Owner’s Manual...00X31-ZV1-6600 BF5A BF5A Owner’s Manual 31ZV1660 00X31-ZV1-6600 2eY1500.2011.04 N Printed in China BF5AK2 PANTONE 288 CVC DIC F101 BLACK Includes US and Canadian

00X31-ZV1-6600 BF5A

BF5AOwner’s Manual

31ZV166000X31-ZV1-6600

2eY1500.2011.04Printed in ChinaN

BF5AK2

PANTONE 288 CVC DIC F101 BLACK

Includes US and Canadian Models

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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.

2011 Honda Motor Co., Ltd. All Rights Reserved

11/03/07 16:26:14 31ZV1660_001

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.

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.

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 (see page ).84

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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 . 6................IMPORTANT SAFETY INFORMATION . 6

................................SAFETY LABEL LOCATIONS . 8

..................................CONTROLS AND FEATURES . 11CONTROL AND FEATURE

................................IDENTIFICATION CODES . 11....COMPONENT AND CONTROL LOCATIONS . 12

..............................................................CONTROLS . 14Emergency Stop Switch Clip and Emergency

.......................................................Stop Switch . 14..........................................................Choke Knob . 14..........................................................Throttle Grip . 15

..........................................Throttle Friction Knob . 15.....................................................Gearshift Lever . 15

............................................................Starter Grip . 16.....................................Engine Cover Lock Lever . 16

.............................Transom Angle Adjusting Rod . 16............................................Steering Friction Bolt . 17

...............................................................Tilt Lever . 17.......................................................INSTRUMENTS . 17

............................................................Fuel Gauge . 17

...........................................................INDICATORS . 18............................................Oil Pressure Indicator . 18

.....................................Cooling System Indicator . 18................................................OTHER FEATURES . 18

...........................................................Rev Limiter . 18....................................................................Anode . 19

................................................Portable Fuel Tank . 19....................................Fuel Filler Cap Vent Knob . 19

.................................................Fuel Priming Bulb . 20

..........................................................INSTALLATION . 21.....................................POWER REQUIREMENTS . 21

..................................INSTALLATION POSITION . 21.......................................................ATTACHMENT . 22

.....................TRANSOM ANGLE ADJUSTMENT . 22

................................................BEFORE OPERATION . 23........ARE YOU READY TO GET UNDER WAY? . 23

IS YOUR OUTBOARD MOTOR..................................................READY TO GO? . 23

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4

CONTENTS

................................................................OPERATION . 25....................SAFE OPERATING PRECAUTIONS . 25

.......................................BREAK-IN PROCEDURE . 25.....................TRANSOM ANGLE ADJUSTMENT . 25

.......................................PORTABLE FUEL TANK . 26................................FUEL HOSE CONNECTIONS . 26

.......................................................FUEL PRIMING . 27...............INFREQUENT OR OCCASIONAL USE . 27

......................................STARTING THE ENGINE . 28.....................................EMERGENCY STARTING . 30

.......................................STOPPING THE ENGINE . 32................................Emergency Engine Stopping . 32

.......................................Normal Engine Stopping . 32.....GEARSHIFT AND THROTTLE OPERATION . 33

...............................................................STEERING . 34................................................................CRUISING . 35

........................SHALLOW WATER OPERATION . 36...............MOORING, BEACHING, LAUNCHING . 37

..............SERVICING YOUR OUTBOARD MOTOR . 38...........THE IMPORTANCE OF MAINTENANCE . 38

.....................................MAINTENANCE SAFETY . 39

TOOL KIT AND EMERGENCY STARTER.....................................................................ROPE . 40

...............................MAINTENANCE SCHEDULE . 41ENGINE COVER REMOVAL AND

..................................................INSTALLATION . 43........................................Engine Oil Level Check . 43

................................................Engine Oil Change . 44..............................Engine Oil Recommendations . 45

...................................Gear Case Oil Level Check . 45...........................................Gear Case Oil Change . 46

.................................................Lubrication Points . 48................................................Spark Plug Service . 49

.............................................................REFUELING . 50...............................FUEL RECOMMENDATIONS . 52

...............Fuel Filter Inspection and Replacement . 53.......Portable Fuel Tank and Tank Filter Cleaning . 55

.............................Recoil Starter Rope Inspection . 56..............................................Anode Replacement . 56

...................Propeller and Shear Pin Replacement . 57

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5

CONTENTS

....................................CLEANING AND FLUSHING . 59..........................................Cleaning and Flushing . 59

....................................................................STORAGE . 61........................................................................Fuel . 61

.............................................................Engine Oil . 63...................................STORAGE PRECAUTIONS . 63

...............................REMOVAL FROM STORAGE . 64

........................................................TRANSPORTING . 65WITH OUTBOARD MOTOR INSTALLED

.............................................................ON BOAT . 65WITH OUTBOARD MOTOR REMOVED

.......................................................FROM BOAT . 65

TAKING CARE OF UNEXPECTED..........................................................PROBLEMS . 66

..................................ENGINE WILL NOT START . 66HARD STARTING OR STALLS AFTER

...........................................................STARTING . 68...........................................ENGINE OVERHEATS . 69

..ENGINE WILL NOT DRIVE THE PROPELLER . 70OIL PRESSURE INDICATOR GOES OFF AND

............................ENGINE SPEED IS LIMITED . 71...................SUBMERGED OUTBOARD MOTOR . 72

..TECHNICAL AND CONSUMER INFORMATION . 74...............................TECHNICAL INFORMATION . 74

........................................Serial Number locations . 74Carburetor Modification for High Altitude

...........................................................Operation . 75.................Emission Control System Information . 76

..............................................................Star Label . 78........................................................Specifications . 80

...............................CONSUMER INFORMATION . 81...............................................Honda Publications . 81

..............................Customer Service Information . 81.............................................Warranty Statements . 84

............................Distributor’s Limited Warranty . 84.....................Emission Control System Warranty . 89

..........................................Distributor’s Warranty . 93

...........................................................................INDEX . 96

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6

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.

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.

The Honda BF5A outboard motor isdesigned for use with boats that havea suitable manufacturer’s powerrecommendation. Other uses canresult in injury to the operator ordamage to the outboard motor andother property.

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7

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.

Remove any portable fuel tankfrom the boat for refueling. Keepthe portable fuel tank away fromthe battery or other potential sparksources.

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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US, Puerto Rico, and US Virgin Islands Types

CAUTION

DANGER

KEEP TOTALLY CLOSED WHEN

NOT IN USE. KEEP AWAY FROM

HEAT, SPARKS, AND OPEN FLAME.

SECURE ABOVE DECK IN WELL

VENTILATED AREA. DO NOT USE

FOR LONG TERM FUEL STORAGE.

HARMFUL OR FATAL IF SWALLOWED.

KEEP OUT OF REACH OF CHILDREN.

IF SWALLOWED, DO NOT INDUCE

VOMITING. CALL A PHYSICIAN

IMMEDIATELY.

GASOLINE FLAMMABLE DANGER

GASOLINE FLAMMABLE DANGER

8

SAFETY LABEL LOCATIONS


PORTABLE FUEL TANK

The labels shown here contain important safety information. Please read them carefully. These labels are consideredpermanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized HondaMarine dealer for a replacement.

11/03/07 18:16:03 31ZV1660_009

GASOLINE FLAMMABLE DANGERGAZOLINE INFLAMMABLE DANGEREUX

GASOLINE FLAMMABLE DANGERGAZOLINE INFLAMMABLE DANGEREUXGASOLINA PELIGRO FLAMABLE

CAUTION

DANGER

KEEP TOTALLY CLOSED WHEN

NOT IN USE. KEEP AWAY FROM

HEAT, SPARKS, AND OPEN FLAME.

SECURE ABOVE DECK IN WELL

VENTILATED AREA. DO NOT USE

FOR LONG TERM FUEL STORAGE. HARMFUL OR FATAL IF SWALLOWED.

KEEP OUT OF REACH OF CHILDREN.

IF SWALLOWED, DO NOT INDUCE

VOMITING. CALL A PHYSICIAN

IMMEDIATELY.

9


Canadian Types

READ OWNER’S MANUAL

FUEL CAUTION

PORTABLE FUEL TANK

The labels shown here contain important safety information. Please read them carefully. These labels are consideredpermanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized HondaMarine dealer for a replacement.

