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Graco Inc. 02748 Paint Sprayer User Manual

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1. Inu i a H 118 A rpa TENT 2 247 0200 99 16 WIRING DIAGRAM TILLER HANDLE TYPE with electric starter cM Ul anha ado BF25A outboard i d CS wem 2 NUDO U mel lt lt _ EINEN COLON ee 100 l i 00302 247 7500 16 WIRING DIAGRAM REMOTE CONTROL TYPE ombord 2 outboard p PPT TTI EE Otk362 2V 7BOU 101 17 INDEX Anode Metal sess eese eres 21 Battery not included 79 Break in Procedure 48 Choke Knob 11 Choke Fast Idle Lever 18 CLEANING AND FLUSHING 65 COMPONENT IDENTIFICATION CONTROLS amp INSTRUMENTS common 20 CONTROLS TILLER HANDLE s 11 REMOTE CONTROL 15 Cooling System Indicator 21 Cruising TILLER HANDLE TYPE 30 REMOTE CONTROL TYPE 4 52 Emergency Starting e 42 Emergency Stop Switch Lanyard TILLER HANDLE s 13 REMOTE CONTROL
2. 17 Engine Cover Removal Installation 26 Engine Fuel 83 Engine Oil Level check 27 Pressure and Overheat Warning System 57 Replacement 74 102 Over Rev Limiter 2 2 00 0 59 Start Button Stop 5 13 Fuel Cap Gauge Vent Knob 4 23 Level 28 Line Connection 33 Tank and Filter 85 Tank and Vent Knob 33 Fuse 86 Fuel Recommendations 2 29 Gear 76 Gear Shifting TILLER HANDLE 49 REMOTE CONTROL 2 51 High Altitude Operation 60 Ignition Switch 16 Lubrication MAINTENANCE 67 EMISSION CONTROL SYSTEM INFORMATION 2 2 2000 68 MAINTENANCE SAFETY 67 222 40002 410 72 THE IMPORTANCE MAINTENANCE 67 Manual Choke Knob MOTOR PROTECTION SYSTEM 57 Neutral Release Lever 16 17 INDEX Pressure Indicator Light 14 90 Pressure Indicator gt Ligh Buzze
3. 30 ALEL 1 gt n _ Prset pd 02 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Thank you for purchasing Honda Outboard Motor This manual describes the operation and maintenance of the Honda BF25A and BF30A Outboard Motors information in this publication is based on the latest product informa tion available at the time of printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission This manual should be considered permanent part of the Outboard Motor and it must stay with the Outboard Motor if resold READ THIS OWNER S MANUAL CAREFULLY Pay special attention to these symbols and any instructions that foliow You WILL be KILLED or SERIOUSLY HURT if vou don t follow instructions You CAN be KILLED or SERIOUSLY HURT if vou don t follow instructions You CAN be HURT if vou don t follow instructions NOTICE Your outboard motor or other property can be damaged if vou don t follow instructions Honda Outboard Motors are designed to give safe and dependable service if operated according to instructions Operating this Outboard M
4. 2 24 2 2 2 Tilting Motor Fuse Replacement 86 Tilt Lever m B Propeller Trim Tab Adjustment M Motor 88 MOTOR PROTECT ION SYSTEM Engine Pressure and Overheat Warning System sssesssss OF rdi E High Altitude Operation 60 TE WIRING DIAGRAM inn 102 i Wilt 1 SAFETY LABELS These labels are in the locations shown They warn you of potential hazards that could seriously injure you Read these labels carefully C GASOLINE EXTREMELY FLAMMABLE FOR LGE MOTOR FLEL ONL CONTAIN LEAD ANTI SHOCK DANGER HARMFLL GA FATAL F OWED KEEP OF REACH OF CHLDREN SWALLOWED DO MOT YOAT MG CALL PHTSTOLAM JMMEDTATELT CAUTION KEEP TOTALLY 21 5520 IN USE WEEP FROM HEAT SPARKS FLAME SECURE ABOVE WELL VENT LATED AREA DO LE FUR LONG TERM FUEL STORAGE DD MOT LSE FUEL GIL BIXTURE FOLLOW MOTOR HAMUFACTLRERZ OS uy D ur OWNERS Burr 452 dde MER _ STARTING We CaO STARTER OR at d out Dea uus ire aae E pel VEUIRALI b VS CLOT RISE T v id DF ENGINE FLAMMA
5. fler Replaceifnecessay _ _____ Fuel filter Check 10900 Change Thermostat Check line Check Replace if necessary Battery cable Check tightness Bolts Nuts Check tightness Emission related items 1 Lubricate more frequently when used salt water 2 These items should be serviced by an authorized Honda Marine dealer unless the owner has the proper tools and 15 mechanically proficient See the Honda Shop Manual 3 For professional commercial use log hours of operation to determine proper maintenance intervals 73 11 MAINTENANCE Engine Oil Engine oil is a major factor affecting engine performance and service life Oil check interval Each use change interval After the first 20 hours then every 100 hours Refer to the maintenance schedule 72 74 CAPACITY 1 7 US 1 6 lit When oil filter is not replaced 2 0 US qt 1 9 lit When oil filter is replaced Recommended oil BF25A SAEIOW 20 engine oil or equivalent API Service classfication SG SH BF30A SAE5W 30 engine oil API Service classification Fuel Efficient 5 SH FILLER Engine Oil Replacement Drain the oil while the engine is still warm to assure rapid and complete draining 1 Position the outboard motor verti cally and remove the engine cover Remove the oil filler cap 11 MAINTENANCE 5 Reinstall the
6. N f j 3 i EMERGENCY STOP SWITCH CLIP Disengage the emergency stop switch clip from the emergency engine stop switch by pulling the emergency stop switch lanyard It is a good idea to stop the engine with the emergency stop switch lanyard from time to time to be sure that the switch 1s operating properly Normal Engine Stop N neutral LEVER IGNITION KEY 2 When the boat is not in use remove and store the ignition key 1 Move the control lever to the N neutral position and turn the igni tion key to the OFF position 63 9 TRANSPORTING Trailering If there insufficient road clearance STEERING FRICTION ADJUSTER with the motor in the normal run po sition then trailer the motor tn the tilted position using a motor support bar refer to motor support bar zd manufacturer s instructions or re move the motor from the boat 2 _ 2 When trailering or transporting the boat with the motor attached it 15 recom mended that the motor remain in the normal run position Tighten the steering friction adjuster securely to stop the motor s side to side movement Horizontal Transport CASE PROTECTORS Before removing the motor from the boat drain the carburetors Follow the carburetor drain procedure on page 90 Always rest the motor on the case protectors and be sure to protect it from impact and damage 10 CLEANING AND FLUSHING 5 Move the gearshift leve
7. PLUG CAPS SPARK PLUG WRENCH 3 Disconnect the spark plug caps from the spark plugs 4 Use the wrench and screwdriver supplied in the tool kit to remove the spark plugs 5 Check the spark plugs Replace the spark plugs if there is apparent wear or if the insulators are cracked or chipped Clean the spark plugs with a wire brush if they are to be reused 77 11 MAINTENANCE d 0 024 0 028 in 0 6 0 7 mm 6 Measure the plug gaps with a feeler gauge The gaps should be 0 024 0 028 in 0 6 0 7 mm Correct as necessary by carefully bending the side elec trode 78 NOTICE The spark plugs must be securely tightened A loose spark plug can become very hot and may cause engine damage Overtightening the spark plugs can damage the threads 7 Thread the plugs in by hand to pre vent cross threading 8 After the spark plugs are seated tighten with spark plug wrench to compress the washers If installing new spark plugs tighten 1 2 turn after the spark plugs seat to com press the washers If reinstalling used spark plugs tighten 1 8 1 4 turn after the spark plugs seat to compress the wash CTs 11 Battery not included Minimum requirements 12V 70AH manne cranking battery To protect the battery from mechani 4 Put the cover on the battery box and cal damage and to prevent the bat secure the b
8. The fuel tank must be in a well venti lated area to reduce the chance of a gasolme vapor explosion Avoid di rect sunlight on the fuel tank Due to the fuel pump capacity do not place the fuel tank more than 6 feet away from the motor or lower than 3 feet below the outboard end fuel hose connector 1 Open the fuel t nk vent by turn ing the vent knob at least 2 or 3 turns counterclockwise Allow the air pressure inside the fuel tank to equalize with the outside air With the vent open air can en ter the fuel tank to displace the fuel as the fuel level goes down 2 Remove the fuel and inspect the condition of the fuel cap and gasker Replace the fuel cap or gasket if they are cracked dam aged or icak fuel Fuel Line Connection FUEL HOSE CONNECTOR FUEL TANK END Inspect the fuel hose and the O ring seals in the fuel hose connectors Re place the fuel hose or fuel hase connec tors if they are cracked damaged or leak fuel Be sure the fuel hose 1s not kinked 1 Connect the fuel hose connector to the fuel tank Be sure the fuel hose connector is securely snapped in place 33 6 STARTING THE ENGINE FUEL HOSE CONNECTOR OUTBOARD END 2 Connect the fuel hose connector to If the outboard end the outboard motor Install the fuel hose connector is forcibly in outboard end fuel hose connector stalled in the reversed direction with the clip toward the outside the fuel hose connecto
9. ica BAS 27 L7 UA Y MNA CHOKE KNOB A manual choke knob is provided on the right side of the motor which can be used in the event the battery is dis charged Pull the manual choke knob and arich fuel mixture will be provid ed to the engine 3 CONTROLS REMOTE CONTROL Oil Pressure Indicator Light Buzzer Overheat Indicator Light Buzzer The green oil pressure indicator light The red overheat indicator light turns turns OFF and the buzzer sounds ON and the buzzer sounds when the when the oil level is low and or the engine cooling system is faulty The engine lubrication system is faulty engine speed slows down gradually 19 3 CONTROLS amp INSTRUMENTS common Tilt Lever TILT K EK Use the ult lever to temporarily tilt the motor when the boat is operating or mooring in shallow water OA TILT LEVER Tilt lever in the TILT position The lock mechanism between the motor and stern bracket is unlocked The motor can be tilted up to either the 30 45 or 75 tilt position Tilt lever in the RUN position The lock mechanism between the motor and stern bracket 1s locked when the motor 1s in contact with the transom angle adjusting rod 20 Trim Tab TIGHTENING BOLT TRIM PROPELLER When making a turn if unequal amount of effort is required to turn the steering wheel tiller handle right or left adjust the trim tab
