the engine exhaust from this · 2013. 6. 18. · the engine exhaust from this product contains...

The engine exhaust from thisproduct contains chemicalsknown to the State of California tocause cancer, birth defects, orother 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.

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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 Honda marinedealer is dedicated to yoursatisfaction and will be pleased toanswer your questions and concerns.

2004 Honda Motor Co., Ltd. AllRights Reserved

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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 LOCATIONS . 9

..................................CONTROLS AND FEATURES . 10CONTROL AND FEATURE IDENTIFICATION

..................................................................CODES . 10....COMPONENT AND CONTROL LOCATIONS . 11

..............................................................CONTROLS . 15Side-Mount Type

......................................................Ignition Switch . 15.............Switch Clip and Emergency Stop Switch . 16

..........................Gearshift/Throttle Control Lever . 16.......................................................Fast Idle Lever . 18

Panel-Mount Type......................................................Ignition Switch . 18

.............Switch Clip and Emergency Stop Switch . 19.....................................................Fast Idle Button . 20

..........................Gearshift/Throttle Control Lever . 20

Top-Mount Type......................................................Ignition Switch . 22

.............Switch Clip and Emergency Stop Switch . 22.....................................................Fast Idle Button . 23

..........................Gearshift/Throttle Control Lever . 23Common Controls

........................................Power Trim/Tilt Switch . 25..................................................Power Tilt Switch . 26

.............................................Manual Relief Valve . 26.....................................................Tilt Lock Lever . 26

..............................................Engine Cover Latch . 27................................................................Trim Tab . 27

.......................................................INSTRUMENTS . 27.........................Trim Meter (optional equipment) . 27.........................Tachometer (optional equipment) . 28

.............Digital Tachometer (optional equipment) . 28...........Digital Speedometer (optional equipment) . 28

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4

CONTENTS

...........................................................INDICATORS . 29...................................Alternator (ACG) Indicator . 29

..Programmed Fuel Injection (PGM-FI) Indicator . 29............................................Oil Pressure Indicator . 29...........................................Overheating Indicator . 30

.....................................Cooling System Indicator . 31................................................OTHER FEATURES . 31

........................................Water Separator Buzzer . 31.....................................................Overrev Limiter . 31

...................................................................Anodes . 32.................................................Fuel Priming Bulb . 32

................................................BEFORE OPERATION . 33........ARE YOU READY TO GET UNDER WAY? . 33

IS YOUR OUTBOARD MOTOR..................................................READY TO GO? . 33

................................................................OPERATION . 35....................SAFE OPERATING PRECAUTIONS . 35

.......................................BREAK-IN PROCEDURE . 35.......................................................FUEL PRIMING . 36

......................................STARTING THE ENGINE . 37..................................................Side-Mount Type . 37.................................................Panel-Mount Type . 40

...................................................Top-Mount Type . 42.......................................STOPPING THE ENGINE . 44

................................Emergency Engine Stopping . 44.......................................Normal Engine Stopping . 45

GEARSHIFT AND..............................THROTTLE OPERATION . 46

..................................................Side-Mount Type . 46.................................................Panel-Mount Type . 47

...................................................Top-Mount Type . 47...............................................................STEERING . 48................................................................CRUISING . 49

........................SHALLOW WATER OPERATION . 51...............MOORING, BEACHING, LAUNCHING . 51

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5

CONTENTS

..............SERVICING YOUR OUTBOARD MOTOR . 53...........THE IMPORTANCE OF MAINTENANCE . 53

.....................................MAINTENANCE SAFETY . 54...................TOOL KIT and OWNER’S MANUAL . 55

SPARE EMERGENCY STOP SWITCH CLIP.............................................(optional equipment) . 55

...............................MAINTENANCE SCHEDULE . 56....................................TRIM TAB ADJUSTMENT . 58....................................MANUAL RELIEF VALVE . 59

ENGINE COVER REMOVAL AND..................................................INSTALLATION . 59

............................................Engine Oil Level Check . 60....................................................Engine Oil Change . 60

.......................................................Oil Filter Change . 62..................................Engine Oil Recommendations . 63

.....................................................Lubrication Points . 64

....................................................Spark Plug Service . 66.............................................................REFUELING . 69

...............................FUEL RECOMMENDATIONS . 70...................Fuel Filter Inspection and Replacement . 71...................Water Separator Inspection and Service . 74

..................................................Anode Replacement . 76..............................................Propeller Replacement . 77

....................................................................STORAGE . 78...................................STORAGE PREPARATION . 78

..........................................Cleaning and Flushing . 78........................................................................Fuel . 80

.............................................................Engine Oil . 81................HOISTING THE OUTBOARD MOTOR . 82

...................................STORAGE PRECAUTIONS . 82...............................REMOVAL FROM STORAGE . 83

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6

CONTENTS

........................................................TRANSPORTING . 84WITH OUTBOARD MOTOR

......................................INSTALLED ON BOAT . 84WITH OUTBOARD MOTOR

..................................REMOVED FROM BOAT . 84

....TAKING CARE OF UNEXPECTED PROBLEMS . 85.......................................................................FUSES . 90

..........................Electric Starter Will Not Operate . 90.......................................Battery Will Not Charge . 90

.................................................Fuse Replacement . 90OIL PRESSURE INDICATOR GOES OFF AND

