includes us and canadian models€¦ · cap securely. if any fuel is spilled, make sure the area is...

PANTONE 288 CVC DIC F101 BLACK BF115_AH_OM表紙_31ZX1600BF115_AH_OM表紙_31ZX1600BF115_AH_OM表紙_31ZX1600背幅5mm背幅5mm背幅5mm

Includes US and Canadian Models

BF115D

英 N HCAHEM331ZX160000X31-ZX1-6000

300.2010.05Printed in Japan

－

The engine exhaust from thisproduct contains chemicals

known to the State of California tocause cancer, birth defects, or

other reproductive harm.

Keep this Owner’s Manual handy, so you can refer to it at any time. This Owner’sManual is considered a permanent part of the outboard motor and should remain withthe outboard motor if resold.

The information and specifications included in this publication were in effect at thetime of approval for printing. Honda Motor Co., Ltd. reserves the right, however, todiscontinue or change specifications or design at any time without notice and withoutincurring any obligation whatever. No part of this publication may be reproducedwithout written permission.

2010 Honda Motor Co., Ltd. All Rights Reserved

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1

INTRODUCTION

Congratulations on your selection ofa Honda outboard motor. We arecertain you will be pleased with yourpurchase of one of the finestoutboard motors on the market.

We want to help you get the bestresults from your new outboardmotor and to operate it safely. Thismanual contains information on howto do that; please read it carefully.

As you read this manual you willfind information preceded by a

symbol. That informationis intended to help you avoid damageto your outboard motor, otherproperty, or the environment.

We suggest you read the warrantypolicy to fully understand itscoverage and your responsibilities ofownership.

When your outboard motor needsscheduled maintenance, keep in mindthat your Honda Marine dealer isspecially trained in servicing Hondaoutboard motors. Your HondaMarine dealer is dedicated to yoursatisfaction and will be pleased toanswer your questions and concerns.

Best Wishes,Honda Motor Co., Ltd.

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2

A FEW WORDS ABOUTSAFETY

INTRODUCTION

Safety Messages

Safety Headings

Safety Labels

Safety Section

Instructions

IMPORTANT SAFETY INFORMATION.

OUTBOARD MOTOR SAFETY.

Your safety and the safety of othersare very important. And using thisoutboard motor safely is an importantresponsibility.

To help you make informeddecisions about safety, we haveprovided operating procedures andother information on labels and inthis manual. This information alertsyou to potential hazards that couldhurt you or others.

Of course, it is not practical orpossible to warn you about all thehazards associated with operating ormaintaining an outboard motor. Youmust use your own good judgment.

You will find important safety information in a variety of forms, including:

This entire book is filled with important safety information please read itcarefully.

preceded by a safety alert symbol and one ofthree signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

such as

on the outboard motor.

such as

how to use this outboard motor correctly and safely.

You WILL be KILLED or SERIOUSLYHURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLYHURT if you don’t follow instructions.

You CAN be HURT if you don’t followinstructions.

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3

CONTENTS

...................................OUTBOARD MOTOR SAFETY . 7................IMPORTANT SAFETY INFORMATION . 7

..................................SAFETY LABEL LOCATION . 9

..................................CONTROLS AND FEATURES . 12CONTROL AND FEATURE IDENTIFICATION

..................................................................CODES . 12....COMPONENT AND CONTROL LOCATIONS . 13

..............................................................CONTROLS . 17Side-Mount Type

......................................................Ignition Switch . 17Emergency Stop Switch Clip and Emergency

.......................................................Stop Switch . 17..........................Gearshift/Throttle Control Lever . 18

.......................................................Fast Idle Lever . 19Panel-Mount Type

......................................................Ignition Switch . 20Emergency Stop Switch Clip and Emergency

.......................................................Stop Switch . 21..........................Gearshift/Throttle Control Lever . 22

.....................................................Fast Idle Button . 23

Top-Mount Type......................................................Ignition Switch . 24

Emergency Stop Switch Clip and Emergency.......................................................Stop Switch . 24

..........................Gearshift/Throttle Control Lever . 25.....................................................Fast Idle Button . 27

Common Controls........................................Power Trim/Tilt Switch . 28

..................................................Power Tilt Switch . 29.............................................Manual Relief Valve . 29

.....................................................Tilt Lock Lever . 29TRL (Trolling) Control Switch

.........................................(optional equipment) . 30..............................................Engine Cover Latch . 30

................................................................Trim Tab . 30.......................................................INSTRUMENTS . 31

.........................Trim Meter (optional equipment) . 31

.........................Tachometer (optional equipment) . 31.............Digital Tachometer (optional equipment) . 31...........Digital Speedometer (optional equipment) . 32

......................................NMEA Interface Coupler . 32

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4

CONTENTS

...........................................................INDICATORS . 33...................................Alternator (ACG) Indicator . 33

...........................................Malfunction Indicator . 33............................................Oil Pressure Indicator . 34

.................................................Overheat Indicator . 34.....................................Cooling System Indicator . 35

................................................OTHER FEATURES . 35........................................Water Separator Buzzer . 35

...........................................................Rev Limiter . 36...................................................................Anodes . 36

.................................................Fuel Priming Bulb . 36

................................................BEFORE OPERATION . 37.........ARE YOU READY TO GET UNDERWAY? . 37

IS YOUR OUTBOARD MOTOR..................................................READY TO GO? . 37

................................................................OPERATION . 39....................SAFE OPERATING PRECAUTIONS . 39

.......................................BREAK-IN PROCEDURE . 39.......................................................FUEL PRIMING . 40

......................................STARTING THE ENGINE . 41..................................................Side-Mount Type . 41.................................................Panel-Mount Type . 44

...................................................Top-Mount Type . 46.......................................STOPPING THE ENGINE . 49

................................Emergency Engine Stopping . 49.......................................Normal Engine Stopping . 50

GEARSHIFT AND..................................THROTTLE OPERATION . 51

...............................................................STEERING . 52................................................................CRUISING . 53

.........................................Trolling Speed Control . 55................................................................TRIM TAB . 56

........................SHALLOW WATER OPERATION . 56...............MOORING, BEACHING, LAUNCHING . 57

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5

CONTENTS

..............SERVICING YOUR OUTBOARD MOTOR . 59...........THE IMPORTANCE OF MAINTENANCE . 59

.....................................MAINTENANCE SAFETY . 60...................TOOL KIT and OWNER’S MANUAL . 61

SPARE EMERGENCY STOP SWITCH CLIP.............................................(optional equipment) . 61

...............................MAINTENANCE SCHEDULE . 62....................................TRIM TAB ADJUSTMENT . 64....................................MANUAL RELIEF VALVE . 65

ENGINE COVER REMOVAL AND..................................................INSTALLATION . 65

............................................Engine Oil Level Check . 66....................................................Engine Oil Change . 66

.......................................................Oil Filter Change . 68..................................Engine Oil Recommendations . 69

.....................................................Lubrication Points . 70

....................................................Spark Plug Service . 72.............................................................REFUELING . 75

...............................FUEL RECOMMENDATIONS . 76...................Fuel Filter Inspection and Replacement . 77...................Water Separator Inspection and Service . 80

..................................................Anode Replacement . 82..............................................Propeller Replacement . 82

....................................................................STORAGE . 84...................................STORAGE PREPARATION . 84

..........................................Cleaning and Flushing . 84........................................................................Fuel . 85

.............................................................Engine Oil . 87................HOISTING THE OUTBOARD MOTOR . 88

...................................STORAGE PRECAUTIONS . 88...............................REMOVAL FROM STORAGE . 89

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6

CONTENTS

........................................................TRANSPORTING . 90WITH OUTBOARD MOTOR

......................................INSTALLED ON BOAT . 90WITH OUTBOARD MOTOR

..................................REMOVED FROM BOAT . 90

....TAKING CARE OF UNEXPECTED PROBLEMS . 91.....ELECTRIC STARTER WILL NOT OPERATE . 91

..................................ENGINE WILL NOT START . 92HARD STARTING OR STALLS AFTER

...........................................................STARTING . 94...........................................ENGINE OVERHEATS . 95

.......................................................................FUSES . 96..........................Electric Starter Will Not Operate . 96

.......................................Battery Will Not Charge . 96.................................................Fuse Replacement . 96

OIL PRESSURE INDICATOR GOES OFF AND............................ENGINE SPEED IS LIMITED . 98

OVERHEAT INDICATOR COMES ON AND............................ENGINE SPEED IS LIMITED . 99

........WATER SEPARATOR BUZZER SOUNDS . 101...................WATER SEPARATOR INDICATOR . 101.................SUBMERGED OUTBOARD MOTOR . 101

TECHNICAL AND CONSUMER.................................................INFORMATION . 103

.............................TECHNICAL INFORMATION . 103....................................Serial Number Locations . 103

.................................................................Battery . 104...............Emission Control System Information . 104

............................................................Star Label . 107......................................................Specifications . 109

.............................CONSUMER INFORMATION . 110.............................................Honda Publications . 110

............................Customer Service Information . 110...........................................Warranty Statements . 113

..........................Distributor’s Limited Warranty . 113...................Emission Control System Warranty . 118

........................................Distributor’s Warranty . 122

.........................................................................INDEX . 125

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7

IMPORTANT SAFETYINFORMATION

Operator Responsibility

OUTBOARD MOTOR SAFETY

It is the operator’s responsibility toprovide the necessary safeguardsto protect people and property.Know how to stop the enginequickly in case of emergency.Understand the use of all controls.

Attach the emergency stop switchlanyard securely to the operator.

Stop the engine immediately ifanyone falls overboard, and do notrun the engine while the boat isnear anyone in the water.

Always stop the engine if youmust leave the controls for anyreason.

Always wear a PFD (PersonalFlotation Device) while on theboat.

Familiarize yourself with all lawsand regulations relating to boatingand the use of outboard motors.

Be sure that anyone who operatesthe outboard motor receives properinstruction.

Be sure the outboard motor isproperly mounted on the boat.

Do not remove the engine coverwhile the engine is running.

The Honda BF115D outboard motoris designed for use with boats thathave a suitable manufacturer’s powerrecommendation. Other uses canresult in injury to the operator ordamage to the outboard motor andother property.

Most injuries or property damage canbe prevented if you follow allinstructions in this manual and on theoutboard motor. The most commonhazards are discussed in this chapter,along with the best way to protectyourself and others.

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8

Carbon Monoxide HazardRefuel With Care


Gasoline is extremely flammable,and gasoline vapor can explode.Refuel outdoors, in a well-ventilated area, with the enginestopped. Never smoke neargasoline, and keep other flamesand sparks away.

Refuel carefully to avoid spillingfuel. Avoid overfilling the fueltank.

After refueling, tighten the fillercap securely. If any fuel is spilled,make sure the area is dry beforestarting the engine.

Exhaust contains poisonous carbonmonoxide, a colorless, odorless gas.Breathing carbon monoxide cancause loss of consciousness and maylead to death.

If you run the engine in an area thatis confined, or even partly enclosed,the air you breathe could contain adangerous amount of exhaust gas.

Never run your outboard inside agarage or other enclosure.

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9

SAFETY LABEL LOCATIONUS, Puerto Rico, and US Virgin Islands Types


The label shown here contains important safety information. Please read it carefully. This label is considered apermanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized HondaMarine dealer for a replacement.

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10

Canadian Types


READ OWNER’S MANUAL

The label shown here contains important safety information. Please read it carefully. This label is considered apermanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized HondaMarine dealer for a replacement.

10/04/13 15:07:31 31ZX1600_011

Honda outboard motor isdesigned to give safe anddependable service ifoperated according toinstructions.Read and understand theOwner’s Manual beforeoperating the outboardmotor. Failure to do socould result in personalinjury or equipmentdamage.

11

Canadian Types


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12

CONTROL AND FEATURE IDENTIFICATION CODES

CONTROLS AND FEATURES

Model

Transom Height

Type

Power Trim/Tilt

Standard Rotating Propeller Shaft

Counterrotating Propeller Shaft

BF115D

20.0 in (508 mm)

25.0 in (635 mm)

LA LC XA XC XCA

Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications.

TYPE CODE (example)X C A

DestinationA: American, C: CanadianRotating direction of propeller shaftC: Counterrotating propeller shaftNone: Standard rotating propeller shaftTransom HeightL: 20.0 in (508 mm), X: 25.0 in (635 mm)

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13

COMPONENT AND CONTROL LOCATIONS


ENGINE COVER

ENGINE COVERLATCH

STERNBRACKET

MANUALRELIEF VALVE

ANODE

PROPELLER(optional equipment)

EXHAUST PORT/WATEROUTLET PORT

ANTIVENTILATIONPLATE

ANODE

COOLING SYSTEMINDICATOR

OIL LEVEL DIPSTICK

FLUSH PORTCONNECTOR

ENGINE OILDRAIN BOLT(inside cover)

ANODE

TRIM TAB GEAR OIL DRAIN/FILL SCREW

COOLING WATERINTAKE PORT

PRODUCTIDENTIFICATIONNUMBER

TILT LOCKLEVER

SPARK PLUG(under coil)

OIL FILLER CAP

NMEA INTERFACECOUPLER

POWER TILTSWITCH

GEAR OIL LEVELCHECK SCREW

JUNCTION BOX(FUSES)

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14

Remote Controls (optional equipment)

Side-Mount Control Type Panel-Mount Control Type

Control Panel(for Panel-Mount Type)


NEUTRAL RELEASELEVER

GEARSHIFT/THROTTLECONTROL LEVER

POWER TRIM/TILTSWITCH

BUZZER(inside)

CONTROL LEVERFRICTION ADJUSTER

EMERGENCY STOPSWITCH LANYARD

EMERGENCY STOPSWITCH CLIP

EMERGENCYSTOP SWITCH

IGNITIONSWITCH

FAST IDLELEVER

BUZZER

IGNITIONSWITCH




IGNITIONSWITCH KEY

SPARE EMERGENCYSTOP SWITCH CLIP

NEUTRAL RELEASE LEVER



FAST IDLE BUTTON

INDICATORS(Oil pressure, Overheat,Alternator, Malfunction)


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15

(for Top-Mount Dual Type)Control Panel(Top-Mount Single Type)

Top-Mount Type(Single Outboard Motor Type) (Dual Outboard Motor Type)



BUZZER

IGNITIONSWITCH



POWER TRIM/TILTSWITCH (LEFT)

GEARSHIFT/THROTTLECONTROL LEVERS




FAST IDLE BUTTON

POWER TRIM/TILTSWITCH (RIGHT)

FAST IDLE BUTTON

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16

Digital SpeedometerTachometer Trolling Control Switch Panel

Instruments(optional equipment)

Trim Meter Digital Tachometer


TRL (Trolling) CONTROL SWITCH

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17

CONTROLS

Side-Mount Type


EMERGENCY STOP SWITCH

EMERGENCYSTOP SWITCHLANYARD




IGNITIONSWITCH

OOFFFFOONN START

Ignition Switch

Emergency Stop Switch Clip andEmergency Stop Switch

Turning the ignition switch key to theSTART position operates the startermotor. The key automatically returnsto the ON position when releasedfrom the START position.

The ignition switch controls theignition system and the starter motor.

Turning the ignition switch to theOFF position stops the engine.

The engine will not start unless thegearshift/throttle control lever is inthe N (neutral) position (p. ) andthe emergency stop switch clip is inthe emergency stop switch.

41

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18


SPARE SWITCH CLIP


NEUTRAL RELEASELEVER

Gearshif t/Throttle ControlLever

The gearshift/throttle control levercontrols engine speed and selects F(forward), N (neutral), or R (reverse)gears.

The emergency stop switch clip mustbe inserted in the emergency stopswitch in order for the engine to startand run. The emergency stop switchlanyard must be attached securely tothe operator or to the operator’s PFD(Personal Flotation Device).

A spare switch clip is stored in a slotin the control housing (optionalequipment).

When used as described, theemergency stop switch clip andemergency stop switch lanyardsystem stops the engine if theoperator falls away from the controls.

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19


N (NEUTRAL)

FAST IDLE LEVERF (FORWARD)

30° 30°R (REVERSE)

SHIFT SHIFT

MMIINNIIMMUUMM MMIINNIIMMUUMMTTHHRROOTTTTLLEE OOPPEENNIINNGG

MAXIMUMTTHHRROOTTTTLLEE OOPPEENNIINNGG

MAXIMUM


Fast Idle Lever

Less friction allows easier controllever movement. More friction helpsto hold a steady throttle setting whilecruising.

