockwise. Gasoline is highly flammable and explosive. Place the portable fuel tank (optional equipment) in a well-ventilated location, away from direct sunlight, to reduce the possibility of a gasoline vapor explosion.
08/08/04 18:46:18 31ZY9600_051 OPERATION FUEL HOSE CONNECTIONS HOSE PLUG FUEL HOSE ASSEMBLY FUEL HOSE HOSE CLAMP FUEL HOSE (motor side) FUEL HOSE JOINT HOSE CLAMP (stainless steel) (outboard motor side) 50 FUEL HOSE CONNECTOR (fuel tank side) 2. Connect the fuel hose to the tank, as shown. Be sure the connectors snap securely into place. BARB ARROW 1. Remove the hose plug from the motor side fuel hose. Insert the fuel hose joint into the motor side fuel hose and secure it with the hose clamp.
08/08/04 18:46:29 31ZY9600_052 OPERATION (Using the fuel tank mounted on the boat) FUEL HOSE ASSEMBLY (optional equipment) (motor side) FUEL PRIMING UP OUTLET END (motor) FUEL HOSE (tank side) PRIMING BULB BARB HOSE CLAMP (stainless steel) (FUEL TANK SIDE) INLET END (tank) 1. Remove the hose plug from the motor side fuel hose. Insert the fuel hose joint into the motor side fuel hose and secure it with the hose clamp. (Refer to the page 50 .
08/08/04 18:46:37 31ZY9600_053 OPERATION STARTING THE ENGINE Control Page Side-Mount Type ......................... 55 Panel-Mount Type ....................... 58 Top-Mount Type ......................... 60 LHT Type (tiller handle) EMERGENCY STOP SWITCH The engine will not start or run unless the emergency stop switch clip is in the emergency stop switch.
08/08/04 18:46:46 31ZY9600_054 OPERATION START POSITION ON START POINTER Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can damage it. OFF Turning the ignition switch key to the START position while the engine is running can damage the starter motor and f lywheel. THROTTLE GRIP IGNITION SWITCH KEY 3. Align the engine start symbol ‘‘ ’’ on the tiller handle with the pointer ‘‘ ’’ on the throttle grip. 5.
08/08/04 18:46:53 31ZY9600_055 OPERATION 6. Before getting underway, allow the engine to warm-up sufficiently to ensure good performance. Above 41°F (5°C), warm-up the engine for at least 3 minutes. Below 41°F (5°C), warm-up the engine for at least 5 minutes at 2,000 rpm. Raise the fast idle lever to achieve approximately 2,000 rpm.
08/08/04 18:47:01 31ZY9600_056 OPERATION LRT and XRT Types (remote control) Side-Mount Type EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP The engine will not start or run unless the emergency stop switch clip is in the emergency stop switch. The emergency stop switch clip and emergency stop switch lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat.
08/08/04 18:47:10 31ZY9600_057 OPERATION ON OFF START LOWEST POSITION FAST IDLE RANGE 3. Leave the fast idle lever in the OFF (fully lowered) position. The fast idle lever cannot be raised unless the control lever is in the N (neutral) position. The control lever cannot be moved away from the N (neutral) position unless the fast idle lever is lowered. 4. Turn the ignition switch key to the ON position; the buzzer will sound two times.
08/08/04 18:47:19 31ZY9600_058 OPERATION MAXIMUM FAST IDLE FAST IDLE RANGE 6. Before getting underway, allow the engine to warm-up sufficiently to ensure good performance. Above 41°F (5°C), warm-up the engine for at least 3 minutes. Below 41°F (5°C), warm-up the engine for at least 5 minutes at 2,000 rpm. Raise the fast idle lever to achieve approximately 2,000 rpm.
08/08/04 18:47:27 31ZY9600_059 OPERATION Panel-Mount Type EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH CLIP LANYARD 1. Put the emergency stop switch clip in the emergency stop switch, and attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD (Personal Flotation Device). The engine will not start or run unless the emergency stop switch clip is in the emergency stop switch.
08/08/04 18:47:35 31ZY9600_060 OPERATION START ON OFF IGNITION SWITCH KEY N (neutral) 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. CONTROL LEVER FAST IDLE BUTTON 4. Turn the ignition switch key to the START position and hold it there until the engine starts.
08/08/04 18:47:42 31ZY9600_061 OPERATION If the engine is not properly warmed up bef ore raising the engine speed, the buzzer and overheat indicator may activate and the engine speed will be automatically reduced. The cooling system may f reeze in areas where the temperature reaches 32°F (0°C) or below. Cruising at high speed without warming the engine up may cause engine damage. 60 During the warm-up period, check the oil pressure indicator (p. 39 ), overheat indicator (p.
08/08/04 18:47:51 31ZY9600_062 OPERATION The engine will not start or run unless the emergency stop switch clip is in the emergency stop switch. The emergency stop switch clip and emergency stop switch lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat. Always attach the emergency stop switch lanyard securely to the operator or to the operator’s PFD before starting the engine. START N (neutral) ON OFF CONTROL LEVER 2.
