IMPORTANCE OF PROPER SET-UP, INSTALLATION, AND PRE-DELIVERY SERVICE

Transcription

1 IMPORTANCE OF PROPER SET-UP, INSTALLATION, AND PRE-DELIVERY SERVICE For Your Customer s Safety Proper set-up, installation and pre-delivery service are essential to the customer s safety and the reliability of the outboard motor. Any error or oversight made during assembly can result in faulty operation, damage to the outboard motor, or injury to others. WARNING Improper service or pre-delivery service can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. For Your Safety Some of the most important general safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing set-up, installation and predelivery service. Only you can decide whether or not you should perform a given task. WARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. IMPORTANT SAFETY PRECAUTIONS Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment. When performing set-up, installation and predelivery service, be especially careful of the following: Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. Use protective wear when necessary, for example, gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. Protect yourself and others whenever you have engine-powered equipment up in the air. Any time you lift an outboard motor with a hoist, make sure the hoist hook is securely attached to the outboard motor. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. Burns from hot parts. Let the engine and exhaust system cool before working in those areas. Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Never drain or store gasoline in an open container. Keep all cigarettes, sparks, and flames away from all fuel-related parts.

2 To ensure proper operation, you must install a PGM-FI panel indicator or a key switch panel with PGM-FI lights. See the Honda Marine Accessories Catalog (MO045) or the in (Parts>Publications>Marine Accessory). UNPACKING SPECIFICATIONS PARTS LISTING TYPICAL RIGGING TABLES INSTALLATION HEIGHT RECOMMENDATIONS TRANSOM DRILLING STEERING CONNECTIONS BOLTING MOTOR TO TRANSOM DUAL MOTOR INSTALLATION REMOTE CABLE INSTALLATION THROTTLE CABLE ADJUSTMENT AVAILABLE ACCESSORIES FUEL HOSE CONNECTION American Honda Motor Co., Inc. 9-1

3 UNPACKING Wear heavy gloves during unpacking to protect hands from the sharp edges and burrs on the steel crate frame. 1. Remove the eight bolts attaching the upper frame and the four nuts attaching the engine hanger bracket. 8 mm BOLT (8) NUT (4) 3. Lift and remove the corrugated cardboard protector that contains the engine, then slide and remove the corrugated cardboard protector that contains the engine cover. CORRUGATED CARDBOARD PROTECTORS 2. Lift up the upper frame slowly with care not to hit the outboard motor. Have an assistant to help remove the crate frame. Then remove the corrugated cardboard cover. UPPER FRAME PARTS CARTON 4. Cut the tie and remove the parts carton from the crate. Compare the parts to the parts list on page Remove the engine hanger brackets from the engine hangers. Remove clear plastic chaf guards. CHAF GUARD (2) ENGINE HANGER CORRUGATED CARDBOARD COVER ENGINE HANGER ENGINE HANGER BACKET (2) American Honda Motor Co., Inc.

4 6. Attach engine hanger, T/N VSB02C000021, only to the two upper engine hangers. As necessary, use clean protective pads between the anchors and the engine belt cover or other related parts. Use an overhead gantry type crane with a lift capacity of at least 2000 lbs. Do not use an automotive type telescoping hydraulic crane. This type of crane may tend to tip when the boom is extended and the engine is lifted to the installation height. Before each use, inspect the sling and all fasteners and attachments for damage or defects. Additional inspections should be performed during sling use. Damaged or defective slings must be immediately removed from service. Lift the motor with the crate frame still attached. With the crate frame upright and the lower crate frame resting on the floor, remove the crate frame from the motor by removing the four flange nuts. FLANGE NUT (4) NOTICE Before installing the engine cover, remove the plastic covers from the air intake mouths of the engine to prevent damage to the engine. LOWER CRATE FRAME ENGINE HANGER T/N VSB02C (NEW) OR T/N VSB02C PLASTIC COVERS (Remove covers before installing the engine cover.) The lower engine hanger is used for power head removal. Do not lift outboard using this hanger. LIFT POINTS American Honda Motor Co., Inc. 9-3