11/03/07 16:27:23 31ZV1660_010

Gasoline is harmful or fatalif swallowed. Keep the fueltank out of reach ofchildren.

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.

Gasoline is extremelyflammable and is explosiveunder certain conditions.Refuel in a well-ventilatedarea with the enginestopped.Do not smoke or allowflames or sparks where theengine is refueled or wheregasoline is stored.Do not overfill the fuel tank.After refueling make surethat the fuel filler cap isclosed properly andsecurely.

Be careful not to spill anyfuel while refueling. Spilledfuel or fuel vapor mayignite. If any fuel is spilled,make sure that the area isdry before starting theengine.

10


Canadian Types

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11

CONTROL AND FEATURE IDENTIFICATION CODES

CONTROLS AND FEATURES

Shaft Length

Type

Model

S

L

S: Short ShaftL: Long Shaft

BF5A

BF5A is provided with the following typesaccording to the shaft length.

Shaft Length

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

SASC

LALC

(Example)L A

Destination

S=Short ShaftL=Long Shaft

A=American, C=Canadian

11/03/07 16:27:41 31ZV1660_012

12

COMPONENT AND CONTROL LOCATIONS


ANODE

SPARK PLUG

THROTTLE GRIP

CHOKE KNOB

FUEL HOSECONNECTOR(MALE)

TRANSOM ANGLEADJUSTING ROD

PROPELLER

GEARSHIFT LEVER

THROTTLEFRICTION KNOB

COOLING SYSTEMINDICATOR

WATER INTAKE PORT(each side)

OIL PRESSUREINDICATOR

WASH SCREW(FLUSH SCREW)

STEERINGFRICTION BOLT

EMERGENCYSTOP SWITCH

EMERGENCY STOPSWITCH CLIP

EMERGENCY STOPSWITCH LANYARD

ENGINE COVERLOCK LEVER

OIL FILLER CAP/DIPSTICK

STARTER GRIP

ENGINE OILDRAIN BOLT

EXHAUST PORT

GEAR OIL DRAIN/FILL SCREW

GEAR OILLEVEL SCREW

STERN BRACKET

CLAMP SCREW

TILLERHANDLE

ENGINE COVER

TILT LEVER

ANTIVENTILATIONPLATE

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13

Portable Fuel Tank


VENT KNOB

PRIMING BULB

FUEL HOSE CONNECTOR(FEMALE)

FUEL FILLER CAP

FUEL GAUGE

PORTABLE FUEL TANK

FUEL HOSE(standard equipment)

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14

CONTROLS Choke Knob

Emergency Stop Switch Clipand Emergency Stop Switch



EMERGENCYSTOP SWITCHCLIP

PUSH



CHOKE KNOB

OONN

OOFFFF


The choke knob opens and closes thechoke valve in the carburetor.

The ON position enriches the fuelmixture for starting a cold engine.

The OFF position provides thecorrect fuel mixture for operationafter starting, and for restarting awarm engine.

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 emergency stop switch clip issupplied with the tool kit.

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

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15

Throttle Grip Throttle Friction Knob Gearshift Lever


INDEX MARKTTOO DDEECCRREEAASSEEFFRRIICCTTIIOONN

TTOO IINNCCRREEAASSEEFFRRIICCTTIIOONN

THROTTLE GRIPTHROTTLEFRICTION KNOB

R (reverse) N (neutral) F (forward)

GEARSHIFT LEVER

The gearshift lever is used to select F(forward), N (neutral), or R (reverse)gears.

The throttle grip controls enginespeed.

The engine can be started with thegearshift lever in the N (neutral)position only.

The throttle friction knob adjustsresistance to throttle grip rotation.

Turn the knob clockwise to increasefriction for holding a throttle settingwhile cruising.

Turn the knob counterclockwise todecrease friction for easy throttle griprotation.

If the gearshift lever is in the F(forward) or R (reverse) position, therecoil starter will not operate.

An index mark on the tiller handleshows throttle position and is helpfulfor setting the throttle correctly whenstarting (p. ).28

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16

Engine Cover Lock Lever Transom Angle Adjusting RodStarter Grip


UNLOCK

TRANSOM ANGLE ADJUSTING ROD

ENGINE COVER LOCK LEVER

STARTER GRIP

Direction to pull

The engine cover lock lever fastensthe engine cover to the outboardmotor.

The transom angle adjusting rodadjusts the transom angle of theoutboard motor when fully lowered.

Proper adjustment prevents theoutboard motor from being adjustedtoo low (p. ).

Pulling the starter grip operates therecoil starter to crank the engine forstarting.

The engine will start only when thegearshift lever (p. ) is in the N(neutral) position, and the emergencystop switch clip is in the emergencystop switch.

3528

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17

INSTRUMENTSSteering Friction Bolt Tilt Lever

Fuel Gauge


STEERING FRICTION BOLT

TTOO DDEECCRREEAASSEEFFRRIICCTTIIOONN


ENGINE COVER GRIP

TILT LEVER

FUEL GAUGE

Less friction allows the outboardmotor to turn more easily. Morefriction helps to hold a steady coursewhile cruising or to prevent theoutboard motor from swinging whiletrailering the boat.

The tilt lever enables the outboardmotor to be raised for shallow wateroperation, beaching, launching, ormooring.

The steering friction bolt adjustssteering resistance.

To tilt, raise the outboard motor bypulling on the cover grip until the tiltmechanism engages at 18°, 38°, or58° (p. and ).

A fuel gauge is built into the fueltank connector of the portable fueltank.

36 37

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18

INDICATORS

Oil Pressure Indicator

Cooling System Indicator OTHER FEATURES

Rev Limiter


COOLING SYSTEM INDICATOR

OIL PRESSURE INDICATOR

TAKINGCARE OF UNEXPECTEDPROBLEMS

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, that indicates acooling system problem, such asclogged water intakes, which willcause engine overheating.Low oil pressure indicates that the

engine 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, the oilpressure indicator will go off, and theengine protection system will limitengine speed. Refer to

, p. .

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 is tiltedexcessively, or when propellerventilation occurs during a sharp turn.

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

Improper propeller selection mayalso cause the rev limiter to activate.

Check to see if the correct propelleris installed.71

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19

Portable Fuel TankAnode Fuel Filler Cap Vent Knob


ANODE

CCLLOOSSEE

OOPPEENN

VENT KNOB

FUEL FILLER CAPFUEL HOSE(standard equipment)

The anode is made of a sacrificialmaterial that helps to protect theoutboard motor from corrosion.

There is an anode on theantiventilation plate.

The portable fuel tank has a capacityof US gal ( L) and has a fuelgauge built into the fuel tankconnector.

The fuel filler cap is provided with avent knob to seal the portable fueltank for carrying it to and from theboat. Open the vent by turning thevent knob counterclockwise all theway before starting the engine.

3.2 12

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20

Fuel Priming Bulb


PRIMING BULB

INLET END(tank side)

OUTLET END(outboard motor side)

UP

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.

11/03/07 16:29:31 31ZV1660_021

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22.1 in (561 mm)17.1 in (434 mm)

21

POWER REQUIREMENTS

INSTALLATION POSITION

INSTALLATION

CENTER LINE

ANTIVENTILATIONPLATE

IDLE PORT

0 2 in(0 50 mm)

OOUUTTBBOOAARRDDMMOOTTOORRTTRRAANNSSOOMMHHEEIIGGHHTT

BBOOAATTTTRRAANNSSOOMMHHEEIIGGHHTT

Correct and secure installation isessential for safe boating and goodperformance. Follow the installationinstructions provided in this manual.

Before installation, check to be surethat the outboard motor does notexceed the recommended maximumhorsepower for the boat on which itis to be installed. Refer to the boat’scertification plate for recommendedmaximum horsepower. If thecertification plate information is notavailable, contact the boat dealer ormanufacturer.

For most applications, the outboardmotor should have a horsepowerrating which provides 80% of themaximum recommended horsepowerfor the boat.

Install the outboard motor on thecenter of the boat transom.

The antiventilation plate of theoutboard motor should be 0 2 in(0 50 mm) below the bottom ofthe boat.The correct dimensions differaccording to the type of boat and theconfiguration of the bottom of theboat. Follow the manufacturer’srecommended installation height.

When the outboard motor is installedextremely low, the idle port may beimmersed and the engine maybecome hard to start or may runpoorly. Check that the idle port ishigh enough from the water levelwhen the engine is stopped with theboat fully loaded.