Moving the control lever 30° from N(neutral) selects the gear, and furthermovement increases engine speed.

The control lever automatically locksitself in the N (neutral) position. Tomove the lever out of the N (neutral)position, you must squeeze theneutral release lever on the undersideof the lever handle.

Use the fast idle lever to accelerateengine warm-up after starting theengine. Do not use the fast idle leverwhen starting the engine.

See page for engine warm-upinstructions.

A friction adjuster near the base ofthe control lever adjusts the operatingresistance of the control lever. Referto p. .52

43

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20

Panel-Mount Type


N (neutral)

MAXIMUM FAST IDLE

LOWESTPOSITION

FAST IDLE LEVERIGNITIONSWITCH

OFF

ON START

Ignition Switch

The fast idle lever allows you toincrease the idle speed only when thecontrol lever is in the N (neutral)position. Place the fast idle lever inits lowest position to cancel the fastidle and return the control lever tonormal operation.





44

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21


SPARE SWITCH CLIP(optional equipment)








A spare switch clip (optionalequipment) can be stored in the toolbag.


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22


NEUTRALRELEASELEVER


N (NEUTRAL)

35° 35°F (FORWARD) R (REVERSE)

SHIFT SHIFT

MMIINNIIMMUUMMMMIINNIIMMUUMM

TTHHRROOTTTTLLEE OOPPEENNIINNGG


MAXIMUM

MAXIMUM




The control lever automatically locksitself in the N (neutral) position. Tomove the lever out of the N (neutral)position, you must squeeze theneutral release lever on the undersideof the lever handle.

A friction adjuster near the base ofthe control lever adjusts the operatingresistance of the control lever. Referto p. .


The gearshift/throttle control levercontrols engine speed and selects F(forward), N (neutral), or R (reverse)gears. 52

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23


FAST IDLE BUTTON

F (forward)N (neutral)

R (reverse)

CONTROLLEVER

PPuullll uuppNEUTRALRELEASELEVER

Push

FAST IDLE BUTTON

Fast Idle Button It is necessary to position the controllever in the N (neutral) position topush in the fast idle button.

The fast idle button allows you toincrease the idle speed withoutengaging the drive gears. Move thecontrol lever forward or reverse afterpushing in the fast idle button toincrease the idle speed.

Return the control lever to N(neutral) position to cancel the fastidle operation.

Use the fast idle button to accelerateengine warm-up after starting theengine. Do not use the fast idlebutton when starting the engine.


45

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24

Top-Mount Type


OFF

ONSTART

IGNITIONSWITCH






Ignition Switch






47

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25


SPARE SWITCH CLIP(optional equipment) GEARSHIFT/THROTTLE

CONTROL LEVERS


SINGLE TYPE

DUAL TYPE



The gearshift/throttle control lever(s)controls engine speed and selects F(forward), N (neutral), or R (reverse)gears.

A spare switch clip (optionalequipment) can be stored in the toolbag.


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26


N (NEUTRAL)

35° 35°F (FORWARD) R (REVERSE)

MMIINNIIMMUUMM

MMIINNIIMMUUMM


TTHHRROOTTTTLLEE OOPPEENNIINNGG MAXIMUM

MAXIMUM

GEARSHIFT/THROTTLE CONTROL LEVER

SHIFT SHIFT


A friction adjuster inside the controlbox adjusts the operating resistanceof the control lever(s). Refer top. .


52

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27


FAST IDLE BUTTON

N (neutral)F (forward)

R (reverse)

CONTROLLEVER

Push

FAST IDLE BUTTON

Fast Idle Button

The fast idle button allows you toincrease the idle speed withoutengaging the drive gears. Move thecontrol lever forward or reverse afterpushing in the fast idle button toincrease the idle speed.

Use the fast idle button to accelerateengine warm-up after starting theengine. Do not use the fast idlebutton when starting the engine.


Return the control lever to N(neutral) position to cancel the fastidle operation.

It is necessary to position the controllever in the N (neutral) position topush in the fast idle button.

48

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28

Common Controls

Power Trim/Tilt Switch


CONTROLLEVER

POWER TRIM/TILT SWITCH

CONTROL LEVER

SINGLE TYPE


CONTROLLEVER

DUAL TYPEPOWER TRIM/TILT SWITCH

(LEFT)

CCOONNTTRROOLLLLEEVVEERRSS

(RIGHT)

(Side-Mount Type) (Top-Mount Type)

(Panel-Mount Type)


The power trim/tilt switch is locatedon the control lever. It is a rockerswitch with UP and DN (down)positions for changing the angle ofthe outboard motor.

You can use the power trim/tiltswitch anytime whether the boat isunderway, stopped, or the ignitionswitch is in the OFF position. It isnecessary for the ignition switch tobe in the ON position for the trimmeter to indicate the outboard motorangle.

For dual mount outboard motors, tiltthem up at the same time.

Tilt the outboard motor for shallowwater operation, beaching, launching,or mooring.

Trim the outboard motor to obtainthe best performance and stability(p. ).53

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29

Power Tilt Switch Manual Relief Valve Tilt Lock Lever


POWER TILT SWITCH

MMAANNUUAALL RREELLIIEEFF VVAALLVVEE FFRREEEE

LLOOCCKK

TILT LOCK LEVER

PPOOWWEERR((TToo ffiixx))

MMAANNUUAALL((TToo rreelleeaassee))

This switch is used with the enginestopped to raise the outboard motorfor mooring, trailering, ormaintenance.

The power tilt switch will operatewithout turning the ignition switchON.

The power tilt switch is located onthe engine pan. It is a rocker switchwith UP and DN (down) positionsfor changing the angle of theoutboard motor. When the boat is to be moored for a

long time, tilt the outboard motor upas far as it will go. Then move the tiltlock lever to the LOCK position, andgently lower the outboard motor untilthe lever contacts the stern bracket.

The tilt lock lever is used to supportthe outboard motor in the fully-raisedposition.

Check that nobody is under theoutboard motor before opening themanual relief valve. If the manualrelief valve is loosened (turnedcounterclockwise) when the outboardmotor is tilted up, the outboard motorwill suddenly tilt down.

The outboard motor can be tiltedmanually after opening the manualrelief valve. This allows the outboardmotor to be tilted up or down whenno battery is connected.

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30

Trim TabEngine Cover LatchTRL (Trolling) Control Switch(optional equipment)


ENGINE COVER LATCH TRIM TAB

TRIM TABBOLT


SWITCHPANEL

UNLOCK

The trim tab compensates for‘‘torque steer,’’ which is a reaction ofthe outboard motor to propellerrotation.

If uncompensated, torque steer wouldmake the outboard motor tend to turnto one side.

The engine cover latch fastens theengine cover to the outboard motor.

The Trolling Control Switch is arocker switch with UP and DN(down) positions to adjust the trollingspeed up or down in 50 RPMincrements within the range of 650 to900 RPM.

If you press and hold the TRLcontrol switch while cruising with thethrottle closed, the mode changes totrolling mode (p. ).

When the trim tab is correctlyadjusted (p. ), steering effort isequal in both directions.

6455

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31

Digital TachometerTachometer(optional equipment)(optional equipment)

INSTRUMENTS

(optional equipment)Trim Meter


Digital Tachometer includes thefollowing functions.

TachometerHour MeterTrim MeterOil Pressure IndicatorOverheat IndicatorACG IndicatorMalfunction Indicator

Refer to the Operation Guideincluded with the Digital Tachometerfor operation information.

The tachometer shows engine speedin revolutions per minute.

Refer to the tachometer when usingthe throttle and power trim/tiltcontrols to achieve the bestperformance from the boat.

The trim meter indicates the relativetrim angle of the outboard motor.

Refer to the trim meter when usingthe power trim/tilt switch to achievethe best performance from the boat.

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32

Digital Speedometer(optional equipment)

NMEA Interface Coupler


NMEA INTERFACE COUPLER(6 pin black)

Digital Speedometer includes thefollowing functions.

SpeedometerFuel Level MeterVoltmeterTripmeterFuel Integration MeterFuel Economy MeterFuel Flow Meter

Refer to the Operation Guideincluded with the DigitalSpeedometer for operationinformation.

Water Separator Indicator

NMEA2000 based information onengine speed, fuel consumption, andvarious warnings can be read byconnecting to the motor with theinterface cable (optional equipment).Contact your dealer for moreinformation.

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33

INDICATORS Malfunction IndicatorAlternator (ACG) Indicator


ACG INDICATOR

ACG INDICATOR

(RED)

(RED)

MALFUNCTIONINDICATOR

(RED)

MALFUNCTIONINDICATOR

(RED)

BUZZER

BUZZER

BUZZER

BUZZER

(side-mount type)

(panel-mount/top-mount types)

(side-mount type)


The indicator lights come on and thebuzzer sounds when you turn theignition switch ON, allowing you tosee that they are working. If anindicator does not light during thistest, it cannot alert you if that systemdevelops a problem. Have yourHonda Marine dealer check forburned-out bulbs or other problems.Under normal conditions, thefollowing occur when the ignitionswitch is turned ON:

The ACG, Malfunction, OilPressure, and Overheat indicatorslight.The buzzer will beep twice.The Malfunction, Oil Pressure,and Overheat indicators will go outafter the second beep.The ACG indicator will go outafter the engine starts.The Oil Pressure indicator willlight again after the engine startsand will stay lit to indicate the oilpressure is normal.

When the engine control systemdetects an engine control systemmalfunction, the malfunctionindicator turns on and the buzzersounds at one-second intervals.

The ACG indicator turns on and thebuzzer sounds in one-secondintervals when the charging system isfaulty.

1.

2.3.

4.

5.

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34

Overheat IndicatorOil Pressure Indicator


(side-mount type)OIL PRESSUREINDICATOR

(GREEN)

BUZZER


OIL PRESSUREINDICATOR

(GREEN)

BUZZER

(side-mount type) OVERHEATINDICATOR

(RED)

BUZZER


OVERHEATINDICATOR

(RED)

BUZZER

TAKING CARE OFUNEXPECTED PROBLEMS,

When the oil pressure indicator is lit,oil pressure is OK.

If oil pressure becomes low, theindicator will go off, and the engineprotection system will limit enginespeed. Refer to

on p. .

All models are equipped with abuzzer that sounds continuouslywhen the oil pressure indicator goesoff.

Low oil pressure indicates that theengine oil level is low or that there isa problem with the engine lubricationsystem.

98

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35

OTHER FEATURES

Water Separator Buzzer

Cooling System Indicator


COOLING SYSTEM INDICATOR

WATER SEPARATOR

TAKING CARE OFUNEXPECTED PROBLEMS

The water separator buzzer sounds arapid, repeating signal when waterhas accumulated in the waterseparator.

Water should flow from the coolingsystem indicator while the engine isrunning. This shows that water iscirculating through the coolingsystem.

If water stops flowing while theengine is running, it indicates acooling system problem, such asclogged water intakes, which willcause engine overheating.

The cooling system indicatordischarge port can also becomeplugged.

When the alert triggers, the overheatindicator comes on and the buzzersounds a steady tone as the enginespeed is reduced to 1,800 rpm. If thecondition persists for another 20seconds, the engine shuts off. Referto

, onp. .

All models are equipped with abuzzer that sounds continuouslywhen the red light comes on.

Engine overheating may be the resultof clogged water intakes.

99

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36

Fuel Priming BulbAnodesRev Limiter


ANODE(each side)

ANODE(stern bracket)

PRIMING BULB

INLET END (tank side)

UP

OUTLET END(outboard motor side)

A priming bulb is built into the fuelhose that connects the fuel tank to theoutboard motor.

Before starting the engine, hold thepriming bulb up in the direction ofthe arrow; then squeeze the primingbulb until it feels firm. This willensure that fuel is supplied to theengine (p. ).

The anodes are made of a sacrificialmaterial that helps to protect theoutboard motor from corrosion.

There are two anodes on the gearcase, one on the stern bracket andtwo small anodes in the waterpassages of the engine block.

The engine is equipped with a revlimiter to prevent the possibility ofmechanical damage from excessiveengine speed.

The rev limiter may be activatedduring operation, limiting enginespeed, if the outboard motor istrimmed or tilted up excessively, orwhen propeller ventilation occursduring a sharp turn.

If the rev limiter is activated, checkthe trim angle of the outboard motor.

Check to see if the correct propelleris installed.

40

10/04/13 15:11:05 31ZX1600_037

Improperly maintainingthis outboard motor orfailing to correct a problembefore operation can causea malfunction in which youcould be seriously hurt orkilled.

Always perform a pre-operation inspection beforeeach operation, and correctany problem.

37

ARE YOU READY TO GETUNDERWAY?

Safety

KnowledgeIS YOUR OUTBOARDMOTOR READY TO GO?

BEFORE OPERATION

Your safety is your responsibility. Alittle time spent in preparation willsignificantly reduce your risk ofinjury.

Read and understand this manual.Know what the controls do and howto operate them.

Familiarize yourself with theoutboard motor and its operationbefore you get underway. Knowwhat to do in case of an emergency.

Familiarize yourself with all lawsand regulations relating to boatingand the use of outboard motors.

Always wear a PFD (PersonalFlotation Device) while on the boat.

Attach the emergency stop switchlanyard securely to the operator or tothe operator’s PFD.

For your safety, and to maximize theservice life of your equipment, it isvery important to take a fewmoments before you operate theoutboard motor to check its condition.Be sure to take care of any problemyou find, or have your authorizedHonda Marine dealer correct it,before you operate the outboardmotor.

Before beginning your pre-operationchecks, be sure the ignition switch isin the OFF position.

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38

Safety Inspection

Maintenance Inspection

BEFORE OPERATION

Look around the outboard motorfor signs of oil or gasoline leaks.

Check that the fuel hose isundamaged and properlyconnected.

Wipe up any spills before startingthe engine.

Check the stern bracket to be surethe outboard motor is securelyinstalled.

Check that all controls areoperating properly.

Replace any damaged parts.

Check that all fasteners are inplace and securely tightened.

Check the emergency stop switchfor proper operation. Start theengine (p. , or ). Makesure the engine stops by pulling

the emergency stop switch clipfrom the emergency stop switch.

Check the engine oil level (p. ).Running the engine with a low oillevel can cause engine damage.

Check to be sure the propeller isundamaged and the castle nut issecured with the cotter pin(p. ).

Check that the anodes are securelyattached to the stern bracket andthe gear case (p. ) and are notexcessively worn. The anodes helpprotect the outboard motor fromcorrosion.

Make sure the tool kit is onboard(p. ). Replace any missing items.

Check the fuel level in the fueltank (p. ).

Check that the battery fluid is

between the upper and lower levels,and the battery leads are connectedsecurely.

Check the water separator forwater contamination (p. ).

41 44 46

66

83

82

61

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39

SAFE OPERATINGPRECAUTIONS

BREAK-IN PROCEDURE

Break-in period: 10 hours

Next 60 minutes:

Next 45 minutes:

First 15 minutes:

Next 8 hours:

OPERATION

IMPORTANT SAFETYINFORMATION

BEFORE OPERATION.

To safely realize the full potential ofthis outboard motor, you need acomplete understanding of itsoperation and a certain amount ofpractice with its controls.

Before operating the outboard motorfor the first time, please review the

on page and thechapter titled

Proper break-in operation allows themoving parts to wear in smoothly forbest performance and long servicelife. Avoid continuous operation at asteady speed.

Run the engine up to a maximum of4,000 to 5,000 rpm, which is about50% to 80% of maximum throttleopening. Operating at maximum4,000 5,000 rpm should be limitedto 50% of the 60 minutes.

For your safety, do not start or runthe engine in a confined or partlyenclosed area. Your engine’s exhaustcontains poisonous carbon monoxide,a colorless, odorless gas that cancollect rapidly. Breathing carbonmonoxide can cause loss ofconsciousness and may lead to death.

Run the engine up to a maximum of2,000 to 3,000 rpm, which is about10% to 30% of maximum throttleopening. Operating at maximum2,000 3,000 rpm should be limitedto 50% of the 45 minutes.

Run the engine at trolling speed. Usethe minimum throttle openingnecessary to operate the boat at a safetrolling speed.

Do not run the engine at full throttlefor more than 5 minutes at a time.

For boats that plane easily, bring theboat up on plane, and then reduce thethrottle opening to the recommendedrpm range.