5 SPECIFICATIONS ENGINE Type LOWER UNIT Model BF200A BF225A Water cooled 4-stroke, S.O.H.C., 60 V6 Water cooled 4-stroke, S.O.H.C., 60 V6, VTEC Displacement 3,471 cm³ (211.7 cu in) Bore x stroke 89 x 93 mm (3.5 x 3.7 in) Full throttle range 5,000 6,000 rpm 5,000 6,000 rpm Rated horsepower (full throttle range) 200 5,500 rpm 225 5,500 rpm Maximum torque ,000 rpm Compression ratio 9.4:1 Fuel consumption ratio 303 g (10.7 oz.) / kwh Cooling system Forced water circulation by impeller pump with thermostat Ignition system MicroComputer programmed Ignition timing 10 at 650 rpm B.T.D.C. Spark plug IZFR6F 11 (NGK) Fuel supply system Programmed fuel injection Fuel injection system Electronic control Fuel injection nozzle Pintle type Fuel Unleaded gasoline with a pump octane rating of 86 or higher Fuel pump Electric and mechanical plunger type Lubrication system Pressure lubrication by trochoid pump Lubrication capacity Recommended oil Starter system Battery system Stopping system Exhaust system 7.6 liter (8.0 US qt) 7.8 liter (8.2 US qt) with oil filter replacement SAE 10W-30, API Service classification SG, SH, SJ Electric starter 1040 MCA (800 CCA, 110 AH) minimum (engine only) Primary circuit ground Thru-hub type Model BF200A BF225A Clutch Dog clutch (forward-neutral-reverse) Gear ratio 1.86:1 (15/28) Reduction type Spiral bevel gear Gear case oil capacity 1.17 liter (1.24 US qt) Recommended gear case oil SAE 90, API Service classification GL4 or GL5 Clockwise (viewed from rear): LA, XA and XXA types Propeller rotating direction Counterclockwise (viewed from rear): XCA and XXCA types American Honda Motor Co., Inc.

6 PARTS LISTING REF. NO. DESCRIPTION LA BF200A XA XCA LA XA BF225A XCA XXA XXCA PART NO. 1 Indicator wire harness ZW Indicator panel assembly ZW Pan-head screw (5 x 40mm) B 4 Flange nut (5 mm) Plain washer (5 mm) Lock washer (5 mm) ZW5-U00 7 Band, case grommet (lower) ZY Undercase grommet A ZY3-U00 9 Propeller castle nut (18 mm) ZW1-B00 10 Propeller thrust washer ZY Propeller washer ZY Cotter pin (4.0 mm) ZW1-B00 13a Wrench (14x17) (open end) b Wrench (10x12) (open end) c Wrench (8 mm) (open end) d Pliers (135 mm) GBJ-J10 13e Wrench, hex. (6 mm) f Grip g Screwdriver, check bolt h Screwdriver 3, straight slot (no. 2) i Screwdriver 1, Phillips (no. 2) j Wrench, plug SF k Puller, mini fuse S l Wrench, eye (19 mm) m Wrench, box (P16x17) n Bag, tool ME Hex bolt (12 x 119 mm) ZW Plain washer (12 mm) ZV Fender washer (12 mm) ZV Self-locking nut (12 mm) ZW Remote control cable plate ZY Front separate cover ZY3-000ZA 20 Hex bolt (6 x 25 mm) ZV Shouldered bolt (6 x 17 mm) ZY Shouldered bolt (6 x 37 mm) ZY Emergency lock clip ZV Emission hang tag (CARB 3 stars) REMARKS Use with REF. NO. 2 Propeller installation Outboard motor installation Use with REF. NO N/A Give to customer. 25 Instruction (CARB) N/A 27 Fuel tube assembly ZY Band tube clip (12.5 mm) ZV Hex bolt (6 x 16 mm) ZV American Honda Motor Co., Inc. 9-5

7 REF. NO. DESCRIPTION LA BF200A XA XCA LA XA BF225A XCA XXA XXCA PART NO. 30 Washer (6 mm) ZY Cable clamp (7.5 mm) ZA8-E50 32 Cable tie Cable end ZY Connector cover ZY Gear case cover ZY3-710ZA 36 Owner s Manual (1) REMARKS Give to customer. (1) Model year specific. See in>emall>helm for owner s manual listings American Honda Motor Co., Inc.