10. 2 or 3 minutes Below 41 F 5 C run the engine for at least 5 minutes at approximately 2 000 rpm 3 000 rpm Failure to completely warm up the engine will result in poor engine performance 6 STARTING THE ENGINE REMOTE CONTROL EMERGENCY EMERGENCY STOP EMERGENCY STOP SWITCH CLIP SWITCH LANYARD NOTICE propeller must be lowered into the water Running the outboard motor out of the water will damage the water pump and over heat tlie engine 1 Engage the emergency stop switch clip located at one end of the emer gency stop switch lanyard with the emergency engine stop switch Attach the other end of the emer gency stop switch lanyard securely to the operator If the operator does not attach the emergency stop switch lanyard and is thrown from his seat or out of the boat the out of control boat can seri ously injure the operator 5 sengers or bystanders Always properly attach the lanyard before starting the motor The engine will not start unless the emergency stop switch clip is engaged with the emergency engine stop switch SPARE EMERGENCY STOP SWITCH CLIP N neutral spare emergency stop switch clip is provided on the remote control box 2 Move the control lever to the N neutral position The engine will not start unless the control lever is in the N neutral position 39 6 STARTING THE ENGINE REMOTE CONTROL TYPE CHOKE FAST IDLE LEVE
11. 50 80 30 20 1D 10 20 3D 4C Inspection 1 Position the outboard motor verti cally and remove the engine cover 2 Remove the oil level dipstick and wipe with a clean rag 3 Reinsert the dipstick all the way in then pull it out and read the If the oil registers near or below the lower limit mark remove the oil filler cap and fill to the upper limit mark with the recommended oil NOTICE Do not overfill Excessive can damage the engine OIL LEVEL DIPSTICK 4 Reinstall the oil filler cap and tighten securely 5 Install the engine cover and lock it securely When the engine oil is contaminated or discolored replace with fresh engine oil refer to page 74 for oil capacity replacement interval and procedure To avoid incorrect gauging of the engine oil level inspect the oil level when the engine has cooled 27 5 PRE OPERATION CHECKS Fuel Level FUEL GAUGE Check the fuel gauge and refill the tank to the SAFE FILL level mark if necessary Fuel tank capacity 6 6 US gal 25 lit 28 Gasoline is extremely flammable and gaso line vapor can explode causing serious injury or death Do not smoke or allow flames or sparks in your working area KEEP OUT OF REACH OF CHILDREN VENT KNOB FUEL CAP Refilling Remove the fuel tank from the boat for refilling Turn the vent knob coun terclockwise to the open position and remove the fuel
12. boat moves forward N neutral The transmission gears are disengaged from the engine R reverse The boat reverses Choke Knob _ When the engine is cold pull the choke knob A rich fuel mixture is provided to the engine by pulling the choke knob 3 CONTROLS TILLER HANDLE Throttle Grip INCREASE THROTTLE GRIP Turn the grip clockwise or counter clockwise to adjust the engine speed Turning the grip in the direction shown by the arrow increases engine speed 12 Throttle Opening Indicator THROTTLE OPENING INDICATOR The curve on the grip indicates throttle opening Throttle Friction Knob THROTTLE FRICTION KNOB RELEASE Use the throttle friction knob to set the throttle grip at a certain position while cruising Turning the friction knob clockwise sets the throttle grip and it is released by turning the friction knob counterclockwise 3 CONTROLS TILLER HANDLE Emergency Stop Switch Lanyard ENGINE STOP SPARE EMERGENCY SWITCH STOP SWITCH CLIP Engine Stop Switch it if T gt EMERGENCY STOP SWITCH CLIP ENGINE STOP SWITCH t EMERGENCY STOP SWITCH LANYARD Push the engine stop switch to stop the The emergency stop switch lanyard is Attach the emergency stop switch lan engine provided to stop the engine immedi yard securely to the operator when ately in the event the operator should operating t
13. collec tively referred to as oxygenated fuels To meet clean air standards some areas of ihe United States and Canada use oxygenated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information be posted on the pump The follawing are the EPA approved percentages of oxy penates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline con taining ethanol may be marketed under the name Gasohol MTBE Methyl Tertiary Butyl Ether 15 by volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 590 methanol by volume may cause starting and or performance problems may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try an other service station or switch to another brand of gaso line Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not
14. freely 32 Other Checks TO INCREASE Check the following items 1 The fuel hose for kinking 5 ing or loose connections 2 The stern bracket for damage Make sure the clamp screws and mounting bolts 1f equipped are tight 3 The tool kit contents Compare your tool kit contents against the tool kit illustration above Replace any missing items 4 anode for damage looseness or excessive corrosion The anode helps to protect the outboard motor from corrosion any time it is exposed directly to the water 3 Tool Kit 13 WRENCH A 9 3 EMERGENCY Sim WRENCH STARTER FLAT SCREWDRIVER ac PLIERS PHILLIPS 729 SCREWDRIVER SCREWDRIVER C HANDLE TOOL CHECK d SCREWDRIVER 15 x mm WRENCH Replace the anode when it has been visibly reduced in size NOTICE Painting or coating the anode will lead to rust and corrosion damage to the outboard motor The following materials should be kept with the boat 1 Owner s Manual 2 Tool Kit 3 Spare engine oil spark plugs propeller propeller cotter pins and nut 4 Required information regarding boating laws and regulations 6 STARTING THE ENGINE Fuel Tank and Vent Knob VENT KNOB The tank must be properly se cured in the boat This will protect the fuel tank from mechanical dam age caused by the fuel tank shifting
15. manu al choke knob to start the engine slowly return it to its initial position 13 Slowly return the throttle grip to the SLOW position or the choke fast idle lever to the lowest position to where the engine does not stall Exposed moving parts can cause injury Use extreme care when installing the engine cover Do not oper ate the outboard motor without the engine cover 14 Leave the flywheel cover off and install the engine cover Lock the engine cover latches Attach the emergency stop switch lanyard securely to the operator and return to the closest boat landing Contact your closest authorized Honda Marine dealer and have outboard motor and the electrical system checked 6 STARTING ENGINE Troubleshooting Starting Problems SYMPTOM POSSIBLE CAUSE REMEDY Starter motor 1 Shift lever not in neutral set shift lever in neutral doesn t turn position position OVET Blown fuse Replace fuse refer te page 86 Weak battery by using starter rope trefer rofpage 421 Set shift lever in neutral position Shift lever not in neutral position Emergency starting proce dure will not start the engine 2 Emergency stop switch clip is not engaged 2 Engage the emergency stop swi tch clip refer to page 13 and 17 3 Supply fuel refer tolpage 28 4 Open vent knob refer to 5 Squeeze primer
16. oil filler cap SEALING WASHI Always wash your hands after handling used oil Also please dispose of used motor oil in DRAIN BOLT a manner that is compatible with the environment We suggest you take it in sealed container to your local service station reclamation center Do not throw it in the trash pour it on the ground down a drain or into the water 2 Remove the engine oil drain bolt 4 Refill to the upper limit mark on the and washer using a 12 mm wrench oil level dipstick with the recom and drain the engine oil mended oil 3 Install a new sealing washer on the 22 drain bolt and tighten the bolt To avoid incorrect gauging of the securely engine oil level inspect the oil level when the engine has cooled outboard motord motor needs to be in the vertical position 75 11 MAINTENANCE Gear Oil Oil check interval Every 100 hours Oil change interval After the first 20 hours then every 200 hours Refer to the maintenance schedule OIL CAPACITY 0 33 US qt 0 29 lit Recommended oil Outboard motor SAE 90 hypoid gear oil API Service Classification GL 4 or GL 5 76 LEVEL PLUG S DRAIN PLUG Gear Oil Level Check 1 Position the outboard motor verti cally 2 Remove the level plug and see if oil flows out If no oil flows out fill through the drain plug hole until the oil starts to flow out through the level plug hole If there is water in the oi
17. position Turn the throttle grip in the SLOW direction to a position where the engine does not stall 37 6 STARTING THE ENGINE TILLER HANDLE COOLING SYSTEM INDICATOR WATER INTAKE each side 9 After the engine starts verify water is flowing through the cooling system by monitoring the cooling system indicator The amount of water coming out of the cooling system indicator will vary due to thermostat operation Stop the engine if water does not come out of the cooling system indicator or if you see steam Check the water intake screens and the cooling system indicator discharge port and if necessary remove any obstructions If the problem continues contact your closest authorized Honda Marine or Honda Gutboard Motor dealer NOTICE Running the outboard motor with an obstruc tion in the cooling system can damage the water pump and overheat the engine 38 OIL PRESSURE INDICATOR LIGHT NORMAL GREEN LIGHT ON ABNORMAL GREEN LIGHT BLINKING OR OFF With the engine running check to see if the green engine oil pressure indicator light turns Stop the engine if the oil pressure indicator light does not turn ON Check the engine oil level see page 27 If the oil level 15 normal and the oil pressure indicator light does not turn ON contact your closest authorized Honda Marine or Honda Outboard Motor dealer Warm up engine as follows Above 41 F 5 C run engine for
18. rpm 94 14 SPECIFICATIONS MODEL Code Short shaft BAJS Long shaft BAIL Extra lung shaft BAJU Type _ 5 OO LH ___ PRS Oil capacity Engine 1 7 Us qt 1 6 lit When oil filter is not replaced 2 0 Us qt 1 9 lit When oil filter is replaced Gear case 0 30 Us qt 0 29 11 Cooling system Water cooling with thermostat DR7EA X22ESR U DENSO Fuel pump Diaphragm tvpe Fuel Automotive gasoline 86 pump octane Tank capacity 6 6 US gal 25 lit Gear change Forward Neutral Reversc dog type Steering angle 40 right and lett Transom angle 5 stages 4 8 127 16 20 Specifications are subject to change without notice 95 14 SPECIFICATIONS MODEL BFE30A Description Code Short shaft BAWS Long shaft BAWL Overall length 26 57 in 675 mm Rated power 30 HP 22 4 KW Spark plug gap 0 024 0 028 in 0 6 0 7 mm Ignition system Specified oil Engine API standard Fuel Efficient 30 SH 5AE 5W 30 Crear case standard GL 4 5 SAE 90 outboard motor gear oil 96 14 SPECIFICATIONS MODEL BF30A Short shaft BAWS Long shaft BAWL capacity Engine 1 7 Us qt 1 6 lit When oil filter is not replaced 2 0 Us qi 1 9 lit When oil filter is replaced Gear case 0 30 Us qt 0 29 lit Automotive gasoline 86 pump octane 6 6 US gal 25 lir Gear change Forward Neutral Reverse dog type Stecring angle 40 right
