INTRODUCTION. Best Wishes, Honda Motor Co., Ltd.

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2 Caifornia Proposition 65 Warning WARNING: Engine Exhaust, some of its constituents, and certain vehice components contain or emit chemicas known to the State of Caifornia to cause cancer and birth defects or other reproductive harm. Keep this owner s manua handy, so you can refer to it at any time. This owner s manua is considered a permanent part of the outboard motor and shoud remain with the outboard motor if resod. The information and specifications incuded in this pubication were in effect at the time of approva for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obigation whatever. No part of this pubication may be reproduced without written permission.

3 INTRODUCTION Congratuations on your seection of a Honda outboard motor. We are certain you wi be peased with your purchase of one of the finest outboard motors on the market. We want to hep you get the best resuts from your new outboard motor and to operate it safey. This manua contains the information on how to do that; pease read it carefuy. As you read this manua, you wi find information preceded by a m symbo. That information is intended to hep you avoid damage to your outboard motor, other property, or the environment. We suggest you read th,e warranty poicy to fuy understand its coverage and your responsibiities of ownership. The warranty poicy is a separate document that shoud have been given to you by your deaer. When your outboard motor needs schedued maintenance, keep in mind that your Honda servicing deaer is speciay trained in servicing Honda outboard motors. Your Honda servicing deaer is dedicated to your satisfaction and wi be peased to answer your questions and concerns. ~ Best Wishes, Honda Motor Co., Ltd. 1

4 INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. outboard motor safey is an important responsibiity. And using this To hep you make informed decisions about safety, we have provided operating procedures and other information on abes and in this manua. This information aerts you to potentia hazards that coud hurt you or others. Of course, it is not practica or possibe to warn you about a the hazards associated with operating or maintaining aoutboard motor. You must use your own good judgment. You wi find important safety information in a variety of forms, incuding: Safety Labes - on the outboard motor. Safety Messages- preceded by a safety aert symbo A and one of three signa words, DANGER, WARNING, or CAUTION. These signa words mean: You WILL be KILLED or SERIOUSLY you don t foow instructions. You CAN be KILLED or SERIOUSLY you don t foow instructions. HURT if HURT if Safety Headings - such as IMPORTANT SAFETY INFORMATION. Safety Section - such as OUTBOARD MOTOR SAFETY. 0 Instructions - how to use this outboard motor correcty and safey. This entire book is fied with important safety information - carefuy. 2 pease read it

5 CONTENTS OUTBOARD MOTOR SAFETY... 7 IMPORTANT SAFETY INFORMATION Operator Responsibiity....7 Refue With Care....8 Carbon Monoxide Hazard....8 SAFETY LABEL LOCATIONS....9 CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS CONTROLS Engine Stop Switch Choke Knob Throtte Grip Throtte Friction Knob Gearshift Lever Recoi Starter Grip Steering Friction Bot Tit Lever Transom Ange Adjusting Rod Engine Cover Lock Lever Fue Priming Bub Fue Cap Vent Knob FEATURES Fue Gauge Oi Pressure Indicator Light Water Check Hoe Anode INSTALLATION INSTALLATION POSITION INSTALLATION HEIGHT OUTBOARD MOTOR ATTACHMENT

6 CONTENTS INSTALLATION (continued) MOTOR ANGLE FOR CRUISING MOTOR ANGLE ADJUSTMENT BEFORE OPERATION ARE YOU READY TO GET UNDER WAY? Knowedge Safety Appare IS YOUR OUTBOARD MOTOR READY TO GO? Safety Inspection Maintenance Inspection OPERATION SAFE OPERATING PRECAUTIONS BREAK-IN PROCEDURE PORTABLE FUEL TANK PLACEMENT AND CONNECTIONS Fue Tank Pacement Fue Hose Connections Fue Priming STARTING THE ENGINE EMERGENCY STARTING STOPPING THE ENGINE Emergency Engine Stopping Norma Engine Stopping GEAR SHIFTING STEERING CRUISING TILTING THE OUTBOARD MOTOR SERVICING YOUR HONDA OUTBOARD MOTOR THE IMPORTANCE OF MAINTENANCE MAINTENANCE SAFETY Safety Precautions I 4

7 CONTENTS SERVICING YOUR HONDA OUTBOARD MOTOR (continued) TOOL KIT AND SPARE PARTS MAINTENANCE SCHEDULE REFUELING FUEL RECOMMENDATIONS COOLING SYSTEM CLEANING AND FLUSHING Ceaning and Fushing With the Fush Kit Ceaning and Fushing Without the Fush Kit ENGINE OIL LEVEL CHECK ENGINE OIL CHANGE ENGINE OIL RECOMMENDATIONS GEAR OIL LEVEL CHECK GEAR OIL CHANGE LUBRICATION SPARK PLUG SERVICE FUEL FILTER REPLACEMENT RECOIL STARTER ROPE INSPECTION ANODE REPLACEMENT SHEAR PIN REPLACEMENT HELPFUL TIPS & SUGGESTIONS STORING YOUR OUTBOARD MOTOR Storage Preparation Storage Precautions Remova From Storage TRANSPORTING TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START SUBMERGED MOTOR

8 CONTENTS TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Seria Number Locations Carburetor Modification for High Atitude Operation Oxygenated Fues Emission Contro System Information Star Labe Specifications WIRING DIAGRAM CONSUMER INFORMATION Honda Pubications Warranty Service Information INDEX QUICK REFERENCE INFORMATION Inside back cover

9 OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION Honda BF5A outboard motor is designed for use with boats that have a suitabe manufacturer s power recommendation, and other uses can resut in injury to the operator or damage to the outboard motor and other property. Most accidents can be prevented if you foow a instructions in this manua and on the outboard motor. The most common hazards are discussed beow, aong with the best way to protect yoursef and others. Operator Responsibiity It is the operator s responsbiity to provide the necessary safeguards to protect peope and property. Know how to stop the engine quicky in case of emergency. Understand the use of a contros. Stop the engine immediatey if anyone fas overboard, and do not run the engine whie the boat is near anyone in the water. Aways stop the engine if you must eave the contros for any reason. Attach the emergency stop switch anyard securey to the operator. Aways wear a PERSONAL FLOTATION DEVICE (PFD) whie on the boat. Famiiarize yoursef with a aws and reguations reating to the boating and the use of outboard motors. Be sure that anyone who operates the outboard motor receives proper instruction. Be sure the outboard motor is propery mounted on the boat. Do not remove the engine cover whie the engine is running. Do not attempt to modify the outboard motor. Do not remove any abes, covers, or safety devices; they are instaed for your safety. 7

10 OUTBOARD MOTOR SAFETY Refue With Care Gasoine is extremey fammabe, and gasoine vapor can expode. Refue outdoors, in a we-ventiaed area, with the engine stopped. Never smoke near gasoine, and keep other fames and sparks away. Remove any portabe fue tank from the boat for refueing. Keep the portabe fue tank away from the battery or other potentia spark sources. Refue carefuy to avoid spiing fue. Avoid overfiing the fue tank. After refueing, tighten the fier cap securey. If any fue is spied, make sure the area is dry before starting the engine. Carbon Monoxide Hazard Exhaust gas contains poisonous carbon monoxide. Avoid inhaation of exhaust gas. Never run the engine in a cosed garage or confined area. 8

11 OUTBOARD MOTOR SAFETY SAFETY LABEL LOCATIONS The abes shown here contain important safety information. Pease read them carefuy. These abes are considered permanent parts of your outboard motor. If a abe comes off or becomes hard to read, contact an authorized Honda servicing deaer for a repacement. I PLACE YMNSMISSION IN NEUTRAL BEFORE STARTING I DO NOT OPERATE WTN ENGINE COVES REMOVED. 1 GE SURE THE ANNTIVENTKATION PLATE IS BELOW THE I 00 NOT SHIFT TO REVERSE SUDDENLY AT HIGH I CHECK OIL LEVEL BEFORE STARTING. I RUSH THE SYSTEM TNOKOUGNLY WTt FRESH WATER AFKR EACN USE IN SALT WAYEK. 1 GASOLINE FLAMMABLE DANGER 1 1 GASOLINE FLAMMABLE DANGER 1 DANGER HARMFUL OR FATAL IF SWALLOWED. KEEP OUT OF REACH OF CHILDREN. IF SWALLOWED, DO NOT INDUCE VOMITING. CALL A PHYSICIAN IMMEDIATELY.