08/08/04 18:47:58 31ZY9600_063 OPERATION N (neutral) Using the electric starter f or more than 5 seconds at a time will overheat the starter motor and can damage it. CONTROL LEVER Turning the ignition switch key to the START position while the engine is running can damage the starter motor and f lywheel. FAST IDLE BUTTON 5. Before getting underway, allow the engine to warm-up sufficiently to ensure good performance. Above 41°F (5°C), warm-up the engine for at least 3 minutes.
08/08/04 18:48:09 31ZY9600_064 OPERATION During the warm-up period, check the oil pressure indicator (p. 39 ), overheat indicator (p. 40 ), and cooling system indicator (p. 41 ). If the indicators show any abnormal condition, immediately stop the engine and determine the cause of the problem. Refer to TAKING CARE OF UNEXPECTED PROBLEMS on p. 119 − 122 . 6. If the fast idle button was used to warm up the engine, gradually return the control lever to the N (neutral) position as the engine warms up.
08/08/04 18:48:16 31ZY9600_065 OPERATION 6. Set the controls the same as for normal starting (see pages 52 − 53 , 55 − 56 , 58 ). Use the fast idle control if needed. EMERGENCY STARTER ROPE Keep away from moving parts while pulling the rope. Turn the ignition switch key to the ON position. KNOT ALTERNATOR PULLEY 7. Set the alternator pulley so the cutouts are on the right and left sides of the alternator pulley as shown.
08/08/04 18:48:23 31ZY9600_066 OPERATION 9. 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. 39 ), overheat indicator (p. 40 ), and cooling system indicator (p. 41 ). 10. Leave the alternator cover off, but install the engine cover (p. 84) and lock it in place by latching the engine cover latch. 11.
08/08/04 18:48:33 31ZY9600_067 OPERATION STOPPING THE ENGINE LRT and XRT Types (remote control) Emergency Engine Stopping Side-Mount Type LHT Type (tiller handle) EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH LANYARD PULL PULL EMERGENCY STOP SWITCH CLIP Panel-Mount/Top-Mount Types EMERGENCY STOP SWITCH CLIP LANYARD EMERGENCY STOP SWITCH CONTROL PANEL LANYARD PULL EMERGENCY STOP SWITCH CLIP 66 To stop the engine in an emergency, pull the emergency stop switch clip out of the emergency stop switch b
08/08/04 18:48:42 31ZY9600_068 OPERATION LRT and XRT Types (remote control) Normal Engine Stopping Top-Mount Type N (neutral) LHT Type (tiller handle) Side-Mount Type N (neutral) SLOW CONTROL LEVER CONTROL LEVER THROTTLE GRIP N (neutral) Panel-Mount Type N (neutral) 1. Move the throttle grip to the slowest speed and the gearshift lever or control lever to the N (neutral) position.
08/08/04 18:48:51 31ZY9600_069 OPERATION LHT Type (tiller handle) OFF OFF IGNITION SWITCH KEY LRT and XRT Types (remote control) Side-Mount Type OFF IGNITION SWITCH KEY 68 Panel-Mount/Top-Mount Types IGNITION SWITCH KEY 2. Turn the ignition switch key to the OFF position to stop the engine. In the event that the engine does not stop when the ignition switch key is turned to OFF, pull the emergency stop switch clip out of the emergency stop switch by pulling the emergency stop switch lanyard (p.
08/08/04 18:48:59 31ZY9600_070 OPERATION GEARSHIFT AND THROTTLE OPERATION LHT Type (tiller handle) POINTER THROTTLE GRIP SLOW To shift gears, turn the throttle grip to the SLOW position; then move the gearshift lever to select F (forward), N (neutral), or R (reverse) gears. THROTTLE FRICTION ADJUSTER THROTTLE GRIP FIX The engine can be started with the gearshift lever in the N (neutral) position only.
08/08/04 18:49:09 31ZY9600_071 OPERATION Panel-Mount Type LRT and XRT Types (remote control) To shift gears, move the control lever to select the F (forward), N (neutral), or R (reverse) gear.
08/08/04 18:49:16 31ZY9600_072 OPERATION Side-Mount Type Top-Mount Type TO INCREASE FRICTION TO INCREASE FRICTION CONTROL LEVER FRICTION ADJUSTER TO DECREASE FRICTION TO DECREASE FRICTION Panel-Mount Type CONTROL LEVER FRICTION ADJUSTER TO INCREASE FRICTION CONTROL LEVER FRICTION ADJUSTER Adjust the control lever friction adjuster so the control lever will hold a constant throttle setting while cruising.
08/08/04 18:49:24 31ZY9600_073 OPERATION LRT and XRT Types (remote control) STEERING LHT Type (tiller handle) RIGHT TURN STEERING FRICTION KNOB LEFT TURN DECREASE FRICTION Move the tiller handle to the left. Move the tiller handle to the right. Steer by moving the tiller handle opposite the direction you want the boat to turn. INCREASE FRICTION Use the steering friction knob to help hold a steady course while cruising.
08/08/04 18:49:35 31ZY9600_074 OPERATION CRUISING Engine Speed For best fuel economy, limit the throttle opening to 80%. Use the throttle friction control (p. 69 − 71 ) 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.