19. so that an equal amount of effort 15 required Distribute the load evenly in the boat and run the boat in straight course at full throttle Slightly turn the steering wheel or tiller handle for both right and left turns to determine if an equal amount of effort is required f adjust ment is necessary loosen the tighten ing bolt and turn the trim tab right or left Make small adjustments at time and retest Incorrect trim tab adjustment can cause adverse steering The trim tab also functions as an anode Anode Metal trim tab 4 The anode is made from sacrificial material which helps to protect the outboard motor from corrosion Painting or coating anode will lead to rust and corrosion damage to the outboard motor 3 CONTROLS amp INSTRUMENTS common Water Intakes Acer Cooling System Indicator COOLING SYSTEM INDICATOR Water Intakes The cooling system is monitored here to make sure cooling water is circulat ing through the engine The engine cooling water is drawn into the water pump through these water intakes 21 3 CONTROLS amp INSTRUMENTS common Transom Angle Adjusting Rod BRACKET TRANSOM ANGLE ADJUSTING ROD The transom angle adjusting rod is used to adjust the motor angle to achieve the correct boat trim There are 5 adjustment holes located in the stern bracket Push in and turn the transom angle adjusting rod
20. sure to apply sealant to the bolt holes This modification should be made by your authorized Honda Marine dealer For battery handling and installation information refer to pages 79 25 4 INSTALLATION Engine Cover Removal Installation UNLATCH E ENGINE COVER LATCH FIX To remove release the engine cover latch and remove the engine cover install position the engine cover over the engine and hook and lock the latch 26 5 PRE OPERATION CHECKS Engine Oil Engine oil is a major factor affecting engine performance and service life NOTICE Running the engine with insufficient oil can cause serious engine damage Kecommended oil Use high detergent premium quality 4 stroke engine oil certified to meet or exceed U S automobile manufac tures requirements for American Petroleum Institute APT Service Classification SG SH Engine oils classified SG SH will show these designations on the container Select the appropriate viscosity for the average temperature in your area SAE 10W 30 is recommended for general all temperature use 2 SAE 5 30 is recommended for gen eral all temperature use Service Grade Use a Fuel Efficient SG SH ail NOTE This oil is usually identified by words such as Energy Conserving II Gas Saving Fuel Saving etc u qum 50 730 D 20 20 46
21. up to remove To install insert into the proper hole and turn down to lock After installation pull the transom angie adjusting rod out ward to be sure it 15 locked in place Start with the transom angle adjusting rod in the hole closest to the boat tran 22 TRANSOM ANGLE TO ADJUSTING ROD UNLOCKED x LOCK LOCKED POSITION som lower the motor and operate the boat at full speed If the bow is exces sively low stop the boat and motor Tilt the motor up and raise the transom angle adjusting rod one more hole away from the transom and retest The optimum boat trim is when the boat 15 parallel with the water The transom angle adjusting rod stops the motors forward movement The motor should never be operated with the transom angle adjusting rod removed 3 CONTROLS amp INSTRUMENTS common Fuel Cap Gauge Vent Knob VENT KNOB Before transporting or storing the fuel tank turn the vent knob fully clock wise to the closed position AMA Gasoline is extremely flammable and gaso line vapor can explode causing serious injury or death Do not smoke or allow flames or sparks in your working area KEEP OUT OF REACH OF CHILDREN FUEL FILLER CAP GAUGE The fuel gauge is part of the fuel cap The fuel cap vent knob controls air entering and leaving the fuel tank When refilling the fuel tank turn the vent knob counterclock wise to the open position and remove the fuel cap Before transportin
22. 5 minutes to clean the inside of the motor 9 Stop the motor and remove the flush kit coupler 10 the sealing washer from the flush kit coupler and install the sealing washer on the wash plug If tape was used to cover the three water intakes in step 7 remove the tape now 11 Install the wash plug into the gear case securely 11 MAINTENANCE THE IMPORTANCE OF MAINTENANCE Good maintenance 15 essential for safe economical and trouble free operation It will also help reduce pollution Improper mainte nance or failure to correct a problem before operation can cause a malfunction in which you can be seriously hurt or killed Always follow the inspection and maintenance recommen dations and schedules in this owner s manual help you properly care for your outboard motor the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are inore difficult or require special tools are best handled by professionals and are normally performed by a Honda techni cian or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your outboard motor under unusual conditions consult your servic ing dealer for recommendations applica ble to your individual needs and use Maintenance replacement or repair of the emission control devices a
23. AR SHIFT LEVER neutral 2 Move the gearshift lever to the N neutral position The engine will not start unless the gearshift lever 15 im the neutral position 35 6 STARTING THE ENGINE TILLER HANDLE STARTER GRIP a THROTTLE GRIP 3 Align the engine start symbol 4 When the engine is cold or ambient 5 Pull the starter rope slowly until a on the throttle grip with the temperature is low pull the choke resistance is felt then pull briskly pointer on the tiller handle knob NOTICE not allow the starter grip to snap back against the engine Return it gently to prevent dam age to the starter Do not pull the starter grip while the engine is running as that may damage the starter 36 6 STARTING THE ENGINE TILLER HANDLE Electric Starter Electric starter Type START BUTTON 6 Press the start button and start the engine The starter motor consumes large amount of current Do not run it continuously for more than 5 seconds at a If the engine does not start within 5 seconds wait at least 10 seconds before using the starter motor again Do not press the start but ton while the engine is running This can damage the starter motor and flywheel gt THROTTLE GRIP If it was necessary to use the choke knob to start the engine slowly return it to its initial
24. BLE DANGEROUS GASOLINE REMOVE FROM BOAT FOR FILLING 6 NFLAMMABLE DANGEREUX GAZOLINE QU PONA REFAIRE LE PLEINOY ESSERE READ OWNERS MANUAL BEFORC A WARNING PLACE TRANSMISSION MELITRAL BEFORE E 00 WITH ENGINE COVER E BE SURE THE ANTIVEMTILATION PLATE 15 THE PATER LINE E MOT SHIFT TO REVERSE SUDDEMLT AT HIGH SPEED CAREFULLY CHECK OIL LEVEL BEFORE STARTING FLUSH THE STSTEM THOROUGHLY WITH FRESH WATER AFTER EACH USE SALT WATER EMERGENCY STARTING INSTRUCTIONS ARE ON GF ENGINE 1 SAFETY SAFETY INFORMATION For your safety and the safety of oth ers pay special attention to these pre cautions Operator Responsibility Know how to stop the engine quickly case of emergency Understand the use of all controls Do not exceed the boat manufactur ers power recommendation and be sure that the outboard motor is property mounted Never permit to operate the outboard metor without proper instruction stop the engine immediately any one falls overboard Do not run the motor while the boat is near anyone in the water Attach the emergency stop switch lanyard securely to the operator Do not open the engine cover while the engine 25 running Before operating the outboard motor familiarize yourself with all laws and regulations relati
25. EMERGENCY LANYARD WASH PLUG WYTER INTAKE STOP SWITCH Flush plug 4 AUST PORT WA CLIP SPARE EMERGENCY PROPELLER STOP SWITCH CLIP GEAR OIL DRAIN PLUG 8 2 COMPONENT IDENTIFICATION REMOTE CONTROL CONTROL NEUTRAL ENGINE COVER OIL FILLER CAP LEVER RELEASE LEVER CHOKE KNOB OIL LEVEL DIPSTICK PRESSU RE FUEL LINE STOP SWITCH CLIP OVERHEAT CLAMP INDICATOR SCREW LIGHT CHOKE FAST IDLE LEVER TRANSOM BUZZER ANGLE LAM LEVER inside the box ADM USTING INDICATOR T RO STERN BRACKET AEN S C IGNITION LEVEL PLUG ENGINE SWITCH UG DRAIN BOLT SP WASH PLUG ANTI VENTILATION EN Flush plug TRIM TAB PLATE ANODE METAL EMERGENCY GEAR DIL EXHAUST PORT WATER INTAKE EMERGENCY STOP ENGINE STOP DRAIN PLUG SWITCH LANYARD SWITCH PROPELLER EMERGENCY STOP SWITCH CLIP 2 COMPONENT IDENTIFICATION VENT KNOB FUEL GAUGE FUEL TANK FUEL CAP FUEL HOSE FUEL HOSE CONNECTOR FEMALE PRIMER BULB 10 Engine Start Button Electric Starter Type R reverse N neutral SHIFT LEVER 7 ENGINE START BUTTON Move the gearshift lever to the N neutral position before starting The engine will not start unless the gearshift lever is in the neutral position 3 CONTROLS TILLER HANDLE TYPE Gearshift Lever R reverse neutral forward GEARSHIFT LEVER There are three gearshift lever posi tions F forward The
26. R 3 When the engine is cold or the ambient temperature is low lift the choke fast idle lever up fully This will provide a rich fuel mixture When the engine is warm it may be necessary to raise the choke fast idle lever shghtly Hold it in this position The choke fast idle lever will not move unless the control lever 15 in the neutral position 40 Hold the choke fast idle lever in position turn the ignition key to the START position and release the key when the engine starts The starter motor consumes a large amount of current Do not run it continuously for more than 5 seconds at a time the engine does not start within 5 seconds wait at least 10 seconds before using the starter motor again NOTICE Do not turn the ignition key to the start position while the CHOKE FAST IDLE LEVER LOWEST POSITION engine is running This can damage the starter motor and flywheel 5 After starting the engine return the lever slowly to the position where the engine does not stall and hold the lever in the position The control lever will not move unless the choke fast idle lever 15 returned to the lowest position 6 STARTING THE ENGINE REMOTE CONTROL COOLING SYSTEM INDICATOR WATER INTAKE each side 6 After the engine starts verify water is flowing through the cooling system by monitoring the cooling system indica tor The amount of water coming out of the cooling