12 CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS GEARSHIFT LEVER ENGINE COVER TRANSOM ADJUSTING ANGLE ROD ANTIVENTILATION PL WATER INTAKE VENT KNOB FUEL GAUGE FUEL TANK FUEL CAP PRIMING BULB FUEL HOSE 10 FUEL HOSE CONNECTOR (FEMALE)

13 CONTROLS & FEATURES OIL FILLER CAP STARTER GRIP SPARK PLUG THROTTLE GRIP / THROTLE 2 FRICTION KNOB. ENGINE COVER LOCK LEVER OIL PRESSURE INDICATOR LAMP WATER HOLE ENGINE OIL DRAIN PLUG CHECK STERN BRACKET FLUSHING PORT BOLT GEAR OIL LEVEL PLUG ANODE GEAR OIL DRAIN PLUG EXHAUST 11

14 CONTROLS & FEATURES CONTROLS Engine Stop Switch The engine stop switch has contros for norma engine stopping and emergency engine stopping. ENGINE STOP SWITCH In norma operation, press the engine stop button to stop the engine. A cip and anyard system stops the engine automaticay if the operator fas away from the contros. LANYARD The switch cip must be inserted in the engine stop switch in order for the engine to start and run. The other end of the anyard attaches to the operator s wrist. If the operator fas away from the contros, the anyard pus the cip out of the switch. Aways attach the anyard to your wrist before operating the outboard motor. A spare switch cip is suppied with the too kit. Choke Knob Thechokeknobopensandcoses the choke vave in the carburetor. CHOKE KNOB The CLOSED position enriches the fue mixture for starting. The OPEN position provides the correct fue mixture for operation after starting, and for restarting a warm engine. 12

15 CONTROLS & FEATURES Throtte Grip The throtte grip contros engine speed. An index mark on the tier arm indicates throtte position. The gearshift mechanism imits throtte grip movement when the gearshift ever (p. 14) is in the R (reverse) or N (neutra) position. INDEX MARK I TiROTLE GRIP Throtte Friction Knob The throtte friction knob adjusts THROTLE FRICTION resistance to throtte grip rotation. KNOB Turn the knobcockwise to increase friction for hoding a throtte setting whie cruising. Turn the knob countercockwise to decrease friction for easy throtte grip rotation. 13

16 CONTROLS & FEATURES Gearshift Lever The gearshift ever is used to seect F (forward), N (neutra), or R (reverse) gears. The engine can be started with the gearshift ever in the N (neutra) position ony. If the gearshift ever is in the F (forward) or R (reverse) position, the recoi starter wi not operate. GEARSHIFT LEVER Recoi Starter Grip Pu the starter grip to operate the recoi starter for starting the engine manuay. RECOIL STARTER GRIP 14

17 CONTROLS & FEATURES Steering Friction Bot The steering friction bot adjusts sreenrno FnrcrroN eolr steering resistance. ASE Turn the bot cockwise to increase friction for hoding a steady course whie cruising or to prevent the outboard motor from swinging whie traiering the boat. Turn the bot countercockwise reduce steering friction. to Tit Lever The tit ever enabes the outboard motor to be raised for shaow water operation, beaching, aunching, or mooring. TILT LEVER To tit, move the ever to the TILT position, then raise the outboard motor unti the tit mechanism engages at 30, 45 or 70 (p. 35). To return the outboard motor to the norma running position, move the tit ever to the RUN position, raise the outboard motor sighty to disengage the tit mechanism, then sowy ower the engine. 15

18 16 CONTROLS & FEATURES Transom Ange Adjusting Rod The transom ange adjusting rod is used to adjust the ange of the outboard motor in the norma operating position (see page 21). To adjust, first tit the outboard motor, so it is not resting on the rod. Push the rod in, and turn the end of the rod up, so the atch wi fa into ine with the rod. TRANSdh ANGLE ADJUSTING ROD TO REMOVE I (UNLOCKED) Remove the rod, and reinsert it in the desired position. Push the rod in, and turn the end of the rod down, so the atch wi fa to the ocked position. Then reease the rod. TO -LOCK LATCH (LOCKED) Engine Cover Lock Lever The engine cover ock ever fastens the cover to the outboard motor. ENGINE COVER LOCK LEVER To remove the cover, move the ever to the unocked position, then ift off the cover. To insta the cover, position the cover on the outboard motor, then move the ever to the ocked position. UNLOCK I I III

19 CONTROLS & FEATURES Fue Priming Bub A priming bub is buit into the fue hose that connects the portabe fue tank to the outboard motor. Before operating the outboard motor, squeeze the priming bub unti it fees firm. This wi ensure that fue is suppied to the engine (see page 24). Fue Cap Vent Knob PRIMING BULB The cap is provided with a vent knob to sea the portabe fue tank for carrying it to and from the boat. Open the vent knob 2 or 3 turns before operating the outboard motor (see page 25). FEATURES Fue Gauge A fue gauge is buit into the cap of the portabe fue tank (see page 24). Oi Pressure Indicator Light OIL PRESSURE INDICATOR LIGHT The oi pressure indicator ight shoud remain it whie the engine is running. The ight indicates that oi pressure is OK (see page 28). Water Check Hoe Water shoud fow from the water check hoe whie the engine is running. This shows that water is circuating through the engine cooing system (see page 29). WATER CHECK HOLE

20 18 CONTROLS & FEATURES Anode The anode is a sacrificia materia which heps to protect the outboard motor from corrosion. ANODE

21 INSTALLATION It is your responsibiity to choose a boat suitabe for the outboard motor. Exceeding the boat manufacturer s power recommendation coud cause an accident resuting in serious injury. Be sure to match the boat manufacturer s power recommendation with the outboard power output. INSTALLATION POSITION STERNCENTER Insta at the stern, at the center ine of the boat. INSTALLATION HEIGHT For proper propeer depth and engine cooing, the boat s transom height must match the motor s shaft ength. The short shaft motor requires a transom height of about: 15.0 in (381 mm) The ong shaft motor requires a transom height of about: 20.0 in (508 mm) Once the boat is in the water and oaded, check proper motor depth by ooking at the antiventiation pate: with the motor not running, the pate shoud be beow the surface of the water. It shoud be about: 3.9 in (100 mm) TER SURFACE ANTIVENTILATION PLATE pi5ie-j Running the outboard motor without sufficient cooing water wi damage the water pump and overheat the engine. 19

22 20 INSTALLATION OUTBOARD MDTOR ATTACHMENT Attach the stern bracketjo the Vansom and tighten the camp screws. Before operating the bdat, check the tightness of the camp screws. Tie a rope through the hoe in the stern bracketandsecure the other end of the rope to the boat. This wipreventaccidentaossofthe motor. The hoes in the camp screw handes may be padocked together to prevent theft of the motor. MOTOR ANGLE FOR CRUISING / SAFETY ROPE CLAMP SCREW Adjust the motor so the propeer shaft is parae with the water surface. INCORRECT INCORRECT CAUSES BOAT TO CAUSES BOAT TO SQUAT PLOW CORRECT GIVES MAXIMUM PERFORMANCE

