2005 - American Honda Motor Company€¦ · 4 CONTENTS INDICATORS . 29..... Alternator (ACG)...

BF200A/BF225AOwner’s Manual

©2004 Honda Motor Co., Ltd. -All Rights Reserved31ZY260400X31-ZY2-6040

2eY1800.2004.04Printed in JapanN 2005

PANTONE 288 CVC DIC F101 31ZY2604 00X31-ZY2-6040 BLACK

The engine exhaust from thisproduct contains chemicalsknown to the State of California tocause cancer, birth defects, orother reproductive harm.

Keep this owner’s manual handy, so you can refer to it at any time. This owner’smanual is considered a permanent part of the outboard motor and should remain withthe outboard motor if resold.

The information and specifications included in this publication were in effect at thetime of approval for printing. Honda Motor Co., Ltd. reserves the right, however, todiscontinue or change specifications or design at any time without notice and withoutincurring any obligation whatever. No part of this publication may be reproducedwithout written permission.

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1

INTRODUCTION

Congratulations on your selection ofa Honda outboard motor. We arecertain you will be pleased with yourpurchase of one of the finestoutboard motors on the market.

We want to help you get the bestresults from your new outboardmotor and to operate it safely. Thismanual contains information on howto do that; please read it carefully.

We suggest you read the warrantypolicy to fully understand itscoverage and your responsibilities ofownership.

When your outboard motor needsscheduled maintenance, keep in mindthat your Honda marine dealer isspecially trained in servicing Hondaoutboard motors. Your Honda marinedealer is dedicated to yoursatisfaction and will be pleased toanswer your questions and concerns.

2004 Honda Motor Co., Ltd. AllRights Reserved

As you read this manual you willfind information preceded by a

symbol. That informationis intended to help you avoid damageto your outboard motor, otherproperty, or the environment.

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2

A FEW WORDS ABOUTSAFETY

INTRODUCTION

Safety Messages

Safety Headings

Safety Labels

Safety Section

Instructions

IMPORTANT SAFETY INFORMATION.

OUTBOARD MOTOR SAFETY.

Your safety and the safety of othersare very important. And using thisoutboard motor safely is an importantresponsibility.

To help you make informeddecisions about safety, we haveprovided operating procedures andother information on labels and inthis manual. This information alertsyou to potential hazards that couldhurt you or others.

Of course, it is not practical orpossible to warn you about all thehazards associated with operating ormaintaining an outboard motor. Youmust use your own good judgment.

You will find important safety information in a variety of forms, including:

This entire book is filled with important safety information please read itcarefully.

preceded by a safety alert symbol and one ofthree signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

such as

on the outboard motor.

such as

how to use this outboard motor correctly and safely.

You WILL be KILLED or SERIOUSLYHURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLYHURT if you don’t follow instructions.

You CAN be HURT if you don’t followinstructions.

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3

CONTENTS

...................................OUTBOARD MOTOR SAFETY . 7................IMPORTANT SAFETY INFORMATION . 7

..................................SAFETY LABEL LOCATION . 9

..................................CONTROLS AND FEATURES . 10CONTROL AND FEATURE IDENTIFICATION

..................................................................CODES . 10....COMPONENT AND CONTROL LOCATIONS . 11

..............................................................CONTROLS . 15Side-Mount Type

......................................................Ignition Switch . 15.............Switch Clip and Emergency Stop Switch . 16

..........................Gearshift/Throttle Control Lever . 16.......................................................Fast Idle Lever . 18

Panel-Mount Type......................................................Ignition Switch . 18

.............Switch Clip and Emergency Stop Switch . 19.....................................................Fast Idle Button . 20

..........................Gearshift/Throttle Control Lever . 20

Top-Mount Type......................................................Ignition Switch . 22

.............Switch Clip and Emergency Stop Switch . 22.....................................................Fast Idle Button . 23

..........................Gearshift/Throttle Control Lever . 23Common Controls

........................................Power Trim/Tilt Switch . 25..................................................Power Tilt Switch . 26

.............................................Manual Relief Valve . 26.....................................................Tilt Lock Lever . 26

..............................................Engine Cover Latch . 27................................................................Trim Tab . 27

.......................................................INSTRUMENTS . 27.........................Trim Meter (optional equipment) . 27.........................Tachometer (optional equipment) . 28

.............Digital Tachometer (optional equipment) . 28...........Digital Speedometer (optional equipment) . 28

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4

CONTENTS

...........................................................INDICATORS . 29...................................Alternator (ACG) Indicator . 29

..Programmed Fuel Injection (PGM-FI) Indicator . 29............................................Oil Pressure Indicator . 30

.................................................Overheat Indicator . 30.....................................Cooling System Indicator . 31

................................................OTHER FEATURES . 31........................................Water Separator Buzzer . 31

.....................................................Overrev Limiter . 32...................................................................Anodes . 32

.................................................Fuel Priming Bulb . 32

................................................BEFORE OPERATION . 33........ARE YOU READY TO GET UNDER WAY? . 33

IS YOUR OUTBOARD MOTOR..................................................READY TO GO? . 33

................................................................OPERATION . 35....................SAFE OPERATING PRECAUTIONS . 35

.......................................BREAK-IN PROCEDURE . 35.......................................................FUEL PRIMING . 36

......................................STARTING THE ENGINE . 37..................................................Side-Mount Type . 37.................................................Panel-Mount Type . 40

...................................................Top-Mount Type . 42.......................................STOPPING THE ENGINE . 44

................................Emergency Engine Stopping . 44.......................................Normal Engine Stopping . 45

GEARSHIFT AND..............................THROTTLE OPERATION . 46

..................................................Side-Mount Type . 46.................................................Panel-Mount Type . 47

...................................................Top-Mount Type . 47...............................................................STEERING . 48................................................................CRUISING . 49

........................SHALLOW WATER OPERATION . 51...............MOORING, BEACHING, LAUNCHING . 51

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5

CONTENTS

..............SERVICING YOUR OUTBOARD MOTOR . 53...........THE IMPORTANCE OF MAINTENANCE . 53

.....................................MAINTENANCE SAFETY . 54...................TOOL KIT and OWNER’S MANUAL . 55

...............................MAINTENANCE SCHEDULE . 56....................................TRIM TAB ADJUSTMENT . 58....................................MANUAL RELIEF VALVE . 59

ENGINE COVER REMOVAL AND..................................................INSTALLATION . 59

............................................Engine Oil Level Check . 60....................................................Engine Oil Change . 60

.......................................................Oil Filter Change . 61..................................Engine Oil Recommendations . 63

.....................................................Lubrication Points . 64

....................................................Spark Plug Service . 65.............................................................REFUELING . 68

...............................FUEL RECOMMENDATIONS . 69...................Fuel Filter Inspection and Replacement . 70...................Water Separator Inspection and Service . 72

..................................................Anode Replacement . 74..............................................Propeller Replacement . 75

....................................................................STORAGE . 76...................................STORAGE PREPARATION . 76

..........................................Cleaning and Flushing . 76........................................................................Fuel . 78

.............................................................Engine Oil . 79................HOISTING THE OUTBOARD MOTOR . 79

...................................STORAGE PRECAUTIONS . 80...............................REMOVAL FROM STORAGE . 81

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6

CONTENTS

........................................................TRANSPORTING . 82WITH OUTBOARD MOTOR

......................................INSTALLED ON BOAT . 82WITH OUTBOARD MOTOR

..................................REMOVED FROM BOAT . 82

....TAKING CARE OF UNEXPECTED PROBLEMS . 83BATTERY WILL NOT CHARGE AND

ELECTRIC STARTER WILL NOT.........................................................OPERATE . 88

.................................................Fuse Replacement . 88OIL PRESSURE INDICATOR LIGHT GOES OFF

...................AND ENGINE SPEED IS LIMITED . 90OVERHEAT INDICATOR COMES ON AND

............................ENGINE SPEED IS LIMITED . 91..........WATER SEPARATOR BUZZER SOUNDS . 92

.....................WATER SEPARATOR INDICATOR . 92..........................................SUBMERGED MOTOR . 93

..TECHNICAL AND CONSUMER INFORMATION . 95...............................TECHNICAL INFORMATION . 95

......................................Serial Number Locations . 95..................................................Oxygenated Fuels . 96

...................................................................Battery . 97.................Emission Control System Information . 97

............................................................Star Label . 100......................................................Specifications . 102

.............................CONSUMER INFORMATION . 105

.........................................................................INDEX . 110

........................WIRING DIAGRAMS . Inside Back Cover

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7

IMPORTANT SAFETYINFORMATION

Operator Responsibility

OUTBOARD MOTOR SAFETY

Most accidents can be prevented ifyou follow all instructions in thismanual and on the outboard motor.The most common hazards arediscussed below, along with the bestway to protect yourself and others.

It is the operator’s responsibility toprovide the necessary safeguardsto protect people and property.Know how to stop the enginequickly in case of emergency.Understand the use of all controls.

Attach the emergency stop switchlanyard securely to the operator.

Stop the engine immediately ifanyone falls overboard, and do notrun the engine while the boat isnear anyone in the water.

Always stop the engine if youmust leave the controls for anyreason.

Always wear a PFD (PersonalFlotation Device) while on theboat.

Familiarize yourself with all lawsand regulations relating to boatingand the use of outboard motors.

Be sure that anyone who operatesthe outboard motor receives properinstruction.

Be sure the outboard motor isproperly mounted on the boat.

Do not remove the engine coverwhile the engine is running.

Honda BF200A/BF225A outboardmotors are designed for use withboats that have a suitablemanufacturer’s powerrecommendation. Other uses canresult in injury to the operator ordamage to the outboard motor andother property.

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8

Carbon Monoxide HazardRefuel With Care


Exhaust gas contains poisonouscarbon monoxide. Avoid inhalationof exhaust gas. Never run the enginein a closed garage or confined area.

Gasoline is extremely flammable,and gasoline vapor can explode.Refuel outdoors, in a well-ventilated area, with the enginestopped. Never smoke neargasoline, and keep other flamesand sparks away.

Refuel carefully to avoid spillingfuel. Avoid overfilling the fueltank.

After refueling, tighten the fillercap securely. If any fuel is spilled,make sure the area is dry beforestarting the engine.

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9

SAFETY LABEL LOCATION


The label shown here contains important safety information. Please read it carefully. These label is considered apermanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized Hondamarine dealer for a replacement.