08/08/04 18:49:48 31ZY9600_075 OPERATION LHT Type (tiller handle) Panel-Mount Type POWER TRIM/TILT SWITCH CONTROL LEVER MOTOR TRIMMED TOO LOW MOTOR TRIMMED TOO HIGH MOTOR TRIMMED CORRECTLY Top-Mount Type (single type) POWER TRIM/ TILT SWITCH POWER TRIM/TILT SWITCH LRT and XRT Types (remote control) CONTROL LEVER Side-Mount Type BOW TOO LOW DUE TO 1. LOAD IN THE FRONT 2.
08/08/04 18:49:57 31ZY9600_076 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. GEAR CASE GROMMET When the trim tab is correctly adjusted, steering effort will be equal in both directions. Refer to TRIM TAB ADJUSTMENT on p. 83 . SHALLOW WATER OPERATION An excessive trim/tilt angle during operation can cause propeller ventilation, overheating, and water pump damage.
08/08/04 18:50:04 31ZY9600_077 OPERATION MOORING, BEACHING, LAUNCHING Before tilting up, leave the outboard motor in the running position for one minute after stopping the engine to drain the water from inside the engine. To raise the outboard motor out of the water while the engine is stopped and the boat is moored, or for maximum clearance when beaching or launching, use the power tilt switch on the engine pan to tilt the outboard motor up as far as it will go.
08/08/04 18:50:09 31ZY9600_078 OPERATION motor will tilt up when operated in reverse. MANUAL RELIEF VALVE POWER (To f ix) MANUAL (To release) Check that nobody is under the outboard motor before opening the manual relief valve. If the manual relief valve is loosened (turned counterclockwise) when the outboard motor is tilted up, the outboard motor will suddenly tilt down. The outboard motor can also be tilted manually after opening the manual relief valve.
08/08/04 18:50:16 31ZY9600_079 SERVICING YOUR OUTBOARD MOTOR THE IMPORTANCE OF MAINTENANCE Proper maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. Improperly maintaining this outboard motor, or failure to correct a problem before operation, can cause a malfunction in which you could be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this Owner’s Manual.
08/08/04 18:50:25 31ZY9600_080 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.
08/08/04 18:50:33 31ZY9600_081 SERVICING YOUR OUTBOARD MOTOR TOOL KIT and OWNER’S MANUAL 10 × 14 mm WRENCH SPARK PLUG WRENCH 8 × 12 mm WRENCH 18 × 19 mm BOX WRENCH OIL CHECK SCREWDRIVER PHILLIPS/FLAT SCREWDRIVER SCREWDRIVER HANDLE EMERGENCY STARTER ROPE 10 mm BOX WRENCH PLIERS EMERGENCY STARTER ROPE FUSE PULLER TOOL BAG OWNER’S MANUAL SPARE EMERGENCY STOP SWITCH CLIP The tool kit can be used for simple maintenance procedures and emergency repairs.
08/08/04 18:50:44 31ZY9600_082 SERVICING YOUR OUTBOARD MOTOR MAINTENANCE SCHEDULE Follow the MAINTENANCE SCHEDULE table and service your outboard motor accordingly. Please note, a claim for warranty coverage will not be denied simply because the maintenance schedule for your outboard was not followed. However, any part(s) that fails specifically due to lack of maintenance, or improperly performed maintenance, would not be covered under the Distributor’s Limited Warranty.
08/08/04 18:50:56 31ZY9600_083 SERVICING YOUR OUTBOARD MOTOR REGULAR SERVICE PERIOD (3) Perform at every indicated month or operating hour interval, whichever comes first.
08/08/04 18:51:06 31ZY9600_084 SERVICING YOUR OUTBOARD MOTOR TRIM TAB ADJUSTMENT RIGHT 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. LEFT RIGHT LEFT When the trim tab is correctly adjusted, steering effort is equal in either direction.
08/08/04 18:51:14 31ZY9600_085 SERVICING YOUR OUTBOARD MOTOR MANUAL RELIEF VALVE POWER (To f ix) MANUAL (To release) 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. ENGINE COVER REMOVAL AND INSTALLATION ENGINE COVER LATCHES (front/rear) UNLATCH MANUAL RELIEF VALVE The outboard motor can be tilted manually after opening the manual relief valve.
08/08/04 18:51:26 31ZY9600_086 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. Rid of the alternator cover 1. Unlock and remove the engine cover (p. 84 ). 2. Remove the dipstick and wipe it clean. UPPER LIMIT 4. If the oil level is low, remove the oil filler cap, and add oil to reach the upper limit mark shown on the dipstick. Use the oil recommended on p. 88 .
08/08/04 18:51:34 31ZY9600_087 SERVICING YOUR OUTBOARD MOTOR Engine Oil Change An engine oil evacuation device may be used to remove the engine oil. DRAIN BOLT SEALING WASHER GUIDE Drain the used oil while the engine is warm. Warm oil drains quickly and completely. 1. Unlock and remove the engine cover (p. 84 ). 2. Place a suitable container below the oil drain guide to catch the used oil, and then remove the oil filler cap (p. 85 ) and the drain bolt. 3. Allow the used oil to drain completely.