23 21 INSTALLATION MOTOR ANGLE ADJUSTMENT If the propeer shaft is not parae with the water surface, adjust by changing the transom ange adjusting rod position. There are four adjustment positions. 1. Push in (A) the adjusting rod, twist upwards (B) and pu out to remove. TRANSdM ADJUSTING ANGLE ROD 2. Inserting the rod in the proper hoe, twist it down to ock. TO CHANGE UNLOCKED POSITION 1 NOTICE 1 To prevent damage to the motor or boat, make sure the transom ange adjusting rod is ocked. TO LOCK LOCKED POSITION

24 BEFORE OPERATION ARE YOU READY TO GET UNDERWAY? Your safety is your responsibiity. A itte time spent in preparation wi significanty reduce your risk of injury. Knowedge Read and understand operate them. this manua. Know what the contros do and how to Famiiarize yoursef with the outboard motor and its operation before you get underway. Know what to do in case of emergencies. Famiiarize yoursef with a aws and reguations use of outboard motors. reating to boating and the Safety Appare Aways wear a PFD whie on the boat. Attach the emergency stop switch anyard securey to your PFD or your wrist. IS YOUR OUTBOARD MOTOR READY TO GO? For your safety, and to maximize the service ife of your equipment, it is very important to take a few moments before you operate the outboard motor to check its condition. Be sure to take care of any probem you find, or have your servicing deaer correct it, before you operate the outboard motor. Impropery maintaining this outboard motor, or faiing to correct a probem before operation, coud cause a mafunction in which you coud be seriousy injured. Aways perform a preoperation inspection before each operation, and correct any probem.

25 BEFORE OPERATION Safety Inspection Look around for signs of oi or gasoine eaks. Make sure the fue tank is in good condition and propery secured in the boat (see page 24). Check that the fue hose is undamaged and propery connected (see page 25). Wipe up any spis before starting the engine. Check the stern bracket to be sure the outboard motor is securey instaed. Check that a contros are operating propery. Repace any damaged parts. Check that a fasteners are in pace and securey tightened. Maintenance Inspection Check the engine oi eve (see page 45). Running the engine with a ow oi eve can cause engine damage. Check to be sure the propeer is undamaged, and the retaining nut is secured with a cotter pin (see page 55). Check that the anode is securey attached to the antiventiation pate and is not excessivey worn (see page 54). The anode heps to protect the outboard motor from corrosion. Make sure the too kit and spare parts are onboard (see page 39). Repace any missing items. Check the fue eve in the fue tank (see page 41).

26 OPERATION SAFE OPERATING PRECAUTIONS To safey reaize the fu potentia of this outboard motor, you need acompete understanding of its operation and a certain amount of practice with its contros. Before operating the outboard motor for the first time, pease review the IMPORTANT SAFETY NFORMAT/ON on page 7 and the chapter tited BEFORE OPERATION. For your safety, avoid starting or operating the engine in an encosed area, such as a garage. Your engine s exhaust contains poisonous carbon monoxide gas which can coect rapidy in an encosed area and cause iness or death. BREAK-IN PROCEDURE Proper break-in procedure aows the moving parts to wear in smoothy for best performance and ong service ife. For the first 10 hours, run the outboard motor at ow speed, and avoid futhrotte operation. PORTABLE FUEL TANK PLACEMENT AND CONNECTIONS Fue Tank Pacement Pace the portabe fue tank in a we-ventiated sunight. ocation, away from direct Gasoine is highy fammabe and exposive. You can be burned or seriousy injured when handing fue. 24 Stop the engine and keep heat, sparks, and fame away. Hande fue ony outdoors. Wipe up spis immediatey.

27 OPERATION To ensure that the outboard motor wi be abe to draw fue from the tank, pace the tank within 6 feet of the outboard motor and not more than 3 feet beow the fue connector on the outboard motor. VENT KNOB FUEL TANK CAP Secure the portabe fue tank in the boat, so it won t move around and become damaged. CLIP Before use, open the fue tank vent by turning the vent knob at east 2 or 3 turns countercockwise. Fue Hose Connections Connect the fue hose to the tank and the outboard motor, as shown. Be sure both connectors snap securey into pace. FUEL HOSE CONNECTOR FOR OUTBOARD MOTOR Fue Priming Hod the priming bub with the outet end higher than the inet end. Squeeze the primer bub severa times, unti it fees firm, indicating that fue has reached the carburetor. FiEL HOSE CONNECTOR FOR FUEL TANK PRIMING BULB Check to be sure there are no fue eaks before starting the engine. OUTLET (to motor) Do not squeeze the priming bub when the engine is running, because that coud food the carburetor. INLET (from fue tank) 25

28 OPERATION STARTING THE ENGINE 1. Put the emergency engine stop switch cip in the engine stop switch, and attach the anyard to your wrist. The engine wi not start or run, uness the cip is in the switch. The emergency engine stop switch cip and anyard system is a safety device that wi stop the engine if you fa away from the contros whie operating the boat. Aways attach the anyard to your wrist before starting the engine. EMERGENCY SWITCH CLIP ENGINE STOP ENGINE STOP LAN-YARD 2. Check the position of the gearshift ever. It must be in the N (neutra) position for starting. If the gearshift ever is in the F (forward) or R (reverse) position, the recoi starter wi not operate, and the eectric starter button (appicabe modes) is bocked. GEARSHIFT LEVER 26

29 27 OPERATION 3. Aign the throtte grip START position with the mark on the tier hande. MARK THROTLE 4. To start a cod engine, pu out the choke knob. To restart a warm engine, eave the choke knob oushed in. GRIP CHOKE KNOB 5. Pu the recoi starter grip sowy unti you fee resistance, then pu brisky. Do not aow the startergrip to snap back against the engine. Return it genty to prevent damage to the starter. Do not pu the starter grip whie the engine is running, as that may damage the starter. If the engine fais to start, check the engine stop switch cip.

30 OPERATION 6. After starting, check the oi pressure indicator ight. The ight shoud be on whie the engine is running. If the ight is off, stop the engine immediatey, check the engine oi eve, and inspect the engine for oi eaks. OIL PRESSURE INDICATOR LIGHT If the oi eve is OK, but the ight stays off whie the engine is running, take the motor to an authorized Honda marine deaer immediatey.

31 OPERATION 7. After starting, be sure water is fowing out of the water check hoe. If water does not fow out, or if steam comes out, stop the engine. check to see if the screen in the cooing water inet is obstructed. Do not operate the engine unti the probem has been corrected. O.K. WATER CiiECK HOLE 8. If the choke was used, push it in graduay as the engine warms up. 9. Before eaving the dock, check the operation of the engine stop switch. 29

32 30 OPERATION EMERGENCY STARTING If the recoi starter is not working propery, the engine can be started with the spare starter rope in the too kit. 1. Remove the engine cover. 2. Foow steps 1 through 4 of the norma engine starting procedure (see pages 26 and 27). 3. Wind the spare rope cockwise around the puey, and then pu it straight out to start the engine. Keep cear of moving parts. 4. Leave the recoi starter off and carefuy reinsta engine cover. Exposed moving parts can cause injury. Use extreme care when instaing the engine cover. Do not operate the outboard motor without the engine cover. STARTER ROPE.-. :

33 OPERATION STOPPING THE ENGINE Emergency Engine Stopping Disengage the emergency engine stop switch cip from the engine stop switch by puing the anyard. It is a good idea to stop the engine with the emergency engine stop switch anyard from time to time to be sure that the switch is operating propery. ENGINE STOP SWITCH LANYARD Norma Engine Stopping EMERGENCY ENGINE STOP SWITCH CLIP 1. Turn the throtte grip to the SHIFT position, and move the gearshift ever to the N (neutra) position. N (neutra) THRbTLE GRIP GEiRSHIFT LEVER 2. Push the engine stop switch button unti the engine stops. STOP BUTON In the event that the engine does not stop when you push the engine stop switch, pu the emergency engine stop switch anyard. If the engine continues to run, pu the choke knob to stop the engine. 31