............................ENGINE SPEED IS LIMITED . 92OVERHEAT INDICATOR COMES ON AND

............................ENGINE SPEED IS LIMITED . 93..........WATER SEPARATOR BUZZER SOUNDS . 95

.....................WATER SEPARATOR INDICATOR . 95..........................................SUBMERGED MOTOR . 95

..TECHNICAL AND CONSUMER INFORMATION . 97...............................TECHNICAL INFORMATION . 97

......................................Serial Number Locations . 97..................................................Oxygenated Fuels . 98

...................................................................Battery . 99...............Emission Control System Information . 100

............................................................Star Label . 102......................................................Specifications . 104

.............................CONSUMER INFORMATION . 107.............................................Honda Publications . 107

............................Customer Service Information . 107

.........................................................................INDEX . 112

........................WIRING DIAGRAMS . Inside Back Cover

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7

IMPORTANT SAFETYINFORMATION

Operator Responsibility

OUTBOARD MOTOR SAFETY

Most accidents can be prevented ifyou follow all instructions in thismanual and on the outboard motor.The most common hazards arediscussed below, along with the bestway to protect yourself and others.

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.

Honda BF135A/BF150A outboardmotors are designed for use withboats that have a suitablemanufacturer’s powerrecommendation. Other uses canresult in injury to the operator ordamage to the outboard motor andother property.

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8

Carbon Monoxide HazardRefuel With Care


Exhaust gas contains poisonouscarbon monoxide. Avoid inhalationof exhaust gas. Never run the enginein a closed garage or confined area.

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.

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9

SAFETY LABEL LOCATION


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

CONTROL AND FEATURE IDENTIFICATION CODES

CONTROLS AND FEATURES

Model

Type

BF135A BF150A

Transom Height

LA XA XCA LA XA XCA

Standard Rotating Propeller Shaft

Counterrotating Propeller Shaft

Power Trim/Tilt

20.0 in (508 mm)

25.0 in (635 mm)

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

Destination

ACTYPE CODE (example)

A: AmericaRotating direction of propeller shaftC: Counterrotating propeller shaftNone: Standard rotating propeller shaftTransom Height

X

L: 20.0 in (508 mm), X: 25.0 in (635 mm)

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11

COMPONENT AND CONTROL LOCATIONS


ENGINE COVER

ANODE

OIL LEVEL DIPSTICK

ANODE

TRIM TAB

STERNBRACKET

FRAME SERIALNUMBER

TILT LOCKLEVER

POWER TILTSWITCH

ENGINE COVERLATCH

COOLING SYSTEMINDICATOR

ENGINE OILDRAIN BOLT(inside cover)

ANTIVENTILATIONPLATE

EXHAUST PORT/WATEROUTLET PORT

GEAR OILLEVEL PLUG

GEAR OIL DRAIN/FILL PLUG

FLUSH PORTCONNECTOR

ANODE

SPARK PLUG(under coverand/or coil)

PROPELLER(optional equipment)

MANUALRELIEF VALVE

COOLING WATERINTAKE PORT

OIL FILLER CAP

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12

Remote Controls (optional equipment)


EMERGENCYSTOP SWITCH

FAST IDLELEVER

IGNITIONSWITCH

POWER TRIM/TILTSWITCH

CONTROL LEVERFRICTION ADJUSTER

NEUTRALRELEASELEVER

POWER TRIM/TILTSWITCH

BUZZER(inside)

(SIDE-MOUNT REMOTE CONTROL) (PANEL-MOUNT REMOTE CONTROL)

GEARSHIFT/THROTTLECONTROL LEVER

FAST IDLEBUTTON


LANYARD SWITCH CLIP

SPARE SWITCHCLIP

NEUTRAL RELEASELEVER

OIL PRESSUREINDICATOR

OVERHEATINDICATOR

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POWERTRIM/TILTSWITCH

POWER TRIM/TILTSWITCH (RIGHT)

POWER TRIM/TILTSWITCH (LEFT)

BUZZERIGNITIONSWITCH

CONTROL PANEL(for PANEL/TOP-MOUNT type)

(SINGLE TOP-MOUNT REMOTE CONTROL) (DUAL TOP-MOUNT REMOTE CONTROL)


FAST IDLEBUTTON FAST IDLE

BUTTON

GEARSHIFT/THROTTLECONTROL LEVER GEARSHIFT/THROTTLECONTROL LEVERS

SWITCH CLIP

LANYARD

(for TOP-MOUNT DUAL type)OIL PRESSUREINDICATOR

OVERHEATINDICATOR

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14

Trim Meter(optional equipment)

Tachometer(optional equipment)

Digital Speedometer(optional equipment)

Digital Tachometer(optional equipment)


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15

CONTROLS

Side Mount Type


STARTOONNOOFFFFIGNITIONSWITCH

Ignition Switch

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

Turning the ignition switch to theOFF position stops the engine.

The ignition switch controls theignition system and starter motor.

The ignition switch can be used tostart the engine only when the controllever (p. ) is in the N (neutral)position, and the switch clip is in theemergency stop switch.

17

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16



SWITCH CLIPLANYARD

SWITCH CLIPLANYARD

SPARE SWITCH CLIP

CONTROL LEVER


Switch Clip and Emergency StopSwitch

Gearshif t/Throttle ControlLever

The switch clip must be inserted inthe emergency stop switch in orderfor the engine to start and run. Thelanyard must be attached to theoperator’s PFD (Personal FlotationDevice) or worn around the wrist asshown.