27. STOP SPARE EMERGENCY SWITCH LANYARD STOP SWITCH CLIP The emergency stop switch lanyard is The emergency engine stop switch spare emergency stop switch clip is provided to stop the engine immedi should not be used to normally stop provided on the remote control box ately in the event the operator should the engine Use the ignition switch to fall overboard or away from the con normally stop the engine trols Attach the emergency stop switch lan The emergency stop switch clip must yard securely to the operator when be engaged with the emergency engine operating the outboard motor stop switch or the engine will not start When the emergency stop switch clip becomes disengaged from the emer gency engine stop switch the engine will stop immediately 17 3 CONTROLS REMOTE CONTROL Choke Fast Idle Lever N neutral The choke fast idle lever provides two functions 1 Electric choke solenoid activation for easy engine start up 2 Engine fast idle The choke fast idle lever will not move unless the remote control lever the N neutral position Conversely the remote control lever will not move unless the choke fast idle lever is in the lowest position 18 Lift and hold the choke fast idle lever up fully this will provide a rich fuel mixture and the correct fast idle Gradually lower the choke fast idle lever to the lowest position to decrease the choke and fast idle Manual Choke Knob
28. and left Transom angle 5 stages 4 8 12 16 20 Specifications are subject to change without notice 97 15 WARRANTY SERVICE Warranty Service Information Or telephone 770 497 6400 Servicing dealership personnel are When you write or call please give us trained professionals They should be this information able to answer any question you may have If you encounter a problem that Model and serial numbers see your dealer does not solve to your satisfaction please discuss it with the dealereship s management of the dealer who sold the The Service Manager or General outboard motor to you Manager can help Almost all problems are solved this way Name and address of the dealer who services your outboard motor If you are dissatisfied with the decision made by the dealership s management Date of purchase contact the Honda Marine Customer Relations Office Your name address and telephone You can write number American Honda Motor Co Inc A detailed description of the problem Marine Division Customer Relations Office 4475 River Green Parkway Duluth Georgia 30136 2565 Current customer service contact information Your owner s manual was written to cover most of the questions you might ask about your Honda Any questions not answered in the owner s manual can be answered by your Honda dealer If your dealer doesn t have an immediate answer they shoul
29. attery box to the boat tery from falling or tipping over the battery must be Installed in the correct size corro sion resistant battery box Properly secured in the boat Secured in a location free from di rect sunlight and water spray Secured away from the fuel tank to avoid potential sparks near the fuel tank 1 Install the battery in the battery box 2 Connect the positive battery cable first then connect the nege tive battery cable Tighten the cable nuts securely 3 Coat the battery terminals and ca ble ends with marine anticor rosion grease 79 11 MAINTENANCE DC Receptacle Equipped type only DC RECEPTACLE BATTERY Refer page 79 for battery requirements and additional battery handling proce dures Batteries produce explosive gases Keep sparks flames and cigarettes away To prevent the possibility of creating spark near the battery connect the charging cord first to the battery and then to the outboard motor when disconnecting the charging cord remove it from the outboard first 80 The DC receptacle provides a 12 volt 6 amp output for battery charging The charging circuit is protected by a 15 amp fuse that is mounted inside the engine cover Be sure that the positive Red battery lead is connected to plug termi nal e Reversing the battery leads will damage the charging system and or the battery When it is not in use kee
30. bulb to supply fuel refer to 6 Clean and dry spark plug page 77 refer to Starter motor tums over but engine will not start 3 fuel Yent knob not open 5 Primer bulb has not been squeezed Engine flooded 47 7 Break in Procedure Break in period 10 hours Break in operation allows the moving parts to wear in evenly and thus ensures proper performance and longer outboard motor life Break in your new outboard motor as follows First 15 minutes Run the outboard motor at trolling speed Use the minimum amount of throttle opening necessary to operate the boat at a safe trolling speed Next 45 minutes Run the outboard motor up to a maximum of 2 000 to 3 000 rpm or 1095 to 30 throttle opening Next 60 minutes Run the outboard motor up to maxi mum of 4 000 to 5 000 rpm or 50 to 80 throttle opening Short 48 bursts of full throttle are acceptable but do not operate the motor contin uously at full throttle Next 8 hours Avoid continuous full throttle oper ation 100 throttle opening Do not run the outboard motor at full throttle for more than 5 minutes at a time For boats that plane easily bring the boat up on plane then reduce the throttle opening to the specified break in settings called out above 7 OPERATION TILLER HANDLE Gear Shifting POINTER Gearshift lever has 3 posi
31. cap Refuel in a well ventilated area Fill the fuel tank up to the SAFE FILL level mark only Inspect the condition of the fuel cap gasket and replace if necessary After refilling install and tighten the fuel cap securely Turn the vent knob clockwise to the closed position Return the fuel tank to the boat 5 PRE OPERATION CHECKS Fuel Recommendations Use unleaded gasoline with a pump octane rating of 86 or higher These outboard motors are certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or oil gasoline mixture Avoid getting dirt or water in the fuel tank Occasionally you may hear light spark knock or pinging metallic rapping noise while operating under heavy loads This in no cause for If spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline If spark knack or pinging persists see an authorized Honda Marine dealer NOTICE Running the engine with persistent spark knock or pinging can cause engine damage Running the engine with persistent spark knock or ping ing is misuse and the Distributor s Limited Warranty does not cover parts damaged by misuse 29 5 PRE OPERATION CHECKS Oxygenated Fuels Some conventional gasolines are being blended with alco hol or an ether compound These gasolines arc
32. covered under warranty Propeller and Cotter Pin COTTER PIN stainless steel Propeller Check the propeller blades for damage wear or deformation and replace if necessary Never operate the outboard motor with a damaged pro peller Carrying a spare propeller propeller nuts and cotter pins are common prac tice If the propeller 15 damaged and no spare propeller is available consult an authorized Honda Marine dealer Refer to page 87 propeller change information 5 PRE OPERATION CHECKS PROPELLER Cotter Pin Check the cotter pin for damage and correct installation H the cotter pin needs replacement use only a new genuine Honda stainless steel cotter pin Steering Friction Adjustment common DECREASE FRICTION STEERING FRICTION ADJUSTER Operate the steering wheel or tiller handle right and left and check for the amount of drag felt 1 TO INCREASE FRICTION Adjust the steering friction adjuster so that a slight amount of drag 1s felt The steering should move smoothly and freely 3l 5 PRE OPERATION CHECKS Remote Control Friction Adjustment W FRICTION CONTROL FRICTION ADJUSTER TO DECREASE FRICTION Operate the remote control lever into forward and reverse gears and check for the amount of drap felt Adjust the remote control friction adjuster so that a slight amount of drag is felt The remote control lever should move smoothly and
33. d be able to get it for you If you have a difference of opinion with your dealer please remember that each dealership is independently owned and operated That s why it s important to work to resolve any differences at the dealership level If the service personnel are unable to assist you please discuss your concerns with the dealer management such as the Service Manager or the dealership s owner If you need to contact American Honda regarding your experiences with your Honda product or with your dealer please send your comments to the following address American Honda Motor Co Inc Marine Division Customer Relations Office 4900 Marconi Drive Alpharetta GA 30005 8847 Or telephone 770 497 6400 M F 8 30 am 7 00 pm EST When you write or call please provide the following information Your name address and telephone number complete with area code Model and complete serial number Date of purchase Name and location of the selling dealer Name and location of the servicing dealer if different A detailed description of your concerns 16 WIRING DIAGRAM TILLER HANDLE TYPE with recoil starter FLYWHEEL ina SO 12 V 10A coL Equipped 1 mi MN CHAR GREG us ms Ww Ad Equippa typa only RF EE ILE Hu TRECTIPER 4
34. e engine is cold or the ambient control type turn the ignition key to provided on the remote control box temperature is low pull the manual the ON position Engage the emer choke knob located on the front of gency stop switch clip located at the outboard motor one end of the emergency stop Switch lanyard with the emergency engine stop switch 44 6 STARTING THE ENGINE CHOKE FAST ENGINE START SYMBOL POINTER THROTTLE GRIP REMOTE CONTROL TYPE TILLER HANDLE TYPE If the fuel system 18 working properly it 9 On the tiller handle type align the should only be necessary to pull thc engine start symbol 0 on the engine or 2 times with the choke knob throttle grip with the pointer p out on the tiller handle On the remote control type lift the choke fast idle lever The choke fast idle lever wiil stay up in the fast idle position 45 6 STARTING THE ENGINE FLYWHEEL KNOT ks aii ptt ut IPM et Tm CHRON OSS AL a EMERGENCY STARTER ROPE 11 Pul the emergency starter rope lightly until resistance is felt then pull briskly 10 Set the emergency starter rope knot in the notch in the flywheel and wind the emergency starter rope clockwise around the flywheel If the engine fails to start refer to Troubleshooting page 92 46 12 it was necessary to use the
35. e on horsepower will be greater than this if no carburetor modification is made When the carburetors have been modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 5 000 feet 1 524 meters with modified carburetors cause the engine to overheat and result in serious engine damage For use at low altitudes have an authorized Honda Marie or Outboard Motor dealer return the carburetors to original factory specifications 8 STOPPING THE ENGINE TILLER HANDLE Emergency Engine Stop Normal Engine Stop ENGINE STOP SWITCH EMERGENCY STOP SWITCH CLIP GEARSHIFT LEVER N neutral EMERGENCY STOP SWITCH LANYARD THROTTLE GRIP Disengage the emergency stop switch 1 Turn the throttle grip to SLOW clip from the engine stop switch by position and move the gearshift lev pulling the emergency stop switch lan er to N neutral yard It is a good idea to stop the engine with the emergency stop switch lanyard from time to time to be sure that the switch 15 operating properly 61 8 STOPPING THE ENGINE TILLER HANDLE PUSH 0 Waly at d zs gt T ut ENGINE STOP SWITCH 7 SUME 2 Push the engine stop switch until the engine stops 62 8 STOPPING THE ENGINE CONTROL Emergency Engine Stop EMERGENCY SWITCH STOP EMERGENCY STOP SWITCH LANYARD
