PRODUCT UPDATE BF200A • BF225A ENGINE WILL NOT START …
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bf225 main relay pub.fm© 2005 American Honda Motor Co., Inc.— All
Rights Reserved Page 1 of 17 PTB53849 (TM027-2005.09)
CONSUMER INFORMATION: The information in this service bulletin is
intended for use only by skilled technicians who have the proper
tools, equipment, and training to correctly and safely service and
repair your Honda outboard motor. These procedures should not be
attempted by “do-it-yourselfers”, and you should not assume that
this bulletin applies to your equipment, or that your outboard
motor has the condition described. To determine whether this
information applies, contact an authorized Honda Marine
dealer.
OUTBOARD MOTOR #49 SEPTEMBER 2005
PRODUCT UPDATE BF200A • BF225A
ENGINE WILL NOT START DUE TO MAIN RELAY FAILURE SYMPTOM The main
relay may fail, causing the engine not to start.
AFFECTED UNITS
CORRECTIVE ACTION The main relay potting material separates from
the main relay housing, allowing the electrical components inside
the main relay to corrode due to exposure to moisture.
The potting material has been changed to eliminate cracking and
moisture entering and corroding the relay contacts.
American Honda is performing a Product Update to install the new
main relay on all affected units
Units in dealer inventory: Install the new main relay kit on ALL
dealer inventory units in the affected frame serial number range
prior to retail sale.
Retailed units: American Honda will notify all registered owners of
affected units to contact their servicing dealer to arrange to have
the main relay kit installed. Please contact owners of any
unregistered units, as listed on the attached wholesale purchase
report.
Warehouse units: Affected units in American Honda’s inventory will
have the new main relay kit installed. These units can be
identified by the green “•” mark on the crate serial number sticker
and the white paint dot on the new main relay.
Install a new main relay kit on any affected unit by following the
procedure starting on the next page.
MODEL FRAME SERIAL NUMBER RANGE
BF200A BAEJ-1000001~1400255 BAFJ-1000001~1400001
BF225A BAGJ-1000001~1400878 BAHJ-1000001~1400282
The engine will not start because the main relay has failed.
CRATE GREEN MARKING “•“
Nne
OUTBOARD #49 SEPTEMBER 2005
Page 2 of 17 © 2005 American Honda Motor Co., Inc.— All Rights
Reserved PTB53849 (TM027-2005.09)
INSTALLATION 1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Release the rubber strap securing the electric parts cover and
remove the electric parts cover.
4. Disconnect the S terminal from the starter motor solenoid.
ENGINE COVER
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 3
of 17 PTB53849 (TM027-2005.09)
5. All except A6 models: Loosen the harness band clip and pull the
S terminal cable from the harness band clip.
A6 models: Remove and discard the cable clip securing the S
terminal cable.
6. Loosen the harness band clip located above the electric parts
cover strap that secures the alternator fuse cable, fuse cable, and
main wire harness.
HARNESS BAND CLIP
S TERMINAL CABLE
CABLE CLIP Discard.
S TERMINAL CABLE
HARNESS BAND CLIP
ELECTRIC PARTS COVER STRAP
OUTBOARD #49 SEPTEMBER 2005
Page 4 of 17 © 2005 American Honda Motor Co., Inc.— All Rights
Reserved PTB53849 (TM027-2005.09)
7. All except A6 models: Loosen the wire harness clip that secures
the main wire harness, alternator B terminal cable, and service
check connector cable.
A6 models: Loosen the harness band.
8. Pull off the boot of the alternator B terminal and remove the 10
mm nut. Remove the B terminal cable from the alternator.
9. Disconnect the green alternator 4P connector.
10. Remove the harness band clip securing the main wire harness to
connector bracket A.
WIRE HARNESS CLIP
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 5
of 17 PTB53849 (TM027-2005.09)
11. Disconnect, then remove the following connectors from the
connector bracket A.
PGM-FI main relay 6P connector PGM-FI main relay 2P connector Fuse
box 4P connector PGM-FI main relay 4P connector Fuse box 3P
connector
12. Position the connectors as shown.
PGM-FI MAIN RELAY 6P CONNECTOR
PGM-FI MAIN RELAY 2P CONNECTOR FUSE BOX 4P
CONNECTOR
CONNECTOR BRACKET A
FUSE BOX 4P CONNECTOR
FUSE BOX 3P CONNECTOR
OUTBOARD #49 SEPTEMBER 2005
Page 6 of 17 © 2005 American Honda Motor Co., Inc.— All Rights
Reserved PTB53849 (TM027-2005.09)
13. Remove the top two 6 × 10 mm flange bolts securing connector
bracket A to connector bracket B.