8 PARTS LISTING American Honda Motor Co., Inc. 9-7

9 TYPICAL RIGGING TABLES Add throttle and shift cables to all remote models. Water separating filters are recommended on all permanent fuel tank applications. Add a propeller to BF40A models and larger. A dual cable steering kit is available for BF200A/BF225A. See the Honda Marine Accessories Catalog (MO045) for all available accessories including propellers, control boxes, harness extensions, key switch panels, gauges and gauge harnesses. Fuel-injected models must have PGM-FI light indicators, either panel or switch units. Side Mount Control Box ZY3-010 Includes 16.5 ft main harness. Main Harness ZY6-020AH 20 ft. (20 wire) ZY6-025AH 25 ft. (20 wire) ZY6-030AH 30 ft. (20 wire) ZY6-050AHR 50 ft. (23 wire) Key Switch Comes with the control box. PGM-FI Light Panel and Harness ZW7-000AH Used as optional warning light panel where necessary. Gauges Analog or digital gauges; 6-pin PGM-FI harness will supply information. Gauge Harness Use brand-specific harness American Honda Motor Co., Inc.

10 Flush Mount Control Box ZW7-U00 Premium Flush Type Main Harness (optional) ZY6-020AH 20 ft. (20 wire) ZY6-025AH 25 ft. (20 wire) ZY6-030AH 30 ft. (20 wire) ZY6-050AHR 50 ft. (23 wire) Single Engine Key Switch Panel ZW7-100AH or ZW7-100AHR Includes all 4 warning lights, emergency stop switch. PGM-FI Light Panel and Harness ZW7-000AH Used as optional warning light panel where necessary. Gauges Analog or digital gauges; 6-pin PGM-FI harness will supply information. Gauge Harness Use brand-specific harness American Honda Motor Co., Inc. 9-9

11 R.H. Single Binnacle Mount Control Box ZW5-U40 Premium Type Single Binnacle Mount Control Spacer Used only when the control box handle has interference with the console ZW5-U00 Main Harness ZY6-020AH 20 ft. (20 wire) ZY6-025AH 25 ft. (20 wire) ZY6-030AH 30 ft. (20 wire) ZY6-050AHR 50 ft. (23 wire) Single Engine Key Switch Panel ZW7-100AH or ZW7-100AHR Includes all 4 warning lights, emergency stop switch. PGM-FI Light Panel and Harness ZW7-000AH Used as optional warning light panel where necessary. Gauges Analog or digital gauges. Gauge Harness Use brand-specific harness American Honda Motor Co., Inc.

12 R.H. Dual Binnacle Mount Control Box ZW5-U60 Premium Type Dual Binnacle Mount Control Spacer Used only when the control box handle has interference with the console ZW5-U10 Main Harness (two required) ZY6-020AH 20 ft. (20 wire) ZY6-025AH 25 ft. (20 wire) ZY6-030AH 30 ft. (20 wire) ZY6-050AHR 50 ft. (23 wire) Dual Engine Key Switch Panel (one required) ZW7-100AH or ZW7-100AH Includes all 8 warning lights, emergency stop switch. PGM-FI Light Panel and Harness ZW7-000AH Used as optional warning light panel where necessary. Gauges Analog or digital gauges. Gauge Harness Use brand-specific harness American Honda Motor Co., Inc. 9-11