Type:

S:L:

Outboard MotorTransom Height

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22

TRANSOM ANGLEADJUSTMENT

ATTACHMENT

INSTALLATION

SAFETY ROPE CLAMP SCREWS

STERNBRACKET

WATER LEVEL

FULLY TRIM/TILT DOWN

5.9 in(150 mm) or more

IDLE PORTIf the outboard motor is installed toolow, the boat will squat and be hardto plane, and the outboard motor willspray water that may enter the boat. Itwill tend to porpoise, and high-speedstability will be reduced.

If the outboard motor is installed toohigh, that will cause propellerventilation.

Optimum installation height varieswith boat type and bottom shape.Contact the boat manufacturer forany special recommendations that areunique to a specific model of boat.

If the transom needs to be modifiedto accommodate the outboard motor,contact the boat manufacturer andfollow their recommendations forcorrective action.

Adverse effect to the engine canoccur if the installation position ofthe outboard motor is too low. Trim/tilt down the outboard motor with theboat fully loaded and stop the engine.Check that the idle port is 5.9 in (150mm) or more above the water level.

Use the transom angle adjustment rod(p. ) to adjust the angle of theoutboard motor so the propeller isperpendicular to the surface of thewater.

Attach a rope from the boat to thehole in the stern bracket. This willhelp to prevent accidental loss of theoutboard motor.

Attach the stern bracket to the boattransom by tightening the clampscrews.

25

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

23

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 emergency stopswitch clip is removed from theemergency stop switch.

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24

Safety Inspection

Maintenance Inspection

BEFORE OPERATION

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

Make sure the tool kit andemergency starter rope areonboard (p. ). Replace anymissing items.

Check that all fasteners are inplace and securely tightened.

Check the emergency stop switchfor proper operation (p. , ).Start the engine (p. ). Make surethe engine stops by pulling theemergency stop switch clip fromthe emergency stop switch (p. ).

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

Check to be sure the propeller andshear pin are undamaged (p. ).

Check that the anode is securelyattached to the antiventilation plate(p. ) and is not excessivelyworn. The anode helps to protectthe outboard motor from corrosion.

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

If you are using the portable fueltank, make sure it is in goodcondition and properly secured inthe boat (p. ).

Check that the fuel hose isundamaged and properlyconnected (p. ).

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.

43

14 2727

32

57

56

40

50

26

26

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25

SAFE OPERATINGPRECAUTIONS

BREAK-IN PROCEDURE

TRANSOM ANGLEADJUSTMENT

OPERATION


TO CHANGE

TO LOCK

UNLOCKEDPOSITION

LOCKED POSITION

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

To adjust, first tilt the outboardmotor so it is not resting on the rod.

Push the rod in and turn the end ofthe rod up, so the latch will fallinto line with the rod.

Remove the rod and reinsert it inthe desired position.

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.

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

For the first 10 hours, run theoutboard motor at low speed, andavoid full-throttle operation.

The transom angle adjusting rod isused to adjust the angle of theoutboard motor in the normaloperating position (p. ).

Push the rod in and turn the end ofthe rod down, so the latch will fallto the locked position. Thenrelease the rod.

6

1.

2.

3.

4.

35

11/03/07 16:30:38 31ZV1660_026

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.

26

PORTABLE FUEL TANK FUEL HOSE CONNECTIONS

OPERATION

(OUTBOARD MOTOR SIDE)

FUEL HOSE CONNECTOR

FUEL HOSE CONNECTOR

(FUEL TANK SIDE)FUEL HOSE(standard equipment)

Secure the portable fuel tank in theboat so that it won’t move aroundand become damaged. Turn the portable fuel tank vent knob

counterclockwise to the openposition.

To ensure that the outboard motorwill be able to draw fuel from thetank, place the tank within 6 feet (2m) of the outboard motor and notmore than 3 feet (1 m) below the fuelconnector on the outboard motor.

Place the portable fuel tank in a well-ventilated location, away from directsunlight, to reduce the possibility of agasoline vapor explosion.

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27

FUEL PRIMING INFREQUENT OROCCASIONAL USE

OPERATION

PRIMING BULB

UP OUTLET END(outboard motor side)

INLET END (tank side)

Connect the fuel hose to the tank andthe outboard motor, as shown. Besure both connectors snap securelyinto place. Always disconnect thefuel hose when storing ortransporting the outboard motor.

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.

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

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.

If you are using a portable fuel tank,turn the portable fuel tank vent knobcounterclockwise to the openposition.

61

11/03/07 16:30:59 31ZV1660_028

28

STARTING THE ENGINE

OPERATION

EMERGENCY STOP SWITCH CLIP



N (neutral)

GEARSHIFT LEVER

The engine will not start or rununless 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.

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

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).

Check the position of the gearshiftlever. It must be in the N (neutral)position for starting.

The engine will not start if thegearshift lever is in the F (forward)or R (reverse) position.

1.

2.

11/03/07 16:31:11 31ZV1660_029

29

OPERATION

Direction to pull

STARTER GRIP

OOFFFFOONN

THROTTLE GRIP

MARK

CHOKE KNOB

TAKING CARE OFUNEXPECTED PROBLEMS

If the choke knob was pulled tothe ON position to start the engine,gradually push it to the OFFposition as the engine warms up.

Also, as the engine warms up, thethrottle grip can be turned to theSLOW position without stalling.

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

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

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

onp. and .

To start a cold engine, pull thechoke knob to the ON position. Torestart a warm engine, leave thechoke knob in the OFF position.

Pull the starter grip lightly untilyou feel resistance, then pullbriskly in the direction of thearrow as shown above.

Return the starter grip gently.

Align the START position withthe mark for starting the engine.

5.

6.

7.

69

3.

4.

18

18

71

11/03/07 16:31:24 31ZV1660_030

－

30

EMERGENCY STARTING

OPERATION

EMERGENCY STARTER ROPE

6 mm CAP NUTS

FLYWHEEL COVER

6 mm FLANGEBOLTS

UNLOCK


Pull the emergency starter ropeslowly until resistance is felt, thenpull briskly.

Keep away from moving partswhile pulling the rope.

If the recoil starter is inoperative, youcan start the engine manually usingthe emergency starter rope suppliedwith the tool kit.

Unlock and remove the enginecover.

Remove the two 6 mm cap nutsand 6 mm flange bolts, andremove the flywheel cover.

Set the controls the same as fornormal starting (see pages

). Use the choke control ifneeded.

Set the knotted end of theemergency starter rope in the notchin the flywheel. Wind the ropeclockwise around the flywheel.

2.

3.

4.

5.

1.27

28

11/03/07 16:31:39 31ZV1660_031

Exposed moving parts cancause injury.

Do not operate theoutboard motor withoutthe engine cover.

Use extreme care wheninstalling the enginecover.

31

OPERATION

TAKING CARE OFUNEXPECTED PROBLEMS,

If it was necessary to remove theemergency stop switch lanyardfrom you to perform theemergency starting procedure, besure the lanyard is attachedsecurely to operator beforeoperating the outboard motor.

Have your closest authorizedHonda Marine dealer check yoursystem and correct the problem, soyou can use the recoil starter.

If necessary, rewind the rope andpull again. If the engine does notstart after several attempts, refer to

p. .

If the choke control was used tostart the engine, return the controlto the normal operating position asthe engine warms up.

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

).

Install the engine cover (p. ),and lock it in place by locking theengine cover lock lever.

6.

7.

8.

9.

18

43

18

66

11/03/07 16:31:48 31ZV1660_032

32

STOPPING THE ENGINE

Emergency Engine Stopping

Normal Engine Stopping

OPERATION

EMERGENCY STOP SWITCH

GEARSHIFT LEVER

PUSH

EMERGENCY STOP SWITCH

EMERGENCYSTOP SWITCHLANYARD

PULL


THROTTLE GRIP

N (neutral)

Move the throttle grip to theslowest speed and gearshift leverto the N (neutral) position.

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

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

Press the emergency stop switchuntil the engine stops.

We suggest that you stop the enginethis way occasionally to verify thatthe engine and emergency stopswitch are operating properly.

When the boat is not in use,remove and store the ignitionswitch key and the emergency stopswitch clip and lanyard. If you areusing a portable fuel tank,disconnect the fuel hose if youwill be storing or transporting theoutboard motor.

1.

2.

3.