08/08/04 18:51:44 31ZY9600_088 SERVICING YOUR OUTBOARD MOTOR 4. With the outboard motor in a vertical position, fill to the upper limit mark on the dipstick (p. 85 ) with the recommended oil. Engine oil refill capacity: Without oil filter change: 4.4 US qt (4.2 L) With oil filter change: 4.6 US qt (4.4 L) 5. Install the oil filler cap and tighten it securely (p. 85 ). 6. Install and lock the engine cover. Oil Filter Change FILTER WRENCH, 64 mm 1.
08/08/04 18:51:55 31ZY9600_089 SERVICING YOUR OUTBOARD MOTOR 4. Clean the oil filter mounting base, and coat the rubber seal of the new oil filter with clean engine oil. Use only a Honda Genuine oil f ilter or a f ilter of equivalent quality specif ied f or your model. Using the wrong f ilter, or a nonHonda f ilter which is not of equivalent quality, may cause engine damage. 5.
08/08/04 18:52:04 31ZY9600_090 SERVICING YOUR OUTBOARD MOTOR Spark Plug Service RECOMMENDED SPARK PLUGS: IZFR6K-11E (NGK) Incorrect spark plugs can cause engine damage. This outboard motor uses spark plugs that have an iridium coated center electrode. Be sure to observe the following when servicing the spark plugs. Do not clean the spark plugs. If an electrode is contaminated with accumulated objects or dirt, replace the spark plug with a new one.
08/08/04 18:52:12 31ZY9600_091 SERVICING YOUR OUTBOARD MOTOR BOX WRENCH CONNECTOR 0.039−0.051 in (1.0−1.3 mm) LOCK TAB IGNITION COIL SEALING WASHER INSULATOR 6 × 25 mm FLANGE BOLT 4. Remove the 6 × 25 mm flange bolt. Disconnect the connector by pushing the lock tab and remove the ignition coil. PLUG WRENCH 5. Remove the spark plug using the plug wrench, box wrench and the Phillips /flat-tip screwdrivers (accessories). 6. Inspect the spark plugs.
08/08/04 18:52:20 31ZY9600_092 SERVICING YOUR OUTBOARD MOTOR 8. Install the spark plugs carefully, by hand, to avoid cross-threading. 10. Install the ignition coil. Reinstall the bolt. 9. After each spark plug seats, tighten with a spark plug wrench supplied in the tool kit to compress the sealing washer. 11. Push the wire connector onto the ignition coil. Make sure it locks in place. If reinstalling used spark plugs, tighten 1/8−1/4 turn after the spark plugs seat. 12.
08/08/04 18:52:31 31ZY9600_093 SERVICING YOUR OUTBOARD MOTOR Lubrication Points Apply Honda Marine waterproof grease to the parts shown below: THROTTLE ARM/ LINK/PIVOT/PLATE THROTTLE ROD/LINK Lubrication interval: After the first 20 hours or 1 month, then every 100 hours or 6 months (refer to the maintenance schedule on page 81 ). TILLER HANDLE (LHT type) TILT BRACKET Apply anticorrosion oil to pivot surf aces where grease cannot penetrate.
08/08/04 18:52:38 31ZY9600_094 SERVICING YOUR OUTBOARD MOTOR SHIFT LINK BRACKET/ SHIFT PIVOT/SHIFT ARM/ LINK PIN/PIVOT PLATE/ SLIDE PIVOT/ CLICK SPRING ROLLER TILT LOCK LEVER (each side) TILT SHAFT THREAD UPPER CYLINDER PIN/BUSHING MOUNT FRAME SWIVEL SHAFT LOWER CYLINDER BUSHING/COLLAR 93
08/08/04 18:52:49 31ZY9600_095 SERVICING YOUR OUTBOARD MOTOR REFUELING Using the fuel tank mounted in the boat. Portable Fuel Tank (optional equipment) Check the fuel level and refill if necessary. Do not fill the fuel tank above the UPPER LIMIT. Refer to the boat manufacturer’s instructions. FUEL TANK CAPACITY: 6.6 US gal (25 L) FUEL GAUGE Check the fuel gauge and refill the tank when necessary. SAFE FILL LEVEL Remove the fuel tank from the boat for refueling.
08/08/04 18:52:59 31ZY9600_096 SERVICING YOUR OUTBOARD MOTOR Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. Never refill the fuel tank inside a building where gasoline fumes may reach flames or sparks. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc.
08/08/04 18:53:08 31ZY9600_097 SERVICING YOUR OUTBOARD MOTOR Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty. Water Separator Inspection and Service Gasoline is highly flammable and explosive. If your outboard will be used on an infrequent or intermittent basis, please refer to the fuel section of the STORAGE chapter (p. 107 ) for additional information regarding fuel deterioration.