34 32 GEAR SHIFTING Put the tit ever in the RUN position to prevent the outboard motor from titing up when operating in reverse (refer to page 35). The gearshift ever has 3 positions : FORWARD, NEUTRAL, and REVERSE. An indicator at the base of the gearshift ever aigns with etters F, N, or R on the engine case to show the gear that has been seected. Turn the throtte grip to SHIFT to decrease engine speed before moving the gearshift ever. When operating in reverse, proceed with caution to avoid hitting any underwater obstructions with the propeer. The gear shift mechanism imits throtte opening in the N (neutra) and R (reverse) positions. The outboard motor aows the throtte to be opened to FAST with the gear shift ever in the F (forward) position. THROTTLE GRIP R GEARSHIFT LEVER

35 OPERATION To turn to the right, swing the tier hande to the eft. To turn to the eft, swing the tier hande to the right. Boats equipped with a remove contro steering whee are controed in the same way as a car. LEFT TURN RIGHT TURN Swing the tier hande to the right. Swing the tier hande to the eft. The steering friction shoud be adjusted so that stabe boat operation maintained with a minimum of operator effort. is STEERING FRICTION BOLT TODECREASE 33

36 34 CRUISING With the gearshift ever in the forward position F, turn the throtte grip toward FAST to increase speed. For norma cruising, open the throtte about 3/4. FORWARD To hod the throtte at a steady setting, turn the throtte friction knob cockwise. To free the throtte grip for manua speed contro, turn the friction knob countercockwise. For best performance, passengers and equipment shoud be distributed eveny to baance the boat. THROTLE FRICTION KNOB TO DECREASE

37 35 TILTING THE OUTBOARD MOTOR Tit the motor up to prevent the propeer and gear case from hitting the bottom when the boat is beached or stopped in shaow water. Aways tit the motor up out of the water when docked in sat water. 1. Stop the engine and put the gearshift ever into NEUTRAL. 2. Pu the tit ever toward you, set the ever in the TILT position, and raise the engine to either the 30, 45 or 70 tit position. 1 NOTICE 1 Do not use the throtte grip to tit the outboard motor. 3. To return the engine to the norma RUN position, move the tit ever away from you unti it stops, tit the engine up sighty, then ower the engine sowy. 1 NOTICE 1 Make sure water comes out from the cooing water check hoe. When the outboard motor is tited, cruise at ow speed. Never operate in reverse when the outboard motor is tited, because the outboard motor wi rise suddeny. TILT LEVER

38 OPERATION To avoid damaging the motor, be very carefu when mooring a boat, especiay when its motor is tited up. Don t aow the motor to strike against the pier or other boats.

39 37 SERVICING YOUR HONDA OUTBOARD MOTOR THE IMPORTANCE OF MAINTENANCE Good maintenance is essentia for safe, economica, and troube-free operation. It wi aso hep reduce air poution. Impropery maintaining this outboard motor, or faiure to correct a probem before operation, can cause a mafunction in which you can be seriousy hurt or kied. Aways foow the inspection and maintenance recommendations and schedues in this owner s manua. To hep you propery care for your outboard motor, the foowing pages incude a maintenance schedue, routine inspection procedures, and simpe maintenance procedures using basic hand toos. Other service tasks that are more difficut, or require specia toos, are best handed by professionas and are normay performed by a Honda technician or other quaified mechanic. The maintenance schedue appies to norma operating conditions. If you operate your outboard motor under unusua conditions, consut an authorized Honda marine deaer for recommendations appicabe to your individua needs and use. Remember that your authorized Honda marine deaer knows your outboard motor best and is fuy equipped to maintain and repair it. To ensure the best quaity and reiabiity, use ony new, genuine Honda parts or their equivaents for repair and repacement. Maintenance, repacement, or repair of emission contro devices and systems may be performed by any engine repair estabishment or individua, using parts that are certified to EPA standards.

40 38 SERVICING YOUR HONDA OUTBOARD MOTOR MAINTENANCE SAFETY Some of the most important safety precautions foow. However, we cannot warn you of every conceivabe hazard that can arise in performing maintenance. Ony you can decide whether or not you shoud perform a given task. Faiure to propery foow maintenance instructions and precautions can cause you to be seriousy hurt or kied. Aways foow the procedures and precautions in the owner s manua. Safety Precautions Make sure the engine is off before you begin any maintenance or repairs. This wi eiminate severa potentia hazards: - Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventiation whenever you operate the engine. - Burns from hot parts. Let the engine and exhaust system coo before touching. - Injury from moving parts. Do not run the engine uness instructed to do so. Read the instructions before you begin, and make sure you have the toos and skis required. To reduce the possibiity of fire or exposion, be carefu when working around gasoine. Use ony a nonfammabe sovent, not gasoine, to cean parts. Keep cigarettes, sparks, and fames away from a fue-reated parts.

41 SERVICING YOUR HONDA OUTBOARD MOTOR TOOL KIT AND SPARE PARTS The foowing toos and spare parts are suppied with the outboard motor for maintenance, adjustment, and emergency repairs. Spare shear pins and cotter pins are ocated near the oi fier cap inside the engine cover. HOSE CONNECTOR FOR FLUSHING FLUSH KIT Too Kit SHEAR PINS WATER MOUTH NUT WATER HOSE CONNECTOR WATER MOUTH SEAT G 10 X 12 mm WRENCH FLAT SCREWDRIVER c I PHILIPS SCREWDRIVER TOOL BAG B PLUG WRENCH 8 mm WRENCH STARTER ROPE iie% SPARE SPARK PLUG EMERGENCY SWITCH CLIP ENGINE STOP 39

42 40 SERVICING YOUR HONDA OUTBOARD MOTOR MAINTENANCE SCHEDULE F I \REGULAR SERVICE PERIOD (3) First Everv Everv Each use ITEM Perform at every indicated month or operating hour interva, whichever comes first. 1 Enoine oi Check eve Gear case oi Change Check eve Change Check for water contamination 0 month 6 monihs yea; or or or 20 hrs. 100 hrs. 200 hrs Starter rope Check 0 Carburetor inkage Check-Adjus t 0 (2) 0 (2) Vave cearance Check-Adjust 0 (2) (21,-, Spark pug Check-Adjust 0 Repace i Shear pin Check 0 Propeer (cotter pin) Check O- Anode Check 0 Iding speed Check-Adiust j Lubrication Grease * I -\ I I - Fue tank and tank Cean I 0 fiter Thermostat Check IF (2) Fue fiter Change 0 Fue ine Check 0 Check (Repace if necessary) _ Every 2 years (2) Bots and Nuts Check-tightness 0 (2) 0 (2) Crank case breather Check 0 (2) tube Emission-reated items. NOTE: (1) Lubricate more frequenty when used in sat water. (2) These items shoud be serviced by an authorized Honda marine deaer, uness you have the proper toos and are mechanicay proficient. Refer to Honda Shop Manua for service procedures. (3) For professiona commercia use, og hours of operation to determine proper maintenance intervas. 0

43 SERVICING YOUR HONDA OUTBOARD MOTOR Fue tank capacity 3.2 US ga (12.0 & 2.6 Imp ga) FiEL GAUGE Check the fue gauge and refi the tank to the SAFE FILL LEVEL mark if necessary. Gasoine is highy fammabe and exposive. You can be burned or seriousy injured when handing fue. Stop the engine and keep heat, sparks, and fame away. Hande fue ony outdoors. Wipe up spis immediatey. VENT KNOB FUEL CAP Remove the fue tank from the boat for refiing. Turn the vent knob countercockwise to the open position and remove the fue cap. Refue in a we-ventiated area. Fi the fue tank up to the SAFE FILL LEVEL mark ony. Inspect the condition of the fue cap gasket and repace if necessary. After refiing, insta and tighten the fue cap securey. Turn the vent knob cockwise to the cosed position. Return the fue tank to the boat. 41