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10

CONTROL AND FEATURE IDENTIFICATION CODES

CONTROLS AND FEATURES

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

Destination

ACTYPE CODE (example)

A: AmericaRotating direction of propeller shaftC: Counterrotating propeller shaftNone: Standard rotating propeller shaftTransom Height

X

L: 20.0 in (508 mm), X: 25.0 in (635 mm), XX: 30.0 in (762 mm)

Transom Height

Standard Rotating Propeller Shaft

Counterrotating Propeller Shaft

Power Trim/Tilt

Model

Type LA XA XCA XXA XXCA LA XA XCA XXA XXCA

BF200A BF225A

20.0 in (508 mm)

25.0 in (635 mm)

30.0 in (762 mm)

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11

COMPONENT AND CONTROL LOCATIONS


ENGINE COVER

ANODE

OIL LEVEL DIPSTICK

ANODE

TRIM TAB

ANODE

OIL FILLER CAP(inside engine cover)

STERNBRACKET

PROPELLER

COOLINGWATERINTAKE PORT

FRAME SERIALNUMBER

TILT LOCKLEVER

POWER TILTSWITCH

MANUALRELIEFVALVE

ENGINE COVERLATCH

SPARK PLUG(under coil)

COOLING SYSTEMINDICATOR

ENGINE OILDRAIN BOLT(inside cover)

ANTIVENTILATIONPLATE

EXHAUST PORT/WATEROUTLET PORT

GEAR OILLEVEL PLUG

GEAR OIL DRAIN/FILL PLUG

FLUSH PORTCONNECTOR

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12

Remote Controls (optional equipment)


EMERGENCYSTOP SWITCH

FAST IDLELEVER

IGNITIONSWITCH

POWER TRIM/TILTSWITCH

NEUTRALRELEASELEVER

CONTROL LEVERFRICTION ADJUSTER

NEUTRALRELEASELEVER

POWER TRIM/TILTSWITCH

BUZZER(inside)

(SIDE-MOUNT REMOTE CONTROL) (PANEL-MOUNT REMOTE CONTROL)

GEARSHIFT/THROTTLECONTROL LEVER

FAST IDLEBUTTON


SPARE SWITCH CLIP

LANYARD

SWITCH CLIP

OIL PRESSUREINDICATOR

OVERHEATINDICATOR

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13


POWERTRIM/TILTSWITCH

POWER TRIM/TILTSWITCH (RIGHT)

POWER TRIM/TILTSWITCH (LEFT)

BUZZERIGNITIONSWITCH

CONTROL PANEL(for PANEL/TOP-MOUNT type)

(SINGLE TOP-MOUNT REMOTE CONTROL) (DUAL TOP-MOUNT REMOTE CONTROL)


FAST IDLEBUTTON FAST IDLE

BUTTON

GEARSHIFT/THROTTLECONTROL LEVER GEARSHIFT/THROTTLE

CONTROL LEVERS

SWITCH CLIP

LANYARD

(for TOP-MOUNT DUAL type)OIL PRESSUREINDICATOR

OVERHEATINDICATOR

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14

Trim Meter(optional equipment)

Digital SpeedometerTachometer(optional equipment) (optional equipment)

Digital Tachometer(optional equipment)


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15

CONTROLS

Side-Mount Type


STARTOONNOOFFFF

IGNITIONSWITCH

Ignition Switch

Turning the ignition switch key to theSTART position operates the startermotor. The key automatically returnsto the ON position when releasedfrom the START position.

The ignition switch can be used tooperate the starter motor only whenthe control lever (p. ) is in the N(neutral) position, and the switch clipis in the emergency stop switch.

Turning the ignition switch to theOFF position stops the engine.

The ignition switch controls theignition system and starter motor.

17

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16



SWITCH CLIPLANYARD

SWITCH CLIPLANYARD

SPARE SWITCH CLIP

CONTROL LEVER

NEUTRAL RELEASELEVER

Switch Clip and Emergency StopSwitch

Gearshif t/Throttle ControlLever

The switch clip must be inserted inthe emergency stop switch in orderfor the engine to start and run. Thelanyard must be attached to theoperator’s PFD (Personal FlotationDevice) or worn around the wrist asshown.

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

A spare switch clip is stored in a slotin the control housing (optionalequipment).

The gearshift/throttle control levercontrols engine speed and selects F(forward), N (neutral), or R (reverse)gears.

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17


F (FORWARD)


30° 30°

TTHHRROOTTTTLLEE OOPPEENNIINNGG


MAXIMUM

MAXIMUM

SHIFT SHIFT

MMIINNIIMMUUMMMMIINNIIMMUUMM

N (NEUTRAL)

R (REVERSE)

Moving the control lever 30° from N(neutral) selects the gear, and furthermovement increases engine speed.

A friction adjuster near the base ofthe control lever(s) adjusts theoperating resistance of the controllever(s).

The control lever automatically locksitself in the N (neutral) position. Tomove the lever out of the N (neutral)position, you must squeeze theneutral release lever on the undersideof the lever handle.

Less friction allows easier controllever movement. More friction helpsto hold a steady throttle setting whilecruising.

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18

Panel-Mount Type


FAST IDLE LEVER

MAXIMUM FAST IDLE

LOWEST POSITION

STARTON

OFF

IGNITIONSWITCH KEY

N (neutral)Fast Idle Lever

Ignition Switch


After the engine starts and if theoutside temperature is below 41°F(5°C), the fast idle lever can be usedto accelerate engine warm up.

The fast idle lever will not moveunless the remote control lever is inthe N (neutral) position. Conversely,the remote control lever will notmove unless the fast idle lever is inthe lowest position.

Lower the fast idle lever to thelowest position to decrease the fastidle.

The fast idle lever is only needed forstarting carbureted outboard models.The BF200A and BF225A modelsuse programmed fuel injection so,this lever will not be needed forstarting.

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19


LANYARDSWITCH CLIP

LANYARD

SWITCH CLIP


SPARE SWITCH CLIP(optional equipment)







A spare switch clip (optionalequipment) can be stored in the toolbag.

21

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20


CONTROL LEVER

NEUTRAL RELEASELEVER

CONTROLLEVER

NEUTRALRELEASELEVER

Push

R (reverse)F (forward)

PPuullll uupp

FAST IDLE BUTTON

N (neutral)


Fast Idle Button It is necessary to position the controllever in N (neutral) to push in the fastidle button.


By moving the control lever forwardor reverse when the fast idle button ispushed in, the throttle opening willbe increased without engaging thegears.

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21



35° 35°

SHIFT SHIFT

MMIINNIIMMUUMMMMIINNIIMMUUMM

MAXIMUM

MAXIMUM

N (NEUTRAL)

F (FORWARD) R (REVERSE)

TTHHRROOTTTTLLEE OOPPEENNIINNGGTTHHRROOTTTTLLEE OOPPEENNIINNGG


The control lever automatically locksitself in the N (neutral) position. Tomove the lever out of the N (neutral)position, you must squeeze theneutral release lever on the undersideof the lever handle.

A friction adjuster near the base ofthe control lever adjusts the operatingresistance of the control lever. Referto p. .


47

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22

Top-Mount Type


EMERGENCYSTOPSWITCH

LANYARDSWITCH CLIP

LANYARD

SWITCH CLIP

ON

OFF

START

IGNITIONSWITCHKEY


Ignition Switch





24

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23


SINGLE TYPE

DUAL TYPE

CCOONNTTRROOLLLLEEVVEERRSS

CCOONNTTRROOLLLLEEVVEERR

CONTROLLEVER

Push

N (neutral)F (forward)

R (reverse)

FAST IDLE BUTTON

SPARE SWITCH CLIP(optional equipment)


Fast Idle Button




By moving the control lever forwardor reverse when the fast idle button ispushed in, the throttle opening willbe increased without engaging thegears.

It is necessary to position the controllever in N (neutral) to push in the fastidle button.

A spare switch clip (optionalequipment) can be stored in the toolbag.

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24




SHIFT SHIFT

MAXIMUM

MAXIMUM

35° 35°

MMIINNIIMMUUMM

MMIINNIIMMUUMM

F (FORWARD)

N (NEUTRAL)

R (REVERSE)

GEARSHIFT/THROTTLE CONTROL LEVER


A friction adjuster inside the controlbox adjusts the operating resistanceof the control lever(s).


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25

Common Controls

Power Trim/Tilt Switch


(side-mount type) (top-mount type)

(panel-mount type)

CONTROLLEVER

CONTROL LEVER

CONTROLLEVER

DUAL TYPE

(LEFT) (RIGHT)

CCOONNTTRROOLLLLEEVVEERR

POWER TRIM/TILT SWITCH

POWERTRIM/TILTSWITCH



SINGLE TYPE

The power trim/tilt switch is locatedon the control lever. It is a rockerswitch with UP and DN (down)positions for changing the angle ofthe outboard motor.

You can use the power trim/tiltswitch anytime whether the boat isunderway, stopped, or the ignitionswitch is in the OFF position. It isnecessary for the ignition switch tobe in the ON position for the trimmeter to indicate the motor angle.

Trim the outboard motor to obtainthe best performance and stability(p. ).

Tilt the outboard motor for shallowwater operation, beaching, launching,or mooring.

For dual mount outboards, tilt themup at the same time.

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26

Power Tilt Switch Manual Relief Valve Tilt Lock Lever


POWER TILT SWITCH MMAANNUUAALL RREELLIIEEFF VVAALLVVEETTIILLTT LLOOCCKKLLEEVVEERR

PPOOWWEERR((TToo ffiixx))

FFRREEEE

MMAANNUUAALL((TToo rreelleeaassee))

LLOOCCKK

This switch is used with the enginestopped to raise the outboard motorfor mooring, trailering ormaintenance.

The power tilt switch will operatewithout turning the ignition switchON.

The power tilt switch is located onthe engine pan. It is a rocker switchwith UP and DN (down) positionsfor changing the angle of theoutboard motor.

The outboard motor can be tiltedmanually after opening the manualrelief valve. This allows the outboardmotor to be tilted when no battery isconnected. When the boat is to be moored for a

long time, tilt the outboard motor asfar as it will go. Then move the tiltlock lever to the LOCK position, andgently lower the outboard motor untilthe lever contacts the stern bracket.

The tilt lock lever is used to supportthe outboard motor in the fully-raisedposition.

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27

INSTRUMENTS

Trim Meter(optional equipment)

Trim TabEngine Cover Latch


TRIM METER

TRIM TAB

TIGHTENINGBOLTENGINE COVER

LATCH

UUNNLLOOCCKK

When the trim tab is correctlyadjusted (p. ), steering effort isequal in either direction.

If uncompensated, torque steer wouldmake the outboard motor tend to turnto one side.

The trim tab compensates for‘‘torque steer,’’ which is a reaction ofthe outboard motor to propellerrotation.

The engine cover latch fastens theengine cover to the outboard motor.

The trim meter has a range of 4° to16° and indicates the trim angle ofthe outboard motor.

Refer to the trim meter when usingthe power trim/tilt switch to achievethe best performance from the boat.

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28

Tachometer(optional equipment)

Digital Tachometer(optional equipment)

Digital Speedometer(optional equipment)


TACHOMETER

The tachometer shows engine speedin revolutions per minute.

Refer to the tachometer when usingthe throttle and power trim/tiltcontrols to achieve the bestperformance from the boat.

Digital Tachometer includes thefollowing functions.

Refer to the Operation Guideincluded with each DigitalTachometer for operationinformation.

Refer to the Operation Guideincluded with each DigitalSpeedometer for operationinformation.

TachometerHour MeterTrim MeterOil pressure IndicatorOverheat IndicatorACG IndicatorPGM-FI Indicator

Water Separator IndicatorFuel Flow MeterFuel Economy MeterFuel Integration MeterTripmeterVolt MeterFuel level MeterSpeedometer

Digital Speedometer includes thefollowing functions.

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29

INDICATORS

Alternator (ACG) Indicator

Programmed Fuel Injection(PGM-FI) Indicator


ACG INDICATOR PGM-FI INDICATOR

Under normal conditions when theignition key is turned on thefollowing will occur:

The ACG indicator turns on and thebuzzer sounds in one-secondintervals when the charging system isfaulty.

When the engine control systemdetects an PGM-FI malfunction, thePGM-FI indicator turns on and thebuzzer sounds at one-secondintervals.

The buzzer will beep twice.The PGM-FI indicator will turnoff shortly after the second beep.The ACG indicator will turn offafter the engine starts.

Both the PGM-FI indicator andACG indicator will turn on.

1.

2.3.

4.

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30

Overheat IndicatorOil Pressure Indicator


(side-mount type) (side-mount type)

(panel-mount/top-mount types) (panel-mount/top-mount types)

(GREEN)

(GREEN)

(RED)

(RED)Low oil pressure indicates that theengine oil level is low, or that there isa problem with the engine lubricationsystem.

When the oil pressure indicator is lit,oil pressure is OK.

If oil pressure becomes low, theindicator will go off, and the engineprotection system will limit enginespeed. Refer to TAKING CARE OFUNEXPECTED PROBLEMS, fromp. .

All models are equipped with abuzzer that sounds when the oilpressure indicator goes off.

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31

Cooling System Indicator OTHER FEATURES

Water Separator Buzzer


COOLING SYSTEM INDICATOR

Water should flow from the coolingsystem indicator while the engine isrunning. This shows that water iscirculating through the coolingsystem.