11/03/07 16:32:04 31ZV1660_033

33

GEARSHIFTING ANDTHROTTLE OPERATION

OPERATION

GEARSHIFT LEVER



THROTTLE GRIP

R (reverse) N (neutral) F (forward)

THROTTLEFRICTION KNOB

To shift gears, turn the throttle grip tothe SLOW position; then move thegearshift lever to select the F(forward), N (neutral), or R (reverse)gears.

Turn the knob counterclockwise todecrease friction for easy griprotation.

Turn the knob clockwise to increasethrottle grip friction for holding aconstant speed.

Use the throttle friction knob to helphold a constant throttle setting whilecruising.

The engine can be started with thegearshift lever in the N (neutral)position only.

The throttle grip can be turned to theFAST position only when thegearshift lever is in the F (forward)position.

11/03/07 16:32:19 31ZV1660_034

34

STEERING

OPERATION

STEERING FRICTION BOLT



Steer by moving the tiller handleopposite the direction you want theboat to turn.

Use the steering friction bolt to helphold a steady course while cruising.

Turn the bolt clockwise to increasesteering friction for holding a steadycourse.

Turn the bolt counterclockwise todecrease friction for easy turning.

11/03/07 16:32:33 31ZV1660_035

35

CRUISING

Engine Speed

Transom Angle

OPERATION

CORRECTGIVES MAXIMUM PERFORMANCE

Transom Angle (Cruising)

ROUGHWAVES

OUTBOARDMOTOR ANGLEADJUSTED TOOLOW

OUTBOARDMOTOR ANGLEADJUSTED TOOHIGH

OUTBOARD MOTORANGLE ADJUSTEDCORRECTLY

Excessive transom angle duringoperation can cause propellerventilation, overheating, and waterpump damage. This type of damageis not covered by the

(p. ).

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

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

Install the outboard motor at the besttransom angle for stable cruising andmaximum power.

Transom angle too large: Causes boatto ‘‘squat.’’

It is necessary to adjust the transomangle of the outboard motor tocompensate for changes in boat load,weight distribution, water conditions,or propeller selection.

Transom angle too small: Causesboat to ‘‘bow steer.’’

Under normal running conditions, theboat will perform best when theantiventilation plate is level with thewater surface.

When cruising into a high wind,adjust the outboard motor downslightly to level the boat and improvestability. With a tail wind, adjust theoutboard motor up slightly (p. ).

Distributor’sLimited Warranty

33

25

84

11/03/07 16:32:46 31ZV1660_036

36

SHALLOW WATEROPERATION

OPERATION

18°

ENGINE COVER GRIP

Do not use the tiller handle as alever to raise the outboard motor.Applying excessive f orce to the tillerhandle can damage it.

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

(p. ).

When operating in shallow water, tiltthe outboard motor, using the tiltlever, so the propeller and gear casewon’t hit the bottom.

To tilt the outboard motor, raise theoutboard motor to the 30° position bypulling on the engine cover grip.

While the outboard motor is tilted,proceed at a low speed, and do notoperate the outboard motor in reverse.The outboard motor will risesuddenly if operated in reverse.

Distributor’sLimited Warranty

Monitor water flow from the coolingsystem indicator (p. ) to be surethe outboard motor is not tilted sohigh that the water intakes are out ofthe water.

18

84

11/03/07 16:32:55 31ZV1660_037

37

MOORING, BEACHING,LAUNCHING

OPERATION

38°, 58° (when mooring)

ENGINE COVER GRIPTILT LEVER

To return the outboard motor to thenormal operating position, raise theoutboard slightly by pulling on theengine cover grip, then pull the tiltlever to release the outboard, andthen slowly lower the outboard motor.

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

To raise the outboard motor out ofthe water while the boat is moored, orfor maximum clearance whenbeaching or launching, tilt theoutboard motor to the 38° or 58°position.

Raise and lower the outboard motoras described on p. .

Stop the engine before tilting theoutboard motor. The 38° or 58°position is not an operating position.

Stop the engine and disconnect thefuel hose from the outboard motorbefore tilting the outboard motor.

36

11/03/07 16:33:08 31ZV1660_038

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.

38

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.

11/03/07 16:33:16 31ZV1660_039

－

－

－

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

Always follow theprocedures andprecautions in the Owner’sManual.

39

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.

11/03/07 16:33:28 31ZV1660_040

×

40

TOOL KIT ANDEMERGENCY STARTERROPE


10 12 mm WRENCH PLIERS

TOOL BAG

FLAT SCREWDRIVER

PHILIPS SCREWDRIVER

8 mm WRENCHSPARE SPARK PLUG

COTTER PINS

SHEAR PINS

WATER MOUTH NUT

SPARK PLUGWRENCH SPARE EMERGENCY

STOP SWITCH CLIP

WATER MOUTHSEAT

WATER HOSECONNECTOR

EMERGENCY STARTER ROPE

FLUSH KITThe following tools are supplied withthe outboard motor for simplemaintenance procedures andemergency repairs. An emergencystarter rope is also supplied. Keepthese items on the boat so that theywill always be available if you needthem.If your tool kit needs replacement, itis not available as a kit and each itemmust be ordered individually.

11/03/07 16:33:38 31ZV1660_041

○

○○

○○

○

○○

○○○○

○

○○

○

41

MAINTENANCE SCHEDULE


Distributor’s Limited Warranty

ITEM

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

REGULAR SERVICE PERIOD

After use

Engine oil

Gear case oilStarter ropeCarburetor linkageValve clearanceSpark plugPropeller and cotter pinAnodeIdling speedLubrication

Each useFirst month

or20 hrs.

(2)

(2)(1)

Every 6 monthsor

100 hrs.

(2)

(2)(1)

Every yearor

200 hrs.

(2)

Check levelChangeChangeCheckCheck-adjustCheck-adjustCheck-adjust/ReplaceCheckCheckCheck-adjustGrease

(3)

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 .

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)

11/03/07 16:33:50 31ZV1660_042

○

○

○

○

○○

○

○

○

○

○

42


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

REGULAR SERVICE PERIODFirst month

or20 hrs.

(2)

After use

(4)

Every 6 monthsor

100 hrs.

(2)

ITEM

Every yearor

200 hrs.

(2)

(2)

(2)

Fuel tank and tank filterThermostatFuel filter

Fuel line

Bolts and nutsCrankcase breather tubeCooling water passagesWater pumpEmergency stop switch

CleanCheckCheckReplaceCheckReplaceCheck-tightnessCheckCleanCheckCheck

Each use

(5)Every 2 years (If necessary) (2) (6)

(3)

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.

When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

Check the fuel line for leaks, cracks or damage. If it is leaking, cracked or damaged, take it to your servicing dealer for replacementbefore using your outboard.

Check the fuel line for leaks, cracks, or damage. Replace the fuel line if there are signs of leaks, cracks or damage.

(1)

(2)

(3)

(4)

(5)

(6)

11/03/07 16:34:05 31ZV1660_043

43

ENGINE COVER REMOVALAND INSTALLATION

Engine Oil Level Check



UNLOCKOIL FILLER CAP/DIPSTICK

OIL FILLER CAP/DIPSTICK

UPPERLIMIT

LOWERLIMIT

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.

To install the engine cover, place thecover on the outboard motor, thenturn the lock lever to the lockedposition.

The engine cover lock lever fastensthe engine cover to the outboardmotor.

To remove the engine cover, turn thelock lever to the unlocked position,then lift the engine cover off theoutboard motor.

Unlock and remove the enginecover.

Remove the oil filler cap/dipstickand wipe it clean.

Insert the dipstick withoutscrewing it in, then remove it andcheck the oil level shown on thedipstick.

If the oil level is low, add oil toreach the upper limit mark shownon the dipstick. Use the oilrecommended on p. .

Install the oil filler cap/dipstickand tighten it securely.

Install and lock the engine cover.

1.

2.

3.

4.

5.

6.

45

11/03/07 16:34:19 31ZV1660_044

44

Engine Oil Change


DRAIN BOLT

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 discard it in a trash bin, dumpit on the ground, or pour it down adrain.Unlock and remove the engine

cover (p. ).

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

Drain the used oil into a suitablecontainer while the engine is warm.Warm oil drains quickly andcompletely.

Remove the oil filler cap, andremove the engine oil drain plugand washer.