30-second full-throttle bursts are OK,but do not operate the enginecontinuously at full throttle.

7

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Gasoline is highlyflammable and explosive.

You can be burned orseriously injured whenhandling fuel.

Stop the engine and keepheat, sparks, and flameaway.Handle fuel onlyoutdoors.Wipe up spillsimmediately.

40

FUEL PRIMING

OPERATION

UP

PRIMING BULB

INLET END(tank side)

OUTLET END(outboard motor side)

Check to be sure there are no fuelleaks before starting the engine.

Hold the priming bulb up in thedirection of the arrow; then squeezethe priming bulb several times until itfeels firm, indicating that fuel hasreached the engine.

Do not touch the priming bulb withthe engine running or when tilting upthe outboard motor. The vaporseparator could overflow.

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41

STARTING THE ENGINE

Side-Mount Type

OPERATION




N (neutral)

CONTROLLEVER

Set the control lever in the N(neutral) position.

The engine will not start if the F(forward) or R (reverse) gears areengaged.

Put the emergency stop switch clipin the emergency stop switch, andattach the emergency stop switchlanyard securely to the operator or

to the operator’s PFD (PersonalFlotation Device).

The engine will not start or run,unless the emergency stop switchclip is in the emergency stopswitch.

Before leaving the dock, check theoperation of the emergency stopswitch.

Always attach the emergency stopswitch lanyard securely to theoperator or to the operator’s PFDbefore starting the engine.

The emergency stop switch clipand emergency stop switch lanyardsystem is a safety device that willstop the engine if you fall awayfrom the controls while operatingthe boat.

Control......................Side-Mount Type . p. 41....................Panel-Mount Type . p. 44

......................Top-Mount Type . p. 46

1.

2.

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42

OPERATION

LOWESTPOSITION

FAST IDLE LEVER

ONOFF START

IGNITION SWITCH KEY

Using the electric starter f or morethan 5 seconds at a time willoverheat the starter motor and candamage it.

Turning the ignition switch key tothe START position while theengine is running can damage thestarter motor and f lywheel.Leave the fast idle lever in the

OFF (fully lowered) position.

The fast idle lever cannot be raisedunless the control lever is in the N(neutral) position.

The control lever cannot be movedaway from the N (neutral) positionunless the fast idle lever is lowered.

If the engine fails to start within 5seconds, release the key and waitat least 10 seconds beforeoperating the starter again.

Turn the ignition switch key to theSTART position and hold it thereuntil the engine starts.When the engine starts, release thekey, allowing it to return to the ONposition.

Turn the ignition switch key to theON position; the buzzer will soundtwice.

3. 4.

5.

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43

OPERATION

MAXIMUM FAST IDLE

FAST IDLERANGE

FAST IDLE LEVER


If the engine is not properlywarmed up bef ore raising theengine speed, the buzzer andoverheat indicator may activateand the engine speed will beautomatically reduced.The cooling system may f reeze inareas where the temperaturereaches 32°F (0°C) or below.Cruising at high speed withoutwarming the engine up may causeengine damage.

Before getting underway, allowthe engine to warm-up sufficientlyto ensure good performance.

Above 41°F (5°C), warm-up theengine for at least 3 minutes.

Below 41°F (5°C), warm-up theengine for at least 5 minutes at2,000 rpm. Raise the fast idle leverto achieve approximately 2,000rpm.

If the fast idle lever was used towarm-up the engine, graduallylower the lever as the enginewarms up.

When the fast idle lever is fullylowered, the control lever can bemoved away from the N (neutral)position.

During the warm-up period, checkthe oil pressure indicator (p. ),overheat indicator (p. ), andcooling system indicator (p. ).

If the indicators show anyabnormal condition, immediatelystop the engine and determine thecause of the problem. Refer to

onp. .

6.7.

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35

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44

Panel-Mount Type

OPERATION

EMERGENCY STOPSWITCH



N (neutral)

CONTROLLEVER



Put the emergency stop switch clipin the emergency stop switch, andattach the emergency stop switchlanyard securely to the operator orto the operator’s PFD (PersonalFlotation Device).

The engine will not start or run,unless the emergency stop switchclip is in the emergency stopswitch.

The emergency stop switch clipand emergency stop switch lanyardsystem is a safety device that willstop the engine if you fall awayfrom the controls while operatingthe boat.



1. 2.

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45

OPERATION

STARTON

OFF

IGNITIONSWITCH KEY

CONTROLLEVER

FAST IDLE BUTTON

N (neutral)


Turning the ignition switch key tothe START position while theengine is running can damage thestarter motor and f lywheel. Before getting underway, allow

the engine to warm-up sufficientlyto ensure good performance.


Below 41°F (5°C), warm-up theengine for at least 5 minutes at2,000 rpm. Push the fast idlebutton, and then move the controllever forward or reverse to openthe throttle and achieveapproximately 2,000 rpm.


Turn the ignition switch key to theSTART position and hold it thereuntil the engine starts.


When the engine starts, release thekey, allowing it to return to the ONposition.

3.

4.

5.

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46

Top-Mount Type

OPERATION






Put the emergency stop switch clipin the emergency stop switch, andattach the emergency stop switchlanyard securely to the operator orto the operator’s PFD (PersonalFlotation Device).


If the fast idle control was used towarm-up the engine, graduallyreturn the control lever to the N(neutral) position as the enginewarms up.


onp. .

1.6.

3434

35

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47

OPERATION

N (neutral)

CONTROLLEVER

STARTON

OFF

IGNITIONSWITCH KEY



The emergency stop switch clip andemergency stop switch lanyardsystem is a safety device that willstop the engine if you fall away fromthe controls while operating the boat.


The engine will not start or run,unless the emergency stop switch clipis in the emergency stop switch.


Turn the ignition switch key to theSTART position and hold it thereuntil the engine starts.When the engine starts, release thekey, allowing it to return to the ONposition.


2. 3.

4.

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48

OPERATION

N (neutral)

CONTROLLEVER

FAST IDLE BUTTON



Turning the ignition switch key tothe START position while theengine is running can damage thestarter motor and f lywheel. Before getting underway, allow

the engine to warm-up sufficientlyto ensure good performance.


Below 41°F (5°C), warm-up theengine for at least 5 minutes at2,000 rpm. Push the fast idlebutton, and then move the controllever forward or reverse to openthe throttle and achieveapproximately 2,000 rpm.


5.

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49

STOPPING THE ENGINE

Emergency Engine Stopping

OPERATION



PULL



CONTROL PANEL


PULL

EMERGENCY STOP SWITCH CLIP

Side-Mount Type

Panel-Mount/Top-Mount Types



If the fast idle control was used towarm-up the engine, graduallyreturn the control lever to the N(neutral) position as the enginewarms up.


onp. .

To stop the engine in an emergency,pull the emergency stop switch clipout of the emergency stop switch bypulling the emergency stop switchlanyard.

We suggest that you stop the enginethis way occasionally to verify thatthe emergency stop switch isoperating properly.


Turn the ignition switch key to theOFF position after verifying theemergency stop switch operation.

6.

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35

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50

Normal Engine Stopping

OPERATION

IGNITIONSWITCH KEY

IGNITIONSWITCH KEY

OFFN (neutral)

CONTROLLEVER

N (neutral)

CONTROLLEVER

N (neutral)

CONTROLLEVER

OOFFFF

Side-Mount Type

Panel-Mount Type

Top-Mount Type Panel-Mount/Top-Mount Types

Side-Mount Type

Turn the ignition switch key to theOFF position to stop the engine.In the event that the engine doesnot stop when the ignition switchkey is turned to OFF, press theemergency stop switch until theengine stops.

When the boat is not in use,remove and store the ignitionswitch key and the emergency stopswitch clip and lanyard.

Move the control lever(s) to the N(neutral) position.

After cruising at full throttle, cooldown the engine by idling for a fewminutes before stopping the engine.

1. 2.

3.

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51

GEARSHIFT ANDTHROTTLE OPERATION

OPERATION

CONTROL LEVER

NEUTRALRELEASELEVER

N (neutral)

F (forward)R (reverse)

N (neutral)F (forward)

R (reverse)

CONTROLLEVER

NEUTRALRELEASELEVER

F (forward)N (neutral)

R (reverse)

CONTROLLEVER

Panel-Mount Type

Top-Mount Type

Side-Mount Type

To shift gears, move the control leverto select the F (forward), N (neutral),or R (reverse) gear.

The control lever cannot be movedfrom the N (neutral) position unlessthe neutral release lever is squeezed(side-mount/panel-mount types).

Moving the control lever beyond thegear selection range increases enginespeed.

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52

STEERING

OPERATION

TO INCREASEFRICTION

TO DECREASEFRICTION


TO INCREASEFRICTION

TO DECREASEFRICTION

TO INCREASEFRICTION

TO DECREASEFRICTION



Top-Mount Type

Panel-Mount Type

Side-Mount Type

Steer the boat in the same manner asan automobile.

Adjust the control lever frictionadjuster so the control lever will holda constant throttle setting whilecruising.

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53

CRUISING

Engine Speed

Trim

OPERATION

Excessive trim/tilt angle duringoperation can cause propellerventilation, overheating, and waterpump damage.

For rough water conditions or largewaves, slow down to prevent thepropeller from rising out of the water.

Under normal conditions, the boatwill perform best when theantiventilation plate is level with thewater surface.

When cruising into a high wind, trimthe outboard motor down slightly tolevel the boat and improve stability.With a tail wind, trim the outboardmotor up slightly.

For best fuel economy, limit thethrottle opening to 80%. Use thethrottle friction control (p. ) tohelp you hold a steady speed.

Use the power trim/tilt switch to trimthe outboard motor for the bestperformance and stability.

You can use the power trim/tiltswitch at any time, whether the boatis underway or stopped.

Press the UP or DN (down) side ofthe switch to adjust the angle of theoutboard motor.

It is necessary to trim the angle of theoutboard motor to compensate forchanges in boat load, weightdistribution, water conditions, orpropeller selection.

The engine is equipped with a revlimiter to prevent the possibility ofmechanical damage from excessiveengine speed.

If, for example, the outboard motoris tilted excessively or propellerventilation occurs during a sharp turn,the engine may overrev, activatingthe rev limiter.If engine speed becomes unstable athigh speed due to activation of therev limiter, reduce speed and checkthe trim angle of the outboard motor.

Refer to the trim meter (p. ) for anindication of whether the outboardmotor is trimmed high or low.

52

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54

OPERATION

(single type)

(dual type)




POWER TRIM/TILT SWITCH(LEFT) (RIGHT)

1.2.

1.2.

OUTBOARDMOTOR TRIMMEDTOO LOW

OUTBOARDMOTOR TRIMMEDTOO HIGH

OUTBOARD MOTOR TRIMMEDCORRECTLY

BOW TOO LOW DUE TO

BOW TOO HIGH DUE TO

LOAD IN THE FRONTOUTBOARD MOTOR TRIMMEDTOO LOW

LOAD IN THE REAROUTBOARD MOTOR TRIMMEDTOO HIGH

Top-Mount TypeSide-Mount Type

Panel-Mount Type

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55

Trolling Speed Control(optional equipment)

OPERATION

SWITCH PANEL


DN: Reduce engine speedUP: Increase engine speed

The engine must be fully warmed upbefore you can activate the TrollingSpeed Control.

The throttle control will operate

when in the Trolling Speed Controlmode, but once the speed reaches3,000 RPM, the Trolling SpeedControl is deactivated. If 3,000 RPMis not reached and the throttle isclosed, the engine speed willdecrease to the Trolling SpeedControl setting.

In Trolling Speed Control mode, theengine speed can be adjustedbetween 650 and 900 RPM.Continuing to press the switch whenat either of these limits will result intwo short sounds from the buzzer.

The engine speed can be adjusted in50 RPM increments by pressing theUP or DN side of the TRL controlswitch. A short sound of the buzzeroccurs each time the engine speed isadjusted.

The initial trolling speed is set at 650RPM.

Place the outboard motor in-gearwith the throttle control in the fullyclosed (idle) position. Press and holdthe UP or DN side of the TRLcontrol switch to activate the TrollingSpeed Control. The buzzer will makeone long sound indicating activation.

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56

SHALLOW WATEROPERATION

TRIM TAB

OPERATION

TRIM TABBOLT

TRIM TAB

TRIM ANGLE(when transom angle is 12°)

68°

16°0°(VERTICAL LINE)

4°

12°

TILT ANGLE0°

TRIM TAB ADJUSTMENT

An excessive trim/tilt angle duringoperation can cause propellerventilation, overheating, and waterpump damage. This type of damageis not covered by the

(p. ).113

When operating in shallow water, usethe power trim/tilt switch (p. ) totilt the outboard motor so that thepropeller and gear case won’t hit thebottom.

Proceed at low speed, and monitorwater flow from the cooling systemindicator (p. ) to be sure theoutboard motor is not tilted so highthat the water intakes are out of thewater.

Adjust the trim tab with the enginestopped. Loosen the bolt above thetrim tab, turn the trim tab, and thentighten the bolt securely.

When the trim tab is correctlyadjusted, steering effort will be equalin both directions.

Refer toon p. .

Distributor’sLimited Warranty

If steering effort is not equal in bothdirections, adjust the trim tab tocompensate for ‘‘torque steer,’’which is the reaction of the outboardmotor to propeller rotation.

54

35

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57

MOORING, BEACHING,LAUNCHING

OPERATION

POWER TILT SWITCH

TILT LOCK LEVER(Lock position)

FFRREEEE

LLOOCCKK

STERN BRACKET

TRIM RODS

Do not attempt to use the power tiltswitch to tilt the outboard motordown while the tilt lock lever is in theLOCK position. Damage to thepower tilt system may occur.

To lower the outboard motor, tilt upusing the power tilt switch, thenmove the tilt lock lever to the FREEposition, and then lower the outboardmotor to the desired position.

To raise the outboard motor out ofthe water while the engine is stoppedand the boat is moored, or formaximum clearance when beachingor launching, use the power tiltswitch on the engine pan to tilt theoutboard motor up as far as it will go.Move the tilt lock lever to the LOCKposition, and then gently lower theoutboard motor until the levercontacts the stern bracket. Use thepower tilt switch to fully shorten thetrim rods.

Before tilting up, leave the outboardmotor in the running position for oneminute after stopping the engine todrain the water from inside theengine.

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58

OPERATION

MANUAL RELIEF VALVE

POWER(To fix)

MANUAL(To release)

The outboard motor can also be tiltedmanually after opening the manualrelief valve. This feature enables theoutboard motor to be tilted up ordown when no battery is connected.

For manual tilting, use a screwdriverto turn the valve counterclockwise 1or 2 turns. Close the valve firmlyafter positioning the engine.

Be sure the valve is closed beforeoperating the outboard motor. If thevalve is not closed, the outboardmotor will tilt up when operated inreverse.


10/04/13 15:14:26 31ZX1600_059

Improperly maintainingthis outboard motor orfailure to correct a problembefore operation can causea malfunction in which youcould be seriously hurt orkilled.

Always follow theinspection andmaintenancerecommendations andschedules in this Owner’sManual.

59

THE IMPORTANCE OFMAINTENANCE

Maintenance, replacement, orrepair of the emission controldevices and systems may beperformed by any marine enginerepair establishment or individual,using parts that are ‘‘certified’’ toEPA standards.

SERVICING YOUR OUTBOARD MOTOR

Proper maintenance is essential forsafe, economical, and trouble-freeoperation. It will also help reduce airpollution.

To help you properly care for youroutboard motor, the following pagesinclude a maintenance schedule,routine inspection procedures, andsimple maintenance procedures usingbasic hand tools. Other service tasksthat are more difficult or requirespecial tools are best handled byprofessionals and are normallyperformed by a Honda technician orother qualified mechanic.

The maintenance schedule applies tonormal operating conditions. If youoperate your outboard motor underunusual conditions, consult anauthorized Honda Marine dealer forrecommendations applicable to yourindividual needs and use.

Remember that your authorizedHonda Marine dealer knows youroutboard motor best and is fullyequipped to maintain and repair it.

To ensure the best quality andreliability, use only new, HondaGenuine parts or their equivalents forrepair and replacement.

10/04/13 15:14:33 31ZX1600_060

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Failure to properly followmaintenance instructionsand precautions can causeyou to be seriously hurt orkilled.