13 INSTALLATION HEIGHT RECOMMENDATIONS Shaft Length L type X type XX type With the boat loaded, stationary and the motor perpendicular to the water surface, there must be a minimum of 5 inches between the water surface and the idle exhaust port. If the motor is mounted lower on the transom, water may enter the exhaust port through wave surge or backwash, potentially causing engine damage. Outboard Transom Height 508 mm (20 in) 635 mm (25 in) 762 mm (30 in) IDLE EXHAUST PORTS Workable Boat Transom Height 483 ~ 508 mm (19 ~ 20 in) 610 ~ 635 mm (24 ~ 25 in) 737 ~ 762 mm (29 ~ 30 in) TRANSOM DRILLING Before drilling, check the thickness of the transom, making sure it does not exceed the maximum allowable thickness shown below. Maximum Boat Transom Board Thickness 85 mm (3.35 in) 1. Set the outboard motor onto the boat transom and verify the correct installation height. 2. Center the Transom Mount Drill Fixture on the boat transom. Position the Drill Fixture flat against the transom. See also TRANSOM CENTER LINE on page Verify no damage will occur when the motor mounting holes are drilled. Look for any structural impediments such as bulkheads, braces, fuel cells, bilge pumps or floor sections before drilling. Ensure there is adequate space for the bolt, washer and transom support plates (if applicable), to bear on a flat surface. The upper bolt holes should be more than 33 mm (1.3 in) from the top of the transom. The lower bolt holes should allow the mounting bolts to contact the upper end of the stern bracket. See also USING THE TRANSOM MOUNT DRILL FIXTURE on page Secure the Transom Drill Fixture with clamps to prevent movement TRANSOM DRILL FIXTURE 07MPZ-ZV3010D USE THE UPPER C AND LOWER D GUIDES. 4. Wear safety glasses and drill four holes with a 12.5 mm (1/2 in) drill bit in the upper C and lower D guides of the Transom Mount Drill Fixture American Honda Motor Co., Inc.

14 Standard Bracket Dimensions STEERING CONNECTIONS 18.5 mm (0.73 in) x 5 TRANSOM BOARD TOP 53.5 mm (2.11 in) SELECTION A single cable steering system is not recommended for either the BF200A or BF225A. 327 mm (12.87 in) BOAT TRANSOM CENTER 251 mm (9.88 in) 254 mm (10 in) 328 mm (12.91 in) Ø13.5 mm (0.53 in) -10 The steering system selection is determined by the particular application. Consult the boat manufacturer or steering manufacturer for recommendations. A hydraulic steering system is the best choice to improve boat stability, minimize lost motion in the steering system and reduce boat chine walk on high-performance boats. A dual cable steering system will help to eliminate steering free play which may cause the outboard motor to move side-to-side slightly at high speeds resulting in chine walk. For further information regarding hydraulic steering or dual cable steering, refer to the hydraulic steering, mechanical steering or dual cable kit manufacturer s instructions. Steering Recommendations: Bay Star Hydraulic Steering by Teleflex Dual Cable Steering Kit P/N 08M61-ZW3-000AH Link Arm Kit P/N ZY3-U00 STEERING PREPARATION Remove the cap from the steering/tilt tube prior to installing the steering system. CAP Loosely install the hydraulic or mechanical steering cables on the motor before final placement of the motor on the transom. Refer to the steering cable or hydraulic steering manufacturer s instruction manual for handling procedures American Honda Motor Co., Inc. 9-13

15 STEERING LINK ARM INSTALLATION Remove the bolts and shipping bracket from the steering arm. Discard the hardware indicated and reinstall the 1/4-28 bolts. BOLT (discard) WASHER (discard) FIBER WASHER (discard) 1/4-28 STAINLESS BOLT (2) (reinstall and tighten) Steering Link Arm P/N ZY3-U00 (optional part, includes all hardware). The steering link arm must be secured between the steering arm and steering system using the bolt, washers, nuts and collar shown. Both the bolt and self-locking nuts, used at each end of the steering link arm, must be in good condition. 3/8-24 UNF BOLT WASHER (3) SHIPPING BRACKET (discard) NUT (discard) STEERING LINK ARM STEERING ARM 3/8-24 UNF SELF LOCKING NUT TORQUE: 3/8-24 UNF bolt: 22 N m (16 lb-ft) 3/8-24 UNF lock nut: 18 N m (13 lb-ft) The steering link arm to steering system selflocking nut is normally tightened to 8 11 N m (7 8 lb-ft) then loosened 1/8 turn. The link arm needs to be able to pivot at the steering attaching point. The steering link arm must have sufficient thread length when the nut is tightened down and the link arm must have at least two or three threads past the end of the self-locking nut. 2. Directly after completing the steering link arm installation, verify the following: Motor turns the proper direction when the steering wheel is turned right and left. If the steering is reversed, correct as necessary. Motor steering angle is equal when steering wheel is turned full right and full left. If the motor steering angles are not equal, corrections can be made at the steering box (refer to the steering box or steering cable manufacturer s instructions). Make the steering angles equal as necessary. The steering mechanism must not come in contact with any part of the boat when the steering wheel is turned full right and full left and at all tilt angles. Correct as necessary and check again. COLLAR (marine grease) 3/8-24 UNF STEERING LINK ARM SELF-LOCKING NUT 1. Install bolt, washer and collar into link arm. Remove access grommet from inside engine cover area and thread bolt into steering arm inside hole. Tighten bolt then tighten lock nut. Do not use forward hole American Honda Motor Co., Inc.