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

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

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

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F (FORWARD)


30° 30°

TTHHRROOTTTTLLEE OOPPEENNIINNGG


MAXIMUM

MAXIMUM

SHIFT SHIFT

MMIINNIIMMUUMMMMIINNIIMMUUMM

N (NEUTRAL)

R (REVERSE)

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.

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

A friction adjuster near the base ofthe control lever(s) adjusts theoperating resistance of the controllever(s). Refer to p. .45

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18

Panel-Mount Type


FAST IDLE LEVER

MAXIMUM FAST IDLE

LOWEST POSITION

STARTON

OFF

IGNITIONSWITCH KEY

N (neutral)Fast Idle Lever

Ignition Switch


After the engine starts and if theoutside temperature is below 41°F(5°C), the fast idle lever can be usedto accelerate engine warm up.

The fast idle lever will not moveunless the remote control lever is inthe N (neutral) position. Conversely,the remote control lever will notmove unless the fast idle lever is inthe lowest position.

Lower the fast idle lever to thelowest position to decrease the fastidle.

The fast idle lever is only needed forstarting carbureted outboard models.The BF135A and BF150A modelsuse programmed fuel injection so,this lever will not be needed forstarting.

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19


LANYARDSWITCH CLIP

LANYARD

SWITCH CLIP


SPARE SWITCH CLIP(optional equipment)






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


21

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20


CONTROL LEVER


CONTROLLEVER

NEUTRALRELEASELEVER

Push

R (reverse)F (forward)

PPuullll uupp

FAST IDLE BUTTON

N (neutral)


Fast Idle Button It is necessary to position the controllever in N (neutral) to push in the fastidle button.


By moving the control lever forwardor reverse when the fast idle button ispushed in, the throttle opening willbe increased without engaging thegears.

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35° 35°

SHIFT SHIFT

MMIINNIIMMUUMMMMIINNIIMMUUMM

MAXIMUM

MAXIMUM

N (NEUTRAL)

F (FORWARD) R (REVERSE)

TTHHRROOTTTTLLEE OOPPEENNIINNGGTTHHRROOTTTTLLEE OOPPEENNIINNGG


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. .


46

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22

Top-Mount Type


EMERGENCYSTOPSWITCH

LANYARDSWITCH CLIP

LANYARD

SWITCH CLIP

ON

OFF

START

IGNITIONSWITCHKEY


Ignition Switch





24

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23


SINGLE TYPE

DUAL TYPE

CCOONNTTRROOLLLLEEVVEERRSS

CCOONNTTRROOLLLLEEVVEERR

CONTROLLEVER

Push

N (neutral)F (forward)

R (reverse)

FAST IDLE BUTTON

SPARE SWITCH CLIP(optional equipment)


Fast Idle Button




By moving the control lever forwardor reverse when the fast idle button ispushed in, the throttle opening willbe increased without engaging thegears.

It is necessary to position the controllever in N (neutral) to push in the fastidle button.

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

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24




SHIFT SHIFT

MAXIMUM

MAXIMUM

35° 35°

MMIINNIIMMUUMM

MMIINNIIMMUUMM

F (FORWARD)

N (NEUTRAL)

R (REVERSE)

GEARSHIFT/THROTTLE CONTROL LEVER


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


46

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25

Common Controls

Power Trim/Tilt Switch


(side-mount type) (top-mount type)

(panel-mount type)

CONTROLLEVER

CONTROL LEVER

CONTROLLEVER

DUAL TYPE

(LEFT) (RIGHT)POWER TRIM/TILT SWITCH

POWERTRIM/TILTSWITCH

POWER TRIM/TILT SWITCH


SINGLE TYPE

CCOONNTTRROOLLLLEEVVEERRSS

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 motor angle.

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

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

For dual mount outboards, tilt themup at the same time.

48

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26

Power Tilt Switch Manual Relief Valve Tilt Lock Lever


POWER TILT SWITCH

MMAANNUUAALL RREELLIIEEFF VVAALLVVEE FFRREEEE

LLOOCCKK

TTIILLTT LLOOCCKK LLEEVVEERRPPOOWWEERR((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 asfar 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.

The outboard motor can be tiltedmanually after opening the manualrelief valve. This allows the outboardmotor to be tilted when no battery isconnected.

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27

INSTRUMENTS

Trim Meter(optional equipment)

Trim TabEngine Cover Latch


TRIM METER

TRIM TAB

TIGHTENINGBOLT

UUNNLLOOCCKK

ENGINE COVER LATCH

When the trim tab is correctlyadjusted (p. ), steering effort isequal in either direction.

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

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

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

The trim meter has a range of 4° to16° and indicates the trim angle ofthe outboard motor.

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

57

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28

Tachometer(optional equipment)

Digital Tachometer(optional equipment)

Digital Speedometer(optional equipment)


TACHOMETER

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.

Digital Speedometer includes thefollowing functions.

SpeedometerFuel level MeterVolt MeterTripmeterFuel Integration MeterFuel Economy MeterFuel Flow MeterWater Separator Indicator

Refer to the Operation Guideincluded with each DigitalSpeedometer for operationinformation.