08/08/04 18:53:16 31ZY9600_098 SERVICING YOUR OUTBOARD MOTOR HOSE CLIPS (commercially available) WATER SEPARATOR WATER SEPARATOR BRACKET HARNESS CLIP WATER SEPARATOR WATER LEVEL SENSOR 2P CONNECTOR CLIP C SUSPENSION STRAP FUEL HOSES 3. Pinch the fuel hoses with hose clips to prevent fuel leakage. 4. Remove the suspension strap from the water separator bracket; then remove the strap from the separator assembly.
08/08/04 18:53:26 31ZY9600_099 SERVICING YOUR OUTBOARD MOTOR BAFFLE PLATE BODY Assemble so the flat part on the back of the suspension is parallel to the water separator joint as shown below. Assemble so the flat part of the suspension and the water separator joint are parallel to each other. CLIP C SUSPENSION STRAP 7. Remove the three screws and separate the water separator cup from the body. JOINT WATER SEPARATOR 8. Thoroughly clean the water separator cup. 9.
08/08/04 18:53:35 31ZY9600_100 SERVICING YOUR OUTBOARD MOTOR 12. Squeeze and release the priming bulb to fill the vapor separator, and check for leaks. If the buzzer sounds or excessive water or sediment accumulation are found in the fuel filter, inspect the fuel tank. Clean the fuel tank and tank filter if necessary. It may be necessary to drain the fuel tank completely and refill with fresh gasoline.
08/08/04 18:53:44 31ZY9600_101 SERVICING YOUR OUTBOARD MOTOR HOSE CLIPS (commercially available) FUEL FILTER (inside strainer cup) 1. Remove the engine cover (see page 84 ). 2. Looking through the translucent strainer cup, check the fuel filter for water accumulation and clogging. If necessary, replace the fuel filter with a new one. 100 FUEL HOSE FUEL FILTER FUEL HOSE 3. Remove the strainer assembly.
08/08/04 18:53:50 31ZY9600_102 SERVICING YOUR OUTBOARD MOTOR FUEL FILTER (inside strainer cup) FUEL INTAKE SIDE JOINT 7. Prime the engine using the priming bulb (refer to page 51 ). Check for fuel leaks. Repair any fuel leaks if necessary. 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.
08/08/04 18:54:02 31ZY9600_103 SERVICING YOUR OUTBOARD MOTOR Portable Fuel Tank and Tank Filter Cleaning (optional equipment) Fuel Tank Fuel Tank Filter FUEL HOSE FUEL FILTER JOINT (Fuel Hose Connector) Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. O-RING FUEL TANK FILTER Empty the portable fuel tank into an approved gasoline container.
08/08/04 18:54:11 31ZY9600_104 SERVICING YOUR OUTBOARD MOTOR Anode Replacement Propeller Replacement Painting or coating the anodes will def eat their purpose and will lead to rust and corrosion damage to the outboard motor. The anodes must be exposed to the water in order to protect the outboard motor. ANODE (each side) ANODE (stern bracket) The anodes are located on each side of the gear case and on the stern bracket.
08/08/04 18:54:23 31ZY9600_105 SERVICING YOUR OUTBOARD MOTOR Installation 1. Apply marine grade grease to the propeller shaft. 2. Install the thrust washer with the grooved side toward the gear case. 3. Install the propeller. cotter pin hole. 8. Be sure to replace the cotter pin with a new one. TIGHTENING TORQUE LIMIT: 33 lbf·ft (44 N·m, 4.5 kgf·m) Do not tighten the castle nut above the TIGHTENING TORQUE LIMIT, or the propeller and shaf t may be damaged. 4. Install the washer. 5.
08/08/04 18:54:32 31ZY9600_106 STORAGE STORAGE PREPARATION Cleaning Proper storage preparation is essential for keeping your outboard motor trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your outboard motor’s function and appearance, and will make the engine easier to start when you use the outboard motor again. Wash the outside of the outboard motor with clean, fresh water, and flush the cooling system as follows.
08/08/04 18:54:39 31ZY9600_107 STORAGE FLUSH PORT CONNECTOR FLUSH PORT CONNECTOR GARDEN HOSE FLUSH PORT CONNECTOR GARDEN HOSE JOINT (Commercially available) 2. Screw the flush port connector onto the garden hose. EXHAUST PORT 3. Turn on the fresh water supply and flush the outboard motor for at least 10 minutes. 4. After flushing, disconnect the garden hose and reconnect the flush port connector. 1. Disconnect the flush port connector.
08/08/04 18:54:50 31ZY9600_108 STORAGE Fuel Gasoline will oxidize and deteriorate in storage. Old gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your fuel tank and vapor separator deteriorates during storage, you may need to have the vapor separator and other fuel system components serviced or replaced.
08/08/04 18:54:59 31ZY9600_109 STORAGE 1. Remove the engine cover (p. 84 ). 2. Release the drain tube from the projection of the intake manifold and set the end of the tube toward the outside of the engine undercase. Place an approved gasoline container below the fuel drain outlet, and use a funnel to avoid spilling fuel. 3. Loosen the vapor separator drain screw. 108 Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
08/08/04 18:55:11 31ZY9600_110 STORAGE Engine Oil HOISTING THE OUTBOARD MOTOR 1. Change the engine oil and the oil filter (p. 86 − 88 ). 2. Remove the spark plugs (p. 89 ), and remove the emergency stop switch clip from the emergency stop switch. HOIST HOOKS ENGINE HANGERS 3. Pour a teaspoon (p. 123 ) (5 − 10 cm3) of clean engine oil into each cylinder. STORAGE PRECAUTIONS Select a well-ventilated storage area. If possible, avoid storage areas with high humidity.