36. eed will increase gradually overheat 7 OPERATION MOTOR PROTECTION SYSTEM When the oil pressure warning sys tems is activated 1 Stop the engine immediately and check the engine oil level refer to page 27 2 the oil is up to the recommended level restart the engine If the oil pressure warning system stops after 30 seconds the system 1s normal 3 If the oil pressure warning system stays activated after 30 seconds retum to the closest boat landing and contact your closest authorized Honda Marine or Honda Outboard Motor dealers 55 COOLING SYSTEM INDICATOR When the overheat warning system is activated Return the gearshift lever or control lever to the N neutral position immediately Check to see if water 15 flowing out of the cooling system indicator 2 If water is flowing out of the cool ing system indicator continue idling for 30 seconds If the over heat warning system stops after 30 seconds the system is normal 3 If the overheat warning system stays activated stop the engine tilt up the motor and check the water intakes for obstructions If there are no obstructions at the water intakes return to the closest boat landing and contact your closest authorized Honda Marine or Honda Outboard Motor dealers Over Rev Limiter This outboard motor is equipped with an engine over rev limiter which activates when the engine speed increases excessively The over rev limiter can be ac
37. en the bolt securely If less effort is required to make right turns Loosen the trim tab tightening bolt and turn the rear end of the trim tab toward the right Tighten the boit securely Make small adjustments at a time and retest Incorrect trim tab adjustment can cause adverse steering The trim tab also functions as a sacrifi cial anode MOTICE Painting or coating the anode will lead to rust and corrosion damage to the outboard motor 7 OPERATION MOTOR PROTECTION SYSTEM Engine Oil Pressure and Overheat Warning System OIL PRESSURE Tiller Handle type gt if the engine oil pressure drops the warning system could be activated and the green oil pressure indicator light will turn OFF If the engine overheats the warning system could be activated and the engine speed will decrease gradually Remote control type If the engine oil pressure drops the warming system could be activated and the green pressure indicator light will turn OFF and a continuous buzzer Over heal will sound Remote Remote If the engine overheats the warning control system could be activated the engine type only speed will decrease gradually the red overheat indicator light will turn ON and a continuous buzzer will sound When the engine overheats gt The engine speed can not be increased with a larger throttle opening until the malfunction is corrected When the maifunction is corrected the engine pressure sp
38. ever to the R position approximately 30 from the N approximately 30 from the N position will engage the forward position will engage the reverse gear Moving the lever further from gear Moving the lever further from the F position will increase the the R position will increase the throttle opening and the boat for throttle opening and the boat ward speed reverse speed N neutral The engine idles and the transmis sion gears are disengaged 15 3 CONTROLS CONTROL Neutral Release Lever NEUTRAL RELEASE LEVER The neutral release lever is on the remote control lever to prevent an accidental gear engagement The remote control lever will not engage forward or reverse gear unless the neutral release lever is pulled up 16 Ignition 5witch gt ON START IGNITION SWITCH The remote control box is equipped with a key type ignition switch Key positions START To activate the starter motor and start the engine the remote control lever must be in the neutral position ON To run the engine after starting the battery will discharge if the key 15 left in this position with the engine not running OFF To stop the engine IGNITION OFF To prevent the battery from dis charging keep the the OFF position when the engine is not run ning 3 CONTROLS REMOTE CONTROL Emergency 5top Switch Lanyard EMERGENCY SWITCH CUP EMERGENCY
39. fuel is spilled make sure the area is dry before starting the engine CONNECTER FUEL HOSE B Check 1 Disconnect the fuel hose connector from the outboard motor 2 Remove the engine cover 83 11 MAINTENANCE x ES LL 1 3 Lift the fuel filter up from the engine under case 4 Check the fuel filter for water accu mulation or sediment no water or sediment are found reinstall the fuel filter properly 84 FUEL HOSES FUEL HOSE CLIPS Change 1 Remove the fuel filter Before removing the fuel filter to prevent fue leakage place fuel hose clamps on the fuel hoses at each side of the fuet filter ARROW Fuel Flow Direction 2 Install the new fuel filter so the arrow on the fuel filter points toward the fuel pump Fuel flow will he reduced if the fuel filter is installed backward 3 Connect the fuel hoses to the fuel filter securely with the hose clips Remove the fuel hose clamps used to close the fuel hoses I1 MAINTENANCE 4 Securely connect fuel hose Fuel Tank and Filter connector to the outboard motor refer to page 33 5 Prime the engine using the primer bulb refer to page 34 Check for fuel leaks Repair any tuel leaks if neces sary If loss of power or hard starting are found to be caused by excessive water or sediment accumulation in the fuel filter inspect the f
40. g storing or refill ing the fuel tank inspect the condition of the fuel cap gasket and replace if necessary Over Rev Limiter This outboard motor is equipped with an engine over rev limiter which limits the maximum engine rpm This over rev limiter protects the engine from mechanical damage The over rev limiter may be activated by putting the propeller in a light load condition or propeller ventilation When the over rev limiter is activated the engine rpm will become unstable or erratic Should this occur reduce the throttle opening and wait for the engine rpm to stabilize then increase the throttle opening 23 4 INSTALLATION Installation i your responsibility to choose a boat suitable for the motor DO NOT OVERPOWER THE BOAT Do not install an outboard motor that exceeds the recommended maximum horsepower for the boat Refer to the boat certification plate for the maxi mum recommended horsepower for the boat For most boat applications the motor should have a horsepower which provides 80 of the maximum recom mended horsepower for the boat If the certification plate information is not avallable contact the boat dealer The BE25A 50A must be installed on transoms which have the following minimum or thickness Boat Transom Thickness Minimum 1 38 in 35 mm Maximum 2 24 in 57 mm 24 STERN CENTER LINE Installation position Install on the stern center line Installatio
41. he outboard motor fall overboard or away from the trols A spare emergency stop switch clip is provided near the engine stop switch The emergency stop switch clip must be engaged with the engine stop switch or the engine will not start When the emergency stop switch clip becomes disengaged from the engine stop switch the engine will stop imme diately 13 3 CONTROLS TILLER HANDLE Oil Pressurc Indicator Light fa s xoc GREEN OIL INDICATOR LIGHT The green pressure indicator light is normally ON when the outboard motor is running When the engine oil level is low or the engine lubrication system is faulty the green oil pressure indicator light turns OFF 14 Recoil Starter STARTER GRIP Recoil starter type Pull the starter grip to start the engine Set the gearshift lever in the N neutral position before starting The engine wil not start unless the gearshift lever is 1n the N neutral position Remote Control Lever NEL TRAL RELEASE LEVER The remote control lever controls gear selection and throttle opening post tions It is necessary to pull up the neutral release lever to operate the remote control lever 3 CONTROLS REMOTE CONTROL TYPE N NEUTRAL F R FORWARD M REVERSE THROTTLE OPENING MAXIMUM REMOTE CONTROL LEVER F forward R reverse Moving the lever to the F position Moving the l
42. hifting CONTROL LEVER PULL UP While pulling up the neutral release lever move the control lever 307 toward F forward 30 toward reverse to engage the desired gear MAXIMUM OPENING Moving the control lever further from 30 will increase throttle opening and boat speed N neutral R reverse amp MAXIMUM OPENING The control lever will not move unless the neutral release lever is pulled up choke fast idle lever 15 in the lowest position 51 7 OPERATION Cruising N F neutral forward MAXIMUM OPENING 1 Move the control lever from neutral 30 toward forward to engage the F forward gear Moving the control lever further from 30 will increase the throttle opening and boat speed For optimum fuel economy limit throttle opening to 2 3 52 7 Tilt Lever N N neutral neutral ENGINE STOP GEARSHIFT LEVER SWITCH TILLER HANDLE TYPE REMOTE CONTROL TYPE Tilt the motor up to prevent the propel Stop the boat ler and gear case from hitting the bottom when beaching or stopping in 2 Move the gearshift lever or control shallow water lever to the neutral position and stop the engine 53 7 OPERATION ENGINE COVER GRIP TILT LEVER 3 Put the tilt lever in the TILT post Use the engine cover grip and raise the motor to either the 30 45 or 75 t
43. ilt position With the motor tilted up Operate the boat at low speed Do not operate in reverse Monitor the cooling system indicator for water discharge Be sure that the motor is not tilted so high that the water intakes are out of the water 54 4 return the motor to the normal position move the tile lever away from you until it stops Tilt the motor up slightly then lower the motor slowly until it locks with the transom angle adjusting rod During cruising the motor must always be in the normal run position 75 when mooring 45 30 when cruising in Shallow water Reverse Operation The tilt lever must be in the RUN position with the motor locked to the transom angle adjusting rod If the rnotor 1s operated in reverse with the tilt lever in the TILT position and or the motor is in one of the three tilt angle positions the motor 15 free to tilt up 7 OPERATION NOTICE To avoid damaging the motor use the utmost care when mooring a boat especially when its motor is tilted up Don t allow the motor to strike against the pier or other hoats Motor angle INCORRECT INCORRECT CAUSES BOAT TO CAUSES BOAT TO T CORRECT GIVES MAXIMUM PERFORMANCE Motor angle controls boat trim The optimum boat trim 15 when the boat 15 parallel with the water If the boat 15 not parallel with the water adjust changing the positio