16 BOLTING MOTOR TO TRANSOM Apply marine hull sealant to the mounting holes and inside sealing surface of the large washer. Use Hondabond HT (P/N ) or equivalent polymer sealant for below waterline use. Adhesives should not be used, as they will result in difficult engine removal or height adjustment. Gel coat damage may also occur when removing/adjusting the engine. With the motor in place against the transom, verify correct motor height. Motor can be raised by using a lower set of mounting holes on the bracket. If the boat transom has molding that prevents the outboard stern bracket from sitting flat against the transom, add a spacer plate or contact the boat manufacturer for information on how to remove molding. Lubricate the mounting bolt threads with marine grease prior to installing the mounting bolt nut to prevent thread galling and locknut insert damage. Apply sealant. 12 mm SELF- LOCKING NUT (4) 12 mm WASHER (4) Install with rounded edge/side against paint surface. 12 mm PLAIN WASHER (8) (marine grease) 12 x 119 mm BOLT (4) 12 mm FENDER WASHER (4) SUPPORT PLATE (2) [optional (refer to boat manufacturer)] PAINTED SURFACE SPACER PLATE Ensure at least one thread of the bolt is visible beyond the nut when the fasteners are tightened. NOTICE Attach the motor with marine grade hardware. Use washers under all bolts and nuts. Use additional fender washers against the transom. Use support plates as recommended by the hull manufacturer. Do not use an air impact tool to tighten or loosen the transom bolts. Using an air impact tool to tighten or loosen the transom bolts can generate enough heat to damage the bolt threads. The air impact tool can also produce enough tightening torque to damage the boat transom. Do not scratch the transom bracket when tightening the mounting bolts. Removing paint promotes corrosion and leads to eventual failure of the bracket. Pay attention to the washers, support plates (if applicable) and boat transom as the nuts are tightened. This is especially important on boats that are being repowered. If the washers and/or support plates (if applicable) are drawn into the transom material, the transom material is weakened and must be inspected and repaired as necessary before the engine is installed. If the transom is found to be soft, water penetration may have occurred and caused the transom material to rot and weaken. Contact the boat manufacturer for boat repair information as needed American Honda Motor Co., Inc. 9-15

17 DUAL MOTOR INSTALLATION 1. Install the steering system of choice. 2. Install a commercially available tie bar. 3. Adjust the toe-in or toe-out. Refer to page 1-67 for details. On a dual motor installation when the minimum distance between motors is used, the engine cover of one motor may interfere with the adjacent motor if only one motor is tilted up when the boat is steered full right or full left. NOTICE Do not tilt only one motor when the boat is steered full right or full left. The engine covers could be damaged. REMOTE CABLE INSTALLATION Route the electrical harnesses and cables through the boat. Connect the cables to remote control before connecting them to the motor. Prior to selecting the appropriate harness, check the style of gauge connection on the motor. Early 2004 BF200A/BF225A motors utilized a 3-pin flat connector, while later 2004 motors utilized a rectangular green 6-pin connector. 1. Route the battery cable to the front cover bracket. Position the battery cable white tape mark so it aligns with the edge of the front cover bracket. WHITE TAPE FRONT COVER BRACKET BATTERY CABLE 2. Spray the grommet with silicone spray. 3. Run the fuel hose, indicator wire harness, battery cable and main harness through the undercase grommet A. REMOTE CONTROL CABLE (Shift control) UNDERCASE GROMMET A FUEL HOSE VIEWED FROM OUTSIDE. REMOTE CONTROL CABLE (Throttle control) INDICATOR PANEL WIRE HARNESS MAIN WIRE HARNESS BATTERY CABLE WATER PRESSURE HOSE [(optional part) puncture rubber membrane] American Honda Motor Co., Inc.

