04/04/01 16:30:33 31ZY6600_001

The engine exhaust from this

product contains chemicals
known to the State of California to
cause cancer, birth defects, or
other reproductive harm.

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

The information and specifications included in this publication were in effect at the
time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to
discontinue or change specifications or design at any time without notice and without
incurring any obligation whatever. No part of this publication may be reproduced
without written permission.
04/04/01 16:30:40 31ZY6600_002

INTRODUCTION
Congratulations on your selection of We suggest you read the warranty
a Honda outboard motor. We are policy to fully understand its
certain you will be pleased with your coverage and your responsibilities of
purchase of one of the finest ownership.
outboard motors on the market.
When your outboard motor needs
We want to help you get the best scheduled maintenance, keep in mind
results from your new outboard that your Honda marine dealer is
motor and to operate it safely. This specially trained in servicing Honda
manual contains information on how outboard motors. Your Honda marine
to do that; please read it carefully. dealer is dedicated to your
satisfaction and will be pleased to
As you read this manual you will answer your questions and concerns.
find information preceded by a
2004 Honda Motor Co., Ltd. All
symbol. That information Rights Reserved
is intended to help you avoid damage
to your outboard motor, other
property, or the environment.

1
04/04/01 16:30:54 31ZY6600_003

INTRODUCTION

A FEW WORDS ABOUT You will find important safety information in a variety of forms, including:
SAFETY
Safety Labels on the outboard motor.
Your safety and the safety of others
are very important. And using this Safety Messages preceded by a safety alert symbol and one of
outboard motor safely is an important three signal words, DANGER, WARNING, or CAUTION.
responsibility.
These signal words mean:
To help you make informed
decisions about safety, we have You WILL be KILLED or SERIOUSLY
provided operating procedures and HURT if you don’t follow instructions.
other information on labels and in
this manual. This information alerts You CAN be KILLED or SERIOUSLY
you to potential hazards that could HURT if you don’t follow instructions.
hurt you or others.
You CAN be HURT if you don’t follow
Of course, it is not practical or instructions.
possible to warn you about all the
hazards associated with operating or Safety Headings such as IMPORTANT SAFETY INFORMATION.
maintaining an outboard motor. You
must use your own good judgment. Safety Section such as OUTBOARD MOTOR SAFETY.

Instructions how to use this outboard motor correctly and safely.

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

2
04/04/01 16:30:58 31ZY6600_004

CONTENTS

OUTBOARD MOTOR SAFETY .................................... 7 Top-Mount Type

IMPORTANT SAFETY INFORMATION ................. 7 Ignition Switch ....................................................... 22
SAFETY LABEL LOCATIONS ................................. 9 Switch Clip and Emergency Stop Switch .............. 22
Fast Idle Button ...................................................... 23
CONTROLS AND FEATURES ................................... 10 Gearshift/Throttle Control Lever ........................... 23
CONTROL AND FEATURE IDENTIFICATION Common Controls
CODES ................................................................... 10 Power Trim/Tilt Switch ......................................... 25
COMPONENT AND CONTROL LOCATIONS ..... 11 Power Tilt Switch................................................... 26
CONTROLS ............................................................... 15 Manual Relief Valve .............................................. 26
Side-Mount Type Tilt Lock Lever ...................................................... 26
Ignition Switch ....................................................... 15 Engine Cover Latch ............................................... 27
Switch Clip and Emergency Stop Switch .............. 16 Trim Tab................................................................. 27
Gearshift/Throttle Control Lever ........................... 16 INSTRUMENTS ........................................................ 27
Fast Idle Lever........................................................ 18 Trim Meter (optional equipment) .......................... 27
Panel-Mount Type Tachometer (optional equipment) .......................... 28
Ignition Switch ....................................................... 18 Digital Tachometer (optional equipment).............. 28
Switch Clip and Emergency Stop Switch .............. 19 Digital Speedometer (optional equipment) ............ 28
Fast Idle Button ...................................................... 20
Gearshift/Throttle Control Lever ........................... 20

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CONTENTS

INDICATORS............................................................ 29 OPERATION ................................................................. 35

Alternator (ACG) Indicator.................................... 29 SAFE OPERATING PRECAUTIONS ..................... 35
Programmed Fuel Injection (PGM-FI) Indicator... 29 BREAK-IN PROCEDURE........................................ 35
Oil Pressure Indicator ............................................. 29 FUEL PRIMING ........................................................ 36
Overheating Indicator ............................................ 30 STARTING THE ENGINE ....................................... 37
Cooling System Indicator ...................................... 31 Side-Mount Type ................................................... 37
OTHER FEATURES ................................................. 31 Panel-Mount Type.................................................. 40
Water Separator Buzzer ......................................... 31 Top-Mount Type .................................................... 42
Overrev Limiter ...................................................... 31 STOPPING THE ENGINE ........................................ 44
Anodes.................................................................... 32 Emergency Engine Stopping ................................. 44
Fuel Priming Bulb .................................................. 32 Normal Engine Stopping........................................ 45
GEARSHIFT AND
BEFORE OPERATION................................................. 33 THROTTLE OPERATION ............................... 46
ARE YOU READY TO GET UNDER WAY?......... 33 Side-Mount Type ................................................... 46
IS YOUR OUTBOARD MOTOR Panel-Mount Type.................................................. 47
READY TO GO? ................................................... 33 Top-Mount Type .................................................... 47
STEERING ................................................................ 48
CRUISING ................................................................. 49
SHALLOW WATER OPERATION ......................... 51
MOORING, BEACHING, LAUNCHING ................ 51