Digital Tachometer includes thefollowing functions.

TachometerHour MeterTrim MeterOil pressure IndicatorOverheat IndicatorACG IndicatorPGM-FI Indicator

Refer to the Operation Guideincluded with each DigitalTachometer for operationinformation.

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INDICATORS

Alternator (ACG) Indicator

Programmed Fuel Injection(PGM-FI) Indicator

Oil Pressure Indicator


ACG INDICATOR

PGM-FI INDICATOR(side-mount type)

(panel-mount/top-mount types)

(GREEN)

BUZZER

BUZZER

(GREEN)

When the engine control systemdetects an PGM-FI malfunction, thePGM-FI indicator turns on and thebuzzer sounds at one-secondintervals.

Under normal conditions when theignition key is turned on thefollowing will occur:

Both the PGM-FI indicator andACG indicator will turn on.The buzzer will beep twice.The PGM-FI indicator will turnoff shortly after the second beep.The ACG indicator will turn offafter the engine starts.

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

1.

2.3.

4.

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30

Overheat Indicator


(side-mount type)

(panel-mount/top-mount types)

(RED)

(RED)

BUZZER

BUZZER

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

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 TAKING CARE OFUNEXPECTED PROBLEMS, fromp. .

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 TAKING CARE OFUNEXPECTED PROBLEMS, fromp. .

All models are equipped with abuzzer that sounds a steady tonewhen the red light comes on.

Engine overheating may be the resultof clogged water intakes.

All models are equipped with abuzzer that sounds when the oilpressure indicator goes off.

92 94

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31

Cooling System Indicator OTHER FEATURES

Water Separator Buzzer

Overrev Limiter


COOLING SYSTEM INDICATOR

WATER SEPARATOR

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

The engine is equipped with anoverrev limiter to prevent thepossibility of mechanical damagefrom excessive engine speed.

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

If the overrev limiter is activated,check the trim angle of the outboardmotor.

Check to see if the correct propelleris installed.

The cooling system indicatordischarge port can also becomeplugged.

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32

Anodes Fuel Priming Bulb


ANODE(each side)

ANODE(stern bracket)

PRIMING BULB

UP

OUTLET END(motor)

INLET END (tank)

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.

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. ).35

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

Always perform apreoperation inspectionbefore each operation, andcorrect any problem.

33

ARE YOU READY TO GETUNDER WAY?

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 under way. Knowwhat to do in case of emergencies.

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 your PFD or toyour wrist.

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 preoperationchecks, be sure the ignition switch isin the OFF position.

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34

Safety Inspection Maintenance Inspection

BEFORE OPERATION

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

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

Wipe up any spills before startingthe engine.

Check that all controls areoperating properly.

Replace any damaged parts.

Check that the fuel hose isundamaged and properlyconnected.

Check that all fasteners are inplace and securely tightened.

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 gear case (p. )and are not excessively worn. Theanodes help to protect the outboardmotor from corrosion.

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

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

Check the water separator forwater contamination (p. ).

Check that the battery fluid isbetween the upper and lower levels,and the battery leads are connectedsecurely.

77

76

69

7460

55

04/04/01 16:36:07 31ZY6600_035

35

SAFE OPERATINGPRECAUTIONS

BREAK-IN PROCEDURE

Break-in period: 10 hours

First 15 minutes:

Next 45 minutes:

Next 60 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

For your safety, avoid starting oroperating the engine in an enclosedarea. Your engine’s exhaust containspoisonous carbon monoxide gaswhich can collect rapidly in anenclosed area and cause illness ordeath.

Proper break-in operation allows themoving parts to wear in smoothly forbest performance and long servicelife.

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

Run the engine up to a maximum of2,000 to 3,000 rpm, which is about10% to 30% of maximum throttleopening.

Run the engine up to a maximum of4,000 to 5,000 rpm, which is about50% to 80% of maximum throttleopening.

Short full-throttle bursts are OK, butdo not operate the enginecontinuously at full throttle.

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

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

7

04/04/01 16:36:20 31ZY6600_036

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.

36

FUEL PRIMING

OPERATION

PRIMING BULB

UPOUTLET END(motor)

INLET END(tank)

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

Do not squeeze the priming bulbwhen the engine is running.

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.

04/04/01 16:36:31 31ZY6600_037

37

STARTING THE ENGINE

Side Mount Type

OPERATION

LANYARDSWITCH CLIP


N (neutral)

CONTROLLEVER

Put the emergency stop switch clipin the emergency stop switch, andattach the lanyard to your PFD(Personal Flotation Device) or toyour wrist, as shown.

The engine will not start or run,unless the clip is in the switch.

The emergency stop switch clipand lanyard system is a safetydevice that will stop the engine ifyou fall away from the controlswhile operating the boat.

Always attach the lanyard to yourPFD, or to your wrist, beforestarting the engine.

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

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

1. 2.

04/04/01 16:36:42 31ZY6600_038

38

OPERATION

IGNITION SWITCH KEY

ONSTARTOFF

FAST IDLE RANGE

LOWESTPOSITION

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 theOFF (fully lowered) position.

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.

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.

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

3. 4.

04/04/01 16:36:51 31ZY6600_039

39

OPERATION

FAST IDLERANGE

MAXIMUM FAST IDLE If the engine is not properlywarmed-up bef ore raising the enginespeed, the buzzer and overheatindicator may activate, and theengine speed will be automaticallyreduced.

