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

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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 12. KEY SWITCHES & PANEL INDICATORS SWITCH PANEL (BF115A BF225A) PGM-FI INDICATOR PANEL (BF115A BF225A) SINGLE ENGINE, DUAL STATION KEY PANEL & HARNESS KIT DUAL ENGINE, DUAL STATION KEY PANEL & HARNESS KIT American Honda Motor Co., Inc. 12-1

3 12. KEY SWITCHES & PANEL INDICATORS SWITCH PANEL (BF115A BF225A) P/N ZW5-013 PARTS LIST Description Part No. Switch panel assembly ZW x 40 mm pan head screw B 5 mm washer mm lock washer mm flange nut When a side flush-mount or top mount remote control is used, locate the switch panel and PGM-FI panel near the operator, in a position where it will not obstruct boat operation. The PGM-FI panel must be installed to provide important engine feedback information to the operator and to provide engine diagnostic information if needed. Do not install the switch panel in a position that the key can come in contact with the operator's knee or leg. Refer to the Marine Accessories Catalog (MO045) for a complete list of switch panels and PGM-FI panels. INSTALLATION (optional) 1. Attach the template on page to the switch panel installation surface. 2. Wear eye protection, then drill and cut as indicated on the template. 3. Connect the wire harness to the remote control wire harness and the trim/tilt switch harness. 4. Install the switch panel on the installation surface using the four 5 x 40 mm screws and four 5 mm washers, lock washers, and flange nuts. 5 mm FLANGE NUT (4) 5 mm LOCK WASHER (4) 5 mm WASHER (4) 5 x 40 mm SCREW (4) SWITCH PANEL American Honda Motor Co., Inc.

4 PGM-FI INDICATOR PANEL (BF115A BF225A) 12. KEY SWITCHES & PANEL INDICATORS P/N ZW7-000AH Refer to the Marine Accessories Catalog (MO045) for a complete list of switch panels and PGM-FI panels. INSTALLATION 1. Attach the template on page to the PGM-FI panel installation surface. 2. Wear eye protection, then drill and cut as indicated on the template. 3. Route the wire harness through the hole in the panel. 4. Install the PGM-FI panel on the installation surface using the four 5 x 40 mm screws and four 5 mm washers, lock washers, and flange nuts. 5. Clamp the PGM-FI panel wire harness using cable clamp F to prevent wire harness vibration damage. 5 x 40 mm SCREW (4) PGM-FI PANEL 6 WIRE PGM-FI PANEL HARNESS 5 mm WASHER (4) CABLE CLAMP F 5 mm FLANGE NUT (4) 5 mm LOCK WASHER (4) American Honda Motor Co., Inc. 12-3

5 12. KEY SWITCHES & PANEL INDICATORS SINGLE ENGINE, DUAL STATION KEY PANEL & HARNESS KIT P/N ZW7-121AH (analog or digital gauge usage) KIT PARTS Remove all kit parts from the box, and check all parts against the following list: ITEM QTY. DESCRIPTION 2 Key switch panel - single engine, single stop switch with all alert lights. 1 "Y" harness - connects upper & lower stations. 1 Single Station Operation Guide This kit contains components that will allow an operator to start & stop the engine in a single engine application from a standard helm location and also from an upper or "fly-bridge" station. Each station is controlled by a key switch panel that contains the ignition switch with an emergency stop switch. Removing the lanyard from either station will stop the engine. Both key panels display all relevant information with regards to engine indicator and warning lights as well as the warning buzzer. Both stations support full instrumentation, either digital or analog, or both. [Separate instrument harness required (not included)]. Standard engine main harness (not included) is needed to connect the engine to the lower station "Y" harness. This kit only addresses the connection and interaction of the engine harness and electrical systems. It does not include any hardware with regards to combining shift and throttle functions between the lower & upper stations. Shift and throttle junction boxes must be purchased separately. See Teleflex Morse for shift and throttle capability. Teleflex Morse Customer Service: (610) American Honda Motor Co., Inc.