If water stops flowing while theengine is running, it indicates acooling system problem, such asclogged water intakes, which willcause engine overheating.

The water separator buzzer sounds arapid, repeating signal when waterhas accumulated in the waterseparator.

When the alert triggers, the overheatindicator comes on and the buzzersounds a steady tone as the enginespeed is reduced to 1,800 rpm. If thecondition persists for another 20seconds, the engine shuts off. Referto TAKING CARE OFUNEXPECTED PROBLEMS, fromp. .

Engine overheating may be the resultof clogged water intakes.

All models are equipped with abuzzer that sounds a steady tonewhen the overheat indicator comeson.

91

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32

Anodes Fuel Priming BulbOverrev Limiter


ANODE(each side)

ANODE(stern bracket)

PRIMING BULB

UP

OUTLET END(motor)

INLET END (tank)

The anodes are made of a sacrificialmaterial that helps to protect theoutboard motor from corrosion.

There are two anodes on the gearcase, one on the stern bracket, andtwo small anodes in the waterpassages of the engine block.

Before starting the engine, hold thepriming bulb up in the direction ofthe arrow, then squeeze the primingbulb until it feels firm. This willensure that fuel is supplied to theengine (p. ).

A priming bulb is built into the fuelhose that connects the fuel tank to theoutboard motor.

The engine is equipped with anoverrev limiter to prevent thepossibility of mechanical damagefrom excessive engine speed.

The overrev limiter may be activatedduring operation, limiting enginespeed, if the outboard motor istrimmed or tilted excessively, orwhen propeller ventilation occursduring a sharp turn.

Check to see if the correct propelleris installed.

If the overrev limiter is activated,check the trim angle of the outboardmotor.

36

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Improperly maintainingthis outboard motor, orfailing to correct a problembefore operation, can causea malfunction in which youcould be seriously hurt orkilled.

Always perform apreoperation inspectionbefore each operation, andcorrect any problem.

33

ARE YOU READY TO GETUNDER WAY?

Safety

KnowledgeIS YOUR OUTBOARDMOTOR READY TO GO?

BEFORE OPERATION

Your safety is your responsibility. Alittle time spent in preparation willsignificantly reduce your risk ofinjury.

Read and understand this manual.Know what the controls do and howto operate them.

Familiarize yourself with theoutboard motor and its operationbefore you get under way. Knowwhat to do in case of emergencies.

Familiarize yourself with all lawsand regulations relating to boatingand the use of outboard motors.

Always wear a PFD (PersonalFlotation Device) while on the boat.

Attach the emergency stop switchlanyard securely to your PFD or toyour wrist.

For your safety, and to maximize theservice life of your equipment, it isvery important to take a fewmoments before you operate theoutboard motor to check its condition.Be sure to take care of any problemyou find, or have your authorizedHonda marine dealer correct it,before you operate the outboardmotor.

Before beginning your preoperationchecks, be sure the ignition switch isin the OFF position.

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34

Safety Inspection Maintenance Inspection

BEFORE OPERATION

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

Check the stern bracket to be surethe outboard motor is securelyinstalled.

Wipe up any spills before startingthe engine.

Check that all controls areoperating properly.

Replace any damaged parts.

Check that the fuel hose isundamaged and properlyconnected.

Check that all fasteners are inplace and securely tightened.

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

Check to be sure the propeller isundamaged, and the castle nut issecured with the cotter pin (p. ).

Check that the anodes are securelyattached to the gear case (p. )and are not excessively worn. Theanodes help to protect the outboardmotor from corrosion.

Make sure the tool kit is onboard(p. ). Replace any missing items.

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

Check the water separator forwater contamination (p. ).

Check that the battery fluid isbetween the upper and lower levels,and the battery leads are connectedsecurely.

60

75

74

55

68

72

04/03/29 10:33:56 31ZY2600_035

35

SAFE OPERATINGPRECAUTIONS

BREAK-IN PROCEDURE

Break-in period: 10 hours

First 15 minutes:

Next 45 minutes:

Next 60 minutes:

Next 8 hours:

OPERATION

IMPORTANT SAFETYINFORMATION

BEFORE OPERATION.

To safely realize the full potential ofthis outboard motor, you need acomplete understanding of itsoperation and a certain amount ofpractice with its controls.

Before operating the outboard motorfor the first time, please review the

on page and thechapter titled

For your safety, avoid starting oroperating the engine in an enclosedarea. Your engine’s exhaust containspoisonous carbon monoxide gaswhich can collect rapidly in anenclosed area and cause illness ordeath.

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

Run the engine at trolling speed. Usethe minimum throttle openingnecessary to operate the boat at a safetrolling speed.

Run the engine up to a maximum of2,000 to 3,000 rpm, which is about10% to 30% of maximum throttleopening.

Run the engine up to a maximum of4,000 to 5,000 rpm, which is about50% to 80% of maximum throttleopening.

Short full-throttle bursts are OK, butdo not operate the enginecontinuously at full throttle.

For boats that plane easily, bring theboat up on plane, and then reduce thethrottle opening to the recommendedrpm range.

Do not run the engine at full throttlefor more than 5 minutes at a time.

7

04/03/29 10:34:11 31ZY2600_036

Gasoline is highlyflammable and explosive.

You can be burned orseriously injured whenhandling fuel.

Stop the engine and keepheat, sparks, and flameaway.Handle fuel onlyoutdoors.Wipe up spillsimmediately.

36

FUEL PRIMING

OPERATION

PRIMING BULB

UPOUTLET END(motor)

INLET END(tank)

Check to be sure there are no fuelleaks before starting the engine.

Do not squeeze the priming bulbwhen the engine is running.

Hold the priming bulb up in thedirection of the arrow, then squeezethe priming bulb several times until itfeels firm, indicating that fuel hasreached the engine.

04/03/29 10:34:22 31ZY2600_037

37

STARTING THE ENGINE

Side-Mount Type

OPERATION

LANYARDSWITCH CLIP


N (neutral)

CONTROLLEVER

Put the emergency stop switch clipin the emergency stop switch, andattach the lanyard to your PFD(Personal Flotation Device) or toyour wrist, as shown.

The engine will not start or run,unless the clip is in the switch.

The emergency stop switch clipand lanyard system is a safetydevice that will stop the engine ifyou fall away from the controlswhile operating the boat.

Always attach the lanyard to yourPFD, or to your wrist, beforestarting the engine.

Set the control lever in the N(neutral) position.

The engine will not start if the F(forward) or R (reverse) gears areengaged.

1. 2.

04/03/29 10:34:32 31ZY2600_038

38

OPERATION

IGNITION SWITCH KEY

ONSTARTOFF

FAST IDLE RANGE

LOWESTPOSITION

Using the electric starter f or morethan 5 seconds at a time willoverheat the starter motor and candamage it.

Turning the ignition switch key tothe START position while theengine is running can damage thestarter motor and f lywheel.

Leave the fast idle lever in theOFF (fully lowered) position.

Fast idle lever cannot be raisedunless the control lever is in the N(neutral) position.

The control lever cannot be movedaway from the N (neutral) positionunless the fast idle lever is lowered.

Turn the ignition switch key to theSTART position and hold it thereuntil the engine starts.

When the engine starts, release thekey, allowing it to return to the ONposition.

If the engine fails to start within 5seconds, release the key and waitat least 10 seconds beforeoperating the starter again.

3. 4.

04/03/29 10:34:43 31ZY2600_039

39

OPERATION

FAST IDLERANGE

MAXIMUM FAST IDLE

TAKING CARE OFUNEXPECTED PROBLEMS

If the engine is not properlywarmed-up bef ore raising the enginespeed, the buzzer and overheatindicator may activate, and theengine speed will be automaticallyreduced.

Before getting under way, allowthe engine to warm up sufficientlyto ensure good performance.

Above 41°F (5°C), warm up theengine for 2 or 3 minutes.

Below 41°F (5°C), warm up theengine for at least 10 minutes at2,000 rpm. Raise the fast idle leverto achieve approximately 2,000rpm.

If the fast idle lever was used towarm up the engine, graduallylower the lever as the enginewarms up.

When the fast idle lever is fullylowered, the control lever can bemoved away from the N (neutral)position.

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

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

from p. .

5.

6.

3030

31

83

04/03/29 10:34:53 31ZY2600_040

40

Panel-Mount Type

OPERATION

LANYARDSWITCH CLIP

EMERGENCY STOPSWITCH

CONTROLLEVER

N (neutral)The engine will not start or run,unless the clip is in the switch.





Put the emergency stop switch clipin the emergency stop switch, andattach the lanyard to your PFD(Personal Flotation Device) or toyour wrist, as shown.

1. 2.

04/03/29 10:35:03 31ZY2600_041

41

OPERATION

ON

OFF

IGNITIONSWITCHKEY

START

CONTROLLEVER

N (neutral)

FAST IDLE BUTTON


Using the electric starter f or morethan 5 seconds at a time willoverheat the starter motor and candamage it.






Below 41°F (5°C), warm up theengine for at least 10 minutes at2,000 rpm. Push the fast idlebutton then move the control leverforward or reverse to open thethrottle and achieve approximately2,000 rpm.

3. 4.

04/03/29 10:35:15 31ZY2600_042

42

Top-Mount Type

OPERATION

EMERGENCY STOPSWITCH

SWITCH CLIP LANYARD



The engine will not start or run,unless the clip is in the switch.



Put the switch clip in theemergency stop switch, and attachthe lanyard to your PFD (PersonalFlotation Device) or to your wrist,as shown.



from p. .

If the fast idle control was used towarm up the engine, graduallyreturn the control lever to the N(neutral) position as the enginewarms up.

1.

5.

3030

31

83

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43

OPERATION

ON

OFF

IGNITIONSWITCHKEY

START

CONTROLLEVER

N (neutral)Using the electric starter f or morethan 5 seconds at a time willoverheat the starter motor and candamage it.







3.2.

04/03/29 10:35:35 31ZY2600_044

44

STOPPING THE ENGINE

Emergency Engine Stopping

OPERATION

N (neutral)

PULL

SWITCH CLIP

LANYARD


LANYARDPULL

CONTROL PANEL

SWITCH CLIP


CONTROLLEVER

FAST IDLE BUTTON

Panel-Mount/Top-Mount Types

Side-Mount Type





Below 41°F (5°C), warm up theengine for at least 10 minutes at2,000 rpm. Push the fast idlebutton then move the control leverforward or reverse to open thethrottle and achieve approximately2,000 rpm.



from p. .

If the fast idle control was used towarm up the engine, graduallyreturn the control lever to the N(neutral) position as the enginewarms up.

4.

5.

3030

31

83

04/03/29 10:35:50 31ZY2600_045

45

Normal Engine Stopping

OPERATION

N (neutral)

CONTROLLEVER

CONTROLLEVER

N (neutral)

N (neutral)

CONTROLLEVER

Top-Mount Type

Panel-Mount Type

Side-Mount Type

Move the control lever(s) to the N(neutral) position.

To stop the engine in an emergency,pull the clip out of the emergencystop switch by pulling the lanyard.

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

1.

04/03/29 10:35:58 31ZY2600_046

46

GEARSHIFT ANDTHROTTLE OPERATION

OPERATION

IGNITION KEY

IGNITION KEY

OFF

N (neutral)

F (forward)R (reverse)

CONTROL LEVER

NEUTRALRELEASE LEVER

OOFFFF

Side-Mount Type


Side-Mount Type

When the boat is not in use,remove and store the ignition keyand the emergency stop switch clipand lanyard.

Turn the ignition switch key to theOFF position.

3.

2.

04/03/29 10:36:08 31ZY2600_047

47

OPERATION

THROTTLEFRICTIONADJUSTER

TO INCREASEFRICTION

TO DECREASEFRICTION

F (forward)

N (neutral)

N (neutral)

R (reverse)

CONTROLLEVER

F (forward)

R (reverse)

TO DECREASEFRICTION

TO INCREASEFRICTION


CONTROLLEVER

Panel-Mount Type Side-Mount Type

Top-Mount Type Panel-Mount Type

To shift gears, move the control leverto select F (forward), N (neutral) andR (reverse) gears.