Always follow theprocedures andprecautions in the Owner’sManual.

60

MAINTENANCE SAFETY Safety Precautions

Burns from hot parts.

Injury from moving parts.

Carbon monoxide poisoningfrom engine exhaust.


Some of the most important safetyprecautions follow. However, wecannot warn you of everyconceivable hazard that can arise inperforming maintenance. Only youcan decide whether or not you shouldperform a given task.

Make sure the engine is off beforeyou begin any maintenance orrepairs. This will eliminate severalpotential hazards:

Read the instructions before youbegin, and make sure you have thetools and skills required.

To reduce the possibility of fire orexplosion, be careful whenworking around gasoline. Use onlya nonflammable solvent, notgasoline, to clean parts. Keepcigarettes, sparks, and flames awayfrom all fuel-related parts.

Wear gloves when handling thepropeller to protect your handsfrom sharp edges.Let the engine and exhaust

system cool before touching.

Do not run the engine unlessinstructed to do so.

Do not start or run the engine ina confined or partly enclosedarea.

10/04/13 15:14:42 31ZX1600_061

×

×

×

61

TOOL KIT and OWNER’S MANUAL SPARE EMERGENCY STOPSWITCH CLIP(optional equipment)


14 17 mm WRENCH 19 mm EYE WRENCH

10 12 mm WRENCH SPARK PLUG WRENCH

8 mm WRENCH 16 17 mm BOX WRENCH

OIL CHECKSCREWDRIVER

PLIERS

FLAT SCREWDRIVER

OWNER’S MANUALPHILLIPSSCREWDRIVER

6 mm HEX. WRENCH

SCREWDRIVER HANDLE

TOOL BAG

Always carry a spare emergency stopswitch clip onboard. The spare clipmay either be stored in the tool bagor in an easily accessible location onthe boat.

The tool kit can be used for simple maintenance procedures and emergencyrepairs. Keep these items on the boat so that they will always be available ifyou need them.

If your tool kit needs replacement, it is not available as a kit and each itemmust be ordered individually.

10/04/13 15:14:49 31ZX1600_062

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62

MAINTENANCE SCHEDULE


Distributor’s Limited Warranty

Follow the MAINTENANCE SCHEDULE table and service your outboard motor accordingly. Please note, a claim forwarranty coverage will not be denied simply because the maintenance schedule for your outboard motor was notfollowed. However, any part(s) that fails specifically due to lack of maintenance, or improperly performed maintenance,would not be covered under the .

ITEM

Perform at every indicated month or operatinghour interval, whichever comes first.

REGULAR SERVICE PERIOD

Engine oil

Engine oil filterGear case oilACG beltThrottle linkageIdle speedValve clearanceSpark plug(Standard plug)Propeller and cotter pinAnode metalAnode metalLubricationWater separator

Check levelChangeReplaceChangeCheck-adjustCheck-adjustCheck-adjustCheck-adjustCheck-adjust/Replace

CheckCheck Outside engineCheck Inside engineGreaseCheck

Each use After use

Firstmonth

or20 hrs.

Every6 months

or100 hrs.

Everyyearor

200 hrs.

Every2 years

or400 hrs.

Refer topage

(3)

(2)

(2)(2)

(1)

(2)

(2)(2)

(1)

(2)

(2)

(2)

(2) (6)

66

68

72 74

8382

70 7180

When there is 1/3 or more consumption, please exchange.For professional commercial use, log hours of operation to determine proper maintenance intervals.

These items should be serviced by an authorized Honda Marine dealer, unless you have the proper tools and are mechanically proficient.Refer to the Honda shop manual for service procedures.

Lubricate more frequently when used in salt water.(1)(2)

(3)(6)

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63


REGULAR SERVICE PERIODPerform at every indicated month or operatinghour interval, whichever comes first.

ITEMCheckReplaceReplace

CheckCheckReplaceCheck level-tightnessCheck-tightnessCheckCleanCheckCheckCheckCheckCheckCheckCheckCleanReplace

Every 2 years (If necessary) (2)

Fuel filter(Low pressure side)Fuel filter(High pressure side)ThermostatFuel line

Battery and cable connectionBolts and nutsCrankcase breather tubeCooling water passagesWater pumpEmergency stop switchEngine oil leakEach operation partEngine condition (5)Power Trim/TiltSpark plug(Optional iridium plug)

Each use After use

Firstmonth

or20 hrs.

Every6 months

or100 hrs.

Everyyearor

200 hrs.

Every2 years

or400 hrs.

Refer topage

(3)

(4)

(2) (2)

(2)

(2)

(2)

(2)

(2)

(2)

77 79

38

38

38

75

75

Upon starting, check for unusual engine sounds and cooling water flowing freely from the check hole.When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.For professional commercial use, log hours of operation to determine proper maintenance intervals.

These items should be serviced by an authorized Honda Marine dealer, unless you have the proper tools and are mechanically proficient.Refer to the Honda shop manual for service procedures.

Lubricate more frequently when used in salt water.(1)(2)

(3)(4)(5)

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64

TRIM TAB ADJUSTMENT


LEFT

TRIM TAB BOLT

LEFT

TRIM TAB

RIGHT

TRIM TAB BOLT

RIGHT

TRIM TAB

The trim tab compensates for‘‘torque steer,’’ which is a reaction ofthe outboard motor to propellerrotation.

If uncompensated, torque steer wouldmake the outboard motor tend to turnto one side.

When the trim tab is correctlyadjusted, steering effort is equal ineither direction.

If steering effort is unequal, loosenthe trim tab bolt and adjust the angleof the trim tab. Retighten the trim tabbolt securely.

If less effort is required to make leftturns, move the back of the trim tableft.

Adjust the trim tab in smallincrements, and retest steering effortwith the boat evenly loaded andrunning at cruising speed.

If less effort is required to make rightturns, move the back of the trim tabright.

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65

MANUAL RELIEF VALVE

ENGINE COVER REMOVALAND INSTALLATION


MANUAL RELIEF VALVE

UNLOCK

ENGINE COVER LATCH

ENGINE COVER

PPOOWWEERR((TToo ffiixx))

MMAANNUUAALL((TToo rreelleeaassee))

Be sure the valve is closed beforeoperating the outboard motor. If thevalve is not closed, the outboardmotor will tilt up when operated inreverse.

For manual tilting, use a screwdriverto turn the valve counterclockwise 1or 2 turns. Close the valve firmlyafter positioning the outboard motor.

The outboard motor can be tiltedmanually after opening the manualrelief valve. This feature enables theoutboard motor to be tilted up ordown when no battery is connected.

The cover should be tight at the mid-case point. If the cover is loose ordifficult to secure, an adjustmentmay be necessary. Please see theshop manual or your Honda Marinedealer for adjustment.

To install the engine cover, place thecover on the outboard motor, andpush down evenly.

To remove the engine cover, pull theengine cover latch to the unlockedposition, then lift the engine coverstraight up from the outboard motor.

The engine cover latch fastens theengine cover to the outboard motor.


10/04/13 15:15:34 31ZX1600_066

66

Engine Oil Level Check Engine Oil Change


UPPERLIMIT

LOWERLIMIT

OIL LEVEL DIPSTICK

OIL FILLER CAP

DRAIN BOLT COVER

LEVER

Running the engine with a low oillevel can cause engine damage.

Check the engine oil level with theengine stopped and the outboardmotor in the vertical position.

Unlock and remove the enginecover (p. ).

Remove the dipstick and wipe itclean.

Insert the dipstick all the way in,then remove it and check the oillevel shown on the dipstick.

If the oil level is low, remove theoil filler cap, and add oil to reachthe upper limit mark shown on thedipstick. Use the oil recommendedon p. .

Install the oil filler cap and tightenit securely. Do not overtighten.

Install and lock the engine cover.

An engine oil evacuation device maybe used to remove the engine oil.

Drain the used oil while the engine iswarm. Warm oil drains quickly andcompletely.


Push the drain bolt cover lever andremove the cover while pulling thecover backward at an angle.

1.

2.

3.

4.

5.

6.

1.

2.

65

69

65

10/04/13 15:15:46 31ZX1600_067

67


DRAIN BOLT COVER

GUIDE

DRAIN BOLT COVER

GUIDE

SEALING WASHER

GUIDE

DRAINBOLTCOVER

DRAIN BOLT COVER

UNDER COVER PUSH

LOCKING LUG

DDRRAAIINNBBOOLLTT

LEVER

PROJECTION

Improper disposal of engine oil canbe harmf ul to the environment. Ifyou change your own oil, pleasedispose of the used oil properly. Putit in a sealed container, and take it toa recycling center. Do not throw it inthe trash, pour it on the ground ordown a drain.

Set the drain bolt cover under theguide.

Place a suitable container belowthe oil drain guide to catch theused oil, and then remove the oilfiller cap, drain bolt, and sealingwasher.

Allow the used oil to draincompletely. Use a new sealingwasher, and then reinstall theengine oil drain bolt and washer.Tighten the drain bolt securely.

3.

4.

5.

10/04/13 15:15:54 31ZX1600_068

6.9 US qt (6.5 L)

7.1 US qt (6.7 L)

68

Oil Filter Change


FILTER WRENCH, 65 mm

OIL FILTER

OIL DRAIN GUIDE

RUBBER SEAL

With the outboard motor in avertical position, fill to the upperlimit mark on the dipstick (p. )with the recommended oil.Engine oil refill capacity:Without oil filter change:

With oil filter change:

Install the oil filler cap and tightenit securely.

Install and lock the engine cover.

Install the oil drain bolt cover.Push the lever of the oil drain boltcover in the direction pointed bythe arrow mark of ‘‘LOCK’’, andinstall the oil drain bolt cover sothat the locking lug securely setson the projection of the undercover.

Use a suitable tool to remove theoil filter, and thoroughly drain thefilter into the used oil container.

Tilt the outboard motor, and placea suitable container below the oildrain guide to catch the used oil.

Drain the engine oil, and thenreinstall the drain bolt and sealingwasher. Reinstall the drain boltcover (see Engine Oil Changeon p. ).

1.

2.

3.

6.

7.

8.

9.

66

66

10/04/13 15:16:04 31ZX1600_069

AMBIENT TEMPERATURE

9 lbf·ft (12 N·m , 1.2 kgf·m)

69

Engine Oil Recommendations


Use only a Honda Genuine oilf ilter or a f ilter of equivalentquality specif ied f or your model.Using the wrong f ilter, or a non-Honda f ilter which is not ofequivalent quality, may causeengine damage.

Running the outboard motorwithout suf f icient cooling waterwill damage the water pump andoverheat the engine.

Oil is a major factor affectingperformance and service life. Use4-stroke detergent oil.

Start the engine and check forleaks (be sure the water level is atleast 2 inches (5 cm) above theantiventilation plate).

OIL FILTER TIGHTENINGTORQUE:

Clean the oil filter mounting base,and coat the rubber seal of the newoil filter with clean engine oil.

If you are changing the oil filterwhile the outboard motor is out ofthe water, use commerciallyavailable ear muffs and water hoseto supply water.

Stop the engine, and check the oillevel as described on page . Ifnecessary, add oil to bring the oillevel to the upper limit mark on thedipstick.

Return the outboard motor to thevertical position, and fill thecrankcase with the specifiedamount of the recommended oil.

Screw on the new filter by handuntil it contacts the engine, thenuse a suitable tool to tighten thefilter an additional 3/4 turn.

Honda 10W-30 FC-W outboardmotor oil is recommended forgeneral use.If Honda 10W-30 FC-W oil is notavailable, Honda recommends thatyou use API service category SG, SHor SJ oil. The SAE oil viscosity andservice category are in the API labelon the oil container.

7.

8.

4.

5.

6.

66

TM

10/04/13 15:16:15 31ZX1600_070

70

Lubrication Points


PTT THRUST RECEIVER

PROPELLER SHAFT SWIVEL CASE

TILT BRACKETTHROTTLE LINK/PIVOT/PLATE

ENGINE COVER BRACKET

THROTTLE ROD/LINK

TILT SHAFT

Apply anticorrosion oil to pivotsurf aces where grease cannot penetrate.

Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover and any exposed metalsurfaces except the belts.

Apply Honda Marine waterproof greaseto the parts shown below:

10/04/13 15:16:21 31ZX1600_071

71


TILT SHAFT THREAD

ENGINE COVER LOCKLEVER/OPEN SHAFT

COVER LOCK BOLTS

ENGINE COVERLOCK CABLE(RIGHT SIDE)

LOWER CYLINDERBUSH/COLLAR

THROTTLE ARM/SHIFT ARM/PIVOTPLATE/NEUTRALSWITCH/CLICKARM ROLLER

ENGINE COVERLOCK CABLE(LEFT SIDE)

ENGINE COVERCABLE (FRONT)

TILT LOCK LEVER

UPPER CYLINDER PIN/BUSH

SWIVEL SHAFT

10/04/13 15:16:26 31ZX1600_072

〈〉

－

KJ20DR-M11 (DENSO)ZFR6K-11 (NGK)

72

Spark Plug ServiceStandard Spark Plug


CLIP

UNDERCOVER

CLIP (2)

IDLE PORT

UNDER COVER GROMMET

UNDER COVERGROMMET

CLIP

Do not try to remove the clip withf orce without raising the inner partof the clip. Otherwise, it can damagethe clip and/or under cover.

Incorrect spark plugs can causeengine damage.

Remove the two clips from theupper part of the under covergrommet.To remove the clips, raise the innerpart of each clip with ascrewdriver, then pull out the clips.

Fold down the upper part of theunder cover grommet withoutremoving it from the idle port.


Disconnect the battery negative( ) terminal.

See page for instructions ofhandling the Iridium spark plugs(optional parts).

RECOMMENDED SPARK PLUGS:

1.

2.

3.

4.

65

75

10/04/13 15:16:37 31ZX1600_073

73


SPARK PLUG COVER

BOLTS

IGNITION COIL

WIRE CONNECTOR

BOLT

SPARK PLUGWRENCH

19 mm EYEWRENCH

Do not strike or drop the ignitioncoil, or it may be damaged andrequire replacement.

Remove the two bolts with the 6mm hex wrench, and remove thespark plug cover.

Use a 6 mm hex. wrench toremove the bolt holding theignition coil. Move the ignitioncoil to a position that allowsremoval of the wire connectoreasily.

Disconnect the wire connectorfrom the ignition coil by pushingon the lock tab and pulling on theconnector. Pull on the plasticconnector, not the wires.

Remove the ignition coil bypulling it up slightly.

Remove the spark plugs with aspark plug wrench and 19 mm eyewrench.

5. 6.

7.

8.

9.

10/04/13 15:16:45 31ZX1600_074

－

－－

－－

0.039 0.043 in(1.0 1.1 mm)

74


SEALINGWASHER

0.039 0.043 in(1.0 1.1 mm)

SIDE ELECTRODE

INSULATOR

CLIPUNDERCOVERGROMMET

UNDERCOVER

Loose spark plugs can overheatand damage the engine.Overtightening the spark plugscan damage the threads in thecylinder head.

Inspect the spark plugs. Replacethem if the electrodes are worn, orif the insulators are cracked orchipped.

Measure the spark plug electrodegap with a wire-type feeler gauge.Correct the gap, if necessary, bycarefully bending the sideelectrode.

Install the spark plugs carefully,by hand, to avoid cross-threading.

After each spark plug seats, tightenwith the spark plug wrenchsupplied in the tool kit to compressthe sealing washer.

If reinstalling used spark plugs,tighten 1/8 1/4 turn after thespark plugs seat.

If installing new spark plugs,tighten 1/2 turn after the sparkplugs seat.

Install the ignition coil. Reinstallthe bolt.

Push the wire connector onto theignition coil. Make sure it locks inplace.

Repeat this procedure for the otherthree spark plugs.

Reinstall the covers. Whenreinstalling the covers, make surenot to jam the wire harnessesbetween the covers and enginecase.

Insert the clips with the inner partraised off, then push in the innerpart securely until they click.

Press the under cover grommet andunder cover and be sure that theyadhere closely to each other.

Clip installation:The gap should be:

10.

11.

12.

13.

14.

15.

16.

17.

10/04/13 15:16:59 31ZX1600_075

〈〉

－－

IZFR6K11 (NGK)SKJ20DR-M11 (DENSO)

75

REFUELINGOptional Parts : IridiumSpark Plug


Incorrect spark plugs can causeengine damage.

