CONSUMER INFORMATION: The information in this service bulletin is intended for use only by skilled technicians who have theproper tools, equipment, and training to correctly and safely service and repair your Honda outboard motor. These procedures should not beattempted by “do-it-yourselfers,” and you should not assume that this bulletin applies to your equipment, or that your outboard motor has thecondition described. to determine whether this information applies, contact an authorized Honda Marine dealer.
OUTBOARD MOTOR #54
REVISED MAY 2012
BF115A • BF130APOOR ENGINE PERFORMANCE CAUSED BY CYLINDER HEAD CRACKS
REVISION SUMMARY
• The complete head assembly is no longer available. The camshaft and rocker arm assembly from the old head must be reused.
• Flat rate labor time increased.
SYMPTOM
On some affected units, cylinder head cracks may allow water to enter one or more of the combustion chambers and may cause the engine to idle poorly (non-firing cylinders), accelerate poorly in the 2000~3000 rpm range, and stall during quick deceleration.
To confirm this condition, remove and inspect the spark plugs for signs of corrosion or moisture (the cracks typically occur in cylinders #2 and #3).
Perform a cylinder leak-down test on all cylinders. If the cylinder head is cracked or the exhaust valves are damaged, there will be excessive leakage (30 - 100%) in cylinders #2 and #3. Air may also escape from the adjacent cylinders.
If any of these symptoms exist on an affected unit, proceed to Corrective Action.
AFFECTED UNITS
NOTE: All repairs pertaining to this bulletin, even during the warranty period, require prior authorization by Techline or your DSM.
MODEL FRAME SERIAL NUMBER RANGE
BF115A BZBD-1200271 ~ 1700773
BF115A BZBG-1200001 ~ 1300071
BF130A BZBE-1201322 ~ 1700019
BF130A BZBH-1200181 ~ 1500113
NNE
Cylinder head cracks (typically #2 and #3) allow water to enter the combustion chamber.
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Rapid engine heating and cooling may cause cracks to form in the water passages in the cylinder head. These crack areas allow water to enter the combustion chamber where it can cause spark plug fouling.
A new cylinder head assembly is available that offers improved designs to help eliminate cracking.
• The new cylinder head has a cooling water jacket added on the exhaust side and can be identified by a “B” next to the flush valve as shown.
• A new head gasket must be installed to match the new head design.
• A cooler 60°C (140°F) thermostat must also be installed.
• If the engine shows signs of excessive corrosion or deterioration due to age or use, contact Techline or your DSM.
The following action has been taken on affected units:
• To ensure customer satisfaction, American Honda is extending the warranty period to 10 years from the original date of purchase for cracks in the cylinder head assembly. This extension only applies to the cylinder head assembly.
Check the original date of purchase on the iN > Unit Information to determine if the unit is still within the 10 year period.
• Registered customers have been notified by letter. A copy of the letter is included at the end of this bulletin.
PROCEDURE
Cylinder Head Removal
When gaskets or non-hardening gasket material must be removed, DO NOT use abrasive materials (Scotch-Brite™, Surface Conditioning Disc, Roloc™, Bristle Disc) or sharp tools that could damage the sealing surfaces.
NOTICEWhen using a gasket removal tool, always be careful not to gouge or scratch the mating surfaces.
CYLINDER HEAD GASKET
Cooling jacket area added.
Cooling jacket added.
CYLINDER HEAD
FLUSH VALVE
“B” MARK
THERMOSTAT
Cooler 60°C (140°F)
BOTTOM VIEW
Typical crack
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2. Drain the engine oil and dispose of it properly.
3. Drain the fuel from the vapor separator and dispose of it properly.
4. Remove the cylinder head following the procedure in section 9 of the shop manual.
5. Inspect the cylinder for pitting, rust, scoring, or other damage that may have been caused by water ingestion. It is necessary to position the pistons at BDC to inspect the complete cylinder wall.
6. If the cylinder block is OK, proceed with the new Cylinder Head Assembly Preparation (page 4 of 7).
10 x 70 mm FLANGE BOLT
CYLINDER HEAD COVER
6 x 65 mm FLANGE BOLT
CYLINDER HEAD COVER GASKET
Replace
6 x 35 mm FLANGE BOLT (9)
OIL CONTROL ORIFICE
10.8 x 2.4 mm O-RING
Replace
CYLINDER HEAD GASKET
Replace
14 x 20 mm DOWEL PIN (2)
Replace if necessary.
12 x 163 mm BOLT-WASHER (10)
8 x 50 mm FLANGE BOLT
Inspect the cylinder walls for pitting, rust, scoring, or other damage.