The control lever cannot be movedfrom the N (neutral) position unlessthe neutral release lever is squeezed(side-mount/panel-mount types).

Moving the control lever beyond thegear selection range increases enginespeed.

04/03/29 10:36:20 31ZY2600_048

48

STEERING

OPERATION

TO INCREASEFRICTION

TO DECREASEFRICTION


Top-Mount Type

Adjust the throttle friction adjuster sothe control lever will hold a constantthrottle setting while cruising.

Steer the boat in the same manner asan automobile.

04/03/29 10:36:27 31ZY2600_049

49

CRUISING

Engine Speed Trim

OPERATION

Excessive trim/tilt angle duringoperation can cause propellerventilation, overheating, and waterpump damage.

If, for example, the outboard motoris tilted excessively, or propellerventilation occurs during a sharp turn,the engine may overrev, activatingthe overrev limiter.

The engine is equipped with anoverrev limiter to prevent thepossibility of mechanical damagefrom excessive engine speed.

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

If engine speed becomes unstable athigh speed due to activation of theoverrev limiter, reduce speed andcheck the trim angle of the outboard

motor.

Use the power trim/tilt switch to trimthe outboard motor for the bestperformance and stability.

You can use the power trim/tiltswitch at any time, whether the boatis under way or stopped.

Press the UP or DN (down) side ofthe switch to adjust the angle of theoutboard motor.

It is necessary to trim the angle of theoutboard motor to compensate forchanges in boat load, weightdistribution, water conditions, orpropeller selection.

Under normal conditions, the boatwill perform best when the

antiventilation plate is level with thewater.

When cruising into a high wind, trimthe outboard motor down slightly tolevel the boat and improve stability.With a tail wind, trim the outboardmotor up slightly.

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

Refer to the trim meter (p. ) for anindication of whether the motor istrimmed high or low.

27

47 48

04/03/29 10:36:42 31ZY2600_050

50

OPERATION



(single type)

(dual type)

(RIGHT)(LEFT)



BOW TOO LOW DUE TO1. LOAD IN THE FRONT2. MOTOR TRIMMED TOO LOW

BOW TOO HIGH DUE TO1. LOAD IN THE REAR2. MOTOR TRIMMED TOO HIGH

MOTORTRIMMED TOOLOW

MOTORTRIMMED TOOHIGH

MOTOR TRIMMEDCORRECTLY

Top-Mount TypeSide-Mount Type

Panel-Mount Type

04/03/29 10:36:53 31ZY2600_051

51

SHALLOW WATEROPERATION

MOORING, BEACHING,LAUNCHING

OPERATION

TIGHTENING BOLT

TRIM TAB

An excessive trim/tilt angle duringoperation can cause propellerventilation, overheating, and waterpump damage. This type of damageis not covered by the Distributor’sLimited Warranty.

If steering effort is not equal in bothdirections, adjust the trim tab tocompensate for ‘‘torque steer,’’which is the reaction of the outboardmotor to propeller rotation.

Adjust the trim tab with the enginestopped. Loosen the bolt above thetrim tab, turn the trim tab, thentighten the bolt securely.

When the trim tab is correctlyadjusted, steering effort will be equalin both directions.

When operating in shallow water, usethe power trim/tilt switch (p. ) totilt the outboard motor, so thepropeller and gear case won’t hit thebottom.

Proceed at low speed, and monitorwater flow from the cooling systemindicator (p. ) to be sure theoutboard motor is not tilted so highthat the water intakes are out of thewater.

To raise the outboard motor out ofthe water while the engine is stoppedand the boat is moored, or formaximum clearance when beachingor launching, use the power tiltswitch on the engine pan to tilt theoutboard motor as far as it will go,move the tilt lock lever to the LOCKposition, then gently lower theoutboard motor until the levercontacts the stern bracket.

To lower the outboard motor, tilt up,move the tilt lock lever to the FREEposition, then lower the outboardmotor to the desired position.

If more clearance is needed to swingthe tilt lock lever into the LOCKposition, rock the outboard motorforward slightly by pulling on theengine cover grip.

50

31

04/03/29 10:37:05 31ZY2600_052

52

OPERATION

FREE

POWER TILT SWITCH

LLOOCCKK



MANUAL RELIEF VALVE

TILT LOCK LEVER(Lock position)

Do not attempt to use the power tiltswitch to tilt the outboard motordown while the tilt lock lever is in thelock position. Damage to the powertilt system may occur.

For manual tilting, use a screwdriverto turn the valve counterclockwise 1or 2 turns. Close the valve firmlyafter positioning the engine.

Be sure the valve is closed beforeoperating the outboard motor. If thevalve is not closed, the outboardmotor will tilt up when operated inreverse.

The outboard motor can also be tiltedmanually after opening the manualrelief valve. This feature enables theoutboard motor to be tilted orlowered when no battery is connected.

04/03/29 10:37:15 31ZY2600_053

Improperly maintainingthis outboard motor, orfailure to correct a problembefore operation, can causea malfunction in which youcould be seriously hurt orkilled.

Always follow theinspection andmaintenancerecommendations andschedules in this owner’smanual.

53

THE IMPORTANCE OFMAINTENANCE

Maintenance, replacement, orrepair of the emission controldevices and systems may beperformed by any marine enginerepair establishment or individual,using parts that are ‘‘certified’’ toEPA standards.

SERVICING YOUR OUTBOARD MOTOR

Good maintenance is essential forsafe, economical, and trouble-freeoperation. It will also help reduce airpollution.

To help you properly care for youroutboard motor, the following pagesinclude a maintenance schedule,routine inspection procedures, andsimple maintenance procedures usingbasic hand tools. Other service tasksthat are more difficult, or requirespecial tools, are best handled byprofessionals and are normallyperformed by a Honda technician orother qualified mechanic.

The maintenance schedule applies tonormal operating conditions. If youoperate your outboard motor underunusual conditions, consult anauthorized Honda marine dealer forrecommendations applicable to yourindividual needs and use.

Remember that your authorizedHonda marine dealer knows youroutboard motor best and is fullyequipped to maintain and repair it.

To ensure the best quality andreliability, use only new, genuineHonda parts or their equivalents forrepair and replacement.

04/03/29 10:37:24 31ZY2600_054

－

－

－

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

Always follow theprocedures andprecautions in the owner’smanual.

54

MAINTENANCE SAFETY Safety Precautions

Burns from hot parts.

Injury from moving parts.

Carbon monoxide poisoningfrom engine exhaust.


Some of the most important safetyprecautions follow. However, wecannot warn you of everyconceivable hazard that can arise inperforming maintenance. Only youcan decide whether or not you shouldperform a given task.

Make sure the engine is off beforeyou begin any maintenance orrepairs. This will eliminate severalpotential hazards:

Read the instructions before youbegin, and make sure you have thetools and skills required.

To reduce the possibility of fire orexplosion, be careful whenworking around gasoline. Use onlya nonflammable solvent, notgasoline, to clean parts. Keepcigarettes, sparks, and flames awayfrom all fuel-related parts.

Wear gloves when handling thepropeller to protect your handsfrom sharp edges.Let the engine and exhaust

system cool before touching.

Do not run the engine unlessinstructed to do so.

Be sure there is adequateventilation whenever youoperate the engine.

04/03/29 10:37:36 31ZY2600_055

×

×

×

55

TOOL KIT and OWNER’S MANUAL SPARE EMERGENCY STOPSWITCH CLIP(optional equipment)


10 12 mm WRENCH

PLIERS

TOOL BAG

14 17 mm WRENCH

8 mm WRENCH

SCREWDRIVER HANDLE

SPARK PLUG WRENCH

OWNER’S MANUAL

FLAT SCREWDRIVER

FUSE PULLER

19 mm EYE WRENCH

PHILLIPSSCREWDRIVER

16 17 mm BOX WRENCH

6 mm HEX. WRENCH

OIL CHECKSCREWDRIVER

Always carry a spare emergency stopswitch clip onboard. The spare clipmay either be stored in the tool bagor in an easily accessible location onthe boat.

The tool kit can be used for simple maintenance procedures and emergencyrepairs. Keep these items on the boat, so they will always be available if youneed them.

If your tool kit needs replacement, it is not available as a kit and each itemmust be ordered individually.

04/03/29 10:37:46 31ZY2600_056

○○

○○○

○

○○

○

○○

○○

○○

○

○○

○○

○

○

56

MAINTENANCE SCHEDULE


REGULAR SERVICE PERIOD

After usePerform at every indicated month oroperating hour interval, whichevercomes first.

ITEM

Engine oil

Gear case oilEngine oil filterACG beltThrottle linkageIdle speedValve clearanceSpark plug

Propeller and Cotter pinAnodeLubricationWater separator

Check levelChangeChangeReplaceCheck-adjustCheck-adjustCheck-adjustCheck-adjustCheckCleanReplaceCheckCheckGreaseCheck

Every yearor

200 hrs.

(2)(2)

(2)

(2)

Each useFirst month

or20 hrs.

(2)

(2)(2)

(2)

(1)

Every 6 monthsor

100 hrs.

(2)

(2)(2)

(1)

Every 2 yearsor

400 hrs.

(3)

Lubricate more frequently when used in salt water.These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and are mechanically proficient.Refer to the Honda shop manual for service procedures.For professional/commercial use, log hours of operation to determine proper maintenance intervals.When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

(1)(2)

(3)(4)

04/03/29 10:37:58 31ZY2600_057

○

○

○

○

○

○

○○

○

○

○

57


REGULAR SERVICE PERIOD

Each use After use

(4)

First monthor

20 hrs.

(2)

Every 6 monthsor

100 hrs.

(2)

Every 2 yearsor

400 hrs.

(2)

Every 2 years (If necessary) (2)

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

ITEM

CheckReplaceReplace

CheckCheckReplaceCheck level-tightness

Check-tightnessCheckCleanCheck

Every yearor

200 hrs.

(2)

(2)

(2)

Fuel filter

Fuel filter(High pressure type)ThermostatFuel line

Battery and cableconnectionBolts and NutsCrankcase breather tubeCooling water passagesWater pump

(3)

When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.For professional/commercial use, log hours of operation to determine proper maintenance intervals.

These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and are mechanically proficient.Refer to the Honda shop manual for service procedures.

Lubricate more frequently when used in salt water.(1)(2)

(3)(4)

04/03/29 10:38:11 31ZY2600_058

58

TRIM TAB ADJUSTMENT


TIGHTENING BOLT

TRIM TAB

TIGHTENING BOLT

TRIM TAB

LEFT RIGHT

The trim tab compensates for‘‘torque steer’’ which is a reaction ofthe outboard motor to propellerrotation.

If uncompensated, torque steer wouldmake the outboard motor tend to turnto one side.

When the trim tab is correctlyadjusted, steering effort is equal ineither direction.

If steering effort is unequal, loosenthe trim tab bolt and adjust the angleof the trim tab. Retighten the trim tabbolt securely. If less effort is required to make left

turns, move the back of the trim tableft.

Adjust the trim tab in smallincrements, and retest steering effortwith the boat evenly loaded andrunning at cruising speed.

If less effort is required to make rightturns, move the back of the trim tabright.

04/03/29 10:38:22 31ZY2600_059

59

MANUAL RELIEF VALVE ENGINE COVER REMOVALAND INSTALLATION


MANUAL RELIEF VALVE



ENGINE COVERLATCH

Be sure the valve is closed beforeoperating the outboard motor. If thevalve is not closed, the outboardmotor will tilt up when operated inreverse.

For manual tilting, use a screwdriverto turn the valve counterclockwise 1or 2 turns. Close the valve firmlyafter positioning the outboard motor.

The outboard motor can be tiltedmanually after opening the manualrelief valve. This feature enables theoutboard motor to be tilted orlowered when no battery is connected.