08/08/04 18:55:19 31ZY9600_111 STORAGE PROTECTOR REMOVAL FROM STORAGE Check your outboard motor as 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. (Port side turned down as shown.) OUTBOARD MOTOR STAND If the outboard motor will be removed from the boat for storage, we recommend storing it vertically by mounting it on a commercially available stand.
08/08/04 18:55:26 31ZY9600_112 TRANSPORTING WITH OUTBOARD MOTOR INSTALLED ON BOAT When trailering a boat with the outboard motor attached, leave the engine in the normal running position, if possible. 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. WITH OUTBOARD MOTOR REMOVED FROM BOAT Secure the outboard motor in either the vertical or horizontal position shown on p. 109 and 110 .
08/08/04 18:55:34 31ZY9600_113 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction 1. Check emergency stop switch clip. Clip not inserted in emergency stop switch. Insert clip in emergency stop switch. 2. Check control positions. Gearshift lever or control lever not in neutral position. Shift to neutral. Fast idle lever raised (side-mount type). Leave fast idle lever OFF (p. 56 ).
08/08/04 18:55:43 31ZY9600_114 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START (continued) 3. Check fuel. Possible Cause Correction Out of fuel. Refuel (p. 94 ). Fuel hose not primed. Squeeze priming bulb (p. 51 ). Fuel filter or fuel tank filter clogged. Replace fuel filters (p. 99 ). Bad fuel; boat stored without treating or draining gasoline, or refueled with bad gasoline. Drain fuel tank and vapor separator (p. 107 ). Refill with fresh gasoline (p. 94 ).
08/08/04 18:55:56 31ZY9600_115 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START (continued) 4. Check battery. Possible Cause Correction Battery connections loose or corroded. Clean and tighten battery connections. Battery discharged. Recharge battery. 5. Check fuses. Fuse(s) blown. Replace fuse(s) (p. 117 ). 6. Remove and inspect spark plugs. Spark plugs faulty, fouled or improperly gapped. Replace spark plugs (p. 89 ). Spark plugs wet with fuel (flooded engine).
08/08/04 18:56:05 31ZY9600_116 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. 56 ). 2. Check fuel. Fuel hose not primed. Squeeze priming bulb (p. 51 ). Fuel filter or fuel tank clogged. Replace fuel filters (p. 99 ). Bad fuel; boat stored without treating or draining gasoline, or refueled with bad fuel. Drain fuel tank and vapor separator (p.
08/08/04 18:56:17 31ZY9600_117 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. Replace spark plugs (p. 89 ). 4. Take outboard motor to an authorized Honda Marine dealer, or refer to the shop manual. Fuel system malfunction, fuel pump failure, ignition malfunction, etc. Replace or repair faulty components as necessary.
08/08/04 18:56:28 31ZY9600_118 TAKING CARE OF UNEXPECTED PROBLEMS FUSES Electric Starter Will Not Operate The 10A, 15A, and 30A main fuses protect the electric starter relay and related circuits. The 10A main fuse protects the ignition switch and related circuits. If this fuse blows, the engine will not start or run, and the power trim/tilt switch will not activate the trim/tilt mechanism. Fuse Replacement 3. Remove the electrical parts cover.
08/08/04 18:56:40 31ZY9600_119 TAKING CARE OF UNEXPECTED PROBLEMS 7. Reconnect the battery. FUSE PULLER ACG Fuse ‘‘70A’’MARK SPARE FUSE (70A) Never use a f use with a rating greater than specif ied. Serious damage to the electrical system could result. If a blown fuse is found, try to determine and correct the electrical problem that caused the blown fuse. An uncorrected electrical problem may cause the fuse to blow again. 5. Use the fuse puller from the tool kit to remove the fuses.
08/08/04 18:56:52 31ZY9600_120 TAKING CARE OF UNEXPECTED PROBLEMS 6. Install a new fuse with the ‘‘70A’’ mark downward. OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMITED LRT and XRT Types (remote control) Side-Mount Type ACG FUSE RATING: 70A LHT Type (tiller handle) 7. After finishing replacement, install the fuse case lid with its hook toward the engine side. (GREEN) (GREEN) 8. Be sure the fuse case lid is securely locked. BUZZER 9. Reinstall the electrical parts cover and engine cover.
08/08/04 18:57:01 31ZY9600_121 TAKING CARE OF UNEXPECTED PROBLEMS Digital Tachometer Normal Abnormal If oil pressure becomes low, the oil pressure indicator will go off, and the engine protection system limits engine speed. If you are at cruising speed, engine speed will decrease automatically. The oil pressure indicator is also equipped with a buzzer that sounds when the oil pressure indicator goes off.