TAKING CARE OFUNEXPECTED PROBLEMS

Before getting under way, allowthe engine to warm up sufficientlyto ensure good performance.

Above 41°F (5°C), warm up theengine for 2 or 3 minutes.

Below 41°F (5°C), warm up theengine for at least 10 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

from p. .

5.

6.

29

30

85

29

04/04/01 16:37:02 31ZY6600_040

40

Panel-Mount Type

OPERATION

LANYARDSWITCH CLIP

EMERGENCY STOPSWITCH

CONTROLLEVER

N (neutral)The engine will not start or run,unless the clip is in the switch.





Put the emergency stop switch clipin the emergency stop switch, andattach the lanyard to your PFD(Personal Flotation Device) or toyour wrist, as shown.

1. 2.

04/04/01 16:37:10 31ZY6600_041

41

OPERATION

ON

OFF

IGNITIONSWITCHKEY

START

CONTROLLEVER

N (neutral)

FAST IDLE BUTTON


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






Below 41°F (5°C), warm up theengine for at least 10 minutes at2,000 rpm. Push the fast idlebutton then move the control leverforward or reverse to open thethrottle and achieve approximately2,000 rpm.

3. 4.

04/04/01 16:37:21 31ZY6600_042

42

Top-Mount Type

OPERATION

EMERGENCY STOPSWITCH

SWITCH CLIP LANYARD


If the engine is not properlywarmed-up bef ore raising the enginespeed, the buzzer and overheatindicator may activate, and theengine speed will be automaticallyreduced.

The engine will not start or run,unless the clip is in the switch.



Put the switch clip in theemergency stop switch, and attachthe lanyard to your PFD (PersonalFlotation Device) or to your wrist,as shown.



from p. .

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

1.

5.

29

3029

85

04/04/01 16:37:32 31ZY6600_043

43

OPERATION

ON

OFF

IGNITIONSWITCHKEY

START

CONTROLLEVER

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







3.2.

04/04/01 16:37:41 31ZY6600_044

44

STOPPING THE ENGINE

Emergency Engine Stopping

OPERATION

N (neutral)

PULL

SWITCH CLIP

LANYARD


LANYARDPULL

CONTROL PANEL

SWITCH CLIP


CONTROLLEVER

FAST IDLE BUTTON

Panel Mount/Top Mount Types

Side Mount Type


If the engine is not properlywarmed-up bef ore raising the enginespeed, the buzzer and overheatindicator may activate, and theengine speed will be automaticallyreduced.



Below 41°F (5°C), warm up theengine for at least 10 minutes at2,000 rpm. Push the fast idlebutton then move the control leverforward or reverse to open thethrottle and achieve approximately2,000 rpm.



from p. .

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

4.

5.

29

30

85

29

04/04/01 16:37:55 31ZY6600_045

45

Normal Engine Stopping

OPERATION

N (neutral)

CONTROLLEVER

CONTROLLEVER

N (neutral)

N (neutral)

CONTROLLEVER

Top Mount Type

Panel Mount Type

Side Mount Type

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

To stop the engine in an emergency,pull the clip out of the emergencystop switch by pulling the lanyard.

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

1.

04/04/01 16:38:04 31ZY6600_046

46

GEARSHIFT ANDTHROTTLE OPERATION

OPERATION

OFF

N (neutral)

F (forward)R (reverse)

CONTROL LEVER

NEUTRALRELEASE LEVER

OOFFFF

IGNITIONSWITCH KEY

IGNITIONSWITCH KEY

Side Mount Type

Panel Mount/Top Mount Types

Side Mount Type

Turn the ignition switch key to theOFF position.

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

3.

2.

04/04/01 16:38:15 31ZY6600_047

47

OPERATION

TO INCREASEFRICTION

TO DECREASEFRICTION

F (forward)

N (neutral)

N (neutral)

R (reverse)

CONTROLLEVER

F (forward)

R (reverse)

TO DECREASEFRICTION

TO INCREASEFRICTION


CONTROLLEVER

NEUTRALRELEASELEVER CONTROL

LEVERFRICTIONADJUSTER

Panel Mount Type Side Mount Type

Top Mount Type Panel-Mount Type

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

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.

04/04/01 16:38:26 31ZY6600_048

48

STEERING

OPERATION

TO INCREASEFRICTION

TO DECREASEFRICTION


Top 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.

04/04/01 16:38:33 31ZY6600_049

49

CRUISING

Engine Speed Trim

OPERATION

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

If, for example, the outboard motoris tilted excessively, or propellerventilation occurs during a sharp turn,the engine may overrev, activatingthe overrev limiter.

The engine is equipped with anoverrev limiter to prevent thepossibility of mechanical damagefrom excessive engine speed.

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

If engine speed becomes unstable athigh speed due to activation of theoverrev limiter, reduce speed andcheck the trim angle of the outboard

motor.

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 under way 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.

Under normal conditions, the boatwill perform best when the

antiventilation plate is level with thewater.

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. , )to help you hold a steady speed.

Refer to the trim meter (p. ) for anindication of whether the motor istrimmed high or low.