The engine cover latch fastens theengine cover to the outboard motor.

To remove the engine cover, pull theengine cover latch to the unlockedposition, then lift the engine coverstraight up from the outboard motor.

To install the engine cover, place thecover on the outboard motor, andpush down evenly.

Lubricate the engine cover rubbersealing ring with silicone spray tomake installation easier.

04/03/29 10:38:34 31ZY2600_060

60

Engine Oil Level Check Engine Oil Change


UPPERLIMIT

LOWERLIMIT

OIL FILLER CAP

OIL LEVEL DIPSTICK

SCREWDRAIN PLUG

DRAIN PLUG COVER

Running the engine with a low oillevel can cause engine damage.

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

Unlock and remove the enginecover (p. ).

Remove the dipstick and wipe itclean.

Insert the dipstick all the way in,then remove it and check the oillevel shown on the dipstick.

An engine oil evacuation/fillingdevice may be used to remove/addthe engine oil.

Drain the used oil while the engine iswarm. Warm oil drains quickly andcompletely.


Remove the screw from the oildrain plug cover, and remove thecover.

If the oil level is low, remove theoil filler cap, and add oil to reachthe upper limit mark shown on thedipstick. Use the oil recommendedon p. .

Install the oil filler cap and tightenit securely. Do not overtighten.

Install and lock the engine cover.

1.

2.

3.

4.

5.

6.

1.

2.

59

63

59

04/03/29 10:38:49 31ZY2600_061

8.0 US qt (7.6 )

8.2 US qt (7.8 )

61

Oil Filter Change


GUIDE

SEALING WASHER

DRAIN PLUG COVERDRAIN PLUG

Improper disposal of engine oilcan be harmf ul to the environment.If you change your own oil, pleasedispose of the used oil properly.Put it in a sealed container, andtake it to a recycling center. Donot discard it in a trash bin ordump it on the ground.

With the outboard motor in avertical position, fill to the upperlimit mark on the dipstick (p. )with the recommended oil.Engine oil refill capacity:Without oil filter change:

Install the oil drain plug cover andsecure it with the screw.

With oil filter change:

Drain the engine oil, and reinstallthe drain plug and oil drain cover(see Engine Oil Change on p. ).

Use a suitable tool to remove theoil filter, and throughly drain thefilter into the used oil container.

Tilt the outboard motor, and placea suitable container below the oildrain guide to catch the used oil.

Install and lock the engine cover.

Install the oil filler cap and tightenit securely.

Place a suitable container belowthe oil drain guide to catch theused oil, then remove the oil fillercap and the drain plug.

Set the drain plug cover under theguide.

Allow the used oil to draincompletely. Use a new sealingwasher then reinstall the engine oildrain plug, and tighten it securely.

3.

1.

2.

3.6.

7.

8.

9.

4.

5.

60

60

04/03/29 10:39:04 31ZY2600_062

16 lbf·ft (22 N·m , 2.2 kgf·m)

62


OIL FILTER

USE A SUITABLE TOOL

OIL DRAIN GUIDE

RUBBER SEAL

Use only a genuine Honda oilf ilter or a f ilter of equivalentquality specif ied f or your model.Using the wrong f ilter, or a non-Honda f ilter which is not ofequivalent quality, may causeengine damage.

Running the engine without watercan cause serious engine damage.If you are changing the oil f ilterwhile the outboard motor is out ofthe water, use the water hose f lushport and a hose to supply water.

Clean the oil filter mounting base,and coat the gasket of the new oilfilter with clean engine oil.

Screw on the new filter by handuntil it contacts the engine, thenuse a suitable tool to tighten thefilter an additional 7/8 turn.

OIL FILTER TIGHTENINGTORQUE:

Return the outboard motor to thevertical position, and fill thecrankcase with the specifiedamount (p. ) of therecommended oil.

Start the engine and check forleaks.

Stop the engine, and check the oillevel as described on page . Ifnecessary, add oil to bring the oillevel to the upper limit mark on thedipstick.

4.

5.

6.

7.

8.

61

60

04/03/29 10:39:16 31ZY2600_063

SAE Viscosity Grades

AMBIENT TEMPERATURE

63

Engine Oil Recommendations


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

SAE 10W-30 is recommended forgeneral use.

The SAE oil viscosity and serviceclassification are in the API label onthe oil container. Honda recommendsthat you use API SERVICE categorySG, SH or SJ oil with the ‘‘starburst’’certification mark displayed on thecontainer.

04/03/29 10:39:23 31ZY2600_064

64

Lubrication Points


ENGINE COVERLATCH

PTT THRUST RECEIVER

THROTTLE REEL

PROPELLER SHAFTSWIVEL

TILT SHAFT

TILT LOCK LEVER/SHAFT CAM

SHIFT ARM/CLICKROLLER/NEUTRALSWITCH

THROTTLE ARM/SHIFTARM SHAFT

Apply anticorrosion oil to pivot surf aces where greasecannot penetrate.

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

Apply marine anticorrosion grease to the following parts:Lubrication interval:After the first 20 hours or 1 month, then every 100 hoursor 6 months. (Refer to the maintenance schedule page

).56

04/03/29 10:39:32 31ZY2600_065

－

IZFR6F11 (NGK)VKJ20RZ-M11 (DENSO)

65

Spark Plug Service


SPECIALSCREWS

R.ENGINE UNDERCOVER

SPECIALSCREWSSPECIALSCREWS

WIRECONNECTOR

IGNITION COIL

BOLT

L.ENGINE UNDER COVER

Do not strike or drop the ignitioncoil, or it may be damaged andrequire replacement.

Incorrect spark plugs can causeengine damage.

Disconnect the wire connectorfrom the ignition coil by pushingon the lock tab and pulling on theconnector. Pull on the plasticconnector, not the wires.

RECOMMENDED SPARK PLUGS:

This outboard motor uses spark plugsthat have an iridium coated centerelectrode. Be sure to observe thefollowing when servicing the sparkplugs.

Do not clean the spark plugs. If anelectrode is contaminated withaccumulated objects or dirt,replace the spark plug with a newone.

Do not adjust the spark plug gap.If the gap is out of specification,replace the spark plug with a newone.

Disconnect the battery negative( ) terminal.


Remove the twenty special bolts,and remove the R. and L. engineunder covers.

Use only a ‘‘wire-type feelergauge’’ to check the spark pluggap if necessary. To preventdamaging the iridium coating ofthe center electrode, never use a‘‘leaf-type feeler gauge.’’

Use a 6 mm hex. wrench toremove the bolt holding theignition coil. Remove the ignitioncoil by pulling it up slightly.

4.

1.

2.

3.

5.

59

04/03/29 10:39:48 31ZY2600_066

－－

－－

66


SPARK PLUGWRENCH

19 mm EYEWRENCH

0.039 0.051 in(1.00 1.30 mm)

SEALINGWASHER

Loose spark plugs can overheatand damage the engine.Overtightening the spark plugscan damage the threads in thecylinder head.

Install the spark plugs carefully,by hand, to avoid cross-threading.

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

If reinstalling used spark plugs,tighten 1/8 - 1/4 turn after thespark plugs seat.

If installing new spark plugs,tighten 1/2 turn after the sparkplugs seat.

Inspect the spark plugs. Replacethem if the electrodes are worn, orif the insulators are cracked orchipped.

Remove the spark plugs with aspark plug wrench and 19 mmwrench.

Measure the spark plug electrodegap with a wire-type feeler gauge.The gap should be 0.039 0.051inches (1.00 1.30 mm). If thegap is out of the specification,replace the plug with a new one.Never try to readjust the gap.

6. 7.

8.

9.

10.

04/03/29 10:39:58 31ZY2600_067

67


Install the ignition coil. Reinstallthe bolt.

Push the wire connector onto theignition coil. Make sure it locks inplace.

Repeat this procedure for the otherfive spark plugs.

Reinstall the covers. Whenreinstalling the covers, make surenot to jam the wire harnessesbetween the covers and enginecase.

11.

12.

13.

14.

04/03/29 10:40:04 31ZY2600_068




68

REFUELING


Check the fuel level and refill ifneccessary. Do not fill the fuel tankabove the UPPER LIMIT. Refer tothe boat manufacturer’s instructions.

Never refill the fuel tank inside abuilding where gasoline fumes mayreach flames or sparks. Keepgasoline away from appliance pilotlights, barbecues, electric appliances,power tools, etc.

Spilled fuel is not only a fire hazard,it causes environmental damage.Wipe up spills immediately.

04/03/29 10:40:13 31ZY2600_069

69

FUEL RECOMMENDATIONS

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


Running the engine with persistentspark knock or pinging can causeengine damage.

Distributor’s LimitedWarranty

Your outboard motor is certified tooperate on unleaded gasoline.Unleaded gasoline produces fewerengine and spark plug deposits andextends exhaust system life.

Never use stale or contaminatedgasoline or an oil/gasoline mixture.Avoid getting dirt or water in the fueltank.

Occasionally you may hear a light‘‘spark knock’’ or ‘‘pinging’’(metallic rapping noise) whileoperating under heavy loads. This isno cause for concern.

If spark knock or pinging occurs at asteady engine speed, under normalload, change brands of gasoline. Ifspark knock or pinging persists, seean authorized Honda marine dealer.

Running the engine with persistentspark knock or pinging is misuse,and the

does not cover partsdamaged by misuse.

04/03/29 10:40:22 31ZY2600_070




70

Fuel Filter Inspection andReplacement


ENGINE COVER LATCH

Water or sediment accumulated inthe filter can cause loss of power orhard starting. To prevent enginemalfunction, inspect the filter andreplace when necessary.

Remove the engine cover.

The fuel filter (inside the strainercup) is located below the engine oilfilter.

1.

04/03/29 10:40:31 31ZY2600_071

3.4 N·m (0.35 kgf·m , 2.5 lbf·ft)

71


FUEL HOSES

ENGINE OIL FILTER

FUEL FILTER (inside strainer cup)

SCREW (3)

SUSPENSION STRAP

Remove the three screws andseparate the fuel strainer cup fromthe strainer body.

Thoroughly clean the strainer cup,and replace with a new fuel filter.

Reassemble the strainer body andthe cup.STRAINER TIGHTENINGTORQUE:

Reinstall the strainer in the originalposition.Remove the suspension strap from

the strainer bracket, then removethe strainer assembly from thestrap.Before removing the fuel filter, toprevent fuel leakage, place fuelhose clamps on the fuel hoses oneach side of the fuel filter.

Looking through the translucentstrainer cup, check the fuel filterfor water accumulation orsediment.

4.

5.

6.

3.2.7.

04/03/29 10:40:41 31ZY2600_072




72

Water Separator Inspection andService


WATER SEPARATOR

The water separator is located besidethe oil level dipstick. Wateraccumulation in the water separatorcan cause loss of power or hardstarting. Check the water separatorperiodically. Clean it or consult withan authorized Honda marine dealerfor cleaning.

8.

If loss of power or hard starting arefound to be caused by excessivewater or sediment accumulation inthe fuel filter, inspect the fuel tank.

Clean the fuel tank and tank filter ifnecessary. It may be necessary todrain the fuel tank completely andrefill with fresh gasoline.

Prime the engine using the primingbulb (refer to page ). Check forfuel leaks. Repair any fuel leaks ifnecessary.

36

04/03/29 10:40:51 31ZY2600_073

3.4 N·m (0.35 kgf·m , 2.5 lbf·ft)

73


SCREW (3)

SUSPENSION STRAP

FUEL TUBES

Thoroughly clean the waterseparator cup.

Reassemble the water separatorbody and the cup.TIGHTENING TORQUE:

Reinstall the strainer in the reverseorder of removal.

Remove the engine cover (seepage ).

Disconnect the water level sensorconnector.

Remove the suspension strap fromthe water separator bracket, thenremove the separator assemblyfrom the strap.