44 SERVICING YOUR HONDA OUTBOARD MOTOR FUEL RECOMMENDATIONS Use uneaded gasoine with a pump octane rating of 86 or higher. This outboard motor is certified to operate on uneaded gasoine. Uneaded gasoine produces fewer engine and spark pug deposits and extends exhaust system ife. Never use stae or contaminated gasoine or an oi/gasoine mixture. Avoid getting dirt or water in the fue tank. Occasionay you may hear ight spark knock or pinging (metaic rapping noise) whie operating under heavy oads. This is no cause for concern. If spark knock or pinging occurs at a steady engine speed, under norma oad, change brands of gasoine. If spark knock or pinging persists, see an authorized Honda marine deaer. Running the engine with persistent spark knock or pinging can cause engine damage. Running the engine with persistent spark knock or pinging is misuse, and the Distributor s Limited Warranty does not cover parts damaged by misuse. 42

45 SERVICING YOUR HONDA OUTBOARD MOTOR COOLING SYSTEM CLEANING AND FLUSHING After each use in sat water or dirty water, thoroughy outboard motor. cean and fush the For safety, the propeer must be removed. Be sure the outboard motor is securey mounted, and do not eave it unattended whie running. Keep chidren and pets away from the area, and stay cear of moving parts during this procedure. Running the engine without water can cause serious engine damage due to overheating. Be sure that water fows from the water check hoe whie the engine is running. If not, stop the engine and determine the cause of the probem. Ceaning and Fushing With the Fush Kit 1. Wash the outside of the outboard motor with cean, fresh water. 2. Fush the cooing system, using the Honda fush kit. a. Remove the fush pug from the WASH pug hoe and insta the water hose connector. b. Attach a hose from a fresh water faucet to the water hose connector of the fush kit. c. Remove the propeer. d. Turn on the fresh water suppy to the hose. e. Start the engine and run in neutra for 10 minutes. WATER HOSE CONNECTOR GEARSHIFT LEVE WATER HOSE 43

46 SERVICING YOUR HONDA OUTBOARD MOTOR Ceaning and Fushing Without the Fush Kit 1. Wash the outside of the outboard motor with cean, fresh water. 2. Remove the propeer. 3. Stand the motor in a suitabe container of water. The water eve must be at east 2 inches above the antiventiation pate. 4. Start the engine and run sowy for at east 10 minutes. ANTIVENTILATION PLATE 44

47 SERVICING YOUR HONDA OUTBOARD MOTOR ENGINE OIL LEVEL CHECK Check the engine oi eve with the engine stopped and the outboard motor in a vertica position. 1. Move the engine cover ock ever down to unock the cover, and remove the cover. 2. Remove the oi fier cap/dipstick and wipe it cean. Insert and remove the dipstick without screwing it into the fier neck. Check the oi eve shown on the dipstick. If the oi eve is near or beow the ower imit mark on the dipstick, fi with the recommended oi to the upper imit mark. 1 NOTICE 1 Running the engine with a ow oi eve can cause engine damage. 3. Insta the oi fier cap and tighten it securey. 4. Insta the engine cover, and ock it by moving the ever up. ENGINE COVER LOCK LEVER DIPSTICK / UNLOCK UPPER LIMIT - LOWER LIMIT

48 46 SERVICING YOUR HONDA OUTBOARD MOTOR ENGINE OIL CHANGE Drain the used oi whie the engine is warm. Warm oi drains quicky and competey. 1. Move the engine cover ock ever (p. 45) down to unock the cover, and remove the cover. 2. Pace a suitabe container beow the engine oi drain ocation to catch the used oi, then remove the oi fier cap and the drain pug. 3. Aow the used oi to drain competey, then reinsta the drain pug, and tighten it securey. Improper disposa of engine oi can be harmfu to the environment. If you change your own oi, pease dispose of the used oi propery. Put it in a seaed container, and take it to a recycing center. Do not discard it in a trash bin or dump it on the ground. 4. With the outboard motor in a vertica position, fi to the upper imit mark on the dipstick (p. 45) with the recommended oi (p. 47). Engine oi capacity: 0.58 US qt (0.55 e, 0.48 Imp qt) 5. Insta the oi fier cap and tighten it securey. 6. Insta the engine cover, and ock it by moving the ever up. I OIL FILLER CAP/DIPSTICK DRAIN PLUG

49 SERVICING YOUR HONDA OUTBOARD MOTOR ENGINE OIL RECOMMENDATIONS Oi is a major factor affecting performance automotive detergent oi. and service ife. Use 4-stroke SAE 1 OW-30 is recommended for genera use. SAE Viscosity Grades w F I I I I I t 1 I % AMBIENT TEMPERATURE The SAE oi viscosity and service cassification are in the API abe on the oi container. Honda recommends that you use API SERVICE category SF or SG oi. 47

50 SERVICING YOUR HONDA OUTBOARD MOTOR GEAR OIL LEVEL CHECK I Check the oi eve when the motor is in the vertica position. Remove the eve pug and see if oi fows out. If no oi fows out, use a commerciay avaiabe oi pump or squeeze tube to fi the gear case with gear oi recommended on page 49. Pump or squeeze fresh oi through the OIL DRAIN pug hoe unti oi begins fowing out through the OIL LEVEL pug hoe.. If there is water in the oi, the water wi fow out first when the drain pug is removed, or the oi wi be a miky coor. If water is detected in the oi, the outboard motor shoud be inspected by an authorized Honda marine deaer. LEVEL PLUG DRAIN PLUG 48

51 GEAR OIL CHANGE Recommended Oi Capacity oi : Marine SAESO hypoid gear oi API Service Cassification (GL-4 or GL-5) : O.US qt (0.1 e, 0.1 Imp qt) Remove the eve pug and drain pug and aow the gear oi to thoroughy drain into a suitabe container. Pump or squeeze the recommended gear oi through the OIL DRAIN pug hoe unti oi starts fowing out through the OIL LEVEL pug hoe. Use new seaing washers. Insta the oi eve pug first and then the oi drain pug. Tighten securey. LEVEL PLUG OIL PUMP \ DRAIN PLUG SQUEEZE TUBE 49

52 50 SERVICING YOUR HONDA OUTBOARD MOTOR LUBRICATION Appy marine anticorrosion grease to the foowing areas: THROTTLE CABLE AND PIVOT SHIFT SHAFT AND PIVOT ENGINE COVER LOCK LEVER SWIVEL CASE TILLER HANDLE PIVOT : I \ TILT LINKAGE CLAMP SCREWS Appy anticorrosion TILT RELEASE LEVER AND PROPELLER SHAFT REVERSE LOCK LEVER oi to pivot surfaces where grease cannot penetrate.