THERMOSTAT COVER GASKET
Replace
6 x 20 mm FLANGE BOLT (2)
THERMOSTAT COVER
ECT SENSOR (OVERHEAT SENSOR)
9.5 x 1.5 mm O-RING (2)
Replace
CYLINDER HEAD ASSEMBLY
31.5 x 2.4 mm O-RING (2)
Replace.
6 x 55 mm FLANGE BOLT (2)
RELIEF VALVE
RELIEF VALVE SPRING
FLUSH VALVE COVER
FLUSH VALVE SPACER
RELIEF VALVE GASKET
THERMOSTAT
Replace with new 60°.
10 x 90 mm FLANGE BOLT (4)
8 x 80 mm FLANGE BOLT (2)
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1. Remove the ten 8 x 76 mm flange bolts, two 6 x 40 mm flange bolts, and remove the camshaft holders from the new cylinder head assembly.
2. Install the ten 10 x 16 mm dowel pins into the head.
3. Completely loosen intake and exhaust rocker arm adjusters from the old cylinder head assembly as shown.
4. Remove the ten 8 x 76 mm flange bolts, two 6 x 40 mm flange bolts, and rocker arm assembly from the old cylinder head assembly.
5. Remove the overheat sensor from the old cylinder head and install it on the new cylinder head assembly using a new 9.5 x 1.5 mm O-ring (P. 8-1 of the shop manual).
6. Remove the camshaft from the old cylinder head and install it in the new cylinder head using a new 35 x 50 x 8 mm oil seal and cylinder head rubber seal.
Lubricate the camshaft journals before installing the camshaft on the new cylinder head assembly.
CAMSHAFT HOLDER #4
CAMSHAFT HOLDER #5
CAMSHAFT HOLDER #3
CAMSHAFT HOLDER #2
10 x 16 mm DOWEL PIN (10)
6 x 40 mm FLANGE BOLT (2)
8 x 76 mm FLANGE BOLT (10)
CAMSHAFT HOLDER #1
OVERHEAT SENSOR
6 x 40 mm FLANGE BOLT (2)8 x 76 mm FLANGE BOLT (10)
ADJUSTER (16)
Loosen.
35 x 50 x 8 mm OIL SEAL
CYLINDER HEAD RUBBER SEAL
9.5 x 1.5 mm O-RING
CAMSHAFT
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7. Disassemble the old rocker arm assembly and discard the camshaft holders.
8. Assemble the rocker arm assembly using the new camshaft holders.
9. Apply Hondabond HT to the areas shown on the new No. 5 and No. 1 camshaft holders as shown, and assemble the rocker arm assembly to the new cylinder head assembly.
10. Apply oil to the 8 mm and 6 mm flange bolts before installing the rocker arm assembly.
CAMSHAFT HOLDER #4
CAMSHAFT HOLDER #5
CAMSHAFT HOLDER #3
CAMSHAFT HOLDER #2
CAMSHAFT HOLDER #1
INTAKE ROCKER SHAFT
EXHAUST ROCKER SHAFT
INTAKE ROCKER COLLAR A
FUEL PUMP ROCKER ARM
INTAKE ROCKER ARM A
INTAKE ROCKER ARM B
INTAKE WAVE WASHER
INTAKE ROCKER COLLAR A
INTAKE ROCKER COLLAR A
INTAKE ROCKER ARM B
INTAKE WAVE WASHER
INTAKE ROCKER ARM A
INTAKE ROCKER COLLAR AINTAKE ROCKER ARM A
INTAKE ROCKER ARM B
INTAKE WAVE WASHER
INTAKE ROCKER ARM AINTAKE ROCKER COLLAR A
ROCKER COLLAR A
INTAKE ROCKER COLLAR BINTAKE WAVE WASHER EXHAUST
ROCKER ARM B
WAVE WASHER
ROCKER COLLAR B
INTAKE ROCKER ARM B
EXHAUST ROCKER ARM B
ROCKER COLLAR A
EXHAUST ROCKER ARM BWAVE WASHER
EXHAUST ROCKER ARM A
ROCKER COLLAR A
EXHAUST ROCKER ARM B
EXHAUST ROCKER ARM B
WAVE WASHER
ROCKER COLLAR A
EXHAUST ROCKER ARM B
EXHAUST ROCKER ARM B
WAVE WASHER
NO. 5 CAMSHAFT HOLDER
Apply Hondabond HT to the shaded area.
NO. 1 CAMSHAFT HOLDER
Apply Hondabond HT to the shaded area.
6 x 40 mm FLANGE BOLT (2)
8 x 76 mm FLANGE BOLT (10)
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1. Inspect the ten 12 x 163 mm bolt-washers for stretching or corrosion (P. 9-20 of the shop manual). Replace if necessary.