27

47 48

04/04/01 16:38:46 31ZY6600_050

50

OPERATION



(single type)

(dual type)

(RIGHT)(LEFT)



BOW TOO LOW DUE TO1. LOAD IN THE FRONT2. MOTOR TRIMMED TOO LOW

BOW TOO HIGH DUE TO1. LOAD IN THE REAR2. MOTOR TRIMMED TOO HIGH

MOTORTRIMMED TOOLOW

MOTORTRIMMED TOOHIGH

MOTOR TRIMMEDCORRECTLY

Top Mount TypeSide Mount Type

Panel Mount Type

04/04/01 16:39:00 31ZY6600_051

51

SHALLOW WATEROPERATION

MOORING, BEACHING,LAUNCHING

OPERATION

TIGHTENING BOLT

TRIM TAB

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

When operating in shallow water, usethe power trim/tilt switch (p. ) totilt the outboard motor, so 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.

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 as far as it will go,move the tilt lock lever to the LOCKposition, then gently lower theoutboard motor until the levercontacts the stern bracket.

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

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

Refer to TRIM TAB ADJUSTMENT,P. .

To lower the outboard motor, tilt up,move the tilt lock lever to the FREEposition, then lower the outboardmotor to the desired position.

30

58

50

04/04/01 16:39:11 31ZY6600_052

52

OPERATION

POWER TILT SWITCH

LLOOCCKK

TILT LOCK LEVER(Lock position)

STERN BRACKET

MANUAL RELIEF VALVE

FFRREEEEPPOOWWEERR((TToo ffiixx))


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

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.

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

04/04/01 16:39:19 31ZY6600_053

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.

53

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

Good 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, genuineHonda parts or their equivalents forrepair and replacement.

04/04/01 16:39:29 31ZY6600_054

－

－

－

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

Always follow theprocedures andprecautions in the owner’smanual.

54

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.

Be sure there is adequateventilation whenever youoperate the engine.

04/04/01 16:39:41 31ZY6600_055

×

×

×

55

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


10 12 mm WRENCH

PLIERS

TOOL BAG

14 17 mm WRENCH

8 mm WRENCH

SCREWDRIVER HANDLE

SPARK PLUG WRENCH

OWNER’S MANUAL

FLAT SCREWDRIVER

FUSE PULLER

19 mm EYE WRENCH

16 17 mm BOX WRENCH

6 mm HEX. WRENCH

OIL CHECKSCREWDRIVER

PHILLIPSSCREWDRIVER

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 they will always be available if youneed them.

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

04/04/01 16:39:48 31ZY6600_056

○

○○

○

○○

○○

○

○○

○○○

○

○○

○○

○○

○

56

MAINTENANCE SCHEDULE


REGULAR SERVICE PERIOD

After usePerform at every indicated month oroperating hour interval, whichevercomes first.

Check levelChangeChangeReplaceCheck-adjustCheck-adjustCheck-adjustCheck-adjustCheckCleanReplaceCheckCheckGreaseCheck

Each useEvery 6 months

or100 hrs.

(2)

(2)(2)

(1)

Every yearor

200 hrs.

(2)(2)

(2)

(2)

Every 2 yearsor

400 hrs.

First monthor

20 hrs.

(2)

(2)(2)

(2)

(1)

ITEM

Engine oil

Gear case oilEngine oil filterACG beltThrottle linkageIdle speedValve clearanceSpark plug

Propeller and Cotter pinAnodeLubricationWater separator

(3)

Lubricate more frequently when used in salt water.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.For professional/commercial use, log hours of operation to determine proper maintenance intervals.

(1)(2)

(3)

04/04/01 16:40:01 31ZY6600_057

○

○

○

○

○

○

○○

○

○

○

57


REGULAR SERVICE PERIOD

Each use After use

(4)

First monthor

20 hrs.

(2)

Every 6 monthsor

100 hrs.

(2)

Every 2 yearsor

400 hrs.

(2)

Every 2 years (If necessary) (2)

Perform at every indicated month oroperating hour interval, whichevercomes first.

ITEM

CheckReplaceReplace

CheckCheckReplaceCheck level-tightness

Check-tightnessCheckCleanCheck

Every yearor

200 hrs.

(2)

(2)

(2)

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

Battery and cableconnectionBolts and NutsCrankcase breather tubeCooling water passagesWater pump

(3)

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)

04/04/01 16:40:13 31ZY6600_058

58

TRIM TAB ADJUSTMENT


TIGHTENING BOLT

TRIM TAB

TIGHTENING BOLT

TRIM TAB

LEFT RIGHT

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 left

turns, 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.

04/04/01 16:40:23 31ZY6600_059

59

MANUAL RELIEF VALVE ENGINE COVER REMOVALAND INSTALLATION


MANUAL RELIEF VALVE

ENGINE COVER LATCH

UNLOCKPPOOWWEERR((TToo ffiixx))


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 orlowered when no battery is connected.

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

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

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

04/04/01 16:40:32 31ZY6600_060

60

Engine Oil Level Check Engine Oil Change


UPPERLIMIT

LOWERLIMIT

OIL FILLER CAP

OIL LEVEL DIPSTICKLEVER

DRAIN PLUG COVER

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 plug cover leverand remove the cover whilepulling the cover backward at anangle.

1.

2.

3.

4.

5.

6.

1.

2.