08/08/04 18:57:13 31ZY9600_122 TAKING CARE OF UNEXPECTED PROBLEMS Digital Tachometer LRT and XRT Types (remote control) Side-Mount Type (RED) Normal Abnormal If the engine is stopped after running at full throttle, and then restarted soon afterward, that could activate the engine protection system momentarily.
08/08/04 18:57:23 31ZY9600_123 TAKING CARE OF UNEXPECTED PROBLEMS If water is flowing from the cooling system indicator, continue idling for 30 seconds. If the cooling system is OK, the overheat indicator should go off within 30 seconds, and the engine will respond normally to throttle control lever operation. 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.
08/08/04 18:57:33 31ZY9600_124 TAKING CARE OF UNEXPECTED PROBLEMS SUBMERGED MOTOR A submerged outboard motor must be serviced immediately after it is recovered from the water in order to minimize corrosion. If there is a Honda Marine dealership nearby, take the motor to the dealer immediately. If you are far from a dealer, proceed as follows: 1. Remove the engine cover, and rinse the outboard motor with fresh water to remove salt water, sand, mud, etc. 2. Drain the vapor separator as described on p. 107 .
08/08/04 18:57:38 31ZY9600_125 TAKING CARE OF UNEXPECTED PROBLEMS If the engine fails to start, remove the spark plugs and dry them, then reinstall the spark plugs and attempt to start the engine again. If the engine starts, and no mechanical damage is evident, continue to run the engine for a half hour or longer. Be sure the water level is at least two inches above the antiventilation plate to avoid overheating and water pump damage. 7.
08/08/04 18:57:45 31ZY9600_126 TECHNICAL AND CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Locations PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER Record the product identification number, the engine serial number, and the date of purchase in the space provided on this page. You will need these numbers when ordering parts, and when making technical or warranty inquiries (p. 134 ).
08/08/04 18:57:55 31ZY9600_127 TECHNICAL AND CONSUMER INFORMATION Battery For complete information, refer to the battery manufacturer’s instructions. engaging the starter motor and may prevent the outboard f rom starting. If the outboard starts and the buzzer sounds momentarily, there may be barely suf f icient voltage reaching the engine.
08/08/04 18:58:02 31ZY9600_128 TECHNICAL AND CONSUMER INFORMATION PGM-FI System The PGM-FI system uses sequential multiport fuel injection. It has two subsystems: Engine Control, and Fuel Control. The Engine Control Module (ECM) uses various sensors to determine how much air is going into the engine. It then controls how much fuel to inject under all operating conditions. The U.S.
08/08/04 18:58:11 31ZY9600_129 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.
08/08/04 18:58:21 31ZY9600_130 TECHNICAL AND CONSUMER INFORMATION Star Label A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board. The Star Label means Cleaner Marine Engine This engine has been certified as a: The Symbol for Cleaner Marine Engines: Cleaner Air and Water - for healthier lifestyle and environment.
08/08/04 18:58:30 31ZY9600_131 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.
08/08/04 18:59:04 31ZY9600_132 TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description code Type Overall length Overall width Overall height Transom height (when transom angle at 12°) Dry mass [weight]* Rated power Full throttle range Engine type Displacement Spark plug gap Steering control system Starter system Ignition system Lubrication system BF75D BBAJ Specified oil LHT LRT 35.6 in (904 mm) 29.4 in (746 mm) 25.4 in (646 mm) 17.7 in (449 mm) 61.7 in (1,566 mm) 21.
08/08/04 18:59:40 31ZY9600_133 TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description code Type Overall length Overall width Overall height Transom height (when transom angle at 12°) Dry mass [weight]* Rated power Full throttle range Engine type Displacement Spark plug gap Steering control system Starter system Ignition system Lubrication system BF90D BBCJ LHT 35.6 in (904 mm) 25.4 in (646 mm) Specified oil LRT XRT 29.4 in (746 mm) 17.7 in (449 mm) 61.7 in (1,566 mm) 21.
08/08/04 18:59:49 31ZY9600_134 TECHNICAL AND CONSUMER INFORMATION BF75D/BF90D Tune up Spark plug gap (do not adjust) Idle speed Valve clearance (cold) Other specifications 0.039−0.051 in (1.0−1.3 mm) See page 90 750 ± 50 rpm See shop manual Intake: 0.17 ± 0.02 mm See shop manual Exhaust: 0.28 ± 0.
08/08/04 19:00:00 31ZY9600_135 TECHNICAL AND CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing your outboard motor. Accessory Catalog Your authorized Honda Marine dealer offers a wide selection of accessories (optional equipment, oils and lubricants) to enhance your boating experience. Visit www.honda-marine.com and click on accessories to see the entire catalog of accessories.