44. is not in N position 13 TROUBLESHOOTING 2 Engine starts but immediately stops Engine some times stops while cruising Fuel No gasoline in fuel tank There is gasoline in fuel tank Water is mixed with gasoline Vent knob is not open or vent 1s clogged Fuel filter 15 clogged screw 15 open too wide Idling speed is too slow Carburetor vent is clogged Fuel pump is faulty Air in fuel pump Air enters through fuel line connector Air enters through primer bulb Engine overheats Normal sparking Water intake screens are clogged Spark plug 15 not of speci fied rating Water pump is faulty Thermostat is clogged Thermostat is faulty Water tube or passage is clogged Exhaust gas is entering cooling system 93 14 SPECIFICATIONS Descriplion Code Short shaft BAIS Long shaft Extra long shaft BAJU Overall length 26 57 in 675 mm 25 20 in 640 mm Overall width 14 96 in 380 mm 14 76 in 375 mm 46 85 in 1 190 mm 51 77 in 1 315 mm 54 92 in 1 395 mm 16 97 in 431 mm 21 73 in 552 mm 24 88 in 632 mm 152 1 Ib 69 kg 158 7 Ib 72 kg 156 5 Ib 71 kg 158 7 Ib 72 kg Displacement 30 45 499 Trocheid pump pressure lubrication Specified oil Engine standard SG SH SAE 10 W 30 Gear case standard GI 4 5 SAE 90 outboard motor gear oil 4 stroke OHC in line 3 cylinder 25 HP oe KW Full throttle range 5000 6000
45. l the water will flow out first when the drain plug is removed or the oil will be milky colored If the oil appears abnormal contact your closest authorized Honda dealer Bun GEAR OIL BOTTLE gear oil bottle is recommended to fill the gear case The end of the dram plug 15 mag net Remove all metal particles from the end of the drain plug before reinstalling Do not reinstall the drain plug in the level plug hole 3 Use new sealing washers and rein stall the level plug and drain plug securely 11 MAINTENANCE Gear Oil Change 1 Position the outboard motor verti cally 2 Remove the level plug and drain plug to drain the oil Inject oil through the drain plug hole until it starts flowing out through the level plug hole Use new sealing washers and reinstall the level plug first and then the drain plug securely OIL CAPACITY 0 30 US qt 0 29 Spark Plugs To ensure proper engine operation the spark plugs must be properly gapped and free of deposits Check replace interval After the first 20 hours then every 200 hours Refer to the maintenance schedule page 72 Recommended spark plug 7 X22ESR U DENSO Use only the recommended spark plugs or equivalent NOTICE Spark plugs which have an improper heat range may cause engine damage 1 Allow the engine to cool The spark plugs will be hot if the engine has been running 2 Remove the engine cover
46. n height For proper propeller depth and engine cooling the boat and outboard motor transom height must match Three outboard motor transom heights are available Match your boats tran som height to the outboard motor transom height shown below Outboard Motor Transom Height 16 97 in 431 mm 21 73 552 mm 24 88 632 mm D MOTOR TRANSOM HEIGHT 2 BOAT TRANSOM HEIGHT 3 0 2 in 0 50 4 ANTI VENTLATION PLATE The anti ventilation plate should be 0 2 inches below the bottom of the boat With the boat in the water loaded and motor off the anti ventilation plate should be about 4 inches below the surface of the water NOTICE Running the outboard motor without sufficient cooling water will damage the water pump and overheat the engine 4 INSTALLATION Motor attachment SAFETY ROPE Attach the stern bracket to the transom and tighten clamp screws Before operating the boat check the tightness of the clamp screws Tie a rope through the hole in the stern bracket secure the other end of the rope to the boat This will prevent accidental loss of the motor TRANSOM BOARD To prevent the outboard motor from falling accidentally you may further secure the stern bracket to the transom board with the optional Mounting Bolt Nut Kit Good quality stainless steel commercially available bolts nuts and washers may also be used Before installing the bolts be
47. n of the transom angle adjusting rod refer to page 22 During operation be sure The anti ventilation plate remains under water at all times e Water flows from the cooling system indicator e The load is evenly distributed Excessive or imbalanced loading will affect the motor s water depth Loading too far forward will raise the motor out of the water reducing engine cooling Loading too much too far rearward will push the motor deeper reducing performance The transom angle adjusting rod stops the motors forward movement The motor should never be operated with the transom angle adjusting re moved Always check to be sure the transom angle adjusting rod is locked in place refer tolpage 22 55 7 OPERATION Trim Tab Adjustment The trim tab is provided to adjust for torque steer which is a reaction of the propeller rotation or propeller torque If during a high speed turn an unequal amount of effort is required to turn the boat right or left adjust the trim tab so that an equal amount of effort is required Distribute the load evenly in the boat and run the boat in a straight course at full throttle Slightly turn the steering wheel or tiller handle for both right and left turns to determine the amount of effort required 56 TRIM TAB If less effort is required to make left turns Loosen the trim tab tightening bolt and turn the rear end of the trim tab toward the left Tight
48. nd systems may be performed by any marine engine repair establishment or individual using parts that are certified to EPA standards MAINTENANCE SAFETY Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise performing maintenance Only you can decide whether or not you should pertorm a given task Failure to properly follow maintenance instruc tions and precautions can cause you to be seriously hurt or killed follow the procedures and precautions in this owner s manual 67 11 MAINTENANCE Safety Precautions Make sure the engine is off before you begin any maintenance or repairs This wil eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventila whenever you operate the engine Burns from hot parts Let the engine cool before touch ing Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflam mable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Remember that an authorized Honda Marine dealer knows your outboard motor best and i
49. nds when rotated with the emergency starter rope or recoil starter do not proceed attempt to run the motor until it has been repaired 11 MAINTENANCE 2 m the engine oil refer to page 72 6 Put a teaspoon of engine oil into each spark plug hole then rotate the engine using the pull starter rope or recoil starter several times to lubri cate the inside of the cylinders Reinstall the spark plugs NOTICE Running the outboard motor without sufficient cooling water will damage the water pump and overheat the engine 7 Engage the emergency stop switch clip with the emergency stop switch and attempt to start the engine be sure the water level is at least 2 inches above the ventilation plate Ifthe engine fails to start remove the spark plugs clean and dry the electrodes then reinstall the spark plugs and attempt to start the engine again If the engine starts and mechanical damage is evident continue to run the engine for a 1 2 hour or longer fthere was water in the engine crankcase or the used engine oil showed signs of water contami nation then a second engine oil change should be performed after running the engine for 1 2 hour 8 Take the outboard motor to your closest authorized Honda Marine dealer for inspection and service as soon as possibie 89 12 STORAGE For longer service life of the outboard motor have your outboard motor se
50. ng to beating and the use of outboard motors Do not attempt to modify the out board motor Always wear a PERSONAL FLOTATION DEVICE PFD when on board Do not remove any guards labels shields covers or safety devices they are installed for your safety Fire and Burn Hazards Gasoline is extremely flammabie and gasoline vapor can explode Use extreme care when handling gasoline Remove the fuel tank from the boat for refueling Refuel well ventilated area with the engine stopped Keep flames and sparks away and do not smoke in the area Refuel carefully to avoid spilling fuel Avoid overfilling the fuel tank there should be no fuel in the filler neck After refueling tighten the filler cap securely If any fuel is spilled make sure the area is dry before starting the engine 2 COMPONENT IDENTIFICATION TILLER HANDLE FUEL LINE OIL LEVEL DIPSTICK STARTER GRIP OIL PRESSURE INDICATOR LIGHT THROTTLE GRIP CONNECTOR Recoil starter OIL FILLER CAP type TILLER HANDLE STOP SWITCH COVER ENGINE OIL ah par DRAIN SCREW eo SLAME COOLING y SYSTEM 5 INDICATOR THROTTLE STERN ET TILT FRICTION KNOB 1 d LEVER F TRANSOM ANTI VENTILATION ty ANGLE PLATE ENGINE START m ADJUSTING BUTTON ROD Electric starter type CHOKE KNOB EMERGENCY R OIL PEU EL PLUG SWITCH SN ANODE METAL
51. nstallation Position 22 2 nnne Installation Height Motor Attachment Engine Cover Removal Installation 5 PRE OPERATION CHECKS Engine Qil Fuel Level Fuel Resommendati ns Oxvsendt d Propeller and Cotter Pin Steering Friction Adjustment common mE Remote Control Friction Adjustment Other Checks Fuel Hose a Stem Bracket Clamp Screws T CONTENTS OO RE ee esac 6 STOPPING THE ENGINE ELA TILLER HANDLE TYPE Ol M REMOTE CONTROL TYPE eres 63 Fuel Tank and Vent Kno EET Fuel Line Connection m 33 Starting the Engine T ILLER HANDLE 35 67 Starting the Engine CONTROL L TYPE 39 THE IMPORTANCE OF MAINTENAN 67 Emergency Starting nu MAINTENANCE SAFETY 67 Troubleshooting Starting Problems ini EMISSION CONTROL SYSTEM INFORMATION TT 68 Tool and Spare Parts nass reak in Procedure 22 2 2222 48 MAINTENANCE SCHEDULE TILLER HANDLE TYPE d Qil Cruising Battery not included 79 REMOTE CONTROL TYPE CAG GN Gear Shifting e 51 Engine Fuel Filter 83 1 Fuel Tank and
52. oduct identification number Engine serial number CONTENTS SAFETY LABELS 6 SAFETY INFORMATION 7 8 TILLER HANDLE Engine Start Button 11 Gearshift Lever 11 Choke Si 11 M 12 Throttle Opening Indicator 12 Throttle Friction 12 Engine Stop SIT bine tue int 13 Emergency Stop Switch Lanyard 13 Oil Pressure Indicator Light 2222220224 14 Recoil Starter 2 0 0 012 14 REMOTE CONTROL Remote Control Lever 212 4 15 Neutral Release Lever ri i 16 Ignition Switch 0244 7 16 Emergency Stop Switch Lanyard 17 Choke Fast Idle Lever asinis 18 Manual Choke Knob sse m 18 Pressure Indicator Light Buzzer 19 Overheat Indicator Light Buzzer 19 CONTROLS amp INSTRUMENTS Tilt Lever Trim Tab Anode Metal iens Cooling System Indicator Water Intakes Transom Angle Adjusting Rod Fuel Cap Gauge Vent Knob Engine Over Rev Limiter eee 4 INSTALLATION Installation ee NR GB I