59

63

59

04/04/01 16:40:48 31ZY6600_061

61


GUIDE

DRAIN PLUG COVER

DRAIN PLUG COVER

GUIDE

GUIDE

SEALING WASHER

DDRRAAIINN BBOOLLTT

DRAINPLUGCOVER

DRAIN PLUG COVER

LEVERPUSHUNDER COVER

LOCKING LUG PROJECTION

Improper disposal of engine oilcan be harmf ul to the environment.If you change your own oil, pleasedispose of the used oil properly.Put it in a sealed container, andtake it to a recycling center. Donot throw it in the trash, pour it onthe ground or down a drain.

Set the drain plug cover under theguide.

Place a suitable container belowthe oil drain guide to catch theused oil, then remove the oil fillercap and the drain plug.

Allow the used oil to draincompletely. Use a new sealingwasher then reinstall the engine oildrain plug, and tighten it securely.

3.

4.

5.

04/04/01 16:40:58 31ZY6600_062

6.9 US qt (6.5 )

7.1 US qt (6.7 )

62

Oil Filter Change


OIL FILTER

OIL DRAIN GUIDE

RUBBER SEAL

FILTER WRENCH, 65 mm

Drain the engine oil, and reinstallthe drain plug and oil drain cover(see Engine Oil Change on p. ).

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

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

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

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.

1.

2.

3.

6.

7.

8.

9.

60

60

04/04/01 16:41:11 31ZY6600_063

AMBIENT TEMPERATURE

SAE Viscosity Grade

16 lbf·ft (22 N·m , 2.2 kgf·m)

63

Engine Oil Recommendations


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

Use only a genuine Honda 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.

The SAE oil viscosity and serviceclassification are in the API label onthe oil container. Honda recommendsthat you use API SERVICE categorySG, SH or SJ oil with the ‘‘starburst’’certification mark displayed on thecontainer.

SAE 10W-30 is recommended forgeneral use.

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

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

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 (p. ) of therecommended oil.

Screw on the new filter by handuntil it contacts the engine, thenuse a suitable tool to tighten thefilter an additional 7/8 turn.

OIL FILTER TIGHTENINGTORQUE:

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

7.

8.59

4.

5.

6.

63

04/04/01 16:41:26 31ZY6600_064

64

Lubrication Points


THROTTLE LINK/PIVOT/PLATE THROTTLE ROD/LINK TILT BRACKET

TILT SHAFT

SWIVEL CASE

PTT THRUST RECEIVER

ENGINE COVER BRACKET

PROPELLER 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 marine anticorrosion grease tothe following parts:

Lubrication interval:After the first 20 hours or 1 month, thenevery 100 hours or 6 months. (Refer tothe maintenance schedule page ).56

04/04/01 16:41:36 31ZY6600_065

65


TILT SHAFT THREAD

ENGINE COVER LOCKLEVER/OPEN SHAFT

ENGINE COVERCABLE (FRONT)

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

TILT LOCK LEVER

SWIVEL SHAFT

UPPER CYLINDERPIN/BUSH

SWIVEL CASEBUSH/COLLAR

ENGINE COVERLOCK CABLE(LEFT SIDE) COVER LOCK BOLTS

ENGINE COVERLOCK CABLE(RIGHT SIDE)

04/04/01 16:41:41 31ZY6600_066

－

SKJ20DR-M11 (DENSO)IZFR6K11 (NGK)

66

Spark Plug Service


MUD GUARD CLIP

UNDERCOVERGROMMET

UNDERCOVER

MUDGUARDCLIP

MUD GUARD CLIP (2)

IDLE PORT

UNDER COVER GROMMET

Incorrect spark plugs can causeengine damage.

RECOMMENDED SPARK PLUGS:

This outboard motor uses spark plugsthat have an iridium coated centerelectrode. Be sure to observe thefollowing when servicing the sparkplugs.

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 ofthe center electrode, never use a‘‘leaf-type feeler gauge.’’

Do not adjust the spark plug gap.If the gap is out of specification,replace the spark plug with a newone.

Disconnect the battery negative( ) terminal.


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67


IGNITION COILSPARK PLUG COVER

BOLTS WIRE CONNECTOR

BOLT

Do not try to remove the mud guardclip with f orce without raising theinner part of the mud guard clip.Otherwise, it can damage the mudguard clip and/or under cover.

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

Remove the two mud guard clipsfrom the upper part of the undercover grommet.

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

To remove the mud guard clips,raise the inner part of each mudguard clip with a screwdriver, thenpull out the clips.

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.

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7.

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SPARK PLUGWRENCH

19 mm EYEWRENCH

0.039 0.051 in(1.00 1.30 mm)

SEALINGWASHER

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

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

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

After each spark plug seats, tightenwith a spark plug wrench suppliedin the tool kit to compress thesealing 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.

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.The gap should be 0.039 0.051inches (1.00 1.30 mm). If thegap is out of the specification,replace the plug with a new one.Never try to readjust the gap.

Remove the ignition coil bypulling it up slightly.

Remove the spark plugs with aspark plug wrench and 19 mmwrench.

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69

REFUELING


UNDER COVERGROMMET

MUDGUARDCLIP

UNDER COVER

Push the wire connector onto theignition coil. Make sure it locks inplace.Install the ignition coil. Reinstallthe bolt.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.