08/08/04 19:00:10 31ZY9600_136 TECHNICAL AND CONSUMER INFORMATION Please include the following information in your communication: Your name, address and telephone number (complete with area code) Model and complete serial number Warranty Coverage Your new Honda is covered by the following warranties: Distributor’s Limited Warranty Emission Control System Warranty Date of purchase Name and location of selling dealer Name and location of servicing dealer (if different) A detailed description of your concer
08/08/04 19:00:16 31ZY9600_137 TECHNICAL AND CONSUMER INFORMATION Warranty Service Please remember that recommended maintenance interval servicing is not included in your warranty coverage. Additionally, your warranty does not apply to the normal wear of items (such as spark plug(s), water pump, etc.). As the owner of a Honda product, your servicing dealer may ask you to authorize an inspection. If the problem is covered under warranty, your dealer will perform any warranty repairs for you at no cost.
08/08/04 19:00:27 31ZY9600_138 TECHNICAL AND CONSUMER INFORMATION Distributor’s Limited Warranty This warranty is limited to Honda Outboard Motors distributed by American Honda Motor Co., Inc., Power Equipment Division, 4900 Marconi Drive, Alpharetta, Georgia 30005-8847.
08/08/04 19:00:39 31ZY9600_139 TECHNICAL AND CONSUMER INFORMATION problem. However, if you should require further assistance, write or call the Honda Marine Customer Relations. Please see Contacting Honda page 134 .
08/08/04 19:00:49 31ZY9600_140 TECHNICAL AND CONSUMER INFORMATION Accessories and Replacement Parts This warranty is limited to Honda Power Equipment parts,accessories and apparel when distributed by American Honda Motor Co., Inc., 1919 Torrance Blvd., Torrance, California 90501-2746.
08/08/04 19:00:55 31ZY9600_141 TECHNICAL AND CONSUMER INFORMATION To Obtain Warranty Service: You must take the Honda Outboard Motor product accessory or replacement part or the outboard motor or boat on which the accessory or replacement part is installed, and proof of purchase, at your expense, to any Honda Marine authorized service facility or dealer in the United States, Puerto Rico, or the U.S. Virgin Islands, during normal business hours.
08/08/04 19:01:03 31ZY9600_142 TECHNICAL AND CONSUMER INFORMATION Emission Control System Warranty Your new Honda outboard engine complies with both the U.S. EPA and State of California emission regulations. American Honda provides the same emission warranty coverage for outboard engines sold in all 50 states. YOUR WARRANTY RIGHTS AND OBLIGATION California The California Air Resources Board and American Honda Motor Co., Inc.
08/08/04 19:01:08 31ZY9600_143 TECHNICAL AND CONSUMER INFORMATION OWNER’S WARRANTY RESPONSIBILITY: As the outboard engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. American Honda Motor Co., Inc. recommends that you retain all receipts covering maintenance on your outboard engine, but American Honda Motor Co., Inc. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
08/08/04 19:01:14 31ZY9600_144 TECHNICAL AND CONSUMER INFORMATION may be denied. If the part in question is not related to the reason that your engine requires repair, your claim will not be denied. TO OBTAIN WARRANTY SERVICE: You must take your Honda outboard engine, along with your sales registration card or other proof of original purchase date, at your expense, to any Honda Marine dealer who is authorized by American Honda Motor Co., Inc.
08/08/04 19:01:22 31ZY9600_145 TECHNICAL AND CONSUMER INFORMATION EMISSION CONTROL SYSTEM WARRANTY PARTS: SYSTEMS COVERED BY THIS WARRANTY: Fuel Metering PARTS DESCRIPTION Carburetor assembly, Throttle body, Fuel injector, Fuel pump, Fuel pressure regulator, Throttle position sensor, Intake air temperature sensor, Engine temperature sensor, Manifold absolute pressure sensor, Idle air control valve, Barometric pressure sensor, Fuel line solenoid valve, Intake manifold, Intake valves, and Oxygen sensor or
08/08/04 19:01:26 31ZY9600_146 INDEX Alternator (ACG) Indicator ............................................ 38 Anodes ............................................................................ 44 Replacement ............................................................. 103 ARE YOU READY TO GET UNDERWAY?.............. 45 Battery .......................................................................... 126 Will Not Charge ....................................................... 117 BEFORE OPERATION.......
08/08/04 19:01:29 31ZY9600_147 INDEX Fast Idle Button Panel-Mount Type...................................................... 28 Top-Mount Type ........................................................ 32 Fast Idle Lever ................................................................ 24 Fuel Filler Cap Vent Knob (optional equipment) .............. 43 Filter Inspection and Replacement ............................. 99 Gauge (optional equipment)....................................... 37 HOSE CONNECTIONS ......
08/08/04 19:01:32 31ZY9600_148 INDEX Oil Pressure Indicator ..................................................... 39 OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMITED ............................... 119 OPERATION ................................................................. 48 OTHER FEATURES ..................................................... 42 OUTBOARD MOTOR SAFETY .................................... 7 Overheat Indicator ..........................................................
08/08/04 19:01:35 31ZY9600_149 INDEX Tachometer (optional equipment) .................................. 36 TAKING CARE OF UNEXPECTED PROBLEMS... 112 TECHNICAL AND CONSUMER INFORMATION ...................................................... 125 TECHNICAL INFORMATION .................................. 125 THE IMPORTANCE OF MAINTENANCE ................ 78 Throttle Friction Adjuster (LHT Type).................................... 21 Grip (LHT Type) ........................................................