53 I SERVICING YOUR HONDA OUTBOARD I SPARK PLUG SERVICE MOTOR Recommended spark pug: BPRSES (NGK), W GEPR-U (DENSO) W14EPR-U (DENSO) 1. Remove the engine cover. 2. Remove the spark pug cap. 3. Use the wrench suppied in the too kit to remove the spark pug. 4. Visuay inspect the spark pug. Discard the spark pug if there is apparent wear, or if the insuators are cracked or chipped. Cean the spark pug with a wire brush if they are to be reused. 5. Measure the pug gap with a feeer gauge. Correct as necessary by carefuy bending the side eectrode. The gaps shoud be: in ( mm) PLUG WRENCH in ( mm) i 51

54 SERVICING YOUR HONDA OUTBOARD MOTOR 6. Check that the spark pug washer are in good condition, and thread the spark pug in by hand to prevent cross-threading. i 7. After the spark pug are seated, tighten with a spark pug wrench to compress the washer. \- If instaing a new spark pugs, tighten /2 turn after the spark pugs seat to compress the washers. If reinstaing a used spark pugs, tighten 118- /4 turn after the spark pugs seats to compress the washers. 8. Insta the engine cover. The spark pug must be securey tightened. Impropery tightened pug can become very hot and may cause engine damage. Use ony the recommended spark pug or equivaent. Spark pug which have an improper heat range may cause engine damage. FUEL FILTER REPLACEMENT The fue fiter is ocated between the fue pump and the carburetor. Water or sediment accumuated in the fue fiter can cause oss of power or hard starting. To prevent engine mafunction, repace the fue fiter reguary. Gasoine is highy fammabe and exposive. You can be burned or seriousy injured when handing fue. Keep heat, sparks and fame away. Hande fue ony outdoors. Wipe up spis immediatey. 52

55 1. Disconnect the fue tank ine from the motor. 2. Remove the engine cover, and remove the fue fiter. Before removing the fiter, pace camps on the fue tubes on each side of the fiter to prevent fue eakage. 3. Insta the new fue fiterwith the arrow mark pointing toward the carburetor. Fue fow wi be impeded if the fiter is instaed backward. The arrow mark indicates the fue fow direction. FUEL FILTER If oss of power or hard starting is found to be caused by excessive water or sediment accumuated in the fue fiter, inspect the fue tank. Cean the fue tank if necessary. Remove the camps used to cose the fue tubes. Connect the fue tank ine to the motor. Turn the fue tank vent knob countercockwise to the open position, pump the primer bub, and check for eaks. 53

56 SERVICING YOUR HONDA OUTBOARD MOTOR RECOIL STARTER ROPE INSPECTION Inspect the recoi starter rope, and repace it if it becomes frayed. Aways keep the too kit s emergency starter rope onboard in case the recoi starter rope fais. The anode is a sacrificia materia which heps to protect the outboard motor from corrosion. ANODE Repace the anode when it has been reduced to about haf its origina size, or if it is crumbing. (1 Painting or coating the anode wi defeat its purpose and wi ead to rust and corrosion damage to the outboard motor. The anode must be exposed to the water. \ BOLT 54

57 SERVICING YOUR HONDA OUTBOARD MOTOR SHEAR PIN REPLACEMENT,- A shear pin is used to protect the propeer and drive mechanism from damage when the propeer strikes an obstruction. 1. Remove the cotter pin, the propeer cap, and the propeer. 2. Remove the broken shear pin and repace it with a new one. 3. Insta the propeer, then insta the propeer cap finger tight. 4. Insta a new cotter pin, and spread the ends as shown in the iustration. PROPELLER CAP GOITER PIN COTTER PIN SPARE SHEAR PINS i?r!! 55

58 HELPFUL TIPS & SUGGESTIONS STORING YOUR OUTBOARD MOTOR Storage Preparation Proper storage preparation is essentia for keeping your outboard motor troubefree and ooking good. The foowing steps wi hep to keep rust and corrosion from impairing your outboard motor s function and appearance, and wi make the engine easier to start when you use the outboard motor again. Ceaning and Fushing Wash the outside of the outboard motor with cean, fresh water, and fush the cooing system as described on page 43 or 44. Disengage the emergency engine stop switch cip from the engine stop switch, and pu the recoi starter rope severa times to expe any water remaining in the water pump. Touch up any damaged paint, and coat areas that may rust with a ight fim of oi. Lubricate contros with a siicone spray ubricant. Fue Gasoine wi oxidize and deteriorate in storage. Od gasoine wi cause hard starting, and it eaves gum deposits that cog the fue system. If the gasoine in your fue tank and carburetor deteriorates during storage, you may need to have the carburetor and other fue system components serviced or repaced. The ength of time that gasoine can be eft in your fue tank and carburetor without causing functiona probems wi vary with such factors as gasoine bend, your storage temperatures, and whether the fue tank is partiay or competey fied. The air in a partiay fied fue tank promotes fue deterioration. Very warm storage/temperatures acceerate fue deterioration. Fue deterioration probems may occur within a few months, or even ess if the gasoine was not fresh when you fied the fue tank. The Distributor s Limited Warranty does not cover fue system damage or engine performance probems resuting from negected storage preparation. 56

59 HELPFUL TIPS & SUGGESTIONS 1. Disconnect the fue hose from the outboard motor. 2. With the outboard motor in a vertica position, pace an approved gasoine container beow the fue drain outet, and use a funne to avoid spiing fue. Loosen the drain screw to drain fue from the carburetor. Gasoine is highy fammabe and exposive. You can be burned or seriousy injured when handing fue. Keep heat, sparks, and fame away. Hande fue ony outdoors. Wipe up spis immediatey. DRAIN SCREW 3. After the fue has drained from the carburetor, tighten the drain screw securey. 4. Drain the fue tank into an approved gasoine container, or if you need to store fue in the portabe fue tank, you can extend fue storage ife by fiing the fue tank with fresh gasoine and adding a fue stabiizer that is formuated for that purpose. Firmy cose the fue cap vent knob. Engine Oi 1. Change the engine oi (see page 46). 2. Remove the spark pug (see page 51). 3. Pour a tabespoon (5-10 cc) of cean engine oi into the cyinder. 4. Pu the starter rope severa times to distribute the oi in the cyinder. 5. Reinsta the spark pug. 57

60 HELPFULTIPS & SUGGESTIONS Storage Precautions Seect a we-ventiated humidity. storage area. If possibe, avoid storage areas with high If your portabe fue tank contains gasoine, store it away from any appiance that operates with a fame, such as a furnace, water heater, or cothes dryer. Aso avoid any area with a spark-producing eectric motor, or where power toos are operated. Store the outboard motor either verticay, or horizontay with the tier hande side down, as shown. If storing horizontay, be sure to fod the tier hande, so the outboard motor rests on it s case protectors. Be sure a water has drained from the outboard motor before pacing it on its side, so no residua water can enter the engine exhaust port. Any other storage position may cause damage or oi eakage.. Cover the outboard motor to keep out dust. Do not use sheet pastic as a dust cover. A nonporous cover wi trap moisture, promoting rust and corrosion. 58

61 HELPFUL TIPS & SUGGESTIONS Remova From Storage Check your outboard motor as described in the BEFORE OPERATON chapter of this manua. 7 If the cyinder was coated with oi during storage preparation, the engine may smoke briefy at startup. This is norma. TRANSPORTING When traiering a boat with the outboard motor attached, eave the engine in the norma running position, if possibe, and tighten the steering friction bot securey (p. 33). If there is insufficient road cearance in the norma running position, then tit the outboard motor, eave the tit ever in the tit position, and use a motor support device, such as a transom-saver bar, or remove the outboard motor from the boat. To transport the outboard motor when removed from the boat, secure it in either the vertica or horizonta position shown on page 58. To carry, hod the outboard motor by the carrying hande, or hod by the carrying hande and the ug beneath engine cover ock ever as shown beow. CARRYING HANDLE i Lifting the outboard motor by the engine cover, or using the instaed outboard motor as a hande or ever to move the boat, can damage the outboard motor. I 59