Check the fuel level and refill ifnecessary. Do not fill the fuel tankabove the UPPER LIMIT. Refer tothe boat manufacturer’s instructions.

RECOMMENDED SPARK PLUGS:

Installation and removal procedure ofthe Iridium spark plugs are the sameas the standard spark plugs.

These spark plugs have an iridiumcoated center electrode.Be sure to observe the followingwhen servicing iridium spark plugs.

Do not clean the spark plugs. If anelectrode is contaminated withaccumulated objects or dirt,replace the spark plug with a newone.Use only a ‘‘wire-type feelergauge’’ to check the spark pluggap if necessary. To preventdamaging the iridium coating of

the center electrode, never use a‘‘leaf-type feeler gauge.’’The gap should be 0.039 0.051inches (1.0 1.3 mm).Do not adjust the spark plug gap.If the gap is out of specification,replace the spark plug with a newone.

10/04/13 15:17:08 31ZX1600_076




76

FUEL RECOMMENDATIONS

Use unleaded gasoline with a pumpoctane rating of 86 or higher.


Fuel can damage paint and plastic.Be caref ul not to spill f uel whenf illing your f uel tank. Damagecaused by spilled f uel is not coveredunder warranty.

Never refill the fuel tank inside abuilding where gasoline fumes mayreach flames or sparks. Keepgasoline away from appliance pilotlights, barbecues, electric appliances,power tools, etc.

Spilled fuel is not only a fire hazard,it causes environmental damage.Wipe up spills immediately.

Your outboard motor is certified tooperate on unleaded gasoline.Unleaded gasoline produces fewerengine and spark plug deposits andextends exhaust system life.

Never use stale or contaminatedgasoline or an oil/gasoline mixture.Avoid getting dirt or water in the fueltank.

You may use unleaded gasolinecontaining no more than 10% ethanol(E10) or 5% methanol by volume. Inaddition, methanol must containcosolvents and corrosion inhibitors.Use of fuels with content of ethanolor methanol greater than shownabove may cause starting and/orperformance problems. It may alsodamage metal, rubber, and plasticparts of the fuel system.

10/04/13 15:17:17 31ZX1600_077




77

Fuel Filter Inspection andReplacement


Water or sediment accumulation inthe filter can cause loss of power orhard starting. To prevent enginemalfunction, inspect the filter andreplace when necessary.

The fuel filter (inside the strainercup) is located below the intakemanifold.

Engine damage or performanceproblems that result from using a fuelwith percentages of ethanol ormethanol greater than shown aboveare not covered under warranty.

If your outboard motor will be usedon an infrequent or intermittent basis,please refer to the fuel section of theSTORAGE chapter (p. ) foradditional information regarding fueldeterioration.

85

10/04/13 15:17:25 31ZX1600_078

78


UNLOCK

ENGINE COVER LATCHFUEL FILTER(inside strainer cup)

STRAINERASSEMBLY FUEL HOSES

SUSPENSION STRAP

ENGINE COVER

Looking through the translucentstrainer cup, check the fuel filterfor water accumulation orsediment.

Remove the strainer assembly. If itis difficult to remove the strainerassembly by yourself, consult anauthorized Honda Marine dealer.Remove the suspension strap fromthe fuel filter bracket, and thenremove the strap from the fuelfilter assembly.

Before removing the fuel filter, toprevent fuel leakage, place fuelhose clamps on the fuel hoses oneach side of the fuel filter.

Remove the engine cover (p. ). 3.2.1.

4.

65

10/04/13 15:17:32 31ZX1600_079

2.5 lbf·ft (3.4 N·m , 0.35 kgf·m)

79


STRAINER BODY

STRAINER CUP

SCREW (3)

FUEL FILTER

STRAINERBRACKET

ALIGNMENTPOSITION

SUSPENSIONSTRAP

FUEL STRAINER ASSEMBLY

STRAINER CUP

Remove the three screws andseparate the fuel strainer cup fromthe strainer body.

Reassemble the strainer body andthe cup.STRAINER TIGHTENINGTORQUE:

Thoroughly clean the strainer cup,and replace the fuel filter.

Align the center of suspensionstrap with the screw position andinstall the fuel strainer assembly.

Reinstall the strainer assembly inthe original position.

Prime the engine using the primingbulb (refer to page ). Check forfuel leaks.Repair any fuel leaks if necessary.

If loss of power or hard starting arefound to be caused by excessivewater or sediment accumulation inthe fuel filter, inspect the fuel tank.

Clean the fuel tank and tank filter ifnecessary. It may be necessary todrain the fuel tank completely andrefill with fresh gasoline.

5.

6.

7.

8.

9.

10.40

10/04/13 15:17:42 31ZX1600_080




80

Water Separator Inspection andService


WATER SEPARATOR

SEPARATORASSEMBLY

FUEL TUBES

SUSPENSION STRAP

INTAKE MANIFOLD

The water separator is located belowthe intake manifold. Wateraccumulation in the water separatorcan cause loss of power or hardstarting. Check the water separatorperiodically. Clean it or consult withan authorized Honda Marine dealerfor cleaning.

Remove the engine cover (p. ).

Remove the separator assembly. Ifit is difficult to remove theseparator assembly by yourself,consult an authorized HondaMarine dealer.

Remove the suspension strap fromthe water separator bracket; thenremove the strap from theseparator assembly.During removal of the separatorassembly, take care not to damagethe wire harness with the separatorbracket.

Pinch the fuel tubes with tubeclamps to prevent fuel leakage.

1.

2.

3.

65

10/04/13 15:17:52 31ZX1600_081

2.5 lbf·ft (3.4 N·m , 0.35 kgf·m)

81


SUSPENSIONSTRAP

BOWLALIGNMENTPOSITION

CUP

O-RING

BOWL SUSPENSION STRAP

WATER SEPARATOR BRACKET

WATER SEPARATOR

Squeeze and release the primingbulb to fill the vapor separator, andcheck for leaks.

If the buzzer sounds or water orsediment accumulation are found tobe caused by excessive water orsediment accumulation in the fuelfilter, inspect the fuel tank.

Clean the fuel tank and tank filter ifnecessary. It may be necessary todrain the fuel tank completely andrefill with fresh gasoline.

Align the center of suspensionstrap with the screw position andinstall the water separatorassembly.

Reinstall the water separator in thereverse order of removal.

Remove the three screws andseparate the bowl from the body.

Thoroughly clean the bowl.

Reassemble the water separatorbowl, O-ring, and cup.TIGHTENING TORQUE:

9.

8.

7.

6.

5.

4.

10/04/13 15:18:02 31ZX1600_082

82

Anode Replacement Propeller Replacement


ANODE(each side)

ANODE(stern bracket)

Removal

Painting or coating the anodes willdef eat their purpose and will lead torust and corrosion damage to theoutboard motor. The anodes must beexposed to the water in order toprotect the outboard motor.

The anodes are located on each sideof the gear case and on the sternbracket. They are made of asacrificial material that helps toprotect the outboard motor fromcorrosion.

Before replacing the propeller,remove the emergency stop switchclip from the emergency stop switchto prevent any possibility of theengine being started while you areworking with the propeller.

Inspect the propeller shaft for anyfishing line or debris.

Remove the cotter pin, unscrewthe castle nut, remove the washer,and then remove the propeller andthrust washer.

Operating the outboard motor athigher altitudes will reduce availablepower. This may require decreasingthe propeller pitch to maintain correctengine RPM.

The propeller blades may have sharpedges, so wear heavy gloves toprotect your hands.

Replace the anodes when they havebeen reduced to about one third theiroriginal size, or if they are crumbling.

1.

2.

10/04/13 15:18:10 31ZX1600_083

33 lbf·ft (44 N·m , 4.5 kgf·m)

0.7 lbf·ft (1 N·m, 0.1 kgf·m)

83


MARINE GREASE

THRUST WASHER

PROPELLER

WASHERCASTLE NUT

COTTER PIN(stainless)

Installation

Do not tighten the castle nut abovethe TIGHTENING TORQUE LIMIT,or the propeller and shaf t may bedamaged.

TIGHTENING TORQUE LIMIT:Apply marine grade grease to thepropeller shaft.

Install the thrust washer with thegrooved side toward the gear case.

Install the propeller.

Install the washer with as shown.

Lightly tighten the castle nut byhand or wrench until the propellerhas no free play.

Tighten the castle nut using atorque wrench.

Then, using a torque wrench,tighten the castle nut until the firstavailable groove in the castle nutaligns with the cotter pin hole. Donot tighten past the first alignmentof the castle nut groove and the

cotter pin hole. Be sure to replace the cotter pinwith a new one.

Use a Honda Genuine stainlesssteel cotter pin or equivalentcotter pin and bend the pin endsas shown.

Note that these wrenches are notincluded with the tool set that comeswith the outboard motor. Contactyour authorized Honda Marine dealerfor additional tool information.

1.

2.

3.

4.

5.

8.

6.

7.

CASTLE NUT TIGHTENINGTORQUE:

10/04/13 15:18:21 31ZX1600_084

84

STORAGE PREPARATION

Cleaning and Flushing

STORAGE

FLUSH PORTCONNECTOR

Cleaning

Flushing With a Garden Hose(commercially available)

Do not apply water or corrosioninhibitor directly to the electricalcomponents under the engine cover,

such as the AC generator, HO2Ssensor, or the AC generator belt. Ifwater or corrosion inhibitorpenetrates these components, theymay be damaged. Bef ore applying acorrosion inhibitor, cover the ACgenerator, belt and HO2S sensorwith a protective material to preventdamage.

Do not run the engine when f lushingthe outboard motor with a gardenhose or the outboard motor may bedamaged.

Proper storage preparation isessential for keeping your outboardmotor trouble-free and looking good.The following steps will help to keeprust and corrosion from impairingyour outboard motor’s function andappearance, and will make the engineeasier to start when you use theoutboard motor again.

Thoroughly clean and flush theoutboard motor with fresh water afteroperation in dirty water or salt water.

Touch up any damaged paint, andcoat areas that may rust with HondaCorrosion Inhibitor, or equivalent.Lubricate controls with a siliconespray lubricant.

Wash the outside of the outboardmotor with clean, fresh water, andflush the cooling system as follows.

For safety, remove the emergencystop switch clip so the engine cannotbe started while you are standing nearthe propeller.

Tilt down the outboard motor.

Clean and wash the outside of theoutboard motor with fresh water.

Disconnect the flush portconnector.

1.

2.

3.

10/04/13 15:18:31 31ZX1600_085

85

Fuel

STORAGE

EXHAUST PORT

FLUSH PORTCONNECTOR

GARDEN HOSE

GARDEN HOSE JOINT(Commercially available)

Screw the flush port connectoronto the garden hose.

Turn on the fresh water supply andflush the outboard motor for atleast 10 minutes.

After flushing, disconnect thegarden hose and reconnect theflush port connector.

Gasoline will oxidize and deterioratein storage. Old gasoline will causehard starting, and it leaves gumdeposits that clog the fuel system. Ifthe gasoline in your fuel tank andvapor separator deteriorates duringstorage, you may need to have thevapor separator and other fuel systemcomponents serviced or replaced.

The length of time that gasoline canbe left in your fuel tank and vaporseparator without causing functionalproblems will vary with such factorsas gasoline blend, your storagetemperatures, and whether the fueltank is partially or completely filled.The air in a partially filled fuel tankpromotes fuel deterioration. Verywarm storage temperatures acceleratefuel deterioration. Fuel deteriorationproblems may occur within a fewmonths, or even less if the gasolinewas not fresh when you filled thefuel tank.

Tilt up the outboard motor andmove the tilt lock lever to theLOCK position.

4. 5.

6.

7.

10/04/13 15:18:39 31ZX1600_086

86

STORAGE

DRAIN SCREW

VAPOR SEPARATOR

FRONT BRACKET CLAMP

DRAIN HOSE(Draining the fuel becomes easierwhen the front end of the drainhose is as low as possible)

Adding a Fuel Stabilizer Draining the Fuel System


When adding a fuel stabilizer, fill thefuel tank with fresh gasoline. If onlypartially filled, air in the tank willpromote fuel deterioration duringstorage. If you keep an additionalcontainer of gasoline for refueling,be sure that it contains only freshgasoline.

Turn the engine OFF.

Add fuel stabilizer following themanufacturer’s instructions.

Drain the vapor separator beforeadding fuel stabilizer.

After adding a fuel stabilizer, runthe engine in water for 10 minutesto be sure that the treated gasolinehas replaced the untreated gasolinein the vapor separator.

You can extend fuel storage life byadding a gasoline stabilizer that isformulated for that purpose, or youcan avoid fuel deterioration problemsby draining all the fuel from the fueltank and vapor separator.

The(p. ) does not cover fuel systemdamage or engine performanceproblems resulting from neglectedstorage preparation.

You can avoid fuel deteriorationproblems by draining the fuel tankand vapor separator.

2.

3.

1.

4.

113

10/04/13 15:18:48 31ZX1600_087

－

－－

Wipe up spillsimmediately.

Handle fuel onlyoutdoors.

Stop the engine and keepheat, sparks, and flameaway.



87

Engine Oil

STORAGE

Change the engine oil and the oilfilter (p. ).

Remove the spark plugs (p. ),and remove the emergency stopswitch clip from the emergencystop switch.

Unhook the drain hose from thefront bracket clamp.

Set the end of the hose toward theoutside of the engine undercase.

Tilt the outboard motor up all theway. Leave the outboard motortilted up until the gasoline stopsflowing.

After thoroughly draining, tightenthe drain screw securely and returnthe outboard motor to the verticalposition.

Clamp the drain hose on the frontbracket clamp.

Drain the fuel tank into anapproved gasoline container or, ifyou need to store fuel in the fueltank, you can extend fuel storagelife by filling the fuel tank withfresh gasoline and adding a fuelstabilizer that is formulated forthat purpose.

Place an approved gasolinecontainer below the fuel drainoutlet, and use a funnel to avoidspilling fuel.

Loosen the vapor separator drainscrew.

Reinstall the spark plugs (p. ).

Rotate the engine a fewrevolutions to distribute the oil inthe cylinders.

Pour 1 2 teaspoons (5 10 cm )(p. ) of clean engine oil intoeach cylinder.

1.

2.

3.

4.

5.

4.

5.

6.

7.

1.

2.

3.

66 69

72

102

74

3

10/04/13 15:19:02 31ZX1600_088

88

STORAGE PRECAUTIONSHOISTING THE OUTBOARDMOTOR

STORAGE

ENGINE COVER LATCH

UNLOCK

HOISTHOOKS

LIFTINGEYES

ENGINE COVERSelect a well-ventilated storage area.If possible, avoid storage areas withhigh humidity.

If storing a container of gasoline,store it away from any appliance thatoperates with a flame, such as afurnace, water heater, or clothesdryer. Also avoid any area with aspark producing electric motor, orwhere power tools are operated.

Disconnect the outboard motorfrom the boat, hoist the outboardmotor, and move it to the storagearea.

Attach the hoist hooks to thelifting eyes.

After the outboard motor is placedin storage and disconnected fromthe hoist, install the engine cover.

Remove the engine cover (p. ). 2.

3.

4.

1. 65

10/04/13 15:19:10 31ZX1600_089

89

REMOVAL FROM STORAGE

STORAGE

PROTECTOROUTBOARD MOTOR STAND

BEFOREOPERATION

Check your outboard motor asdescribed in the

chapter of this manual.

If the cylinders were coated with oilduring storage preparation, theengine may smoke briefly at startup.This is normal.

Cover the outboard motor to keep outdust. Do not use plastic sheet as adust cover. A nonporous cover willtrap moisture, promoting rust andcorrosion.

Rest the outboard motor on a cushionof protective material.

If it is necessary to store the outboardmotor horizontally as shown, drainthe vapor separator (p. ), anddrain the engine oil (p. ), beforeremoving the outboard motor fromthe boat.

If the outboard motor will beremoved from the boat for storage,we recommend storing it verticallyby mounting it on a commerciallyavailable stand.

8666

10/04/13 15:19:16 31ZX1600_090

90

WITH OUTBOARD MOTORINSTALLED ON BOAT

WITH OUTBOARD MOTORREMOVED FROM BOAT

TRANSPORTING

OUTBOARD MOTOR SUPPORT BAR(commercially available)

When trailering a boat with theoutboard motor attached, leave theoutboard motor in the normalrunning position, if possible.