Allow the used oil to draincompletely, then reinstall theengine oil drain plug and a newwasher, and tighten it securely.

With the outboard motor in avertical position, fill to the upperlimit mark on the dipstick (p. )with the recommended oil.

Install the oil filler cap and tightenit securely.


1.

2.

3.

4.

5.

6.

43

43

11/03/07 16:34:31 31ZV1660_045

AMBIENT TEMPERATURE

4.8 lbf·ft (6.5 N·m , 0.66 kgf·m)

45

Engine Oil Recommendations Gear Case Oil Level Check


GEAR OILLEVEL SCREW

GEAR OILDRAIN/FILLSCREW

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

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

Remove the oil level screw and seewhether oil flows from the oil levelhole.

If oil flows from the oil level hole,the oil level is OK. Reinstall thescrew and tighten it securely.

OIL LEVEL SCREW TORQUE:

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.

TM

11/03/07 16:34:43 31ZV1660_046

46

Gear Case Oil Change


If no oil flows from the oil level hole,add the recommended oil (p. )following the procedure described inGear Case Oil Change.

Change the gear case oil with theengine stopped and the outboardmotor in the vertical position.

Allow the used oil to draincompletely, then install an oilpump adapter in the oil drain hole.

If water or contaminated (milky-colored) oil flows out the drainhole when the screw is removed,have the outboard motor checkedby an authorized Honda Marinedealer.

Place a suitable container belowthe oil drain hole to catch the usedoil, then remove the oil level screwand oil drain/fill screw.

1.

2.47

11/03/07 16:34:50 31ZV1660_047

0.11 US qt (0.10 L)

4.8 lbf·ft (6.5 N·m, 0.66 kgf·m)

4.8 lbf·ft (6.5 N·m, 0.66 kgf·m)

47


GEAR OIL BOTTLE

GEAR OIL CAPACITY:

OIL LEVEL SCREW TORQUE:

OIL DRAIN SCREW TORQUE:

Add oil through the oil drain holeuntil it flows out the oil level hole,and then install the oil level screw.Remove the pump adapter andinstall the oil drain/fill screw.

Avoid losing more than 1 fl oz (30cm ) while reinstalling the drain/fill screw.

Outboard motor SAE 90 hypoidgear oil API Service category(GL-4)

3.

3

11/03/07 16:34:59 31ZV1660_048

48

Lubrication Points


PROPELLER SHAFT

CLAMP SCREWS

SWIVEL CASE

THROTTLECABLE ANDPIVOTSHIFT SHAFTAND PIVOT

TILLERHANDLE PIVOT

TILT RELEASE LEVERAND REVERSE LOCKROD


ENGINE COVERLOCK LEVER

To prevent corrosion, apply anticorrosion oil to pivotsurf aces where grease cannot penetrate.

Apply Honda Marine waterproof grease to the partsshown below:Lubrication interval:

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

20 operating hours or one month after the date ofpurchase or the initial use, then every 100 hours or 6months (refer to the maintenance schedule on page ).41

11/03/07 16:35:21 31ZV1660_049

－－

－－

W16EPR-U (DENSO)BPR5ES (NGK)

0.028 0.031 in (0.7 0.8 mm)

49

Spark Plug Service


SPARK PLUG WRENCH

SEALING WASHER

SIDE ELECTRODE

0.028 0.031 in(0.7 0.8 mm)

New plug Plug needingreplacement

INSULATOR

Incorrect spark plug can causeengine damage.

RECOMMENDED SPARK PLUGS:

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

The gap should be:

Remove the spark plug with aspark plug wrench and screwdriversupplied in the tool kit.

Disconnect the spark plug capfrom the spark plug.

Unlock and remove the enginecover (p. ).

Inspect the spark plug. Replace itif the electrode is worn, or if theinsulator is cracked or chipped.

1.

2.

3.

4. 5.

43

11/03/07 16:35:35 31ZV1660_050

－

3.2 US gal (12 L)

50

REFUELING

Portable Fuel Tank


OOPPEENN

FUEL GAUGE

VENT KNOB

FUEL FILLER CAP

PRESSURE RELIEF TAB

A loose spark plug can overheatand damage the engine.Overtightening the spark plug candamage the threads in the cylinderhead.

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

If reinstalling the used spark plug,tighten 1/8 1/4 turn after thespark plug seats.

If installing new spark plug,tighten 1/2 turn after the sparkplug seats.

Attach the spark plug cap.


Install the spark plug carefully, byhand, to avoid cross-threading.

Turn the vent knobcounterclockwise all the way toopen the vent.

Turn the fuel filler capcounterclockwise so that it touchesthe pressure relief tab.

If you do not anticipate cyclingthrough at least one complete tank offuel within a 30 day period, werecommend adding Honda MarineFuel Stabilizer each time you refuel.

Remove the fuel tank from the boatfor refueling.

FUEL TANK CAPACITY:

Check the fuel gauge and refill thetank when necessary.

7.

8.

9.

6. 1.

2.

11/03/17 14:39:59 31ZV1660_051



Wipe up spillsimmediately.

Handle fuel onlyoutdoors.

Stop the engine and keepheat, sparks, and flameaway.

51


PRESSURE RELIEF TAB

FUEL FILLER CAP

PRESS

SAFE FILL LEVEL

FUEL FILLER CAPVENT KNOB

CCLLOOSSEE

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.

Press down the pressure relief tab,and then turn the fuel filler cap 1/4counterclockwise. Release thepressure relief tab. Wait to relievepressure.

The fuel filler cap will lock again.Press down the pressure relief tab,and turn counterclockwise toremove the fuel filler cap.

After refueling, install the cap andtighten it until you hear it click. Closethe vent by turning the vent knobclockwise all the way, and return thefuel tank to the boat.

Refuel in a well-ventilated area. Fillthe tank to the SAFE FILL LEVELline.

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.

3.

4.

11/03/17 10:53:28 31ZV1660_052

52

FUEL RECOMMENDATIONS


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

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.

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.

61

11/03/07 16:36:09 31ZV1660_053




53

Fuel Filter Inspection andReplacement


UNLOCK


The fuel filter is located under theengine cover, on the right side of theengine.Water or sediment accumulation inthe filter can cause loss of power orhard starting. To prevent enginemalfunction, inspect the filter andreplace when necessary.

Unlock and remove the enginecover for access to the fuel pumpfilter.

Inspect the filter for water and/orsediment accumulation.

If the filter is OK, reinstall it. Ifwater and/or sediment are present,replace the filter as described inthe following steps. Alwaysreplace the filter at the scheduledreplacement interval (p. ).

Disconnect the fuel hose connectorfrom the outboard motor, andplace commercially available hoseclips on the fuel hoses on each sideof the filter to prevent fuel leakagewhen the fuel hoses aredisconnected.

1.

2.

3.

42

11/03/07 16:36:24 31ZV1660_054

54


HOSE CLAMPS

FUEL FILTER

FUEL HOSE

FUEL HOSE

ARROW(Fuel Flow Direction)

FUEL FILTER

HOSE CLAMPS

Remove the fuel hoses from theused filter, and discard the filter.

To ease hose removal, release thehose clamps by squeezing theclamp ends together with plierswhile pulling off the hoses. Connect the fuel hoses to the fuel

filter securely with the hoseclamps. Remove the fuel hoseclips used to close the fuel hoses.

Install the new filter on the fuelhoses, with the fuel flow arrowpointing toward the fuel pump asshown. Fuel flow will be impededif the filter is installed backward.


4. 5.

6.

Securely connect the fuel hoseconnector to the outboard motor(refer to page ).

Prime the engine using the primingbulb (p. ). Check for fuel 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.

7.

8.

9.

26

27

11/03/07 16:36:39 31ZV1660_055




55

Portable Fuel Tank and TankFilter Cleaning


FUEL HOSE(standard equipment)

Fuel Tank

Empty the portable fuel tank into anapproved gasoline container. Use afunnel to avoid spilling fuel. Rinsethe fuel tank with nonflammablesolvent to remove any accumulatedsediment.

11/03/07 16:36:48 31ZV1660_056

56

Anode ReplacementRecoil Starter Rope Inspection


ANODE

BOLT

RECOIL STARTER ROPE

5 mm SCREWS (4)

FUEL TANK FILTER JOINT(Fuel Hose Connector)

CONNECTORGASKET

FUEL TANKFILTER

Fuel Tank Filter

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.