2. Replace the two 14 x 20 mm dowel pins if they cannot be removed easily.
3. Transfer the ECT sensor (overheat sensor) to the new cylinder head assembly using a new9.5 x 1.5 mm O-ring.
4. Transfer the flush valve components to the new block using two new 31.5 x 2.4 mm O-rings.
5. When installing the new cylinder head assembly, be sure to install the dowel pins, oil control orifice with a new O-ring, and a new head gasket on the cylinder block.
6. Oil the threads and seating surfaces of the head bolts, then install them finger tight.
7. Tighten the ten 12 x 163 mm bolt-washers (1 – 10) in two or three steps to the specified torque in the numbered order shown.
TORQUE:12 mm bolt-washers ( - ): 44 N•m (33 ft-lb)
Use a torque angle gauge (commercially available), and tighten the ten 12 x 163 mm bolt-washers 180° in two steps of 90° in the numbered order shown.
8. After tightening the ten 12 x 163 mm bolt-washers, tighten the other bolts in the numbered order(11 – 18) in two or three steps to the specified torque.
After tightening the ten 12 mm bolt-washers to the initial torque of44 N•m (33 ft-lb), use the gauge and tighten 180° in two steps of 90° in the order shown.
90°
90°
10 x 70 mm FLANGE BOLT
10 x 90 mm FLANGE BOLT (4)
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All repairs pertaining to this bulletin, even during the warranty period, require prior authorization by Techline or your DSM.
Replaced cylinder heads and blocks are subject to parts call-in and must be held for 60 days from the claim paid date.
Duration (10 years from date of purchase)
In warrantyThe normal warranty applies.
Out of warranty Any repair performed after the extended warranty expiration may be eligible for goodwill consideration. Contact Techline or your District Service Manager. You must request consideration and receive a decision before starting work.
VIN Information
Processing
Service Bulletin warranty claim submission requirements apply. After completing the Service Bulletin repair procedure, submit one warranty claim per unit with the following information:
Cylinder Head Replacement Only
Cylinder Head/Short Block Replacement
A Template Number includes only those parts shown in the Parts Information section of this bulletin for that repair. If any additional parts are required, submit a normal warranty claim for Parts Only using Labor Operations Number “000001.”
VIN Prefix Affected Serial Number Range Model
BZBD 1200271 ~ 1700773 BF115A
BZBG 1200001 ~ 1300071 BF115A
BZBE 1201322 ~ 1700019 BF130A
BZBH 1200181 ~ 1500114 BF130A
iN and HondaNet users: All others:
Template Number: 7ANZ Defect Code: 7AN00
Labor Operation Number: 110103
Flat Rate Time: 4.6
Failed Part: 12000-ZW5-020ZA
iN and HondaNet users: All others:
Template Number: 7ANY Defect Code: 7AN00
Labor Operation Number: 110104
Flat Rate Time: 10.5
Failed Part: 12000-ZW5-020ZA
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The following is a copy of the letter sent to registered customers.
TEXT OF CUSTOMER LETTER
September 2006
Dear Honda BF115A or BF130A Owner,
Our records indicate you own a Honda BF115A or BF130A outboard motor. It is likely that some of the reasons you purchased a Honda were for the long service life, outstanding quality, and our reputation for standing behind our products.
That is why we were concerned when we heard that some of the BF115A and BF130A outboard motors were not performing up to our expectations. A small number of these motors have developed localized cylinder head casting cracks. These cracks may cause internal water leaks and reduce the performance characteristics of your outboard motor.
To eliminate your concerns, American Honda is extending the warranty on the cylinder head assembly of your BF115A or BF130A outboard motor to a period of 10 years from the date of original retail purchase.
This warranty extension is limited to cylinder head casting cracks. This extension is applied within Honda’s warranty system according to your outboard motor’s serial number and is transferable to any subsequent owner. However, we do suggest that you retain this letter for your reference.
If casting cracks are found in the cylinder head within the 10 year warranty period, the cracked cylinder head and required related parts will be replaced with a minimum of inconvenience and, of course, at no cost to you for the repair. Transportation of the boat to the dealer and/or related hauling expenses are the responsibility of the owner.
Our goal is to provide you with the highest quality products and best after-sale service. We apologize for any inconvenience this situation may have caused.
If you have any questions regarding this matter that your servicing dealer cannot answer, or if you have previously paid for this repair, please feel free to contact us at:
American Honda Motor Co., Inc.
Customer Service Department
4900 Marconi Drive
Alpharetta, GA 30005
(770) 497-6400
We thank you for purchasing Honda products.
Sincerely,
American Honda Motor Co., Inc.
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NOTES
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