Use an outboard motor support bar toprevent the outboard motor frommoving while trailering the boat.Refer to the manufacturer’sinstructions for using an outboardmotor support bar.

Secure the outboard motor in eitherthe vertical or horizontal positionshown on p. .89

10/04/13 15:19:22 31ZX1600_091

91

TAKING CARE OF UNEXPECTED PROBLEMS

Battery discharged. Recharge battery.

Check battery.

Check fuses.

Use starting procedure (p. ,, ); if engine still will not

start, then take outboard motorto an authorized Honda Marinedealer, or refer to the shopmanual.

Battery connections loose orcorroded.

Fuse(s) blown.

Fuel system malfunction, fuelpump failure, ignition malfunction,stuck valves, starter malfunction,switch malfunction, or electricalproblem in the starting circuit, etc.

Clean and tighten batteryconnections.

Replace fuse(s) (p. ).

Replace or repair faultycomponents as necessary.

ELECTRIC STARTER WILLNOT OPERATE

Possible Cause Correction

1.

2.

3. 4144 46

96

10/04/13 15:19:32 31ZX1600_092

92


ENGINE WILL NOT START Possible Cause Correction

Check emergency stop switchclip.

Check control positions.

Check fuel.

Clip not inserted in emergencystop switch.

Control lever not in neutralposition.

Fast idle lever raised (side-mounttype).

Out of fuel.

Fuel hose not primed.

Fuel filter or fuel tank filter clogged.

Bad fuel; boat stored withouttreating or draining gasoline, orrefueled with bad gasoline.

Insert clip in emergency stopswitch.

Shift to neutral.

Leave fast idle lever OFF (p. ).

Refuel (p. ).

Squeeze priming bulb (p. ).

Replace fuel filters (p. ).

Drain fuel tank and vaporseparator (p. ). Refill withfresh gasoline (p. ).

1.

2.

3.

42

75

40

77

8675

10/04/13 15:19:45 31ZX1600_093

93


CorrectionPossible CauseENGINE WILL NOT START(continued)

Check water separator. Water separator full of wateraccumulation.

Clean water separator (p. ).

Spark plugs faulty, fouled, orimproperly gapped.

Spark plugs wet with fuel (floodedengine).

Dry and reinstall spark plugs. Startengine with the throttle open.

Take outboard motor to anauthorized Honda Marine dealer,or refer to the shop manual.

Remove and inspect spark plugs.


Fuel system malfunction, fuelpump failure, ignition malfunction,etc.

Gap (non-iridium type) or replacespark plugs (p. ).

4.

5.

6.

80

72

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94


CorrectionPossible CauseHARD STARTING OR STALLSAFTER STARTING

Check control positions. Fast idle lever raised (side-mounttype).

Leave fast idle lever OFF (p. ).

Check fuel.

Bad fuel; boat stored withouttreating or draining gasoline, orrefueled with bad fuel.

Squeeze priming bulb (p. ).

Replace fuel filters (p. ).

Drain fuel tank and vaporseparator (p. ). Refill withfresh gasoline (p. ).

Check water separator. Clean water separator (p. ).Water separator full of wateraccumulation.

Fuel hose not primed.

Fuel filter or fuel tank filter clogged.

1.

2.

3.

42

40

77

8675

80

10/04/13 15:20:05 31ZX1600_095

95


HARD STARTING OR STALLSAFTER STARTING

(continued)


Faulty thermostat or water pump. Replace or repair faultycomponents as necessary.

Check water intake screens. Water intake screens clogged. Clean water intake screens.

ENGINE OVERHEATS Possible Cause Correction



Spark plugs faulty, fouled, orimproperly gapped.

Remove and inspect spark plugs.

Possible Cause Correction

Fuel system malfunction, fuelpump failure, ignition malfunction,etc.

Gap (non-iridium type) or replacespark plugs (p. ).

2.

1.

4.

5.

72

10/04/13 15:20:16 31ZX1600_096

－

96

Fuse Replacement

Electric Starter Will NotOperate

FUSES

Battery Will Not Charge


FUSES (10A, 15A, 30A)

SPARE FUSES(10A, 15A, 30A)

FUSEHOLDER

FUSE PULLER

4455°° JUNCTIONBOX LID

RELAYS(Do not remove the relays)

Main Fuse

Disconnect the battery cable at thebattery negative ( ) terminal bef orereplacing the f use.Failure to do so may cause a shortcircuit.

The 10A, 15A, and 30A main fusesprotect the electric starter relay andrelated circuits.

Remove the engine cover.

Stop the engine and disconnect thebattery cable.

The 10A main fuse protects theignition switch and related circuits. Ifthis fuse blows, the engine will notstart or run, and the power trim/tiltswitch will not activate the trim/tiltmechanism.

A 100A ACG fuse protects thealternator circuit. If the ACG fuseblows, the engine will not charge thebattery. Refer to p. .

Remove the junction box lid.

1.

2.

3.

98

10/04/13 15:20:27 31ZX1600_097

10 A, 15 A, 30 A

97


FUSE PULLER

BLOWN FUSE

Never use a f use with a ratinggreater than specif ied. Seriousdamage to the electrical system couldresult.

Use the fuse puller from the fuseholder to remove the fuses. If afuse is blown, install a replacementfuse of the same specified rating.The outboard motor is suppliedwith spare fuses in the junctionbox lid.

MAIN FUSE RATINGS:

Reconnect the battery.

If a blown fuse is found, try todetermine and correct the electricalproblem that caused the blown fuse.An uncorrected electrical problemmay cause the fuse to blow again.

If fuses continue to blow, take theoutboard motor to an authorizedHonda Marine dealer for inspectionand service, or refer to the shopmanual.

Reinstall the junction box lid, andthe engine cover.

5.

6.

4.

10/04/13 15:20:34 31ZX1600_098

100 A

98

OIL PRESSURE INDICATORGOES OFF AND ENGINESPEED IS LIMITED


BUZZER

BUZZER

(GREEN)

(GREEN)



FUSE (100A)SPARE FUSE (100A)

FUSE HOLDER

Side-Mount Type


ACG Fuse

Remove the engine cover.

Stop the engine and disconnect thebattery cable.

Remove the junction box lid (seepage ).

Remove the old fuse by removingtwo 5 mm screws.

Install a new fuse with the ‘‘100A.’’

ACG FUSE:

Reconnect the battery.

A spare fuse is located in the fuseholder.

Reinstall the junction box lid, andthe engine cover.

6.

7.

5.

1.

2.

3.

4.

96

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99

Digital Tachometer OVERHEAT INDICATORCOMES ON AND ENGINESPEED IS LIMITED


BUZZER

BUZZER

(RED)

(RED)

OVERHEATINDICATOR

OVERHEATINDICATOR

Side-Mount Type


If oil pressure becomes low, the oilpressure indicator will go off, and theengine protection system limitsengine speed. If you are at cruisingspeed, engine speed will decreaseautomatically.

The oil pressure indicator is alsoequipped with a buzzer that soundswhen the oil pressure indicator goesoff.

Low oil pressure may be the result ofa low engine oil level, or there maybe a problem with the enginelubrication system.

If the engine protection systemremains activated after 30 seconds,return to the nearest boat landing, andhave the outboard motor inspected byan authorized Honda Marine dealer.

With the engine oil at therecommended level, restart theengine. If the lubrication system isOK, the oil pressure indicator shouldcome on within 30 seconds, and theengine will respond normally tothrottle control lever operation.

If low oil pressure activates theengine protection system, stop theengine, check the engine oil level(p. ), and add oil if needed.

If the throttle is closed suddenly afterfull throttle operation, engine speedmay drop below the specified idlerpm, and that could activate theengine protection systemmomentarily.Normal

Abnormal

66

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100

Digital Tachometer


COOLING SYSTEM INDICATOR

Engine overheating may be the resultof restricted water intake screens, orthere may be a problem with thecooling system thermostat or waterpump.

All types are equipped with a buzzerthat sounds when the overheatindicator comes on.

If the engine overheats, the overheatindicator will come on, and theengine will stop in 20 seconds afterthe engine protection system limitsengine speed. If you are at cruisingspeed, engine speed will decreaseautomatically.

If the engine is stopped after runningat full throttle, and then restartedsoon afterward, that could activatethe engine protection systemmomentarily.

If overheating activates the engineprotection system, idle the engine inneutral, and check the cooling systemindicator.

If water is flowing from the coolingsystem indicator, continue idling for30 seconds. If the cooling system isOK, the overheat indicator should gooff within 30 seconds, and the enginewill respond normally to throttlecontrol lever operation.

If there is no water flowing from thecooling system indicator, stop theengine, and tilt the outboard motor toinspect the water intake screens. Ifrestricted, clean the water intakescreens, return the outboard motor tothe running position, restart theengine, and check the cooling systemindicator again.

If there is still no water flowing fromthe cooling system indicator, or if theengine protection system remainsactivated after 30 seconds, return tothe nearest boat landing, and have theoutboard motor inspected by anauthorized Honda Marine dealer.

Normal

Abnormal

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101

SUBMERGED OUTBOARDMOTOR

WATER SEPARATORBUZZER SOUNDS

WATER SEPARATORINDICATOR

Digital Speedometer


WATER SEPARATOR

When the water separator buzzersounds (a rapid, repeating signal):

When the water separator indicatorblinks:

Check the water separator for watercontamination. If water is present,stop the engine, and clean the waterseparator following the instructionson page , or consult with anauthorized Honda Marine dealer.

Check the water separator for watercontamination. If water is present,stop the engine, and clean the waterseparator following the instructionson page , or consult with anauthorized Honda Marine dealer.

Drain the vapor separator asdescribed on p. .

Remove the engine cover, andrinse the outboard motor withfresh water to remove salt water,sand, mud, etc.

If there is a Honda Marine dealershipnearby, take the outboard motor tothe dealer immediately. If you are farfrom a dealership, proceed asfollows:

A submerged outboard motor mustbe serviced immediately after it isrecovered from the water in order tominimize corrosion.

1.

2.

Normal

Abnormal

808086

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－

102


Running the outboard motor withoutsuf f icient cooling water will damagethe water pump and overheat theengine.

Change the engine oil and oil filteras described on p. . Ifthere was water in the enginecrankcase, or if the used engine oilshowed signs of watercontamination, then a secondengine oil change should beperformed after running the enginefor half an hour.

Remove the spark plugs (p. ).Operate the starter to expel waterfrom the engine’s cylinder.

If the engine fails to start, removethe spark plugs and dry them, thenreinstall the spark plugs andattempt to start the engine again.

If the engine starts, and nomechanical damage is evident,continue to run the engine for ahalf hour or longer. Be sure thewater level is at least 2 inches (5cm) above the antiventilation plateto avoid overheating and waterpump damage.

As soon as possible, take theoutboard motor to an authorizedHonda Marine dealer forinspection and service.If you are changing the oil filter

while the outboard motor is out ofthe water, use commercially availableear muffs and water hose to supplywater.

Attempt to start the engine (be surethe water level is at least 2 inchesabove the antiventilation plate).

If the engine was running when itsubmerged, there may bemechanical damage, such as bentconnecting rods. If the enginebinds when cranked, do notattempt to run the engine until ithas been repaired.

Pour a teaspoon (p. ) of engineoil into each spark plug hole tolubricate the inside of the cylinders.Reinstall the spark plugs.

6.7.

3.

4.

5.

72

66 6987

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103

TECHNICAL INFORMATION

Serial Number Locations

TECHNICAL AND CONSUMER INFORMATION

PRODUCTIDENTIFICATIONNUMBER

RIGHT STERN BRACKET ENGINE SERIAL NUMBER

Product identification number: Engine serial number:

The product identification number isstamped on a plate attached on theright stern bracket.

The engine serial number isstamped on the upper right side ofthe engine.

Record the product identificationnumber, the engine serial number,and the date of purchase in the spaceprovided on this page. You will needthese numbers when ordering parts,and when making technical orwarranty inquiries (p. ).

Date of purchase:

110

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－12V 64Ah/5HR (80Ah/20HR)(CCA622)

104

Battery

Minimum Requirements

Emission Control SystemInformation


WARNING:

Wash yourhands after handling.

Source of Emissions

Be caref ul to avoid connecting thebattery in reverse polarity, as thiswill damage the battery-chargingsystem in the outboard motor.Do not disconnect the batterycables while the engine is running.Disconnecting the cables while theengine is running will damage theoutboard motor’s electrical system.Battery cable extension: Extendingthe original battery cable willcause the battery voltage to dropdue to the increased length of thecable and number of connections.This voltage drop may cause thebuzzer to sound momentarily when

engaging the starter motor andmay prevent the engine f romstarting. If the engine starts andthe buzzer sounds momentarily,there may be barely suf f icientvoltage reaching the engine.

For complete information, refer tothe battery manufacturer’sinstructions.

Battery posts, terminals,and related accessories contain leadand lead compounds.

The combustion process producescarbon monoxide, oxides of nitrogen,and hydrocarbons. Control ofhydrocarbons and oxides of nitrogenis very important because, undercertain conditions, they react to formphotochemical smog when subjectedto sunlight. Carbon monoxide doesnot react in the same way, but it istoxic.

Honda utilizes appropriate air/fuelratios and other emissions controlsystems to reduce the emissions ofcarbon monoxide, oxides of nitrogen,and hydrocarbons.

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105


Tampering and AlteringPGM-FI System

Ignition Timing Control System

The U.S. and Calif ornia CleanAir Acts

Tampering with or altering theemission control system may increaseemissions beyond the legal limit.Among those acts that constitutetampering are:

Removal or alteration of any partof the intake, fuel, or exhaustsystems.

Alterations that would cause theengine to operate outside its designparameters.

The PGM-FI system uses sequentialmultiport fuel injection. It has threesubsystems: Air Intake, EngineControl, and Fuel Control. TheEngine Control Module (ECM) usesvarious sensors to determine howmuch air is going into the engine. Itthen controls how much fuel to injectunder all operating conditions.

The system constantly adjusts theignition timing, reducing the amountof HC, CO, and NOx produced.

EPA and California regulationsrequire all manufacturers to furnishwritten instructions describing theoperation and maintenance ofemission control systems.

The following instructions andprocedures must be followed in orderto keep the emissions from yourHonda engine within the emissionstandards.

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106


Replacement PartsProblems That May Af f ectEmissions

Maintenance

If you are aware of any of thefollowing symptoms, have yourengine inspected and repaired byyour servicing dealer.

Hard starting or stalling afterstarting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuelconsumption.

The emission control systems onyour Honda engine were designed,built, and certified to conform withEPA and California emissionregulations. We recommend the useof Honda Genuine parts wheneveryou have maintenance done. Theseoriginal-design replacement parts aremanufactured to the same standardsas the original parts, so you can beconfident of their performance. Theuse of replacement parts that are notof the original design and qualitymay impair the effectiveness of youremission control system.

A manufacturer of an aftermarketpart assumes the responsibility thatthe part will not adversely affectemission performance. Themanufacturer or rebuilder of the partmust certify that use of the part willnot result in a failure of the engine tocomply with emission regulations.

Follow the maintenance schedule on(p. and ). Remember that thisschedule is based on the assumptionthat your machine will be used for itsdesigned purpose. Sustained high-load operation, or use in unusualconditions, will require morefrequent service.

62 63

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107

Star Label

The Symbol for Cleaner Marine Engines:

Cleaner Air and Water -

Better Fuel Economy -

Longer Emission Warranty -

US, Puerto Rico, and US VirginIslands


The Star Label means Cleaner Marine Engine

for healthier lifestyle and environment.

burns up to 30 - 40 percent less gas and oil thanconventional carbureted two-stroke engines, saving money and resources.

protects consumer for worry-free operation.

This engine has been certified as a:

A Star label was applied to thisoutboard motor in accordance withthe requirements of the CaliforniaAir Resources Board.

10/04/13 15:22:09 31ZX1600_108

108

One StarLowEmission

Two StarsVery LowEmission

Three StarsUltra LowEmission

Four StarsSuper UltraLow Emission


The one-star label identifies engines that meet the Air Resources Board’sPersonal Watercraft and Outboard marine engine 2001 exhaust emissionstandards. Engines meeting these standards have 75% lower emissions thanconventional carbureted two-stroke engines. These engines are equivalentto the U.S. EPA’s 2006 standards for marine engines.