Replace the anode when it has beenreduced to about half its original size,or if it is crumbling.

The anode is located on theantiventilation plate. It is made of asacrificial material that helps toprotect the outboard motor fromcorrosion.

Inspect the recoil starter rope, andreplace it if it becomes frayed.

Always keep the emergency starterrope on the boat in case the recoilstarter rope fails.

Reinstall the filter and hoseconnector in the fuel tank. Tightenthe four 5 mm screws securely.

Clean the filter in nonflammablesolvent. Inspect the fuel tank filterand the connector gasket. Replacethem if damaged.

Remove the four 5 mm screwsusing a flat screwdriver, thenremove the fuel hose connectorand fuel tank filter from the tank.

1.

2.

3.

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57

Propeller and Shear PinReplacement


PROPELLER CAP

SHEAR PIN

COTTER PIN

Removal Remove the cotter pin, thepropeller cap, and the propeller.

Remove the broken shear pin andreplace it with a new one.

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.

A shear pin is used to protect thepropeller and drive mechanism fromdamage when the propeller strikes anobstruction.

Before replacing the propeller or theshear pin, remove the emergencystop switch clip from the emergencystop switch to prevent any possibilityof the engine being started while youare working with the propeller.

1.

2.

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58


COTTER PIN

Installation Spare shear pins and cotter pins areprovided in the engine compartment(p. ).

Install the shear pin and thepropeller, then install the propellercap finger tight.

Use a Honda Genuine stainlesssteel cotter pin or equivalent cotterpin and bend the pin ends asshown.

Be sure to replace the cotter pinwith a new one.

1.

2.

40

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59

Cleaning and Flushing

CLEANING AND FLUSHING

WATER HOSE

WATER HOSE CONNECTOR

Cleaning

Flushing With the HondaWater Hose Connector

After each use in saltwater or dirtywater, thoroughly clean and flush theoutboard motor with fresh water.

Wash the outside of the outboardmotor with clean, fresh water toremove mud, salt, seaweed, etc.

Disengage the emergency stop switchclip from the emergency stop switch,and pull the recoil starter rope severaltimes to expel any water remaining inthe water pump.

Tilt up the outboard motor andmove the tilt lever to the TILTposition.

Reinstall the flush screw and thepropeller (p. ).

After flushing, stop the engine,and disconnect the fuel hose fromthe outboard motor. Remove thehose connector, and leave theoutboard motor in the runningposition for one minute to drainthe water from inside the engine.

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

Tilt down the outboard motor.

Remove the flush screw from theWASH screw hole and install thewater hose connector.

Attach a hose from a fresh waterfaucet to the water hose connectorof the flush kit.

Remove the propeller (P. ).

Turn on the fresh water supply tohose.

Start the engine and run in N(neutral) for 10 minutes.

1.

2.

3.

4.

5.

6.

7.

8.

9.

58

57

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60

CLEANING AND FLUSHING

ANTIVENTILATION PLATE

Flushing Without the HondaWater Hose Connector

Running the engine without goodwater circulation can causeoverheating and water pumpdamage.


It is necessary to run the engineduring the flushing procedure. Forsafety, remove the propeller from theoutboard motor (p. ).

Damage caused by running theoutboard motor without sufficientcooling water is not covered by the

(p. ).

Start the engine and run in the N(neutral) position at low speed forat least 10 minutes.

Tilt down the outboard motor.

Place a container under theoutboard motor, and fill it withclean, fresh water. The water levelmust be at least 2 inches (5 cm)above the antiventilation plate.

After flushing, stop the engine,and disconnect the fuel hose fromthe outboard motor and leave theoutboard motor in the runningposition for one minute to drainthe water from inside the engine.

Tilt up the outboard motor andmove the tilt lever to the TILTposition.

Reinstall the propeller (p. ).

1.

2.

3.

4.

5.

6.

57

84

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61

Fuel

STORAGE

Adding a Fuel Stabilizer

Depending on the region where youoperate your outboard, f uelf ormulations may deteriorate andoxidize rapidly. Fuel deteriorationand oxidation can occur in as littleas 15 days and may cause damage tothe carburetor and f uel system.Please check with your servicingdealer f or local storagerecommendations.


Gasoline will oxidize and deterioratein storage. Deteriorated gasoline willcause hard starting, and it leaves gumdeposits that clog the fuel system. Ifthe gasoline in your fuel tank andcarburetor deteriorates during storage,you may need to have the carburetorand other fuel system componentsserviced or replaced.

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 carburetor.

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

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.

The length of time that gasoline canbe left in your fuel tank andcarburetor 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 in less than 15days, if the gasoline was not freshwhen you filled the fuel tank.

Add Honda Marine fuel stabilizerfollowing the instructions on thelabel.

Turn the engine OFF.

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

2.

1.

3.

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62

STORAGE

DRAINSCREW

DRAINTUBE

AIR GUIDECARBURETORDRAIN PORT

Draining the Fuel System After the fuel has drained from thecarburetor, tighten the drain screwsecurely.

With the outboard motor in avertical position, place anapproved gasoline container belowthe fuel drain outlet, and use afunnel to avoid spilling fuel.Loosen the drain screw to drainfuel from the carburetor.

Reconnect the drain tube to the airguide.Disconnect the fuel hose from the

outboard motor.Disconnect the drain tube from theair guide, then connect it to thecarburetor drain port as shown.

You can avoid fuel deteriorationproblems by draining the fuel tankand carburetor.

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 HondaMarine fuel stabilizer followingthe directions on the container.Close the fuel cap vent.

If using the portable fuel tank,close the fuel filler cap vent knob.Store the portable fuel tank in acool dry place out of directsunlight.

4.3.

2.

1.5.

6.

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63

Engine Oil STORAGE PRECAUTIONS

STORAGE

CARRYING HANDLELif ting the outboard motor by theengine cover, or using the installedoutboard motor as a handle or leverto move the boat, can damage theoutboard motor.

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

If your portable fuel tank containsgasoline, store it away from anyappliance that operates with a flame,such as a furnace, water heater, orclothes dryer. Also avoid any areawith a spark-producing electric motor,or where power tools are operated.

Change the engine oil (p. ).

To carry the outboard motor, hold itby the carrying handle, or hold by thecarrying handle and the lug beneaththe engine cover lock lever, as shown.

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

Pour 1 2 teaspoons (5 10 cm )of clean engine oil into thecylinder.

Reinstall the spark plug (p. ).

Pull the starter grip several timesto distribute the oil in the cylinder.

1.

2.

3.

4.

5.

44

49

50

3

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64

REMOVAL FROM STORAGE

STORAGE

CASE PROTECTORS BEFOREOPERATION

Any other horizontal storage positionmay cause damage to the outboardmotor or oil leakage.

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

Check your outboard motor asdescribed in the

chapter of this manual.

If storing horizontally, be sure to foldthe tiller handle, and rest theoutboard motor on its case protectors.Be sure all water has drained fromthe outboard motor before placing iton its side, so no residual water canenter the engine exhaust port.

Store the outboard motor eithervertically or horizontally with thetiller handle side up.

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

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65

WITH OUTBOARD MOTORINSTALLED ON BOAT

WITH OUTBOARD MOTORREMOVED FROM BOAT

TRANSPORTING

CARRYING HANDLE

OUTBOARD MOTOR SUPPORT BAR(commercially available)

Lif ting the outboard motor by theengine cover, or using theinstalled outboard motor as ahandle or lever to move the boat,can damage the outboard motor.

Remove the outboard motor from theboat and secure the outboard motorin either the vertical or horizontalposition shown on p. .

To carry, hold the outboard motor bythe carrying handle, or hold by thecarrying handle and the lug beneaththe engine cover lock latch, as shown.When trailering a boat with the

outboard motor attached, alwaysdisconnect the fuel line from theportable fuel tank and tighten thesteering friction bolt securely (p. ).

The preferred method is to leave theengine in the normal running position,but if there is insufficient roadclearance, you can tilt the outboardmotor using a commercially availableoutboard motor support bar availablethrough your dealer. Refer to themanufacturer’s instructions for usingan outboard motor support bar.

3464

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66

TAKING CARE OF UNEXPECTED PROBLEMS

Check emergency stop switchclip.

Check control positions.

Clip not inserted in emergencystop switch.

Insert clip in emergency stopswitch.

Shift to neutral (p. ).

ENGINE WILL NOT START Possible Cause Correction

Gearshift lever not in neutralposition.