Pinch the fuel tubes with tube clipsto prevent fuel leakage.

Remove the three screws andseparate the water separator cupfrom the body.

Squeeze and release the primingbulb to fill the vapor separator, andcheck for leaks.

If the buzzer sounds or water orsediment accumulation are found tobe caused by excessive water orsediment accumulation in the fuelfilter, inspect the fuel tank.

Clean the fuel tank and tank filter ifnecessary. It may be necessary todrain the fuel tank completely andrefill with fresh gasoline.

1.

9.

8.

7.

6.

5.

4.

2.

3.

59

04/03/29 10:41:04 31ZY2600_074

74

Anode Replacement


ANODE(each side)

ANODE(stern bracket)

Painting or coating the anodes willdef eat their purpose and will lead torust and corrosion damage to theoutboard motor. The anodes must beexposed to the water in order toprotect the outboard motor.

The anodes are located on each sideof the gearcase. They are made of asacrificial material that helps toprotect the outboard motor fromcorrosion.

Replace the anodes when they havebeen reduced to about half theiroriginal size, or if they are crumbling.

04/03/29 10:41:10 31ZY2600_075

75

Propeller Replacement


PROPELLER

COTTER PIN

THRUST WASHER CASTLE NUT

WASHER

MARINE GREASE

Installation

Removal

Install the thrust washer with thegrooved side toward the gear case.

Use a genuine Honda cotter pinand bend the pin ends as shown.

Before replacing the propeller,remove the clip from the engine stopswitch to prevent any possibility ofthe engine being started while youare working with the propeller.

The propeller blades may have sharpedges, so wear heavy gloves toprotect your hands.

Inspect the propeller shaft for anyfishing line or debris.

Operating the outboard motor athigher altitudes will reduce availablepower. This may require decreasingthe propeller pitch to maintain correctengine RPM.

Remove the cotter pin, unscrewthe castle nut, remove the washer,then remove the propeller andthrust washer.

Some propeller brands requirespecific mounting hardware. Refer toyour specific propeller manufacturer’sinstructions for proper installation.

Apply marine grade grease to thepropeller shaft and beveled surfaceof the thrust washer.

Install the propeller in the reverseorder of removal.

1.

2.

2.

1.

04/03/29 10:41:24 31ZY2600_076

76

STORAGE PREPARATION

Cleaning and Flushing

STORAGE

FLUSH PORTCONNECTOR

Cleaning

Flushing With a Garden Hose

Do not run the motor when f lushingthe motor with a garden hose or themotor may be damaged.

Proper storage preparation isessential for keeping your outboardmotor troublefree and looking good.The following steps will help to keeprust and corrosion from impairingyour outboard motor’s function andappearance, and will make the engineeasier to start when you use theoutboard motor again.

Thoroughly clean and flush theoutboard motor with fresh water afteroperation in dirty water or salt water.

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

Wash the outside of the outboardmotor with clean, fresh water, andflush the cooling system as follows.

Disconnect the flush portconnector.

For safety, remove the emergencystop switch clip so the engine cannotbe started while you are standing nearthe propeller.

1.

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77

STORAGE

EXHAUST PORT

FLUSH PORTCONNECTOR

GARDEN HOSE

Turn on the fresh water supply andflush the outboard motor for atleast 10 minutes.

After flushing, disconnect thegarden hose and reconnect theflush port connector.

Connect the garden hose to theflush port connector.

2. 3.

4.

04/03/29 10:41:41 31ZY2600_078




78

Fuel

STORAGE

DRAIN HOSEDRAIN SCREW

VAPOR SEPARATOR

Distributor’s Limited WarrantyThedoes not cover fuel system damageor engine performance problemsresulting from neglected storagepreparation.

Gasoline will oxidize and deterioratein storage. Old gasoline will causehard starting, and it leaves gumdeposits that clog the fuel system. Ifthe gasoline in your fuel tank andvapor separator deteriorates duringstorage, you may need to have thevapor separator and other fuel systemcomponents serviced or replaced.

The length of time that gasoline canbe left in your fuel tank and vaporseparator without causing functionalproblems will vary with such factorsas gasoline blend, your storagetemperatures, and whether the fueltank is partially or completely filled.The air in a partially filled fuel tankpromotes fuel deterioration. Verywarm storage temperatures acceleratefuel deterioration. Fuel deteriorationproblems may occur within a fewmonths, or even less if the gasolinewas not fresh when you filled thefuel tank.

You can avoid fuel deteriorationproblems by draining the fuel tankand vapor separator.

Drain the fuel into an approved fuelcontainer.

Unhook the drain hose from thelower left of the head cover.

Set the end of the hose toward theoutside of the engine undercaseand below the level of the vaporseparator drain screw.

Loosen the vapor separator drainscrew.

1.

2.

3.

04/03/29 10:41:54 31ZY2600_079

－

－

79

HOISTING THE OUTBOARDMOTOR

Engine Oil

STORAGE

ENGINE COVERLATCH

Pour a tablespoon (5 10 cm ) ofclean engine oil into each cylinder.

Rotate the engine a fewrevolutions to distribute the oil inthe cylinders.

Reinstall the spark plugs (p. ).

Remove the spark plugs (p. ),and remove the clip from theemergency stop switch.

Unlock and remove the enginecover.

Change the engine oil and the oilfilter (p. ).

With the outboard motor turned tothe starboard side, tilt the motor up.Keep the end of the drain hosebelow the level of the vaporseparator drain screw and watchfor the fuel to start flowing out thedrain hose.

Drain the fuel tank into anapproved gasoline container, or ifyou need to store fuel in the fueltank, you can extend fuel storagelife by filling the fuel tank withfresh gasoline and adding a fuelstabilizer that is formulated forthat purpose.

Clip the drain hose on the headcover.

After draining thoroughly, tightenthe drain screw securely.

After the fuel starts flowing outthe drain hose, tilt the motor downand allow the siphon to finishdraining the vapor separator.

1.

2.

3.

4.

5.

1.

4.

5.

6.

7.

8.

60 62

65

66

3

04/03/29 10:42:08 31ZY2600_080

80

STORAGE PRECAUTIONS

STORAGE

HOISTHOOKS

OUTBOARDMOTOR STAND

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

If the outboard motor will beremoved from the boat for storage,we recommend storing it verticallyby mounting it on a stand.Disconnect the outboard motor

from the boat, hoist the outboardmotor, and move it to the storagearea.

After the outboard motor is placedin storage and disconnected fromthe hoist, install the engine cover.

Attach the hoist hooks to thelifting eyes.

If storing a container of gasoline,store it away from any appliance thatoperates with a flame, such as afurnace, water heater, or clothesdryer. Also avoid any area with aspark producing electric motor, orwhere power tools are operated.

2.

3.

4.

04/03/29 10:42:17 31ZY2600_081

81

REMOVAL FROM STORAGE

STORAGE

PROTECTOR

BEFOREOPERATION

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

Check your outboard motor asdescribed in the

chapter of this manual.

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

If it is necessary to store the outboardmotor horizontally, drain the vaporseparator (p. ), and drain theengine oil (p. ), before removingthe outboard motor from the boat.

Rest the motor on a cushion ofprotective material.

7860

04/03/29 10:42:25 31ZY2600_082

－

82

WITH OUTBOARD MOTORINSTALLED ON BOAT

WITH OUTBOARD MOTORREMOVED FROM BOAT

TRANSPORTING

MOTOR SUPPORT BAR(commercially available)

Secure the outboard motor in eitherthe vertical or horizontal positionshown on p. .

When trailering a boat with theoutboard motor attached, leave theengine in the normal running position,if possible.

Use a motor support bar to preventthe outboard motor from movingwhile trailering the boat. Refer to themanufacturer’s instructions for usinga motor support bar.

80 81

04/03/29 10:42:32 31ZY2600_083

83

TAKING CARE OF UNEXPECTED PROBLEMS

Check emergency stop switchclip.

Clip not inserted in stop switch. Insert clip in stop switch.

Possible CauseENGINE WILL NOT START Correction

Check control positions.

Fast idle lever raised (side-mounttype).

Leave fast idle lever OFF (p. ).

Shift to neutral.Control lever not in neutralposition.

1.

2.

18

04/03/29 10:42:42 31ZY2600_084

84


CorrectionPossible CauseENGINE WILL NOT START(continued)

Check fuel. Out of fuel. Refuel (p. ).

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

Replace fuel filters (p. ).

Bad fuel; boat stored withouttreating or draining gasoline, orrefueled with bad gasoline.

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

Fuel filter or fuel tank filterclogged.

3. 68

32

70

7868

04/03/29 10:42:53 31ZY2600_085

85


CorrectionPossible CauseENGINE WILL NOT START(continued)

Check battery. Battery connections loose orcorroded.

Battery discharged.

Clean and tighten batteryconnections.

Recharge battery.

Check fuses. Replace fuse(s) (p. ).

Remove and inspect spark plugs. Spark plugs faulty, fouled orimproperly gapped.

Spark plugs wet with fuel (floodedengine).

Dry and reinstall spark plugs. Startengine with the throttle open.

Fuel system malfunction, fuelpump failure, ignition malfunction,stuck valves, starter malfunction,switch malfunction, or electricalproblem in the starting circuit, etc.

Replace or repair faultycomponents as necessary.

Fuse(s) blown.

Use starting procedure (p. ),if engine still will not start thentake outboard motor to anauthorized Honda marine dealer,or refer to the shop manual.

Replace spark plug (p. ).

4.

5.

6.

7. 37

88

65

04/03/29 10:43:08 31ZY2600_086

86


CorrectionPossible CauseHARD STARTING OR STALLSAFTER STARTING

Check control positions. Fast idle lever raised (side-mounttype).

Leave fast idle lever OFF (p. ).

Check fuel. Squeeze priming bulb (p. ).Replace fuel filters (p. ).

Fuel hose not primed.Fuel filter or fuel tank clogged.

Bad fuel; boat stored withouttreating or draining gasoline, orrefueled with bad fuel.

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

1.

2.

18

3270

7868

04/03/29 10:43:17 31ZY2600_087

87


HARD STARTING OR STALLSAFTER STARTING

(continued)

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

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

Check water intake screens. Water intake screens clogged. Clean water intake screens.

ENGINE OVERHEATS Possible Cause Correction

Replace or repair faultycomponents as necessary.

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

Spark plugs faulty, fouled orimproperly gapped.

Remove and inspect spark plugs.

Possible Cause Correction

Fuel system malfunction, fuelpump failure, ignition malfunction,etc.

Replace spark plug (p. ).

2.

3.

4.

1.

65

04/03/29 10:43:31 31ZY2600_088

10 A, 15 A, 30 A

88

Fuse Replacement

Electric Starter Will NotOperate

FUSES

Battery Will Not Charge


BLOWN

FUSE PULLER

FUSE COVER

FUSE HOLDER

Main Fuse

With the engine stopped, removethe engine cover.The 10A, 15A, and 30A main fuses

protect the electric starter relay andrelated circuits.

The 10A main fuse protects theignition switch and related circuits. Ifthis fuse blows, the engine will notstart or run, and the power trim/tiltswitch will not activate the trim/tiltmechanism.

A 150A ACG fuse protects thealternator circuit. If the ACG fuseblows, the engine will not charge thebattery. Refer to p. .

Remove the fuse cover.

Use the fuse puller from the toolkit to remove the fuses. If a fuse isblown, install a replacement fuseof the same specified rating. Theoutboard motor is supplied withspare fuses in the fuse holder.

MAIN FUSE RATINGS:

1.

2.

3.

89

04/03/29 10:43:46 31ZY2600_089

150 A

89

Replacement


SPARE FUSE

FUSE CASE LID‘‘150A’’MARK

FUSE (150A)ACG Fuse

Disconnect the battery cable at thebattery negative (-) terminal bef orereplacing the f use.Failure to do so may cause a shortcircuit.