Loosen the bottom 6 mm flange bolt securing connector bracket A to
connector bracket B.
14. Pull connector bracket A as close to you as you can, and pull
out the starter motor S terminal cable.
6 × 10 mm FLANGE BOLTS
Remove.
Loosen.
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 7
of 17 PTB53849 (TM027-2005.09)
15. Pull out the fuse box to PGM-FI main relay 4P female connector
above the main wire harness.
16. Remove the two 6 × 22 mm flange bolts and two 6 mm washers, and
remove the PGM-FI main relay assembly.
17. Install two new collars and two new grommets on the new PGM-FI
main relay assembly.
MAIN WIRE HARNESS
6 × 22 mm FLANGE BOLT (2)
PGM-FI MAIN RELAY ASSEMBLY
6 mm WASHER (2)
OUTBOARD #49 SEPTEMBER 2005
Page 8 of 17 © 2005 American Honda Motor Co., Inc.— All Rights
Reserved PTB53849 (TM027-2005.09)
18. Set the PGM-FI main relay assembly to connector bracket A.
Loosely tighten the 6 × 22 mm flange bolts and 6 mm washers, and
then tighten the flange bolts to the specified torque.
TORQUE: 12 N•m (9 ft-lb)
19. Pull the connector bracket A toward you and route the starter
cable S terminal cable as shown.
20. Route the S terminal cable through the harness band clip and
connect the S terminal to the starter motor. Install the boot
securely over the starter motor S terminal.
6 × 22 mm FLANGE BOLT (2)
PGM-FI MAIN RELAY ASSEMBLY
6 mm WASHER (2)
POWER TILT HARNESS
STARTER MOTOR S TERMINAL CABLE
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 9
of 17 PTB53849 (TM027-2005.09)
21. All except A6 models: Tighten the harness band clip
A6 types: Attach a new cable clip to secure the S terminal cable to
connector bracket A.
HARNESS BAND CLIP
S TERMINAL CABLE
OUTBOARD #49 SEPTEMBER 2005
Page 10 of 17 © 2005 American Honda Motor Co., Inc.— All Rights
Reserved PTB53849 (TM027-2005.09)
22. Loosely install the two 6 x 10 mm flange bolts securing
connector bracket A to connector bracket B, then tighten the three
6 mm bolts to the specified torque.
Torque: 12 N•m (9 ft-lb)
23. Route the fuse box to PGM-FI main relay 4P connector under the
main wire harness as shown.
6 × 10 mm FLANGE BOLTS
MAIN WIRE HARNESS
PGM-FI MAIN RELAY 4P CONNECTOR
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 11
of 17 PTB53849 (TM027-2005.09)
24. Reconnect the following connectors, then secure them to
connector bracket A in the order shown.
PGM-FI main relay 6P connector PGM-FI main relay 2P connector Fuse
box 4P connector PGM-FI main relay 4P connector Fuse box 3P
connector
25. Tighten the harness band clip.
PGM-FI MAIN RELAY 6P CONNECTOR
PGM-FI MAIN RELAY 2P CONNECTOR
FUSE BOX 4P CONNECTOR
FUSE BOX 3P CONNECTOR
CONNECTOR BRACKET A
HARNESS BAND CLIP
MAIN WIRE HARNESS
A6 MODELS
FUSE BOX 4P CONNECTOR
FUSE BOX 3P CONNECTOR
CONNECTOR BRACKET A
HARNESS BAND CLIP
MAIN WIRE HARNESS
ANGLE SENSOR HARNESS
OUTBOARD #49 SEPTEMBER 2005
Page 12 of 17 © 2005 American Honda Motor Co., Inc.— All Rights
Reserved PTB53849 (TM027-2005.09)
26. Install the harness band clip securing the main wire harness to
the connector bracket A.
27. Reconnect the green alternator 4P connector to the
alternator.
28. Install the alternator B terminal cable and secure with the 10
mm nut. Make sure the B terminal cable is positioned as shown, then
tighten the 6 mm nut to the specified torque.