Choke OFF. Pull choke knob to ON position,unless engine is warm (p. ).

Throttle grip not in STARTposition.

Turn throttle grip to STARTposition (p. ).

1.

2. 28

28

28

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CorrectionPossible CauseENGINE WILL NOT START(continued)

Check fuel. Out of fuel.

Fuel hose not primed.

Carburetor malfunction, fuel pumpfailure, ignition malfunction, stuckvalves, etc.

Refuel (p. ).

Squeeze priming bulb (p. ).

Replace or repair faultycomponents as necessary.

Fuel vent closed (portable fueltank).

Spark plug faulty, fouled, orimproperly gapped.

Spark plug wet with fuel (floodedengine).

Dry and reinstall spark plug. Startengine with choke and throttle open.

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

Gap or replace spark plug (p. ).Remove and inspect spark plug.

Drain fuel tank and carburetor(p. ). Refill with freshgasoline (p. ).

Fuel filter or fuel tank filterrestricted.

Replace restricted filters (p. or).

Open fuel filler cap vent knob (p.).

Bad fuel; outboard motor storedwithout treating or draining gasoline,or refueled with bad gasoline.

3.

4.

5.

50

26

27

50

49

5356

62

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CorrectionPossible CauseHARD STARTING OR STALLSAFTER STARTING

Check control positions. Choke OFF. Pull choke knob to ON position,unless engine is warm (p. ).

Check fuel.

Throttle grip not in STARTposition.

Turn throttle grip to STARTposition (p. ).

Fuel vent closed (portable fueltank).

Fuel hose not primed. Squeeze priming bulb (p. ).

Bad fuel; outboard motor storedwithout treating or draininggasoline, or refueled with bad fuel.

Drain fuel tank and carburetor(p. ). Refill with freshgasoline (p. ).

Fuel filter or fuel tank filterrestricted.

Replace restricted filters (p. or).

Open fuel filler cap vent knob (p.).

1.

2.

28

28

26

27

50

5356

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HARD STARTING OR STALLSAFTER STARTING

(continued)


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

ENGINE OVERHEATS Possible Cause Correction

Carburetor malfunction, fuel pumpfailure, ignition malfunction, etc.



Possible Cause Correction

Spark plug faulty, fouled, orimproperly gapped.

Remove and inspect spark plug. Gap or replace spark plug (p. ).

Check water intakes. Water intakes clogged. Clean water intakes.

2.

3.

4.

1.

49

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70


Possible Cause Correction


ENGINE WILL NOT DRIVETHE PROPELLER

Check shear pin. Broken shear pin.

Damaged gearshift mechanism.

Replace shear pin (p. ).


2.

1. 57

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71

OIL PRESSURE INDICATORGOES OFF AND ENGINESPEED IS LIMITED


OIL PRESSURE INDICATOR

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

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

If the engine protection systemremains activated after 30 seconds,return to the nearest boat landing,and have the outboard motorinspected by an authorized HondaMarine dealer.

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

If oil pressure becomes low, thegreen indicator will go off. If you areat cruising speed, engine speed willdecrease gradually.

With the engine oil at therecommended level, restart theengine. If the lubrication system isOK, the green indicator should comeon within 30 seconds, and the enginewill respond normally to throttle gripoperation.

43

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72

SUBMERGED OUTBOARDMOTOR


STARTER GRIP

Change the engine oil as describedon p. . If there was water in theengine crankcase, or if the usedengine oil showed signs of watercontamination, then a secondengine oil change should beperformed after running the enginefor half an hour.

If the engine was running when itsubmerged, there may bemechanical damage, such as a bentconnecting rod. If the engine bindswhen cranked, do not attempt torun the engine until it has beenrepaired.

Remove the spark plug (p. ),and remove the emergency stopswitch clip from the emergencystop switch. Pull the starter grip,rotate the flywheel a fewrevolutions to completely expelany water from the cylinder.

Drain the carburetor as describedon 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 dealer, proceed as follows:

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

1.

2.

3.

4.

44

49

62

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73


When cranking the engine withan open ignition circuit (sparkplug removed f rom the ignitioncircuit), remove the emergencystop switch clip f rom theemergency stop switch toprevent possible damage to theignition system.

Reinstall the spark plug, and putthe emergency stop switch clipinto the emergency stop switch.

Pour a teaspoon of engine oil intothe spark plug hole, and then pullthe starter grip several times tolubricate the inside of the cylinder.

If the engine fails to start, removethe spark plug, clean and dry it,then reinstall the spark plug 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.

Attempt to start the engine. Besure the water level is at least 2inches (5 cm) above theantiventilation plate.

5.

6.

7.

8.

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74

TECHNICAL INFORMATION

Serial Number Locations

TECHNICAL AND CONSUMER INFORMATION

PRODUCT IDENTIFICATIONNUMBER

ENGINE SERIAL NUMBER

Engine serial number:Product identification number:

The product identification number isstamped on the swivel case.

The engine serial number isstamped on the right side of theengine.

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:

82

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75

Carburetor Modification forHigh Altitude Operation


When the carburetor has beenmodif ied f or operation at one of thehigher altitude ranges, the air-f uelmixture will be too lean f oroperation at a lower altitude.Operation at altitudes below therange f or which the carburetor is setmay cause the engine to overheatand result in serious engine damage.For use at lower altitudes, have anauthorized Honda Marine dealermodif y the carburetor f or thecorrect altitude range.

At altitudes above 2,000 ft (600meters), the standard carburetor air-fuel mixture will be too rich.Performance will decrease, and fuelconsumption will increase. A veryrich mixture will also foul the sparkplug and cause hard starting.

Your dealer can determine theappropriate carburetor settings for thealtitude at which you operate youroutboard motor.

Operation at an altitude that differsfrom that at which this engine wascertified, for extended periods oftime, may increase emissions.

High altitude operation can beimproved by specific modificationsto the carburetor. If you usuallyoperate your outboard motor at 2,000ft (600 meters) or above, consult withyour authorized Honda Marine dealer.

Even with carburetor modification,engine horsepower will decreaseabout 3.5% for each 1,000-foot (300-meter) increase in altitude. The effectof altitude on horsepower will begreater than this if no carburetormodification is made.

Settings:Standard setting is for sea level to2,000 ft (600 meters).Mid-altitude setting is for 2,000 ft(600 meters) to 5,000 ft (1,500meters).High-altitude setting is for 5,000 ft(1,500 meters) and above.

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Emission Control SystemInformation


Source of Emissions

Tampering and AlteringThe U.S. and Calif ornia CleanAir Acts

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.

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.

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.

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

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77


Maintenance

Replacement PartsProblems That May Af f ectEmissions

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.

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.

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.

41 42

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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.

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Two StarsVery LowEmission

One StarLowEmission

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 equivalent tothe 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 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% lower emissionsthan One 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.

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

www.arb.ca.gov

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－

－－

±±

±

－－

×× ×

BF5ABADS

13.8 in (350 mm)

LS20.7 in (525 mm)

39.6 in (1,005 mm) 44.7 in (1,135 mm)

Diaphragm type fuel pumpUnleaded gasoline

(86 pump octane or higher)

Forward-Neutral-Reverse (dog type)45° right and left

5 stages (4°,8°,12°,16°,20°)

Underwater exhaustWater cooling with thermostat

ULTRA LOW EMISSION

Trochoid pump pressure lubricationDigital Ignition Control Module (ICM)

Recoil starter

7.7 cu-in (127 cm )4 stroke OHV 1 cylinder, water-cooled

4,500 5,000 rpm3.7 kW (5 HP)

59.5 lbs (27.0 kg) 60.6 lbs (27.5 kg)

17.1 in (434 mm) 22.1 in (561 mm)

API standard (GL-4)SAE 90 outboard motor gear oil

0.028 0.031 in (0.7 0.8 mm)

API standard (SG, SH or SJ oil)SAE 10W-30

0.58 US qt (0.55 L)0.11 US qt (0.10 L)

3.2 US gal (12 L)

No other adjustment is needed

0.10 0.04 mm0.15 0.04 mm

1,550 100 rpm

0.028 0.031 in(0.7 0.8 mm)

7-25/32 7-31/64 in (3-200 190 mm)

3 stages adjustment (18°, 38° and 58°)

See page 49

See shopmanual

See shopmanual

BPR5ES (NGK) W16EPR-U (DENSO)

Gear case:

Engine:

Engine:Gear case:

Exhaust:Intake:

,

80

Specifications


Tuneup

MODELDescription codeTypeOverall lengthOverall widthOverall height

Spark plugFuel pumpFuel

Tank capacityGear changeSteering angleTransom angle

Exhaust systemCooling systemCARB star label

Oil capacity

Specified oilLubrication systemIgnition systemStarter systemSpark plug gapDisplacementEngine typeFull throttle rangeRated power

Transom height(when transomangle at 12°)Dry mass [weight]

Tilt up angle(when transom angleat 12°)

Other specifications

Valve clearance(cold)

Idle speed

Spark plug gap

Standard propeller(No. of blades-diameter pitch)

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

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81

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 ManualContacting 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 need to contact Hondaregarding your experiences with yourHonda product or with your dealer,please contact the Honda office inyour region:

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.