Mud guard clip installation:Press the under cover grommet andunder cover and be sure that theyadhere closely to each other.Insert the mud guard clips with theinner part raised off, then push inthe inner part securely until theyclick.

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

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70

FUEL RECOMMENDATIONS


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

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.

Occasionally you may hear a light‘‘spark knock’’ or ‘‘pinging’’(metallic rapping noise) whileoperating under heavy loads. This isno cause for concern.

If spark knock or pinging occurs at asteady engine speed, under normalload, change brands of gasoline. Ifspark knock or pinging persists, seean authorized Honda marine dealer.

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71

Fuel Filter Inspection andReplacement


Running the engine with persistentspark knock or pinging can causeengine damage.

Distributor’s LimitedWarranty

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

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

Running the engine with persistentspark knock or pinging is misuse,and the

does not cover partsdamaged by misuse.

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72


FUEL HOSESSCREW (3)

SUSPENSION STRAPFUEL FILTER(inside strainer cup)

ENGINE COVER LATCH

UNLOCK

Remove the suspension strap fromthe strainer bracket, then removethe strainer assembly from thestrap.Before removing the fuel filter, toprevent fuel leakage, place fuelhose clamps on the fuel hoses oneach side of the fuel filter.

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

Remove the engine cover. 3.2.1.

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2.5 lbf·ft (3.4 N·m , 0.35 kgf·m)

73


FUEL FILTER STRAINERBRACKET

ALIGNMENTPOSITION

STRAINERCUP

SUSPENSIONSTRAP

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

Reinstall the strainer in the originalposition.

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

Thoroughly clean the strainer cup,and replace with a new fuel filter.

Reassemble the strainer body andthe cup.STRAINER TIGHTENINGTORQUE:

Reinstall the strainer in the originalposition.

8.

7.

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

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.7.

4.

5.

6.

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74

Water Separator Inspection andService


WATER SEPARATOR

SCREW (3)FUEL TUBES

SUSPENSION STRAP

The water separator is located besidethe oil level dipstick. Wateraccumulation in the water separatorcan cause loss of power or hardstarting. Check the water separatorperiodically. Clean it or consult withan authorized Honda outboard motordealer for cleaning.

Remove the engine cover (seepage ).

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

Pinch the fuel tubes with tube clipsto prevent fuel leakage.

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3.

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2.5 lbf·ft (3.4 N·m , 0.35 kgf·m)

75


SUSPENSIONSTRAP

CUP

O-RING

SUSPENSIONSTRAP

WATERSEPARATOR

WATER SEPARATORBRACKET

BOWLALIGNMENTPOSITION

BOWL

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.

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76

Anode Replacement


ANODE(each side)

ANODE(stern bracket)

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 gearcase. They are made of asacrificial material that helps toprotect the outboard motor fromcorrosion.

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

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77

Propeller Replacement


PROPELLER

COTTER PINTHRUST WASHER

CASTLE NUT

WASHER

MARINE GREASE

Installation

Removal

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

Use a genuine Honda cotter pinand bend the pin ends as shown.

Before replacing the propeller,remove the clip from the engine stopswitch to prevent any possibility ofthe engine being started while youare working with the propeller.

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

Apply marine grade grease to thepropeller shaft and beveled surfaceof the thrust washer.

Install the propeller in the reverseorder of removal.

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

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

Inspect the propeller shaft for anyfishing line or debris.

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2.

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78

STORAGE PREPARATION

Cleaning and Flushing

STORAGE

FLUSH PORTCONNECTOR

Cleaning

Flushing With a Garden Hose(commercially available)

Do not run the motor when f lushingthe motor with a garden hose or themotor may be damaged.

Proper storage preparation isessential for keeping your outboardmotor troublefree 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.

Disconnect the flush portconnector.

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STORAGE

EXHAUST PORT

FLUSH PORTCONNECTOR

WATER HOSE

WATER HOSE JOINT(Commercially available)

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

Screw the garden hose into theflush port connector.

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

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80

Fuel

STORAGE

DRAIN HOSE

DRAIN SCREW

VAPOR SEPARATOR

FRONT BRACKET CLAMP

Adding a Fuel Stabilizer

Draining the Fuel System

Distributor’s Limited Warranty

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.

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.

Thedoes not cover fuel system damageor engine performance problemsresulting from neglected storagepreparation.

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

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.

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81

Engine Oil

STORAGE

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

Remove the spark plugs (p. ),and remove the clip from theemergency stop switch.

Pour a tablespoon (5 10 cm ) ofclean engine oil into each cylinder.

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

Reinstall the spark plugs (p. ).

Unhook the drain hose from thefront bracket clamp.

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

Loosen the vapor separator drainscrew.

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.

1.

2.

3.

4.

5.

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82

STORAGE PRECAUTIONSHOISTING THE OUTBOARDMOTOR

STORAGE

HOISTHOOKS

ENGINE COVER LATCH

UNLOCK

Select 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.

Unlock and remove the enginecover.

2.

3.

4.

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83

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 sheet plastic as adust cover. A nonporous cover willtrap moisture, promoting rust andcorrosion.

Rest the motor on a cushion ofprotective material.

If it is necessary to store the outboardmotor horizontally as shown, drainthe vapor separator (p. ), and drainthe 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 stand.

8060

04/04/01 16:44:56 31ZY6600_084

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