62 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START 1. Is the emergency stop switch cip in pace? 2. Is the gearshift ever in neutra? 3. Is there fue in the fue tank? 4. Is the fue cap vent knob turned to open? 5. Is the fue system primed by squeezing the primer bub? 6. Is fue reaching the carburetor? Loosen the carburetor drain screw to see if there is fue in the carburetor foat bow. I If any fue is spied, make sure the area is dry before testing the spark pug or starting the engine. Spied fue or fue vapor may ignite. I 7. Is the spark pug firing? a. Remove and inspect the spark pug. Cean and dry the pug, and check the eectrode gap (p. 51). b. Insta the spark pug in the cap, and ground the side eectrode to any engine ground away from the spark pug hoe. c. Pu the recoi starter brisky, and see if the pug spark. d. If the spark pug is OK, reinsta it, and try to start the engine. i. Engine overheats: 1. Is the water intake screen cogged? 2. Is the thermostat fauty? 60

63 TAKING CARE OF UNEXPECTED PROBLEMS SUBMERGED MOTOR A submerged motor must be serviced immediatey the water in order to minimize corrosion. after it is recovered from If there is a Honda marine deaership nearby, take the motor immediatey to the deaer. If you are far from a deaership, proceed as foows: 1. Remove the engine cover, and rinse the motor with fresh water to remove sat water, sand, mud, etc. 2. Loosen the carburetor drain screw (p. 57), drain the contents of the carburetor into a suitabe container, then tighten the drain screw. 3. Change the engine oi (p. 46). If there was water in the engine crankcase, or the used engine oi showed signs of water contaminaton, then a second engine oi change shoud be performed after running the engine for /2 hour. 4. Remove the spark pug. Disengage the emergency engine stop switch cip from the engine stop switch and pu the recoi starter severa times to competey expe water from the cyinder. When cranking the engine with an open ignition circuit (sparkpug removed from the ignition circuit), disengage the emergency engine stop switch cip from the engine stop switch to prevent eectrica damage to the ignition sys tern. If the engine was running when it submerged, there may be mechanica damage, such as bent connecting rod. If the engine binds when cranked, do not attempt to run the engine unti it has been repaired. 61

64 TAKING CARE OF UNEXPECTED PROBLEMS 5. Pour a teaspoon of engine oi into the spark pug hoe, then pu the recoi starter severa times to ubricate the inside of the cyinder. Reinsta the spark pug and engage the emergency engine stop switch cip with the engine stop switch. 6. Attempt to start the engine. If the engine fais to start, remove the spark pug, cean and dry the eectrode, then reinsta the spark pug and attempt to start the engine again. If the engine starts, and no mechanica damage is evident, continue to run the engine for /2 hour or onger (be sure the water eve is at east 2 inches above the antiventiation pate). 7. As soon as possibe, take the motor to a Honda marine deaer for inspection and service. 62

65 TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Seria Number Locations ENGINE SERIAL NUMBER V FRAME SERIAL NUMBER Record the engine and frame seria numbers in the space beow. You wi need these seria numbers when ordering parts, and when making technica or I warranty inquiries (see page 74). Engine seria number: Frame seria number: 63

66 TECHNICAL & CONSUMER INFORMATION Carburetor Modification for High Atitude Operation At high atitude, the standard carburetor air-fue mixture wi be too rich. Performance wi decrease, and fue consumption wi increase. A very rich mixture wi aso fou the spark pug and cause hard starting. High atitude performance can be improved by specific modifications to the carburetor. If you aways operate your engine at atitudes above 5,000 feet (1,500 meters), have an authorized Honda marine deaer perform this carburetor modification. _, Even with carburetor modification, engine horsepower wi decrease about 3.5%for each 1,OOO-foot (300-meter) increase in atitude. The effect of atitude on horsepower wi be greater than this if no carburetor modification is made. When the carburetor has been modified for high atitude operation, the air-fue mixture wi be too ean for ow atitude use. Operation at atitudes beow 5,000 feet (1,500 meters) with a modified carburetor may cause the engine to overheat and resut in serious engine damage. For use at ow atitudes, have an authorized Honda marine deaer return the carburetor to origina factory specifications. 64

67 TECHNICAL 81 CONSUMER INFORMATION Oxygenated Fues Some conventiona gasoines are being bended with acoho or an ether compound. These gasoines are coectivey referred to as oxygenated fues. To meet cean air standards, some areas of the United States and Canada use oxygenated fues to hep reduce emissions. If you use an oxygenated fue, be sure it is uneaded and meets the minimum octane rating requirement. Before using an oxygenated fue, try to confirm the fue s contents. Some states/provinces require this information to be posted on the pump. The foowing are the EPA-approved percentages of oxygenates: ETHANOL - (ethy or grain acoho) 10% by voume You may use gasoine containing up to 10% ethano by voume. Gasoine containing ethano may be marketed under the name Gasoho. MTBE (Methy Tertiary Buty Ether) 15% by voume You may use gasoine containing up to 15% MTBE by voume. METHANOL - (methy or wood acoho) 5% by voume You may use gasoine containing up to 5% methano by voume, as ong as it aso contains cosovents and corrosion inhibitors to protect the fue system. Gasoine containing more than 5% methano by voume may cause starting and/or performance probems. It may aso damage meta, rubber, and pastic parts of your fue system. If you notice any undesirabe operating symptoms, try another service station, or switch to another brand of gasoine. Fue system damage or performance probems resuting from the use of an oxygenated fue containing more than the percentages of oxygenates mentioned above are not covered under warranty. 65

68 TECHNICAL 81 CONSUMER INFORMATION Emission Contro System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Contro of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemica smog when subjected to sunight. Carbon monoxide does not react in the same way, but it is toxic. Honda utiizes ean carburetor settings and other systems to reduce the emissions of carbon monoxide oxides of nitrogen, and hydrocarbons. The U.S. and Caifornia Cean Air Acts EPA and Caifornia reguations require a manufacturers to furnish written instructions describing the operation and maintenance of emission contro systems. The foowing instructions and procedures must be foowed in order to keep the emissions from your Honda engine within the emission standards. Tampering and Atering Tampering with or atering the emission contro system may increase emissions beyond the ega imit. Among those acts that constitute tampering are: Remova or ateration of any part of the intake, fue, or exhaust systems. Aterations that woud cause the engine to operate outside its design parameters.

69 TECHNICAL & CONSUMER INFORMATION Probems That May Affect Emissions If you are aware of any of the foowing symptoms, have your engine inspected and repaired by your servicing deaer. Hard starting or staing after starting. Rough ide. Misfiring or backfiring under oad. Afterburning (backfiring). Back exhaust smoke or high fue consumption. Repacement Parts The emission contro systems on your Honda engine were designed, buit, and certified to conform with EPA and Caifornia emission reguations. We recommend the use of genuine Honda parts whenever you have maintenance done. These origina-design repacement parts are manufactured to the same standards as the origina parts, so you can be confident of their performance. The use of repacement parts that are not of the origina design and quaity may impair the effectiveness of your emission contro system. A manufacturer of an aftermarket part assumes the responsibiity that the part wi not adversey affect emission performance. The manufacturer or rebuider of the part must certify that use of the part wi not resut in a faiure of the engine to compy with emission reguations. Maintenance Foow the maintenance schedue on page 40. Remember that this schedue is based on the assumption that your machine wi be used for its designed purpose. Sustained high-oad or high-temperature operation, wi require more frequent service. 67

70 TECHNICAL & CONSUMER INFORMATION Star Labe A Star abe was appied to this outboard motor in accordance with the requirements of the Caifornia Air Resources Board. The Star Labe means Ceaner Marine Engines This engine has been certified as a: 1 q (XI c The Symbo for Ceaner Marine Engines: Ceaner Air and Water - for a heathier ifestye and environment. Better Fue Economy - burns up to percent ess gas and oi than conventiona carbureted two-stroke engines, saving money and resources. Longer Emission Warranty - protects consumer for worry free operation. I I 68