Torque: 8 N•m (6 ft-lb) 29. Securely install the boot over the
alternator B terminal.
HARNESS BAND CLIP
MAIN WIRE HARNESS
CONNECTOR BRACKET A
B TERMINAL CABLE
6 mm NUT
ALTERNATOR 4-PIN CONNECTOR
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 13
of 17 PTB53849 (TM027-2005.09)
30. All except A6 models: Tighten the wire harness clip that
secures the main wire harness, alternator B terminal cable, and
service check connector cable.
A6 models: Tighten the harness band.
WIRE HARNESS CLIP
OUTBOARD #49 SEPTEMBER 2005
Page 14 of 17 © 2005 American Honda Motor Co., Inc.— All Rights
Reserved PTB53849 (TM027-2005.09)
31. Reinstall the electric parts cover by aligning the knobs with
the grommets.
32. Carefully push on the left side of the cover and hang the cover
on the hook on the back left side of connector bracket A.
33. Install the lower right edge of the electric parts cover so
that it is inside the inner of the engine under cover.
34. Secure the electric parts cover with the rubber strap.
35. Install the engine cover.
36. Connect the battery negative cable.
37. Start and test the outboard motor.
Viewed from top
ELECTRIC PARTS COVER
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 15
of 17 PTB53849 (TM027-2005.09)
PARTS INFORMATION
Kit Contents
WARRANTY INFORMATION In warranty: The normal warranty
applies.
Out of warranty: Any repair performed after warranty expiration may
be eligible for goodwill consideration. Please contact Techline or
your District Service Manager. You must request consideration and
receive a decision before starting work.
VIN Information
Description Qty. Part Number Honda Code
Kit, main relay 1 06380-ZY3-303 8139941
Description Qty. Part Number Honda Code
PGM-FI main relay 1 38580-ZY3-013 8104093
Grommet 2 38551-ZW1-000 4899761
Collar 2 91553-ZV5-010 7492846
Harness band clip 1 91541-SOA-003 6283873
VIN Prefix Affected Serial Number Range Model BAEJ
1000001~1400255
BF200A BAFJ 1000001~1400001 BAGJ 1000001~1400878
BF225A BAHJ 1000001~1400282
OUTBOARD #49 SEPTEMBER 2005
Page 16 of 17 © 2005 American Honda Motor Co., Inc.— All Rights
Reserved PTB53849 (TM027-2005.09)
The following is a copy of the letter sent to registered
customers.
September 2005
What is the reason for this notice?
American Honda Motor Co., Inc. is conducting a product update of
certain Honda BF200A and BF225A
outboard motors. Our records indicate that you may own one of these
products.
What is the problem?
The main relay is sealed with potting material to prevent
corrosion. Over time, the potting material
may separate from the relay housing causing the electrical
components inside the relay to corrode. As a
result of the corrosion, the outboard may not start.
What should you do?
The main relay potting material has been improved to correct this
situation. Please contact your
authorized Honda Marine servicing dealer to make an appointment to
have your BF200A or BF225A
updated. Be aware that not all selling boat dealers are authorized
Honda dealers. The dealer will
complete the main relay update procedure, without cost to you for
parts or labor. Transportation of the
boat to the dealer and/or related hauling expenses are the
responsibility of the owner.
If you need information regarding the location and phone number of
your nearest authorized Honda
Marine servicing dealer, please access our dealer locator on our
website at:
www.honda-marine.com/dea.aspx, or contact us at: (800)
426-7701.
Whom to contact if you experience problems.
If you are not satisfied with the service you receive from your
Honda dealer, you may contact:
American Honda Motor Co., Inc. Marine Group Customer Relations
Department 4900 Marconi Drive Alpharetta, GA 30005 (770)
497-6400
If you have questions.
Should you have any questions or concerns regarding this matter
that your Honda servicing dealer
cannot answer, please call Honda Marine Customer Relations at (770)
497-6400.
American Honda Motor Co., Inc.
4900 Marconi Drive
Alpharetta, GA 30005
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 17
of 17 PTB53849 (TM027-2005.09)
It is our goal to provide you with the highest quality products and
the best after-sale service. We
apologize for any inconvenience this situation may cause.
We thank you for your purchase of a Honda product.
Sincerely,
Wade E. Terry