The two-star label identifies engines that meet the Air Resources Board’sPersonal Watercraft and Outboard marine engine 2004 exhaust emissionstandards. Engines meeting these standards have 20% lower emissions thanOne Star-Low Emission engines.

The three-star label identifies engines that meet the Air Resources Board’sPersonal Watercraft and Outboard marine engine 2008 exhaust emissionstandards or the Sterndrive and Inboard marine engine 2003-2008 exhaustemission standards. Engines meeting these standards have 65% loweremissions than One Star-Low Emission engines.

The four-star label identifies engines that meet the Air Resources Board’sSterndrive and Inboard marine engine 2009 exhaust emission standards.Personal Watercraft and Outboard marine engines may also comply withthese standards. Engines meeting these standards have 90% loweremissions than One Star-Low Emission engines.

Cleaner Watercraft - Get the Facts1-800-END-SMOG

www.arb.ca.gov

10/04/13 15:22:17 31ZX1600_109

－

－

±±

±

－－

－

－－

＊

＊

22.8 in (580 mm)33.3 in (845 mm)

BF115D

4° to 16°

Stageless (72°)

Forward-Neutral-Reverse (dog type)

Unleaded gasoline(86 pump octane or higher)

electrical typemechanical type

ZFR6K-11 (NGK)KJ20DR-M11 (DENSO)

Water exhaustWater cooling with thermostat

12V 40AULTRA · LOW EMISSION

30° right and left

No other adjustment is needed

Intake: 0.23 0.02 mmExhaust: 0.30 0.02 mm

750 50 rpm

0.039 0.043 in(1.0 1.1 mm)

See page 74

See shopmanualSee shopmanual

BBHJ

70.5 in (1,790 mm)65.6 in (1,665 mm)

20.0 in (508 mm) 25.0 in (635 mm)

85.8 kW (115 HP)4,500 6,000 rpm

4 stroke DOHC in-line 4-cylinder143.6 cu-in (2,354 cm )

0.039 0.043 in (1.0 1.1 mm)Electric starter

Fully transistorized, battery ignitionTrochoid pump pressure lubrication

API standard (SG, SH, SJ) SAE 10W-30API standard (GL-4) SAE 90 outboardmotor gear oil

6.9 US qt (6.5 L)7.1 US qt (6.7 L)

1.04 US qt (0.98 L)

LA LC

478 lbs(217 kg)

XA XC XCA

492 lbs(223 kg)

485 lbs(220 kg)

Engine:

Gear case:

Engine:Gear case:

Low pressure side:High pressure side:

without oil filter changewith oil filter change

109

Specifications

Tune Up


Overall heightOverall widthOverall lengthTypeDescription codeMODEL

Trim angle(when transomangle at 12°)

Tilt up angle(when transomangle at 12°)

Steering angleGear change

Fuel

Fuel pump

Spark plugsExhaust systemCooling systemD.C. outputCARB star label

Valve clearance(cold)

Idle speed

Spark plug gap

Other specifications

Transom height(when transomangle at 12°)Dry mass[weight]Rated powerFull throttlerangeEngine typeDisplacementSpark plug gapStarter systemIgnition systemLubricationsystemSpecified oil

Oil capacity

Without battery cable, with propeller

Honda outboard motors are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23.

10/10/12 10:16:33 31ZX1600_110

－

110

CONSUMER INFORMATION

Honda Publications

Customer Service Information

American Honda Motor Co., Inc.

Honda Canada Inc.

(United States, Puerto Rico, andU.S. Virgin Islands)


Accessory Catalog

Parts Catalog

Shop Manual

Contacting Honda

This manual provides complete,illustrated parts lists.The catalog is available through yourHonda Marine dealer.

Available through your HondaMarine dealer or through Helm Inc.at1 888-292-5395 orvisit www.Honda-marine.comand click on OWNERS’RESOURCES.

This manual covers completemaintenance and overhaul procedures.It is intended to be used by a skilledtechnician.

These publications will give youadditional information formaintaining and repairing youroutboard motor.

Your authorized Honda Marinedealer offers a wide selection ofaccessories (optional equipment, oils,and lubricants) to enhance yourboating experience.Visit www.honda-marine.com andclick on PARTS & ACCESSORIESto see the entire catalog ofaccessories.

If you have a difference of opinionwith your dealer, please rememberthat each dealership is independentlyowned and operated. That’s why it’simportant to work to resolve any

differences at the dealership level. Ifthe service personnel are unable toassist you, please discuss yourconcerns with the dealer managementsuch as the Service Manager or thedealership’s owner.

If you need to contact AmericanHonda regarding your experienceswith your Honda product or withyour dealer, please send yourcomments to the following address:

Marine DivisionCustomer Relations Office4900 Marconi DriveAlpharetta, GA 30005-8847Telephone (770) 497 6400M-F 8:30 am-7:00 pm (Eastern TimeZone)

Customer Relations OfficeVisit www.honda.ca for contactinformationTel: 1-888-946-6329 (Toll free)Fax: 1-877-939-0909 (Toll free)

Your Owner’s Manual was written tocover most of the questions youmight ask about your Honda. Anyquestions not answered in the Owner’sManual can be answered by yourHonda dealer. If your dealer doesn’thave an immediate answer, theyshould be able to get it for you.

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111


Warranty CoveragePlease include the followinginformation in your communication:

Model and complete serial number

Date of purchase

Name and location of sellingdealer

Name and location of servicingdealer (if different)

A detailed description of yourconcerns

Your new Honda is covered by thefollowing warranties:

Distributor’s Limited WarrantyEmission Control SystemWarranty

Your name, address and telephonenumber (complete with area code)

To obtain warranty service you musttake your Honda outboard motor,together with proof of original retailpurchase date, at your expense, to aHonda engine dealer or distributorauthorized to sell that product in theUnited States, Puerto Rico, the U.S.Virgin Islands or Canada.

Please read the warranty statementscontained in this manual. There areresponsibilities, restrictions, andexclusions that apply to thesewarranties.

It is important to realize that yourwarranty applies to defects inmaterial or workmanship of yourHonda. Your warranty coverage does

not apply to normal wear ordeterioration associated with usingyour Honda outboard motor.

Your warranty coverage will not bevoided if you choose to perform yourown maintenance. However, youshould have the proper tools andservice information and bemechanically qualified. Failures thatoccur due to modifications, impropermaintenance, or service are notcovered.

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112


Warranty Service

As the owner of a Honda product,your servicing dealer may ask you toauthorize an inspection. If theproblem is covered under warranty,your dealer will perform anywarranty repairs for you at no cost.However, you may be responsible foradditional non-warranty charges.

If you have questions about warrantycoverage or the nature of the repair, itis best to talk to the service managerof your Honda dealer.

Sometimes, in spite of the bestintentions of all concerned, amisunderstanding may occur. If youaren’t satisfied with your dealer’s

handling of the situation, we suggestyou discuss your problem with theappropriate member of thedealership’s management team. If theproblem has already been reviewedwith the appropriate manager of theService, Parts, or Sales department,contact the owner of the dealership ortheir designated representative.

Please remember that recommendedmaintenance interval servicing is notincluded in your warranty coverage.Additionally, your warranty does notapply to the normal wear of items(such as spark plug(s), water pump,etc.).

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113

United states, Puerto Rico and Virgin Islands

Warranty Statements



The American Honda Distributor’s Limited Warranty applies to outboards purchased in the United States, Puerto Rico,or the U.S. Virgin Islands. The Honda Canada Distributor’s Warranty applies to outboards purchased in Canada.The product warranty is only valid in the country where the product was purchased.

This warranty is limited to Honda Outboard Motors and related original equipment distributed by American HondaMotor Co., Inc., Power Equipment Division, 4900 Marconi Drive, Alpharetta, Georgia 30005-8847.

Products Covered by Warranty: Length of Warranty: (from date of original retail purchase)NONCOMMERCIAL/

NONRENTALCOMMERCIAL/RENTAL STATE/LOCAL/FEDERAL

GOVERNMENT

The same duration as the outboard with which they were purchased.

36 months 12 months12 months

24 months24 months60 months

All models purchased before July 1, 2008

All Models purchased on or after July 1, 2008

Related original equipment items:

BF2 through BF30 models: Portable fuel tank

and original propeller.

All models: Primer bulb/fuel line assembly and

tiller handle.

Models purchased prior to July 1, 2008 (unless previously purchased with True-5 warranty from a participating dealer).

35, 65, & 105 Jet models: Jet pump assembly is a dealer installed option. Jet pump warranty is provided by Specialty Manufacturing Co. (Outboard Jets).

Portable fuel tanks: 24 months or the same duration as the outboard they were purchased with, whichever is longer.

(1)

(2)

(3)

(1) (2)

(2)

(3)

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114

To Qualify for This Warranty:

What American Honda Will Repair or Replace UnderWarranty:

To Obtain Warranty Service:


Contacting Honda

The Honda Outboard Motor must be purchased fromAmerican Honda or a dealer authorized by AmericanHonda to sell Honda Outboard Motors in the UnitedStates, Puerto Rico, or the U.S. Virgin Islands. Thislimited warranty applies to the first retail purchaser andeach subsequent owner during the applicable warrantytime period.

American Honda will repair or replace, at its option, anypart that is proven to be defective in material orworkmanship under normal use during the applicablewarranty time period. Warranty repairs and replacementswill be made without charge for parts or labor. Anythingreplaced under warranty becomes the property ofAmerican Honda Motor Company, Inc.

All parts replaced under warranty will be considered aspart of the original product and any warranty on thoseparts will expire coincidentally with the original productwarranty.

You must, at your expense, take your Honda OutboardMotor and proof of the original purchase date to anydealer who is authorized to service Honda OutboardMotors in the United States, Puerto Rico, or the U.S.Virgin Islands, during the dealer’s normal business hours.If you are unable to obtain warranty service, or aredissatisfied with the warranty service you receive, takethe following steps: First, contact the owner of thedealership involved; normally this should resolve theproblem. However, if you should require furtherassistance, write or call the Honda Marine CustomerRelations. Please see page 110 .

10/04/13 15:23:40 31ZX1600_115

‘‘ ’’’

115

Exclusions:

Disclaimer of consequential damage and limitation ofimplied warranties:


This warranty does not extend to the following:Conditions caused by lack of routine maintenance orimproper storage (as outlined in the Owner’s Manual)Conditions caused by the use of propeller (s) that donot allow the outboard motor to run in itsrecommended full throttle rpm rangeOperation inconsistent with the recommendedoperation/duty cycle (as outlined in the Owner’sManual)Parts affected or damaged by an abuse, submersionand/or collisionNormal wear and tearFuel contamination and water entering engine throughthe fuel intake, air intake or exhaust systemOperation with fuels, oils, additives and lubricantswhich are not suitable for use in the productUse in an application for which the outboard motorwas not designed, such as racing or competitive use orany other misuse or neglect

The unauthorized alteration, improper installation and/or rigging, or any causes other than defects in materialor workmanship

Incorporation of unsuitable attachments or parts

Corrosion to steering system or electrical components,corrosion due to electrolysis, water born foreignchemicals, improper service or corrosion caused bydamage or abuse

Reimbursement for towing charges, in and out ofwater charges, or technician travel timeGrowth of marine organisms on outboard motorsurfaces, external or internalAny product that has ever been declared a total loss orsold for salvage by a financial institution or insurer, orthat has been issued a salvage or similar title underany state s law.

American Honda disclaims any responsibility for loss oftime or use of the outboard, revenue, or the equipment inwhich the outboard is installed, transportation,commercial loss, or any other incidental or consequentialdamage. Any implied warranties are limited to theduration of this written limited warranty.Some states do not allow limitations on how long animplied warranty lasts and/or do not allow the exclusionor limitation of incidental or consequential damages, sothe above exclusions and limitations may not apply toyou. This warranty gives you specific legal rights, andyou may also have other rights which vary from state tostate.

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116


To Qualify for This Warranty:

What American Honda Will Repair or Replace UnderWarranty:

Accessories and Replacement Parts

The accessories or replacement parts must bepurchased from American Honda or a dealer,distributor, or distributor’s dealer authorized byAmerican Honda to sell those products in the UnitedStates, Puerto Rico, and the U.S. Virgin Islands. Partsand Accessories must be purchased for installation onoriginal Honda equipment or engines to be eligible forwarranty coverage. Installing parts and accessories onnon-Honda products or engines voids this warranty.You must be the first retail purchaser. This warranty isnot transferable to subsequent owners.

American Honda will repair or replace, at its option, any

marine product accessories or replacement parts that areproven to be defective in material or workmanship undernormal use during the applicable warranty time period.Anything replaced under warranty becomes the propertyof American Honda Motor Company, Inc. All partsreplaced under warranty will be considered as part of theoriginal product and any warranty on those parts willexpire coincidentally with the original product warranty.

Accessories and replacement parts, installed by a dealerwho is authorized by American Honda to sell them, willbe repaired or replaced under warranty without charge forparts or labor. If installed by anyone else, accessories andreplacement parts will be repaired or replaced underwarranty without charge for parts, but any labor chargeswill be the responsibility of the purchaser.

1.

2.

This warranty is limited to Honda Marine parts, accessories and apparel when distributed by American Honda Motor Co.,Inc., 1919 Torrance Blvd., Torrance, California 90501-2746.

Products Covered by Warranty:

12 months 3 months 3 months

Non Commercial Commercial/Rental Local/State/FederalGovernment

Length of Warranty: (from date of original retail purchase)

6 months 3 months 3 months

24 months24 months24 months

Accessories other than noted below

Emission related accessories:

Portable fuel tanks, fuel line assemblies, and

water/fuel separators

Replacement Parts

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117

Disclaimer of consequential damage and limitation ofimplied warranties:

Exclusions:

To Obtain Warranty Service:


You must, at your expense, take the Honda OutboardMotor product accessory or replacement part or theoutboard motor or boat on which the accessory orreplacement part is installed, and proof of purchase toany Honda Marine authorized service facility or dealer inthe United States, Puerto Rico, or the U.S. Virgin Islands,during normal business hours.

This warranty does not extend to accessories or partsaffected or damaged by collision, normal wear, use in anapplication for which the product was not designed orany other misuse, neglect, incorporation or use ofunsuitable attachments or parts, unauthorized alteration,improper installation, or any causes other than defects inmaterial or workmanship of the product.Installing parts and accessories on non-Honda products orengines voids this warranty.

American Honda disclaims any responsibility for loss oftime or use of the outboard motor, or the boat on whichthe product is installed, transportation, commercial loss,or any other incidental or consequential damage. Anyimplied warranties are limited to the duration of thiswritten warranty. Some states do not allow limitations on

how long an implied warranty lasts and/or do not allowthe exclusion or limitation of incidental or consequentialdamages, so the above exclusions and limitations may notapply to you. This warranty gives you specific legalrights, and you may also have other rights which varyfrom state to state.

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118

Emission Control System Warranty

YOUR WARRANTY RIGHTS AND OBLIGATION

CaliforniaMANUFACTURER’S EMISSION CONTROLSYSTEM WARRANTY COVERAGE:

All States


Your new Honda outboard engine complies with both theU.S. EPA and State of California emission regulations.American Honda provides the same emission warrantycoverage for outboard engines sold in all 50 states.

The California Air Resources Board and AmericanHonda Motor Co., Inc. are pleased to explain theemission control system warranty on your 2001 and laterHonda outboard engine. In California, new outboardengines must be designed, built, and equipped to meetCalifornia’s stringent anti-smog emission standards inaddition to the U.S. EPA emissions standards.

In all areas of the United States your outboard enginemust be designed, built, and equipped to meet the U.S.EPA Emission Standard for spark ignited marine engines.American Honda Motor Co., Inc. must warranty theemission control system on your outboard engine for theperiod of time listed below provided there has been noabuse, neglect, or improper maintenance of youroutboard engine. Where a warranty condition exists,American Honda Motor Co., Inc. will repair your

outboard engine at no cost to you including diagnosis,parts and labor.

Your emission control system may include such parts asthe carburetor or fuel injection system and catalyticconverter. Also included may be hoses, connectors andother emission-related assemblies.

Your 2010 and later outboard engine is warranted for aminimum of five years or 250 hours of operation,whichever comes first, or the length of Honda MarineDistributor’s Limited warranty, whichever is longer.However, warranty coverage based on the hourly periodis only permitted for outboard engines equipped withappropriate hour meters. If any emission-related part onyour outboard engine is defective under warranty, thepart will be repaired or replaced by American HondaMotor Co., Inc.