53. ol kit 1 Release the engine cover latch then remove the engine cover 42 6 x 22 mm BOLTS WASHERS WASHERS FLYWHEEL COVER Electric starter type 2 Remove the four 6 x 22 mm bolts and the four washers then remove the flywheel cover Do not lose the washers NEUTRAL START 27 mm CABLE FLANGE BOLT 4 RECOIL STARTER ASSEMBLY Recoil starter type 3 Move the gearsheft lever to F forward position Loosen the neutral start cable lock nut and disconnect the neutral start cable 4 Remove the four 6 x 22 mm flange balts and recoil starter assembly 6 STARTING THE ENGINE N N neutral ENGINE STOP SWITCH EMERGENCY neutral STOP SWITCH 0 CLIP SPARE EMERGENCY EMERGENCY STOP SWITCH STOP SWITCH LANYARD 5 Depending on what type of outboard 6 If your outboard motor is a tiller motor you have move the gearshift handle type engage the emergency stop switch clip located at one end of the emergency stop switch lan yard with the engine stop switch lever or the control lever to the neutral position GEARSHIFT LEVER TILLER HANDLE TYPE spare emergency stop switch clip is provided near the engine stop switch 43 6 STARTING THE ENGINE EMERGENCY Umm ENGINE STOP SWITCH STOP SWITCH SPARE EMERGENCY CHOKE KNOB CLIP STOP SWITCH CLIP TILLER HANDLE TYPE 7 If your outboard motor is a remote spare emergency stop switch clip is 8 If th
54. ort or storage vertically or horizontally as shown Rest the motor on the case protectors above Store the outboard motor in a well ventilated area free from direct Improper transport or sunlight and humidity storage can damage the motor or cause oil leakage Vertical transport or storage Attach the stern bracket to stand 91 13 TROUBLESHOOTING 1 Engine does not start Fuel Fuel is not fed to carburetor Fuel is fed to carburetor Electrical Sparks across Insufficient sparkplug gap sparks Normal sparks 92 There 15 no gasoline in fue tank Vent knob is not open or vent clogged Fuel filter is clogged Fuel line 1s kinked Fuel line 1s connected improperly Fuel pump is faulty Primer bulb is faulty Check valve in connector is faulty Excessive amount of fuel overflow Carburetor vent is clogged Spark plug gap 18 small Weak starter motor rotation Electric starter type Recheck the fuel system No sparks across spark plug gap Spark plug Contamination is faulty Incorrect gap Broken spark plug Pulser coil is faulty Current leaks from high tension cord unit is faulty Exciter coil is faulty Ignition coil is faulty Wire harness is faulty Current leaks from engine stop switch cord Stop switch does not return satisfactorily Spark plug is improperly installed Emergency stop switch is improperly installed Shift lever
55. otor requires special effort on your part to ensure your safety and the safety of others Careless operation or misuse may cause injury or property damage Head and understand this owner s manual before operating the Outboard Motor If a problem should arise or 1f you have any questions about your Outboard Motor see an authorized Honda Marine or Honda Outboard Motor dealer HONDA MOTOR CO LTD 1994 ALL RIGHTS RESERVED TYPES HONDA 25 30 OUTBOARD MOTORS may be necessary to refer to this chan for reference purposes when reading this manual 5 L X Handle Control starter starter e e w fel e e us __ e e SHS ____ 8 Electric Starter Control Tiller Handle R Remote Shaft Length transom height Short 1 A Extra Long IDENTIFICATION NUMBERS RIGHT STERN BRACKET STARTER MOTOR PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER Record the Product Identification The Product Identification Number is Number and the Engine Serial stamped on a plate and attached to the Number for your reference Refer to right stern bracket The Engine Serial the Product Identification Number Number 15 stamped on the cylinder when ordering parts and when mak block under the starter motor which is ing technical or warranty inquiries located in the front of the engine pase 98 Pr
56. p the DC receptacle dry and clean by covering it with the rubber cap provided The outboard motor s 12 volt output is intended for battery charging only Electrical accessories should be con nected to the battery 11 MAINTENANCE Lubrication Lubrication interval After the first 20 hours then every 100 hours Refer to the maintenance sched ule page 72 Apply marine anticorrosion grease to the following parts THROTTLE REEL TILT SHAFT um SWIVEL CASE 81 11 MAINTENANCE ADJUSTING ROD PROPELLER SHAFT 82 11 Engine Fuel Filter FUEL N PUMP a FUEL FILTER The engine fuel filter 13 located under the engine cover between the fuel cou pling and the fuel pump Water or sediment accumulated in the fuel filter can cause loss of power or hard start ing Check interval Every 100 hours Refer to the maintenance schedule page 73 Change interval Every 400 hours Refer to the maintenance schedule Gasoline is extremely flammable and gaso line vapor can explode causing serious injury or death Do not smoke or allow flames or sparks in your working area KEEP OUT OF REACH OF CHILDREN Always work in a well ventilated area sure that any fuel drained from the outboard motor is stored in an approved gasoline container Be careful not to spill any fuel when replacing the filter Spilled fuel or fuel vapor may ignite If any
57. r 10 Submerged Motor 88 Other Checks EK Throttle Over Rev Limiter cc 39 Friction Knob 12 Overheat Indicator Light Buzzer 19 12 Oxygenated Fuels 30 Opening Indicator sss 12 PRE OPERATION CHECKS ___________ 27 Tilt Lever 20 Propeller and Cotter 31 87 Kit 32 Remote Control Tool Kit and Spare Parts I Transom Angle Adjusting 22 t Ad t lever Justment 52 TRANSPORTING 64 Tab un NNNM 2 Adjustment 56 LABELS ss j TROUBLESHOOTING 92 PhP Pte ee dd he uuHEGHENHNEXGENEEEAGNHENEGGEEEAGAEREEJGASN Starting Probletns LLL 47 STARTING THE ENGINE WIRING DIAGRAM 99 REMOTE CONTROL e 39 TILLER HANDLE TYPE eme 38 steering tiller handle Fnction Adjustment common stern bracket PRE OPERATION 22 STOPPING THE ENGINE REMOTE CONTROL TYPE 0 02 63 TILLER HANDLE TYPE 00000 2 06041 103
58. r Hard starting or stalling after starting Rough idle Misfiring or backfiring under load Afterburning backfiring Black exhaust smoke or high fuel consumption 69 11 MAINTENANCE Replacement Parts The emission control systems on your Honda engine were designed built and certified to conform with EPA emission regulations We recommend the use of genuine Honda parts whenever you have maintenance done These onginal design replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the origmal design and quality may impair the effectiveness of your emis sion control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely attect emission performance manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations 70 Maintenance Follow the maintenance schedule on page 72 Remember that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature operation or use in unusu ally wet or dusty conditions will require more frequent service 11 MAINTENANCE Tool Kit and Spare Parts The following tools and spare parts are supplied with the outboard mo
59. r O ring Be sure the fuel hose connector is seal can be damaged damaged securely snapped in place O ring seal can cause a fuel leak 34 OUTLET END MOTOR PRIMER BULB INLET END TANK 3 Hold primer bulb so that the Qutlet end is higher than the inlet end The arrow on the primer bulb points upward Squeeze the primer bulb several times until it feels firm indicating that fuel has reached the carburetors Check for fuel leaks and repair any leaks before starting the motor Do not squeeze the primer bulb when the motor is running because this could cause the carburetors to overflow 6 STARTING THE ENGINE TILLER HANDLE ENGINE STOP SWITCH EMERGENCY STOP SWITCH LANYARD The propeller must be lowered into the water Running the outboard motor out of the water will damage the water pump and overheat the engine 1 Engage the emergency stop switch clip located at one end of the emer gency stop switch lanyard with the engine stop switch Attach the oth er end of the emergency stop switch lanyard securely to the operator spare emergency stop switch clip is provided near the engine stop switch If the operator does not attach the emergency stop switch lanyard and is thrown from his seat or out of the boat the out of control boat can seri ously injure the operator pas sengers or bystanders Always properly attach the lanyard before starting the motor GE
60. r or control lever to the N neutral position Flush the outboard motor in the neutral position only 6 Turn on the fresh water supply to the flush kit coupler NOTICE Running the outboard motor without sufficient cooling water will damage the water pump FLUSH KIT COUPLER WASH PLUG flush plug and overheat the engine Thoroughly clean and flush the out Keep children and board motor with fresh water after pets away from the area and operating in dirty or salty water stay clear of all moving parts during this procedure Flush Kit optional part 3 1 Wash the outside of the outboard 3 Remove the sealing washer from motor with clean fresh water the wash plug and install the sealing washer on the flush kit coupler 2 Remove the wash plug and sealing washer from the WASH plug hole 4 Install the flush kit coupler into the in the gear case Be sure not to WASH plug hole and connect a remove the oil level plug from the fresh water hose to the flush kit OIL LEVEL plug hole in the coupler gear case 65 10 CLEANING AND FLUSHING COOLING SYSTEM INDICATOR 7 Start the engine Monitor the cool ing system indicator Stop the engine if water does not come out of the cooling system indicator and check the fresh water supply If the fresh water supply is insufficient it may be necessary to temporarily cover the three water intakes with duct tape 66 8 Allow the engine to run at idle for at least
61. rviced by an authorized Honda Marine or Honda Outboard Motor dealer betore storage If you are unable to take the motor to your dealer proceed as follows Draining the Carburetors Be careful not to spill gasoline Spilled gasoline or gasoline vapor may ignite If any gasoline is spilled make sure the area is dry before storing or transporting the motor Do not smoke or allow flames or sparks where gasoline is drained or stored Gasoline is extremely flammable and gasoline vapor can causing serious injury or death Do not smoke or allow flames or sparks in your working area KEEP QUT OF REACH OF CHILDREN 90 mue c 1 E g o rell 1 DRAIN SCREW 1 Disconnect the fuel hose connector 2 Pull the 3 carburetor drain hose outside of the motor pan 3 Loosen the drain screw of the 3 carburetor and drain the carburetor Catch the draining gasoline in an approved gasoline container 4 Drain the 1 and 2 carburetors in the same manner using the 3 car buretor drain hose 1 CARBURETOR DRAIN SCREW 2 CARBURETOR DRAIN SCREW 3 CARBURETOR DRAIN SCREW DRAIN HOSE 5 After thoroughly draining the car buretors tighten the drain screws securely 6 Reinstall the drain hose back on the 3 carburetor 12 STORAGE Outboard Motor Position CASE PROTECTORS Transport and store the motor either Horizontal transp