6 HARNESS IDENTIFICATION 12. KEY SWITCHES & PANEL INDICATORS ENGINE "Y" HARNESS The length of this harness from key panel to key panel is 19 feet. This will accommodate an upper station roughly 18 feet high. The trim harness at each station is 56 inches long. The instrument harness pigtail at each station is 19 inches long. Lower Station ENGINE HARNESS CONNECTORS ANALOG OR DIGITAL INSTRUMENT HARNESS TRIM CONTROL CONNECTOR PANEL INDICATOR HARNESS KEY SWITCH PANEL Upper Station ANALOG OR DIGITAL INSTRUMENT HARNESS KEY SWITCH PANEL TRIM CONTROL CONNECTOR American Honda Motor Co., Inc. 12-5

7 2003 American Honda Motor Co., Inc. All Rights Reserved 12. KEY SWITCHES & PANEL INDICATORS DUAL ENGINE, DUAL STATION KEY PANEL & HARNESS KIT P/N ZW7-220AH (analog gauge usage only) P/N ZW7-221AH (analog or digital gauge usage) KIT PARTS Remove all kit parts from the box, and check all parts against the following list: ITEM QTY. DESCRIPTION 2 Key switch panel - dual engine, single stop switch with all alert lights. 1 Port engine "Y" harness - connects upper & lower stations for port engine. (marked with red bands) 1 Starboard engine "Y" harness - connects upper & lower stations for starboard engine. (marked with green bands) 1 Dual Station Operation Guide DUAL STATION OPERATION GUIDE This kit contains components that will allow an operator to start & stop both engines in a dual engine application from a standard helm location and also from an upper or "fly-bridge" station. Each station is controlled by a key switch panel that contains 2 ignition switches with a single emergency stop switch. Removing the lanyard from either station will stop both engines. Both key panels display all relevant information with regards to engine indicator and warning lights as well as the warning buzzer. Both stations support full instrumentation. Standard 17 wire engine main harnesses (not included) are needed to connect to the lower station "Y" harnesses. This kit only addresses the connection and interaction of the engine harnesses and electrical systems. It does not include any hardware with regards to combining shift and throttle functions between the lower & upper stations. Shift and throttle junction boxes must be purchased separately. See Teleflex Morse for shift and throttle capability. Teleflex Morse Customer Service: (610) American Honda Motor Co., Inc.

8 HARNESS IDENTIFICATION 12. KEY SWITCHES & PANEL INDICATORS PORT ENGINE "Y" HARNESS The port side "Y" harness has red bands marking each connector. The length of this harness from key panel to key panel is 19 feet. This will accommodate an upper station roughly 18 feet high. The trim harness at each station is 56 inches long. The instrument harness pigtail at each station is 19 inches long. Lower Station KEY PANEL INSTRUMENT HARNESS CONNECT TO MAIN ENGINE HARNESS TRIM HARNESS PGM-FI PANEL RELAY RED BANDS Upper Station KEY PANEL RED BAND INSTRUMENT HARNESS TRIM HARNESS American Honda Motor Co., Inc. 12-7

9 12. KEY SWITCHES & PANEL INDICATORS HARNESS IDENTIFICATION STARBOARD ENGINE "Y" HARNESS The starboard side "Y" harness has green bands marking each connector. The length of this harness from key panel to key panel is 19 feet. This will accommodate an upper station roughly 18 feet high. The trim harness at each station is 56 inches long. The instrument harness pigtail at each station is 19 inches long. Lower Station RELAY KEY PANEL PGM-FI PANEL GREEN BANDS TRIM HARNESS INSTRUMENT HARNESS CONNECT TO MAIN ENGINE HARNESS Upper Station KEY PANEL GREEN BAND INSTRUMENT HARNESS TRIM HARNESS American Honda Motor Co., Inc.

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