Never use a f use with a ratinggreater than specif ied. Seriousdamage to the electrical system couldresult.

Remove the old fuse by removingtwo 5 mm screws.

Install a new fuse with the ‘‘150A’’ mark downward.

ACG FUSE:

After finishing replacement, installthe fuse case lid with its hooktoward the engine side.

Be sure to check the fuse case lidis securely locked.

A spare fuse is located on the reverseside of the fuse case lid and tightenedwith two 3 mm screws.When the new fuse is set as a sparefuse on the reverse side of the fusecase lid, set the fuse so that you cansee the ‘‘150 A’’ mark on it.Stop the engine.

Remove the engine cover.

Remove the fuse case lid.Reinstall the fuse cover and theengine cover.

If a blown fuse is found, try todetermine and correct the electricalproblem that caused the blown fuse.An uncorrected electrical problemmay cause the fuse to blow again.

If fuses continue to blow, take theoutboard motor to an authorizedHonda marine dealer for inspectionand service or refer to the shopmanual.

1.

2.

3.

4.

5.

6.

7.

4.

04/03/29 10:44:03 31ZY2600_090

90

OIL PRESSURE INDICATORLIGHT GOES OFF ANDENGINE SPEED IS LIMITED

Digital Tachometer


(GREEN)

(GREEN)

Side-Mount Type


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

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

If the engine protection systemremains activated after 30 seconds,return to the nearest boat landing, andhave the outboard motor inspected byan authorized Honda marine dealer.

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

If oil pressure becomes low, the oilpressure indicator will go off, and theengine protection system limitsengine speed. If you are at cruisingspeed, engine speed will decreaseautomatically.

The oil pressure indicator is alsoequipped with a buzzer that soundswhen the oil pressure indicator goesoff.

With the engine oil at therecommended level, restart theengine. If the lubrication system isOK, the oil pressure indicator shouldcome on within 30 seconds, and theengine will respond normally tothrottle control lever operation.

60

Normal

Abnormal

04/03/29 10:44:15 31ZY2600_091

91

OVERHEAT INDICATORCOMES ON AND ENGINESPEED IS LIMITED

Digital Tachometer


(RED)

(RED)

COOLING SYSTEM INDICATOR

Side-Mount Type


If the engine is stopped after runningat full throttle, and then restartedsoon afterward, that could activatethe engine protection systemmomentarily.

All types are equipped with a buzzerthat sounds when the overheatindicator comes on.

If the engine overheats, the overheatindicator will come on, and theengine will stop in 20 seconds afterthe engine protection system limitsengine speed. If you are at cruisingspeed, engine speed will decreaseautomatically.

Engine overheating may be the resultof restricted water intake screens, orthere may be a problem with thecooling system thermostat or waterpump.

If overheating activates the engineprotection system, idle the engine inneutral, and check the cooling systemindicator.

If water is flowing from the coolingsystem indicator, continue idling for30 seconds. If the cooling system isOK, the overheat indicator should gooff within 30 seconds, and the enginewill respond normally to throttlecontrol lever operation.

Normal

Abnormal

04/03/29 10:44:29 31ZY2600_092

92

WATER SEPARATORBUZZER SOUNDS

WATER SEPARATORINDICATOR

Digital Speedometer


WATER SEPARATOR

If there is no water flowing from thecooling system indicator, stop theengine and check the discharge portfirst then tilt the outboard motor toinspect the water intake screens. Ifclogged, clean the water intakescreens, return the outboard motor tothe running position, restart theengine, and check the cooling systemindicator again.

If there is still no water flowing fromthe cooling system indicator, or if theengine protection system remainsactivated after 30 seconds, return tothe nearest boat landing, and have theoutboard motor inspected by anauthorized Honda marine dealer.

When the water separator buzzersounds (a rapid, repeating signal):

Check the water separator forwater contamination. If water isaccumulated, stop the engine, andclean the water separator followingthe instructions on page , orconsult with an authorized Hondaoutboard motor dealer.

When the water separator indicatorblinks.

Check the water separator for watercontamination. If water is accumlated,stop the engine, and clean the waterseparator following the instructionson page , or consult with anauthorized Honda marine dealer.

1.

7273

Normal

Abnormal

04/03/29 10:44:42 31ZY2600_093

－

93

SUBMERGED MOTOR


Running the outboard motor withoutsuf f icient cooling water will damagethe water pump and overheat theengine.

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

If there is a Honda marine dearshipnearby, take the motor to the dealerimmediately. If you are far from adealership, proceed as follows:

Remove the engine cover, andrinse the outboard motor withfresh water to remove salt water,sand, mud, etc.

Drain the vapor separator asdescribed on p. .

Change the engine oil and oil filteras described on p. . Ifthere was water in the enginecrankcase, or if the used engine oilshowed signs of watercontamination, then a secondengine oil change should beperformed after running the enginefor half an hour.

Remove the spark plugs (p. ).Operate the starter to expel waterfrom the engine’s cylinder.

Put a teaspoon of engine oil intoeach spark plug hole to lubricatethe inside of the cylinders.Reinstall the spark plugs.

If the engine was running when itsubmerged, there may bemechanical damage, such as bentconnecting rods. If the enginebinds when cranked, do notattempt to run the engine until ithas been repaired.

Attempt to start the engine (be surethe water level is at least 2 inchesabove the antiventilation plate).

1.

2.

3.

4.

5.

60 62

65

78

6.

04/03/29 10:44:54 31ZY2600_094

94


If the engine fails to start, removethe spark plugs and dry them, thenreinstall the spark plugs andattempt to start the engine again.

If the engine starts, and nomechanical damage is evident,continue to run the engine for ahalf hour or longer. Be sure thewater level is at least two inchesabove the antiventilation plate toavoid overheating and water pumpdamage.

As soon as possible, take theoutboard motor to an authorizedHonda marine dealer forinspection and service.

7.

04/03/29 10:45:00 31ZY2600_095

95

TECHNICAL INFORMATION

Serial Number Locations

TECHNICAL AND CONSUMER INFORMATION

ENGINE SERIAL NUMBER

PRODUCTIDENTIFICATIONNUMBER

STERN BRACKET

Record the product identificationnumber and engine serial number inthe space provided on this page. Youwill need these numbers whenordering parts, and when makingtechnical or warranty inquiries(p. ).

Product identification number: Engine serial number:

The product identification number isstamped on a plate attached on theright stern bracket.

The engine serial number isstamped on the upper right side ofthe motor.

105

04/03/29 10:45:09 31ZY2600_096

96

Oxygenated Fuels

ETHANOL:

MTBE:

METHANOL:


Some conventional gasolines arebeing blended with alcohol or anether compound. These gasolines arecollectively referred to as oxygenatedfuels. To meet clean air standards,some areas of the United States andCanada use oxygenated fuels to helpreduce emissions.

If you use an oxygenated fuel, besure it is unleaded and meets theminimum octane rating requirement.

Before using an oxygenated fuel, tryto confirm the fuel’s contents. Somestates/provinces require thisinformation to be posted on the pump.

The following are the EPA-approvedpercentages of oxygenates:

ethyl or grain alcohol;10% by volume.

You may use gasoline containing upto 10% ethanol by volume. Gasolinecontaining ethanol may be marketedunder the name ‘‘Gasohol’’.

Methyl Tertiary Butyl Ether;15% by volume.

You may use gasoline containing upto 15% MTBE by volume.

methyl or woodalcohol; 5% by volume.

04/03/29 10:45:20 31ZY2600_097

－12V 110AH(CCA800)

97

Battery

Minimum Requirements

Emission Control SystemInformation


Source of Emissions

You may use gasoline containing upto 5% methanol by volume, as longas it also contains cosolvents andcorrosion inhibitors to protect thefuel system. Gasoline containingmore than 5% methanol by volumemay cause starting and/orperformance problems. It may alsodamage metal, rubber, and plasticparts of your fuel system.

If you notice any undesirableoperating symptoms, try anotherservice station, or switch to anotherbrand of gasoline.

Fuel system damage or performanceproblems resulting from the use of anoxygenated fuel containing morethan the percentages of oxygenatesmentioned above are not coveredunder warranty.

For complete information, refer tothe battery manufacturer’sinstructions.

The combustion process producescarbon monoxide, oxides of nitrogen,and hydrocarbons. Control ofhydrocarbons and oxides of nitrogenis very important because, undercertain conditions, they react to formphotochemical smog when subjectedto sunlight. Carbon monoxide doesnot react in the same way, but it istoxic.

Honda utilizes various systems toreduce the emissions of carbonmonoxide, oxides of nitrogen, andhydrocarbons.

04/03/29 10:45:29 31ZY2600_098

98


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

PGM-FI System

Ignition Timing Control System

Tampering with or altering theemission control system may increaseemissions beyond the legal limit.Among those acts that constitutetampering are:

Removal or alteration of any partof the intake, fuel, or exhaustsystems.

Alterations that would cause theengine to operate outside its designparameters.

The following instructions andprocedures must be followed in orderto keep the emissions from yourHonda engine within the emissionstandards.

EPA and California regulationsrequire all manufacturers to furnishwritten instructions describing theoperation and maintenance ofemission control systems.

The PGM-FI system uses sequentialmultiport fuel injection. It has threesubsystems: Air Intake, EngineControl, and Fuel Control. TheEngine Control Module (ECM) usesvarious sensors to determine howmuch air is going into the engine. Itthen controls how much fuel to injectunder all operating conditions.

The system constantly adjusts theignition timing, reducing the amountof HC, CO and NOx produced.

04/03/29 10:45:40 31ZY2600_099

99


Maintenance

Replacement PartsProblems That May Af f ectEmissions

A manufacturer of an aftermarketpart assumes the responsibility thatthe part will not adversely affectemission performance. Themanufacturer or rebuilder of the partmust certify that use of the part willnot result in a failure of the engine tocomply with emission regulations.

Follow the maintenance schedule onp. . Remember that this scheduleis based on the assumption that yourmachine will be used for its designedpurpose. Sustained high-loadoperation, or use in unusualconditions, will require morefrequent service.

If you are aware of any of thefollowing symptoms, have yourengine inspected and repaired byyour servicing dealer.

Hard starting or stalling afterstarting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuelconsumption.

The emission control systems onyour Honda engine were designed,built, and certified to conform withEPA and California emissionregulations. We recommend the useof genuine Honda parts wheneveryou have maintenance done. Theseoriginal-design replacement parts aremanufactured to the same standardsas the original parts, so you can beconfident of their performance. Theuse of replacement parts that are notof the original design and qualitymay impair the effectiveness of youremission control system.

56

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100

Star Label

The Symbol for Cleaner Marine Engines:

Cleaner Air and Water -

Better Fuel Economy -

Longer Emission Warranty -


The Star Label means Cleaner Marine Engine

A Star label was applied to thisoutboard motor in accordance withthe requirements of the CaliforniaAir Resources Board.

for healthier lifestyle and environment.

burns up to 30 - 40 percent less gas and oil thanconventional carbureted two-stroke engines, saving money and resources.

protects consumer for worry free operation.

This engine has been certified as a:

04/03/29 10:46:04 31ZY2600_101

101

One StarLowEmission

Two StarsVery LowEmission

Three StarsUltra LowEmission

Four StarsSuper UltraLow Emission


The one-star label identifies engines that meet the Air Resources Board’sPersonal Watercraft and Outboard marine engine 2001 exhaust emissionstandards. Engines meeting these standards have 75% lower emissions thanconventional carbureted two-stroke engines. These engines are equivalentto the U.S.EPA’s 2006 standards for marine engines.

The two-star label identifies engines that meet the Air Resources Board’sPersonal Watercraft and Outboard marine engine 2004 exhaust emissionstandards. Engines meeting these standards have 20% lower emissions thanOne Star-Low Emission engines.

The three-star label identifies engines that meet the Air Resources Board’sPersonal Watercraft and Outboard marine engine 2008 exhaust emissionstandards or the Sterndrive and inboard marine engine 2003-2008 exhaustemission standards. Engines meeting these standards have 65% loweremissions than One Star-Low Emission engines.