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

Customer Relations Office180 Honda BoulevardMarkham, Ontario L6 0H9Tel: 1-888-946-6329 (Toll free)Fax: 1-877-939-0909 (Toll free)

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.

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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

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

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.

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.

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

It is important to realize that yourwarranty applies to defects inmaterial or workmanship of yourHonda. Your warranty coverage doesnot apply to normal wear or

deterioration associated with usingyour Honda outboard motor.

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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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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).

(1)

(2)

(1) (2)

(2)

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85

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 81 .

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‘‘ ’’’

86

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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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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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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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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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 81 .

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 page92 . 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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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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＊

＊

92

EMISSION CONTROL SYSTEM WARRANTY PARTS:


PARTS DESCRIPTION

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 sensor

Tubing, fittings, seals, gaskets, and clamps associated with these listed systems.Rocker arm oil control valveExhaust manifold and Exhaust valvesCrankcase breather tube, Positive crankcase ventilation valve, Oil filler capOil pump and internal parts

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 sensor

Air intake duct, Vapor separator, Intake manifold tuning valve (Intake air bypasscontrol valve)

Portable fuel tank, Fuel cap, Fuel hoses, Primer bulb, Fuel hose joint

SYSTEMS COVERED BY THISWARRANTY:Fuel Metering

EvaporativeAir Induction

Ignition

Lubrication systemCrankcase Emission Control

ExhaustValve Control System

Miscellaneous PartsCovered up to the first required replacement only. See the Maintenance Schedule on page (p.41 and p.42) .

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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)

Non-commercialuse

Commercialuse

All Honda OutboardModels 36 Months 12 Months

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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.Customer Relations Office180 Honda BoulevardMarkham, Ontario L6 0H9

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

a)

b)

c)

d)

e)

f)g)

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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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INDEX

................................................BEFORE OPERATION . 23...........................................BREAK-IN PROCEDURE . 25

............................................................................Anode . 19..............................................................Replacement . 56

.............ARE YOU READY TO GET UNDERWAY? . 23...........................................................ATTACHMENT . 22

.Carburetor Modification for High Altitude Operation . 75...................................................................Choke Knob . 14

....................................CLEANING AND FLUSHING . 59........COMPONENT AND CONTROL LOCATIONS . 12

...................................CONSUMER INFORMATION . 81..................................................................CONTROLS . 14

CONTROL AND FEATURE IDENTIFICATION......................................................................CODES . 11

..................................CONTROLS AND FEATURES . 11..............................................Cooling System Indicator . 18

....................................................................CRUISING . 35......................................Customer Service Information . 81

.....................................Distributor’s Limited Warranty . 84..................................................Distributor’s Warranty . 93

.........................................EMERGENCY STARTING . 30Emergency Stop Switch Clip and Emergency

...............................................................Stop Switch . 14.........................Emission Control System Information . 76

..............................Emission Control System Warranty . 89Engine

Cover............................................................Lock Lever . 16

...................REMOVAL AND INSTALLATION . 43Oil

...................................................................Change . 44..........................................................Level Check . 43

.................................................Recommendations . 45...............................................ENGINE OVERHEATS . 69

......ENGINE WILL NOT DRIVE THE PROPELLER . 70......................................ENGINE WILL NOT START . 66

Fuel................................................Filler Cap Vent Knob . 19

............................Filter Inspection and Replacement . 53.........................................................................Gauge . 17

...........................................HOSE CONNECTIONS . 26..................................................................PRIMING . 27

.............................................................Priming Bulb . 20..........................................RECOMMENDATIONS . 52

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INDEX

Gear Case Oil.......................................................................Change . 46

...............................................................Level Check . 45..GEARSHIFTING AND THROTTLE OPERATION . 33

..............................................................Gearshift Lever . 15

HARD STARTING OR STALLS AFTER...............................................................STARTING . 68

.......................................................Honda Publications . 81

....................IMPORTANT SAFETY INFORMATION . 6...............................................................INDICATORS . 18

...................INFREQUENT OR OCCASIONAL USE . 27..........................................................INSTALLATION . 21

......................................INSTALLATION POSITION . 21...........................................................INSTRUMENTS . 17

IS YOUR OUTBOARD MOTOR......................................................READY TO GO? . 23

.........................................................Lubrication Points . 48

.........................................MAINTENANCE SAFETY . 39...................................MAINTENANCE SCHEDULE . 41

...................MOORING, BEACHING, LAUNCHING . 37

....................................................Oil Pressure Indicator . 18OIL PRESSURE INDICATOR GOES OFF AND

................................ENGINE SPEED IS LIMITED . 71................................................................OPERATION . 25

....................................................OTHER FEATURES . 18...................................OUTBOARD MOTOR SAFETY . 6

..................................................Portable Fuel Tank . 19, 26...............Portable Fuel Tank and Tank Filter Cleaning . 55

.........................................POWER REQUIREMENTS . 21...........................Propeller and Shear Pin Replacement . 57

......................................Recoil Starter Rope Inspection . 56.................................................................REFUELING . 50

...................................REMOVAL FROM STORAGE . 64....................................................................Rev Limiter . 18

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INDEX

....TAKING CARE OF UNEXPECTED PROBLEMS . 66..TECHNICAL AND CONSUMER INFORMATION . 74

...................................TECHNICAL INFORMATION . 74...............THE IMPORTANCE OF MAINTENANCE . 38

..................................................Throttle Friction Knob . 15..................................................................Throttle Grip . 15

.......................................................................Tilt Lever . 17..TOOL KIT AND EMERGENCY STARTER ROPE . 40

.....................................Transom Angle Adjusting Rod . 16...................TRANSOM ANGLE ADJUSTMENT . 22, 25

........................................................TRANSPORTING . 65WITH OUTBOARD MOTOR INSTALLED

.............................................................ON BOAT . 65WITH OUTBOARD MOTOR REMOVED

.......................................................FROM BOAT . 65

.....................................................Warranty Statements . 84

........................SAFE OPERATING PRECAUTIONS . 25....................................SAFETY LABEL LOCATIONS . 8

...............................................Serial Number Locations . 74..............SERVICING YOUR OUTBOARD MOTOR . 38

............................SHALLOW WATER OPERATION . 36........................................................Spark Plug Service . 49

................................................................Specifications . 80......................................................................Star Label . 78....................................................................Starter Grip . 16

..........................................STARTING THE ENGINE . 28....................................................................STEERING . 34

....................................................Steering Friction Bolt . 17...........................................STOPPING THE ENGINE . 32

.....................................Emergency Engine Stopping . 32...........................................Normal Engine Stopping . 32

....................................................................STORAGE . 61..................................................................Engine oil . 63

............................................................................Fuel . 61........................................STORAGE PRECAUTIONS . 63

.......................SUBMERGED OUTBOARD MOTOR . 72

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99

MEMO

11/03/07 16:45:12 31ZV1660_100

100

MEMO

11/03/07 16:45:14 31ZV1660_101

00X31-ZV1-6600 BF5A

BF5AOwner’s Manual

31ZV166000X31-ZV1-6600

2eY1500.2011.04Printed in ChinaN

BF5AK2

PANTONE 288 CVC DIC F101 BLACK

Includes US and Canadian Models

Documents

Owner’s Manual...00X31-ZV1-6600 BF5A BF5A Owner’s Manual 31ZV1660 00X31-ZV1-6600 2eY1500.2011.04 N Printed in China BF5AK2 PANTONE 288 CVC DIC F101 BLACK Includes US and Canadian