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119

WARRANTY COVERAGE:OWNER’S WARRANTY RESPONSIBILITY:


Contacting Honda

As the outboard engine owner, you are responsible forthe performance of the required maintenance listed inyour owner’s manual. American Honda Motor Co., Inc.recommends that you retain all receipts coveringmaintenance on your outboard engine, but AmericanHonda Motor Co., Inc. cannot deny warranty solely forthe lack of receipts or for your failure to ensure theperformance of all scheduled maintenance.As the outboard engine owner, you should, however, beaware that American Honda Motor Co., Inc. may denyyou warranty coverage if your outboard engine or a parthas failed due to abuse, neglect, improper maintenance,or unapproved modifications.You are responsible for presenting your outboard engineto a Honda Marine dealer as soon as a problem exists.The warranty repair should be completed in a reasonableamount of time, not to exceed 30 days.If you have any questions regarding your warranty rightsand responsibilities, you should contact American HondaMotor Co., Inc., Marine Division Customer RelationsOffice. Please see page 110 .

Honda outboard engines certified to the CARB and EPA2010 regulations are covered by this warranty for aminimum of five years or 250 hours of operation,whichever comes first, or the length of the Honda MarineDistributor’s Limited warranty, whichever is longer fromthe date of delivery to the retail purchaser. This warrantyis transferred to each subsequent purchaser for theduration of the warranty period.Warranty repairs will be made without charge fordiagnosis, parts and labor. All defective parts replacedunder this warranty become the property of AmericanHonda Motor Co., Inc. A list of warranty parts is on page121 . Normal maintenance items, such as spark plugs andfilters, that are on the warranted parts list are warrantedup to their required replacement interval only.American Honda Motor Co., Inc. is also liable fordamages to other engine components caused by a failureof any warranted part during the warranty period.Only Honda approved replacement parts will be used inthe performance of any warranty repairs and they will beprovided without charge to the owner. The use ofreplacement parts not equivalent to the original parts mayimpair the effectiveness of your engine’s emissioncontrol system. If such a replacement part is used in therepair or maintenance of your engine, and an authorizedHonda Marine dealer determines it is defective or causesa failure of a warranted part, your claim for your engine

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120

TO OBTAIN WARRANTY SERVICE:

EXCLUSIONS:

DISCLAIMER OF CONSEQUENTIAL DAMAGEAND LIMITATION OF IMPLIED WARRANTIES:


may be denied. If the part in question is not related to thereason that your engine requires repair, your claim willnot be denied.

You must take your Honda outboard engine, along withyour sales registration card or other proof of originalpurchase date, at your expense, to any Honda Marinedealer who is authorized by American Honda Motor Co.,Inc. to sell and service that Honda Marine product duringhis normal business hours. Claims for repair oradjustment found to be caused solely by defects inmaterial or workmanship will not be denied because theengine was not properly maintained and used.If you are unable to obtain warranty service, or aredissatisfied with the warranty service you received,contact the owner of the dealership involved. Normallythis should resolve your problem. However, if yourequire further assistance, write or call the Honda MarineCustomer Relations Office of American Honda MotorCo., Inc.

Failures other than those resulting from defects inmaterial or workmanship are not covered by this warranty.This warranty does not extend to emission controlsystems or parts which are affected or damaged by ownerabuse, neglect, improper maintenance, misuse, misfueling,improper storage, and/or collision, the incorporation of,or use of, unsuitable attachments, or the unauthorizedalteration of any part.This warranty does not cover replacement of expendablemaintenance items made in connection with requiredmaintenance service after the item’s first scheduledreplacement as listed in the maintenance section of theproduct owner’s manual, such as: spark plugs and filters.

American Honda Motor Co., Inc. disclaims anyresponsibility for incidental or consequential damagessuch as loss of time or the use of outboard engine, or anycommercial loss due to the failure of the equipment; andany implied warranties are limited to the duration of thiswritten warranty. This warranty is applicable only wherethe California or U.S. EPA emission control systemwarranty regulation is in effect.

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＊

＊

121

EMISSION CONTROL SYSTEM WARRANTY PARTS:


PARTS DESCRIPTIONSYSTEMS COVERED BY THISWARRANTY:Fuel Metering

EvaporativeAir Induction

Ignition

Lubrication systemCrankcase Emission Control

ExhaustValve Control System

Miscellaneous Parts

Carburetor assembly, Throttle body, Fuel injector, Fuel pump, Fuel pressureregulator, Throttle position sensor, Intake air temperature sensor, Engine temperaturesensor, Manifold absolute pressure sensor, Idle air control valve, Barometric pressuresensor, Fuel line solenoid valve, Intake manifold, Intake valves, and Oxygen sensoror Air fuel ratio sensorPortable fuel tank, Fuel cap, Fuel hoses, Primer bulb, Fuel hose jointAir intake duct, Vapor separator, Intake manifold tuning valve (Intake air bypasscontrol valve)Flywheel magneto, Ignition pulse generator, Ignition coil assembly, Ignition controlmodule, Engine control module, Crankshaft position sensor, Spark plug cap,Spark plug , Knock sensor, and Camshaft position sensorOil pump and internal partsCrankcase breather tube, Positive crankcase ventilation valve, Oil filler capExhaust manifold and Exhaust valvesRocker arm oil control valveTubing, fittings, seals, gaskets, and clamps associated with these listed systems.

Covered up to the first required replacement only. See the Maintenance Schedule on page 62.

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122

WARRANTY PERIOD RETAILED ON ORAFTER APRIL 1, 2005:

THIS WARRANTY COVERS

Distributor’s Warranty

Canada


HONDA CANADA INC., for and on behalf of HondaMotor Co. Ltd., Tokyo, Japan, gives the followingwritten warranty on each new marine productmanufactured by Honda Motor Co. Ltd., Japan,distributed in Canada by Honda Canada Inc. and sold byauthorized Honda Marine dealers.

Whenever used herein, the word ‘‘Honda’’ refers toHonda Canada Inc. and/or Honda Motor Co. Ltd., asappropriate from the context.

HONDA WARRANTS THAT each new Honda marineproduct will be free, under normal use and maintenance,from any defects in material or workmanship for therelevant warranty period set forth below. If any defectsshould be found in a Honda marine product within therelevant warranty period, necessary repairs andreplacements with a new part or the Honda equivalentshall be made at no cost to the consumer for parts andlabour, when Honda acknowledges that such defects areattributable to faulty material or workmanship at the timeof manufacture.

Any marine product on which required maintenanceservices have been performed as prescribed in theOwner’s Manual.

Any factory installed part (except normal maintenanceparts referred to in ‘‘THIS WARRANTY DOES NOTCOVER’’); and

Any Honda marine product purchased in Canada froman authorized Honda dealer which has been registeredat the time of purchase on a form provided by Honda,which has had set-up and pre-delivery serviceperformed by an authorized Honda dealer and which isnormally operated in Canada;

a)

b)

c)

All Honda OutboardModels

Non-commercialuse

Commercialuse

36 Months 12 Months

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123

THIS WARRANTY DOES NOT COVER THE OWNER’S OBLIGATION

TO OBTAIN WARRANTY SERVICE


Any repairs required as a result of collision, accident,striking any object, misuse or lack of requiredmaintenance;Any repairs required as a result of any attachments,parts or devices installed by or repairs done by a partyother than an authorized Honda dealer;Any outboard that has been operated out of water,(Run Dry) damaging the water pump and or enginecomponents due to insufficient cooling water.Any marine products modified, altered, disassembledor remodelled;Normal maintenance services, including tightening ofnuts, bolts and fittings and engine tune-up and thereplacement of parts made in connection with normalmaintenance services including filters, spark plugs andwires, fuses, belts, lubricants and other expendablessusceptible to natural wear;Outboard propeller or shear pin.All accessories or attachments.

In order to maintain the validity of this DISTRIBUTORSWARRANTY, the required maintenance services as setforth in the Owner’s Manual must be performed at theproper intervals and detailed receipts and records retainedas proof.

You must take your Honda marine product, at yourexpense, during normal service hours, to any authorizedHonda Marine dealership. If you are unable to obtain orare dissatisfied with the warranty service you receive,first contact the owner of the dealership involved; thisshould resolve the problem. If you require furtherassistance, contact Honda Canada’s Customer RelationsDepartment at:

HONDA CANADA INC.Visit www.honda.ca for address/contact information.

TELEPHONE: 1-888-946-6329 TOLL FREEFAX : 1-877-939-0909 TOLL FREE

a)

b)

c)

d)

e)

f)g)

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124

REPLACEMENT PARTS AND ACCESSORYWARRANTY

ENTIRE WRITTEN WARRANTY

DISCLAIMER

NOTICE TO CONSUMER


New genuine Honda replacement parts or accessoriessold to a consumer or installed by an authorized HondaMarine dealer which are not covered by theDISTRIBUTORS WARRANTY are warranted for aperiod of one year from date of purchase, provided,however, that this Replacement Parts and AccessoryWarranty does not apply to any replacement partsmodified, used with, or installed on a marine product forwhich the replacement parts were not intended. Electricalcomponents that are not installed by the dealer (sold overthe counter) are not covered by warranty.

This DISTRIBUTORS WARRANTY and theREPLACEMENT PARTS AND ACCESSORYWARRANTY are the only and the entire writtenwarranties given by Honda for Marine engines. No dealeror his agent or employee is authorized to extend orenlarge on these warranties on behalf of Honda by anywritten or verbal statement or advertisement.

To the extent the law permits, Honda disclaims anyresponsibility for loss of time or use of the product,transportation or towing costs or any other indirect,incidental or consequential damage, inconvenience orcommercial loss.

The provisions contained in these written warranties arenot intended to limit, modify, take away from, disclaimor exclude any warranties set forth in or the operation ofThe Consumer Products Warranties Act, 1977(Saskatchewan), The Consumer Product Warranty andLiability Act (New Brunswick), The ConsumerProtection Act (Quebec), or any other similar provincialor federal legislation.

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125

INDEX

...........................................Alternator (ACG) Indicator . 33...........................................................................Anodes . 36

..............................................................Replacement . 82.............ARE YOU READY TO GET UNDERWAY? . 37

.........................................................................Battery . 104........................................................Will Not Charge . 96

................................................BEFORE OPERATION . 37...........................................BREAK-IN PROCEDURE . 39

.........................................................Common Controls . 28........COMPONENT AND CONTROL LOCATIONS . 13

.................................CONSUMER INFORMATION . 110CONTROL AND FEATURE IDENTIFICATION

......................................................................CODES . 12..................................................................CONTROLS . 17

..................................CONTROLS AND FEATURES . 12..............................................Cooling System Indicator . 35

....................................................................CRUISING . 53....................................Customer Service Information . 110

............................Electric Starter Will Not Operate . 91, 96Emergency Stop Switch Clip and Emergency Stop

Switch.....................................................Panel-Mount Type . 21......................................................Side-Mount Type . 17.......................................................Top-Mount Type . 24

.......................Emission Control System Information . 104............................Emission Control System Warranty . 118

EngineCover

......................................................................Latch . 30...................REMOVAL AND INSTALLATION . 65

Oil...................................................................Change . 66

.........................................................Filter Change . 68..........................................................Level Check . 66

.................................................Recommendations . 69...........................................................OVERHEATS . 95

..................................................WILL NOT START . 92

...................Digital Speedometer (optional equipment) . 32.....................Digital Tachometer (optional equipment) . 31

...................................Distributor’s Limited Warranty . 113................................................Distributor’s Warranty . 122

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126

INDEX

Fast Idle Button.....................................................Panel-Mount Type . 23

.......................................................Top-Mount Type . 27...............................................................Fast Idle Lever . 19

Fuel..................................................................PRIMING . 40

.............................................................Priming Bulb . 36Fuel

..........................................RECOMMENDATIONS . 76............................Filter Inspection and Replacement . 77

.........................................................Fuse Replacement . 96...........................................................................FUSES . 96

HARD STARTING OR STALLS AFTER...............................................................STARTING . 94

....................HOISTING THE OUTBOARD MOTOR . 88.....................................................Honda Publications . 110

.........................................................Lubrication Points . 70

.........................................MAINTENANCE SAFETY . 60...................................MAINTENANCE SCHEDULE . 62

..................................MANUAL RELIEF VALVE . 29, 65...................................................Malfunction Indicator . 33

...................MOORING, BEACHING, LAUNCHING . 57

Gearshift/Throttle Control Lever.....................................................Panel-Mount Type . 22......................................................Side-Mount Type . 18.......................................................Top-Mount Type . 25

.........GEARSHIFT AND THROTTLE OPERATION . 51

Ignition Switch.....................................................Panel-Mount Type . 20......................................................Side-Mount Type . 17.......................................................Top-Mount Type . 24

....................IMPORTANT SAFETY INFORMATION . 7...............................................................INDICATORS . 33

...........................................................INSTRUMENTS . 31IS YOUR OUTBOARD MOTOR

......................................................READY TO GO? . 37

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127

INDEX

....................................................Oil Pressure Indicator . 34OIL PRESSURE INDICATOR GOES OFF AND

................................ENGINE SPEED IS LIMITED . 98................................................................OPERATION . 39

....................................................OTHER FEATURES . 35...................................OUTBOARD MOTOR SAFETY . 7

.........................................................Overheat Indicator . 34OVERHEAT INDICATOR COMES ON AND

................................ENGINE SPEED IS LIMITED . 99

..........................................................Power Tilt Switch . 29................................................Power Trim/Tilt Switch . 28

..................................................Propeller Replacement . 82

.................................................................REFUELING . 75...................................REMOVAL FROM STORAGE . 89

....................................................................Rev Limiter . 36

........................SAFE OPERATING PRECAUTIONS . 39......................................SAFETY LABEL LOCATION . 9

.............................................Serial Number Locations . 103..............SERVICING YOUR OUTBOARD MOTOR . 59

............................SHALLOW WATER OPERATION . 56........................................................Spark Plug Service . 72

SPARE EMERGENCY STOP SWITCH CLIP.................................................(optional equipment) . 61

..............................................................Specifications . 109....................................................................Star Label . 107

..........................................STARTING THE ENGINE . 41.....................................................Panel-Mount Type . 44......................................................Side-Mount Type . 41.......................................................Top-Mount Type . 46

....................................................................STEERING . 52...........................................STOPPING THE ENGINE . 49

.....................................Emergency Engine Stopping . 49...........................................Normal Engine Stopping . 50

....................................................................STORAGE . 84........................................STORAGE PRECAUTIONS . 88........................................STORAGE PREPARATION . 84

..............................................Cleaning and Flushing . 84..................................................................Engine oil . 87

............................................................................Fuel . 85.....................SUBMERGED OUTBOARD MOTOR . 101

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128

INDEX

.................................Tachometer (optional equipment) . 31....TAKING CARE OF UNEXPECTED PROBLEMS . 91

TECHNICAL AND CONSUMER.....................................................INFORMATION . 103

.................................TECHNICAL INFORMATION . 103...............THE IMPORTANCE OF MAINTENANCE . 59

..............................................................Tilt Lock Lever . 29........................TOOL KIT and OWNER’S MANUAL . 61

........................................................TRANSPORTING . 90WITH OUTBOARD MOTOR INSTALLED

.............................................................ON BOAT . 90WITH OUTBOARD MOTOR REMOVED

.......................................................FROM BOAT . 90.................................Trim Meter (optional equipment) . 31

........................................................................Trim Tab . 30........................................TRIM TAB ADJUSTMENT . 64

..TRL (Trolling) Control Switch (optional equipment) . 30..................................................Trolling Speed Control . 55

...................................................Warranty Statements . 113................................................Water Separator Buzzer . 35

............WATER SEPARATOR BUZZER SOUNDS . 101.......................WATER SEPARATOR INDICATOR . 101.......................Water Separator Inspection and Service . 80

10/04/13 15:25:15 31ZX1600_129

PANTONE 288 CVC DIC F101 BLACK BF115_AH_OM表紙_31ZX1600BF115_AH_OM表紙_31ZX1600BF115_AH_OM表紙_31ZX1600背幅5mm背幅5mm背幅5mm

Includes US and Canadian Models

BF115D

英 N HCAHEM331ZX160100X31-ZX1-6010

300.2010.11Printed in Japan

includes us and canadian models€¦ · cap securely. if any fuel is spilled, make sure the area is...

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