18 4. Install the grommet by aligning it with the groove in the front cover bracket. FRONT COVER BRACKET GROOVE UNDERCASE GROMMET A 5. Install the remote control cable plate with the 6 x 16 mm hex bolt. 7. Loosen the control cable lock nuts approximately 1/2 inch from the end of the cable. Thread the cable ends onto the cables with a minimum of 1/2 inch thread engagement as a starting point for adjustment. Do not tighten the lock nuts at this time. With the remote control lever in the NEUTRAL position, the shorter cable will always be the throttle cable. REMOTE CONTROL CABLE PLATE REMOTE CONTROL CABLE PLATE SHIFT CABLE THROTTLE CABLE 6 x 16 mm HEX BOLT 6. Connect the indicator panel (6 pin) and main 14 pin connectors to the engine electrical bracket. Secure the connectors to the locking tabs on the bracket. Route the wires through the locking plastic loop and follow the path to the grommet. Route the two individual portions of the harness through the grommet as indicated. 8. Install the control cables with the throttle cable inside and the shift cable outside. Install the clamp (included with engine) on the undercase grommet A or slip a 50 mm (2 in) corrugated flexible hose over the undercase grommet A and secure the corrugated flexible hose (not included) with the clamp. UNDERCASE GROMMET A ENGINE ELECTRICAL BRACKET 3 PIN (or 6 PIN) CONNECTOR CLAMP INDICATOR PANEL WIRE HARNESS 14 PIN CONNECTOR LOCKING PLASTIC LOOP MAIN WIRE HARNESS American Honda Motor Co., Inc. 9-17

19 SHIFT CABLE CONNECTION 1. Centering remote control lever: a. Move remote control lever to full FORWARD position. b. Slowly return control lever to NEUTRAL position. c. Move control lever to full REVERSE position. d. Slowly return control lever to NEUTRAL position. 2. With the outboard motor in the NEUTRAL position, ensure the detent spring roller is set in the center of the shift arm neutral position groove. If not, move the detent spring LEFT or RIGHT. DETENT SPRING SHIFT ARM After attaching the shift cable to the shift link, check for smooth operation by moving the remote control lever to the forward and the reverse positions. Ensure that the shift link moves smoothly and returns to the neutral detent position when the remote control lever is returned to neutral. NOTICE If the control lever is hard to shift, place a shop towel over the propeller shaft and turn the shaft by hand. Shifting with force will damage the shift mechanism. Once the shift arm moves smoothly and neutral detent aligns, tighten cable lock nut. THROTTLE CABLE CONNECTION 1. Put the remote control lever in the neutral position. 2. Apply a light coat of marine grease to the pivot pin and sliding surface. DETENT SPRING ROLLER (marine grease) THROTTLE ARM NEUTRAL POSITION GROOVE 3. Apply a light coat of marine grease to the pivot pin and sliding surface. CABLE END (marine grease) 3. Adjust the cable end until it will just slip onto the throttle arm. Slide the locking plate forward into the locked position. CABLE END CABLE LOCK NUT SHIFT LINK ROD 4. Adjust the cable end until it will just slip over the shift link rod pivot pin. Slide the locking plate into the locked position American Honda Motor Co., Inc.

20 4. Move the remote control lever to the full throttle position. Make sure the throttle arm contacts the throttle arm stop. If the throttle arm does not contact the throttle arm stop, check for full stroke at the remote control lever. THROTTLE ARM STOPPER LOCK NUT THROTTLE ARM The engine must also return to an ECM controlled idle position when the control lever is returned to the idle position. Tighten the lock nut securely. 5. Operate the control lever to check for smooth, proper shift cable and throttle cable operation American Honda Motor Co., Inc. 9-19