The four-star label identifies engines that meet the Air Resources Board’sSterndrive and Inboard marine engine 2009 exhaust emission standards.Personal Watercraft and Outboard marine engines may also comply withthese standards. Engines meeting these standards have 90% loweremissions than One Star-Low Emission engines.

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

www.arb.ca.gov

04/03/29 10:46:15 31ZY2600_102

－－

－

－

－

BF200A

36.2 in (920 mm)24.6 in (625 mm)

Electric starterFully transistorized, battery ignitionTrochoid pump pressure lubrication

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

API standard (GL-4/5) SAE90 outboard motor gear oil

8.0 US qt (7.6 )

LA XA XCA

65.7 in(1,670mm)

XXA

0.039 0.051 in (1.00 1.30 mm)211.7 cu-in (3,471 cm )

4 stroke SOHC 6-cylinder (V6)5,000 6,000 rpm149.1 kW (200 HP)

589 lbs(267 kg)

600 lbs (272 kg) 611 lbs (277 kg)

20.0 in(508mm)

70.9 in(1,800 mm)

75.8 in(1,925 mm)

25.0 in (635 mm) 30.0 in (762 mm)

XXCABAEJ BAEJ BAFJ BAEJ BAFJ

1.24 US qt (1.17 )ULTRA · LOW EMISSION

12V 60AWater cooling with thermostat

Water exhaustVKJ20RZ-M11 (DENSO)

IZFR6F11 (NGK)Electric powered mechanical

Automotive unleaded gasoline (86 pumpoctane or higher)

Forward-Neutral-Reverse (dog type)30° right and left

4° to 16°

Engine:

Gear case:

Engine:

Gear case:

without oil filter change

102

Specifications


MODELDescription CodeTypeOverall lengthOverall widthOverall height

Starter systemIgnition systemLubrication systemSpecified oil

Oil capacity

Spark plug gapDisplacementEngine typeFull throttle rangeRated power

Weight

Transom height

CARB star labelD.C. outputCooling systemExhaust systemSpark plugs

Fuel pumpFuel

Gear changeSteering angleTrim angle(when transom angle is12°)

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

04/03/29 10:46:55 31ZY2600_103

－－

－

－

－

BF225A

36.2 in (920 mm)24.6 in (625 mm)

Electric starter

Trochoid pump pressure lubricationAPI standard (SG, SH, SJ)SAE 10W-30

API standard (GL-4/5) SAE90 outboard motor gear oil

8.0 US qt (7.6 )

LA XA XCA

65.7 in(1,670mm)

0.039 0.051 in (1.00 1.30 mm)211.7 cu-in (3,471 cm )

4 stroke SOHC VTEC 6-cylinder (V6)5,000 6,000 rpm167.8 kW (225 HP)

611 lbs (277 kg)589 lbs(267 kg)

20.0 in(508mm)

30.0 in (762 mm)

XXA

25.0 in (635 mm)

70.9 in(1,800 mm)

75.8 in(1,925 mm)

600 lbs (272 kg)

XXCABAGJ BAGJ BAHJ BAGJ BAHJ

1.24 US qt (1.17 )ULTRA · LOW EMISSION

12V 60AWater cooling with thermostat

Water exhaustVKJ20RZ-M11 (DENSO)

IZFR6F11 (NGK)Electric powered mechanical

Automotive unleaded gasoline (86 pumpoctane or higher)

Forward-Neutral-Reverse (dog type)30° right and left

Fully transistorized, battery ignition

4° to 16°

Engine:

Gear case:

Engine:

Gear case:

without oil filter change

103

Specifications


MODELDescription CodeTypeOverall lengthOverall widthOverall height

Starter systemIgnition systemLubrication systemSpecified oil

Oil capacity

Spark plug gapDisplacementEngine typeFull throttle rangeRated power

Weight

Transom height

CARB star labelD.C. outputCooling systemExhaust systemSpark plugs

Fuel pumpFuel

Gear changeSteering angleTrim angle(when transom angle is12°)

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

04/03/29 10:47:30 31ZY2600_104

±±

±－－

No other adjustments needed.

0.22 0.02 mm0.30 0.02 mm

650 50 rpm0.039 0.051 in (1.00 1.30 mm) See page 66

See shop manualSee shop manual

Exhaust:Intake:

104


BF200A/BF225A Tune up

Spark plug gapIdle speedValve clearance (cold)

Other specifications

04/03/29 10:47:39 31ZY2600_105

105

CONSUMER INFORMATION

Honda Publications

Customer Service Information

American Honda Motor Co., Inc.


Shop Manual

Parts Catalog

Honda Marine dealership personnelare trained professionals. Theyshould be able to answer anyquestion you may have. If youencounter a problem that your dealerdoes not solve to your satisfaction,please discuss it with the dealership’smanagement. The Service Manageror General Manager can help. Almostall problems are solved in this way.

If you are dissatisfied with thedecision made by the dealership’smanagement, contact the HondaMarine Customer Relations Office.You can write:

Marine DivisionCustomer Relations Office4900 Marconi DriveAlpharetta, Georgia 30005-8847

Or telephone: (770) 497-6400

When you write or call, please giveus this information:

Model and serial numbers (p. )

Name of the dealer who sold theoutboard motor to you

Name and address of the dealerwho services your outboard motor

Date of purchase

Your name, address, and telephonenumber

A detailed description of theproblem

This manual covers completemaintenance and overhaul procedures.It is intended to be used by a skilledtechnician.

This manual provides complete,illustrated parts lists.

These publications will give youadditional information formaintaining and repairing youroutboard motor. You may purchasethem from your Honda marine dealer.

95

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110

INDEX

...........................................Alternator (ACG) Indicator . 29...........................................................................Anodes . 32

..............................................................Replacement . 74............ARE YOU READY TO GET UNDER WAY? . 33

...........................................................................Battery . 97BATTERY WILL NOT CHARGE AND

.....ELECTRIC STARTER WILL NOT OPERATE . 88................................................BEFORE OPERATION . 33

...........................................BREAK-IN PROCEDURE . 35

.........................................................Common Controls . 25........COMPONENT AND CONTROL LOCATIONS . 11

.................................CONSUMER INFORMATION . 105.....................................................Honda Publications . 105

....................................Customer Service Information . 105..................................................................CONTROLS . 15

CONTROL AND FEATURE IDENTIFICATION......................................................................CODES . 10

..................................CONTROLS AND FEATURES . 10..............................................Cooling System Indicator . 31

....................................................................CRUISING . 49

...................Digital Speedometer (optional equipment) . 28.....................Digital Tachometer (optional equipment) . 28

.........................Emission Control System Information . 97Engine

Cover......................................................................Latch . 27

...................REMOVAL AND INSTALLATION . 59Oil

...................................................................Change . 60.........................................................Filter Change . 61..........................................................Level Check . 60

.................................................Recommendations . 63

04/03/29 10:48:09 31ZY2600_111

111

INDEX

Fast Idle Button.....................................................Panel-Mount Type . 20

.......................................................Top-Mount Type . 23...............................................................Fast Idle Lever . 18

Fuel..................................................................PRIMING . 36

.............................................................Priming Bulb . 32..........................................RECOMMENDATIONS . 69

............................Filter Inspection and Replacement . 70.........................................................Fuse Replacement . 88

Gearshift/Trottle Control Lever.....................................................Panel-Mount Type . 20......................................................Side-Mount Type . 16.......................................................Top-Mount Type . 23

.........GEARSHIFT AND THROTTLE OPERATION . 46.....................................................Panel-Mount Type . 47......................................................Side-Mount Type . 46.......................................................Top-Mount Type . 47

....................HOISTING THE OUTBOARD MOTOR . 79

Ignition Switch.....................................................Panel-Mount Type . 18......................................................Side-Mount Type . 15.......................................................Top-Mount Type . 22

....................IMPORTANT SAFETY INFORMATION . 7...............................................................INDICATORS . 29

...........................................................INSTRUMENTS . 27IS YOUR OUTBOARD MOTOR

......................................................READY TO GO? . 33

.........................................................Lubrication Points . 64

.........................................MAINTENANCE SAFETY . 54...................................MAINTENANCE SCHEDULE . 56

........................................MANUAL RELIEF VALVE . 59...................MOORING, BEACHING, LAUNCHING . 51

04/03/29 10:48:13 31ZY2600_112

112

INDEX

....................................................Oil Pressure Indicator . 30OIL PRESSURE INDICATOR LIGHT GOES

..............OFF AND ENGINE SPEED IS LIMITED . 90................................................................OPERATION . 35

....................................................OTHER FEATURES . 31...................................OUTBOARD MOTOR SAFETY . 7

.........................................................Overheat Indicator . 30OVERHEAT INDICATOR COMES

................ON AND ENGINE SPEED IS LIMITED . 91.............................................................Overrev Limiter . 32

..........................................................Oxygenated Fuels . 96

..........................................................Power Tilt Switch . 26................................................Power Trim/Tilt Switch . 25

..........Programmed Fuel Injection (PGM-FI) Indicator . 29..................................................Propeller Replacement . 75

.................................................................REFUELING . 68...................................REMOVAL FROM STORAGE . 81

........................SAFE OPERATING PRECAUTIONS . 35......................................SAFETY LABEL LOCATION . 9

...............................................Serial Number Locations . 95..............SERVICING YOUR OUTBOARD MOTOR . 53

............................SHALLOW WATER OPERATION . 51........................................................Spark Plug Service . 65

..............................................................Specifications . 102....................................................................Star Label . 100

..........................................STARTING THE ENGINE . 37.....................................................Panel-Mount Type . 40......................................................Side-Mount Type . 37.......................................................Top-Mount Type . 42

....................................................................STEERING . 48...........................................STOPPING THE ENGINE . 44

.....................................Emergency Engine Stopping . 44...........................................Normal Engine Stopping . 45

....................................................................STORAGE . 76........................................STORAGE PRECAUTIONS . 80........................................STORAGE PREPARATION . 76

..............................................Cleaning and Flushing . 76..................................................................Engine oil . 79

............................................................................Fuel . 78...............................................SUBMERGED MOTOR . 93

Switch Clip and Emergency Stop Switch.....................................................Panel-Mount Type . 19......................................................Side-Mount Type . 16.......................................................Top-Mount Type . 22

04/03/29 10:48:17 31ZY2600_113

113

INDEX

.................................Tachometer (optional equipment) . 28....TAKING CARE OF UNEXPECTED PROBLEMS . 83..TECHNICAL AND CONSUMER INFORMATION . 95

...................................TECHNICAL INFORMATION . 95...............THE IMPORTANCE OF MAINTENANCE . 53

..............................................................Tilt Lock Lever . 26........................TOOL KIT and OWNER’S MANUAL . 55

........................................................TRANSPORTING . 82WITH OUTBOARD MOTOR INSTALLED

.............................................................ON BOAT . 82WITH OUTBOARD MOTOR REMOVED

.......................................................FROM BOAT . 82.................................Trim Meter (optional equipment) . 27

........................................................................Trim Tab . 27........................................TRIM TAB ADJUSTMENT . 58

..............WATER SEPARATOR BUZZER SOUNDS . 92.......................Water Separator Inspection and Service . 72

........................WIRING DIAGRAMS . Inside Back Cover

04/03/29 10:48:21 31ZY2600_114

114

MEMO

04/03/29 10:48:23 31ZY2600_115

115

MEMO

04/03/29 10:48:25 31ZY2600_116

116

MEMO

04/03/29 10:48:26 31ZY2600_117

BF200A/BF225AOwner’s Manual

©2004 Honda Motor Co., Ltd. -All Rights Reserved31ZY260400X31-ZY2-6040

2eY1800.2004.04Printed in JapanN 2005

PANTONE 288 CVC DIC F101 31ZY2604 00X31-ZY2-6040 BLACK

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