62. s fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair and replacement EMISSION CONTROL SYSTEM INFORMATION Source of Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocar bons and oxides of nitrogen is very important because under certain conditions they react to form photo chemical smog when subjected to sunlight Honda utilizes lean carburetor settings and other systems to reduce the emissions of oxides of nitrogen and hydrocarbons 11 MAINTENANCE The U S Clean Au Acts EPA regulations require all manufactur ers to furnish written instructions describing the operation and mainte nance of emission control systems The following instructions and prace dures must be followed in order to keep the emissions from your Honda engine within the emission standards Tampering and Altering Tampering with or altering the emission control system may mcrease emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems Alterations that would cause the engine to operate outside its design parameters Problems That May Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing deale
63. sys tem indicator will vary due to thermostat operation Stop the engine if water does not come out of the cooling sys tem indicator or if you see steam Check the water intake screens and the cooling system indicator discharge port and if necessary remove any obstructions the problem continues contact your closest authorized Honda Marine dealer NOTICE Running the outboard motor with an obstruc tion in the cooling system can damage the water pump and overheat the engine T PRESSURE INDICATOR LIGHT NORMAL GREEN ABNORMAL GREEN LIGHT BLINKING OR OFF With the engine running check to see if the green engine pressure indicator light turns ON Stop the engine if the oil pressure indicator light does not turn ON Check the engine oil level seepage 27 If the oil level is normal and the oil pressure indicator light does not turn ON contact your closest authorized Honda Marine dealer 8 Warm up the engine as follows Above 41 F 5 C run the engine for 2 or 3 minutes Below 41 F 5 C run the engine for at least 5 minutes at approximately 2 000 rpm 3 000 rpm Failure to completely warm up the engine will result in poor engine performance 41 6 STARTING THE ENGINE Emergency Starting ENGINE COVER LATCHES If the recoil starter and electric starting system will not start the engine the engine can be started by using the emergency starter rope from the to
64. ter type Sm BLOWN FUSE If the fuse is blown running the engine will noi charge the battery and the electric starter will not work FUSE RATING 15A Never use a fuse with a different rat ing from that specified the fuse is blown check the cause then replace the fuse with a spare fuse of the same rated capacity Unless the cause is found the fuse may blow again FUSE COVER SPARE 15A FUSE Replacement 1 Stop the engine 2 Remove the engine cover 3 Pull the blown fuse of the clip 4 Push a new 15 fuse into the clip spare 15A fuse is located in the fuse holder If the spare fuse is not avail able the motor will need to be started with the pull starter rope refer to the emergency start procedure 42 11 MAINTENANCE Propeller PROPELLER COTTER PIN stainless E _ CASTLE NUT PLAIN WASHER COTTER stainless Installation MARINE GREASE Install the thrust washer with the Atm grooved side toward the gear case then install the new propeller in the reverse THRUST WASHER sequence of removal if the propeller is damaged replace it Removal Hand tighten the castle nut until the 3 as follows Remove the cotter pin then remove the mm cotter pin can be installed 14 mm castle nut 15 mm plain washer necessary tighten the castle nut just propeller and thrust washer enough to align the hole with the groove in the nut Use a ne
65. tions FORWARD NEUTRAL and REVERSE An indicator at the base of the gearshift lever aligns with the letters F N and R on the motor pan 1 Align the pointer on the tiller han dle with the SLOW position on the throttle grip to decrease engine speed N neutral R reverse The throttle mechanism is designed to 2 Put the tilt lever in the RUN position limit the throttle grip travel when to prevent the outboard motor from operating in the REVERSE or NEU tilting up when operating in reverse TRAL positions The throttle grip can only be turned to the FAST position 3 Move the gearshift lever to engage when operating in forward gear the desired gear 49 7 OPERATION TILLER HANDLE Steering Cruising F forward RIGHT TURN LEFT TURN GEARSHIFT LEVER THROTTLE FRICTION fer Move the tiller Move the tiller handle to the left handle to the right THROTTLE GRIP RELEASE The tiller handle is moved in the oppo With the gearshift lever in the F for To set the throttle at a steady speed site direction in which you want the ward position turn the throttle grip turn the throttle friction knob clock boat to turn toward the FAST mark to increase wise To release the throttle grip for speed For optimum fuel economy manual speed control turn the friction limit throttle opening to 2 3 knob counterclockwise 50 7 OPERATION REMOTE CONTROL TYPE Gear S
66. tivated while cruising or when ventilation occurs during a sharp turn When the over rev limiter is activated 1 Reduce the throttle opening immedi ately and check the motor angle 2 If the motor angle is correct but the over rev limiter stays activated stop the engine and check the condition of the outboard motor and check the propeller for damage Correct or service as necessary 7 OPERATION MOTOR PROTECTION SYSTEM trim tab The anode is sacrificial material which helps to protect the outboard motor from corrosion NOTICE Painting or coating the anode will lead to rust and corrosion damage to the outboard motor There is a small sacrificial anode the water passages of the engine block 59 7 High Altitude Operation At high altitude the standard carburetor air fuel mixture will be too rich Performance will decrease and fuel con sumption will increase A very rich mixture will also foul the spark plug and cause hard starting High altitude performance be improved by specific modifi cations to the carburetors If you always operate your outboard at altitudes above 5 000 feet 1 524 meters have an authorized Honda Marinc or Outboard Motor dealer perform this carburetor modification Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitud
67. tor for maintenance adjustment and emergency repairs TOOL KIT 56 10 12 mm WRENCH mm WRENCH FLAT SCREWDRIVER SS PHILLIPS SCREWDRIVER _ CHECK SCREWDRIVER EMERGENCY STARTER ROPE PLIERS _ gt SCREWDRIVER HANDLE HA I8 x 19 mm SOCKET WRENCH 2 4 71 11 MAINTENANCE MAINTENANCE SCHEDULE Use only genuine HONDA parts or their equivalent for maintenance or repair Replacement parts which are not of equivalent quality may damage the motor REGULAR SERVICE PERIOD 3 Perform at every indicated month FIRST EVERY EVERY EVERY or operating hour intervals EACH USE 20 HRS 100 HRS OR 200 HRS 400 HRS OR whichever comes first OR MONTH 6 MONTHS OR YEARLY 2 YEARS ITEM Engine oil Check level Change Gear case ou Check Jevel and check for water contamination Engine oil filter _ _ Change 909 oo Carburetor linkage Check Idling Adjust le Valve clearance Check readjust DE Spark plugs Check clean Replace if necessary OQ Propeller and cotter Check Replace if necessary Lubrication 72 11 MAINTENANCE REGULAR SERVICE PERIOD 3 Perform at every indicated month FIRST EVERY EVERY or operating hour intervals EACH USE 20 HRS 100 HRS OR 400 HRS OR whichever comes first OR MONTH 6 MONTHS 2 YEARS ITEM Fuel ankand filler Clean
68. uel tank Cleaning interval Clean the fuel tank and tank filter if Every 200 hours Refer to the necessary t may be necessary to drain maintenance schedule page 73 the fuel tank completely and refill with fresh gasoline Inspect the condition of the fuel cap gasket fuel hose and the O ring seals in the fuel hose connectors Replace the fuel cap gasket hose or fuel con nectors if they are cracked damaged leak fuel Be sure the fuel hose is not kinked Fuel Tank Cleaning 1 Disconnect the fuel hose from the fuel tank 3asoline is extremely flammabie and gaso line vapor can explode causing serious injury or death Do not smoke or allow flames or sparks in your working area KEEP OUT OF REACH OF CHILDREN 2 Empty the gasoline from the fuel tank into an approved gasoline con tainer Pour in a small quantity of fresh gasoline and clean the tank thoroughly Drain and dispose of the gasoline properly 85 11 MAINTENANCE FUEL TANK CONNECTOR gt O RING 4a 2 FUEL TANK FILTER Fuel Tank Filter Cleaning Replacement 1 Turn the fuel tank hose connector counterclock wise to remove the fuel tank filter 2 Clean the fuel tank filter with non flammable cleaner or solvent Replace the fuel tank filter if neces sary 3 After cleaning or replacement rein stall the fuel tank filter and fuel tank hose connector securely 86 Fuse Replacement Electric star
69. w genuine Honda cotter and bend the cotter pin ends as shown 87 11 MAINTENANCE Submerged Motor A submerged motor must be serviced immediately after it is recovered from the water in order to minimize como sion Immediately take the outboard motor to the closest authorized Honda Marine or Honda Outboard Motor dealer or 1f you are far from a dealership proceed as follows 1 Remove the engine cover and rinse motor with fresh water to remove salt water sand mud etc blah Gasoline is extremely flammable and gaso line vapor can explode causing serious injury or death Do not smoke or allow flames or sparks in your working area KEEP OUT OF REACH OF CHILDREN 88 DRAIN SCREW 2 Loosen the carburetor drain screws drain the contents of the carburetors into an approved gasoline container then tighten the drain screws Disengage emergency stop switch clip from the emergency stop switch and remove the spark plugs Pull the recoil starter several times to remove the water from the cylinders Recoil starter type EMERGENCY STARTER Remove the fly wheel cover follow ing the emergency starting dure refer to and remove the water from the cylinders by pulling the emergency starter rope several times Electric starter type If the motor was running when tt submerged there may be mechani cal damage such as bent connecting rods If the engine bi

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