21 THROTTLE CABLE ADJUSTMENT To ensure the throttle valve obtains full throttle position, inspect and adjust the throttle cable assembly using the shop manual (BF200A/ BF225A Shop Manual, page 3-18 through 3-21) and the information provided here. 1. Remove the engine cover. 2. Move the remote control lever to the full throttle position. 7. Tighten the shift cable pivot lock nut. SHIFT CABLE PIVOT THROTTLE ARM PIN NEUTRAL LOCK NUT SHIFT CABLE PIVOT FULL THROTTLE 3. Inspect the throttle arm to see if it is in contact with the full throttle stop. 8. With the remote control lever in the full throttle position, check to see if there is a 1 mm (0.04 in) gap or less between the throttle lever and the full throttle stop. THROTTLE LEVER FULL THROTTLE STOP THROTTLE ARM 1 mm (0.04 in) OR LESS FULL THROTTLE STOP 4. If throttle arm does not contact the full throttle stop, loosen the shift cable pivot lock nut. 5. Remove the shift cable pivot from the throttle arm pin. Turn the shift cable pivot as necessary until the throttle arm contacts the full throttle stop when the remote control lever is in the full throttle position. 6. Grease the throttle arm pin then reconnect the shift cable pivot to the throttle arm pin American Honda Motor Co., Inc.

22 9. If the gap exceeds 1 mm (0.04 in), check the OPEN and CLOSE side throttle cable measurements. OPEN SIDE: 14 mm (0.55 in) CLOSE SIDE: 19 mm (0.75 in) 10. If adjustment is required, move the remote control lever to the full throttle position and loosen the OPEN and CLOSE side lower adjusting nuts. 11. Move the OPEN side adjuster nuts up or down until a 1.0 mm (0.04 in) gap or less is obtained between the throttle lever and the full throttle stop with the remote control lever in the full throttle position. 12. Tighten the OPEN side lower adjuster nut. 13. Move the remote control lever to the NEUTRAL position. 14. Check whether the mark on the throttle cam aligns with the center of the throttle lever roller. 15. If the mark on the throttle cam does not align with the center of the throttle lever roller, move the CLOSE side adjusting nuts up or down as necessary. 16. Tighten the CLOSE side lower adjusting nut. MARK THROTTLE CAM OPEN SIDE ADJUSTING NUTS CLOSE SIDE THROTTLE LEVER ROLLER 14 mm (0.55 in) 19 mm (0.75 in) LOWER ADJUSTING NUTS 17. After all adjustments have been made, move the remote control lever to the full throttle position and check that the throttle lever has a 1 mm (0.04 in) gap or less at the full throttle stop. Readjust if necessary. 18. Start the engine and check the throttle operation and for proper engine idle. 19. Install the engine cover. THROTTLE LEVER 1 mm (0.04 in) OR LESS FULL THROTTLE STOP American Honda Motor Co., Inc. 9-21

23 AVAILABLE ACCESSORIES Consult the Honda Marine Accessories Catalog (MO045) or the in (Parts>Publications>Marine Accessory) for additional information on gauges, instrument harnesses, wiring harnesses, switch panels, and control boxes. FUEL HOSE CONNECTION NOTICE Do not use unlined, worm-type fuel hose clamps. They may cause leaks by damaging the outside of the fuel hose. During operation, check for any fuel or air leaks and repair immediately. If these connections draw air, the engine fuel pump will malfunction. The primer bulb must be positioned so that the outlet end is higher or can be positioned higher than the inlet end. The arrow on the primer bulb must point upward toward the engine. ENGINE SIDE BOAT SIDE The fuel hose is 7.5 mm (5/16 in) and the male hose barb is stepped to 12 mm ( in). The priming bulb hose barbs are 7.5 mm (5/16 in). Make sure the fuel hose is not pinched or crushed as it routes to the boat fuel supply. This could cause an engine malfunction. Fuel Hose Clamp If the outboard motor fuel hose is going to be connected directly into the boat fuel tank supply hose, secure this hose by using a fuel hose clamp type as listed above. Secure the hose joint so that it does not bounce and become damaged on a hard surface. ARROW PRIMER BULB Water Separator A water separator is highly recommended between the boat fuel tank and the motor. Remove the hose barb from the fuel hose end and connect the fuel hose directly to the water separator outlet 7.5 mm (5/16 in) brass hose barb (not included) and clamp securely. If you are unable to properly crimp the band type clamp provided, use a quality stainless steel lined fuel hose clamp American Honda Motor Co., Inc.