71 TECHNICAL & CONSUMER INFORMATION One Star - Low Emission The one-star abe identifies engines that meet the Air Resources Board s 2001 exhaust emission standards. Engines meeting these standards have 75% ower emissions than conventiona carbureted two-stroke engines. These engines are equivaent to the U.S. EPA s 2006 standards for marine engines. Two Stars - Very Low Emission The two-star abe identifies engines that meet the Air Resources Board s 2004 exhaust emission standards. Engines meeting these standards have 20% ower emissions than One Star - Low-Emission engines. Three Stars - Utra Low Emission The three-star abe identifies engines that meet the Air Resources Board s 2008 exhaust emission standards. Engines meeting these standards have 65% ower emissions than One Star - Low-Emission engines. Ceaner Watercraft - Get the Facts END-SMOG 69

72 TECHNICAL & CONSUMER INFORMATION Specifications Honda outboards are power rated in accordance with NMMA procedures and using the ICOMIA standard 28/23. 70

73 TECHNICAL & CONSUMER INFORMATION Tuneur,. Spark pug gap in ( mm) See page 51. Ide speed 1,100 f 50 rpm See shop manua. Vave cearance Intake: mm See shop manua. (cod) Exhaust: mm Other specifications No other adjustments needed. 71

74 TECHNICAL & CONSUMER INFORMATION WIRING DIAGRAM \ I J 72

75 TECHNICAL & CONSUMER INFORMATION CONSUMER INFORMATION Honda Pubications These pubications wi give you additiona information for maintaining and repairing your outboard motor. You may order them from your Honda marine deaer. Shop Manua This manua covers compete maintenance and overhau procedures. It is intended to be used by a skied technician. Parts Cataog This manua provides compete, iustrated parts ists. 73

76 TECHNICAL & CONSUMER INFORMATION Warranty Service Information Honda marine deaership personne are trained professionas. They shoud be abe to answer any question you may have. If you encounter a probem that your deaer does not sove to your satisfaction, pease discuss it with the deaership s management. The Service Manager or Genera Manager can hep. Amost a probems are soved in this way. If you are dissatisfied with the decision made by the deaership s management, contact the Honda Marine Customer Reations Office. You can write: American Honda Motor Co., Inc. Marine Division Customer Reations Office 4900 Marconi Drive Apharetta, Georgia Or teephone: (770) When you write or ca, pease give us this information: Mode and seria number (see page 63) Name of the deaer who sod the outboard motor to you Name and address of the deaer who services your outboard motor Date of purchase Your name, address, and teephone number A detaied description of the probem 74

77 INDEX A Anode ANODE REPLACEMENT BEFORE OPERATION ARE YOU READY TO GET UNDER WAY? Knowedge Safety Appare S YOUR OUTBOARD MOTOR READY TO GO? I Maintenance Inspection Safety Inspection BREAK-IN PROCEDURE C Choke Knob CONTENTS... 3 CONTROLS & FEATURES... t 0 COMPONENT & CONTROL LOCATIONS CONTROLS Choke Knob Engine Cover Lock Lever Engine Stop Switch Fue Cap Vent Knob Fue Priming Bub Gearshift Lever Recoi Starter Grip Steering Friction Bot Throtte Friction Knob Throtte Grip Tit Lever Transom Ange Adjusting Rod FEATURES Anode Fue Gauge Oi Pressure Indicator Light Water Check Tube CONSUMER INFORMATION COOLING SYSTEM CLEANING AND FLUSHING CRUISING Carbon Monoxide Hazard... 8 E EMERGENCY STARTING ENGINE OIL CHANGE ENGINE OIL LEVEL CHECK ENGINE OIL RECOMMENDATIONS ENGINE WILL NOT START

78 INDEX Emergency Engine Stopping Emission Contro System Information Engine Cover Lock Lever Engine Stop Switch F FEATURES Anode Fue Gauge Oi Pressure Indicator Light Water Check Hoe FUEL FILTER REPLACEMENT FUEL RECOMMENDATIONS Fue Cap Vent Knob Fue Gauge Fue Hose Connections Fue Priming Fue Priming Bub Fue Tank Pacement G GEAR OIL CHANGE GEAR OIL LEVEL CHECK GEAR SHIFTING Gearshift Lever H HELPFUL TIPS AND SUGGESTIONS STORING YOUR OUTBOARD MOTOR Remova From Storage Storage Precautions Storage Preparation Honda Pubications I INTRODUCTION... 1 IMPORTANT SAFETY INFORMATION INSTALLATION INSTALLATION HEIGHT INSTALLATION POSITION MOTOR ANGLE ADJUSTMENT MOTOR ANGLE FOR CRUISING OUTBOARD MOTOR ATTACHMENT L LUBRICATION

79 INDEX M Maintenance Inspection MAINTENANCE SAFETY....: Safety Precautions MAINTENANCE SCHEDULE MOTOR ANGLE ADJUSTMENT MOTOR ANGLE FOR CRUISING N Norma Engine Stopping Oi Pressure Indicator Light OPERATION BREAK-IN PROCEDURE CRUISING EMERGENCY STARTING GEAR S-WTNG PORTABLE FUEL TANK PLACEMENT AND CONNECTIONS Fue Hose Connections Fue Priming Fue Tank Pacement SAFE OPERATING PRECAUTIONS STARTING THE ENGINE STEERING STOPPING THE ENGINE Emergency Engine Stopping Norma Engine Stopping TILTING THE OUTBOARD MOTOR OUTBOARD MOTOR ATTACHMENT Qxygenerated Fues P PORTABLE FUEL TANK PLACEMENT AND CONNECTIONS Fue Hose Connections Fue Priming Fue Tank Pacement Q QUICK REFERENCE INFORMATION... Inside back cover R Recoi Starter Grip RECOIL STARTER ROPE INSPECTION REFUELING Remova From Storage

80 INDEX S SAFE OPERATING PRECAUTIONS SAFETY, A FEW WORDS ABOUT Safety Inspection SAFETY, OUTBOARD MOTOR... 2 IMPORTANT SAFETY INFORMATION Carbon Monoxide Hazard... 8 Operating Responsibiity... 7 Refue With Care... 8 SAFETY LABEL LOCATIONS... 9 SHEAR PIN REPLACEMENT SPARK PLUG SERVICE Star Labe STARTING THE ENGINE STEERING STOPPING THE ENGINE STORING YOUR OUTBOARD MOTOR Seria Number Locations Specifications Steering Friction Bot Storage Precautions Storage Preparation SUBMERGED MOTOR T TAKING CARE OF UNEXPECTED PROBLEMS TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION THE IMPORTANCE OF MAINTENANCE Throtte Friction Knob Throtte Grip TILTING THE OUTBOARD MOTOR Tit Lever TOOL KIT AND SPARE PARTS TRANSPORTING Transom Ange Adjusting Rod W Warranty Service Information Water Check Tube WIRING DIAGRAM

81 MEMO 79

82 MEMO i 80

83 QUICK REFERENCE INFORMATION Fue Engine Oi Gear Oi Spark Pug Carburetor Maintenance Type Capacity Type Uneaded gasoine with a pump octane rating of 86 or higher (page 42) 3.2 US ga (12.0 J?) SAE 1 OW-30, API SF or SG, for genera use (page 50) Capacity 0.58 US qt (0.55 1) Type Capacity Type Marine SAE 90 hypoid, API GL-4 or GL us qt (0.1 Q BPR5ES (NGK); W GEPR-U, W14ERR-U (DENSO) Gap in ( mm) (page 51) Ide speed 1,100+50rpm Check engine oi eve (page 45). Before Check fue hose (page 25). each use Check propeer and cotter pin (page 55). Check anode (page 54) First 20 hours Refer to the Subsequent page 40. Change engine oi (page 46). Change gear oi (page 49). Check carburetor inkage. Check/adjust vave cearance. Grease ubrication points (page 50). maintenance schedue on

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