4
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CONTENTS

SERVICING YOUR OUTBOARD MOTOR ............... 53 Spark Plug Service ..................................................... 66

THE IMPORTANCE OF MAINTENANCE ............ 53 REFUELING.............................................................. 69
MAINTENANCE SAFETY ...................................... 54 FUEL RECOMMENDATIONS ................................ 70
TOOL KIT and OWNER’S MANUAL .................... 55 Fuel Filter Inspection and Replacement .................... 71
SPARE EMERGENCY STOP SWITCH CLIP Water Separator Inspection and Service .................... 74
(optional equipment) .............................................. 55 Anode Replacement ................................................... 76
MAINTENANCE SCHEDULE ................................ 56 Propeller Replacement ............................................... 77
TRIM TAB ADJUSTMENT ..................................... 58
MANUAL RELIEF VALVE ..................................... 59 STORAGE ..................................................................... 78
ENGINE COVER REMOVAL AND STORAGE PREPARATION .................................... 78
INSTALLATION................................................... 59 Cleaning and Flushing ........................................... 78
Engine Oil Level Check ............................................. 60 Fuel ......................................................................... 80
Engine Oil Change ..................................................... 60 Engine Oil .............................................................. 81
Oil Filter Change ........................................................ 62 HOISTING THE OUTBOARD MOTOR ................. 82
Engine Oil Recommendations ................................... 63 STORAGE PRECAUTIONS .................................... 82
Lubrication Points ...................................................... 64 REMOVAL FROM STORAGE ................................ 83

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CONTENTS

TRANSPORTING ......................................................... 84 TECHNICAL AND CONSUMER INFORMATION... 97

WITH OUTBOARD MOTOR TECHNICAL INFORMATION ................................ 97
INSTALLED ON BOAT ....................................... 84 Serial Number Locations ....................................... 97
WITH OUTBOARD MOTOR Oxygenated Fuels ................................................... 98
REMOVED FROM BOAT ................................... 84 Battery .................................................................... 99
Emission Control System Information ................ 100
TAKING CARE OF UNEXPECTED PROBLEMS..... 85 Star Label ............................................................. 102
FUSES ........................................................................ 90 Specifications ....................................................... 104
Electric Starter Will Not Operate ........................... 90 CONSUMER INFORMATION .............................. 107
Battery Will Not Charge ........................................ 90 Honda Publications .............................................. 107
Fuse Replacement .................................................. 90 Customer Service Information ............................. 107
OIL PRESSURE INDICATOR GOES OFF AND
ENGINE SPEED IS LIMITED ............................. 92 INDEX.......................................................................... 112
OVERHEAT INDICATOR COMES ON AND
ENGINE SPEED IS LIMITED ............................. 93 WIRING DIAGRAMS......................... Inside Back Cover
WATER SEPARATOR BUZZER SOUNDS ........... 95
WATER SEPARATOR INDICATOR ...................... 95
SUBMERGED MOTOR ........................................... 95

6
04/04/01 16:31:20 31ZY6600_008

OUTBOARD MOTOR SAFETY

IMPORTANT SAFETY Operator Responsibility Attach the emergency stop switch
INFORMATION lanyard securely to the operator.
It is the operator’s responsibility to
Honda BF135A/BF150A outboard provide the necessary safeguards Always wear a PFD (Personal
motors are designed for use with to protect people and property. Flotation Device) while on the
boats that have a suitable Know how to stop the engine boat.
manufacturer’s power quickly in case of emergency.
recommendation. Other uses can Understand the use of all controls. Familiarize yourself with all laws
result in injury to the operator or and regulations relating to boating
damage to the outboard motor and Stop the engine immediately if and the use of outboard motors.
other property. anyone falls overboard, and do not
run the engine while the boat is Be sure that anyone who operates
Most accidents can be prevented if near anyone in the water. the outboard motor receives proper
you follow all instructions in this instruction.
manual and on the outboard motor. Always stop the engine if you
The most common hazards are must leave the controls for any Be sure the outboard motor is
discussed below, along with the best reason. properly mounted on the boat.
way to protect yourself and others.
Do not remove the engine cover
while the engine is running.

7
04/04/01 16:31:26 31ZY6600_009

OUTBOARD MOTOR SAFETY

Refuel With Care Carbon Monoxide Hazard

Gasoline is extremely flammable, Exhaust gas contains poisonous
and gasoline vapor can explode. carbon monoxide. Avoid inhalation
Refuel outdoors, in a well- of exhaust gas. Never run the engine
ventilated area, with the engine in a closed garage or confined area.
stopped. Never smoke near
gasoline, and keep other flames
and sparks away.

Refuel carefully to avoid spilling

fuel. Avoid overfilling the fuel
tank.

After refueling, tighten the filler

cap securely. If any fuel is spilled,
make sure the area is dry before
starting the engine.

8
04/04/01 16:31:33 31ZY6600_010

OUTBOARD MOTOR SAFETY

SAFETY LABEL LOCATION

The label shown here contains important safety information. Please read it carefully. This label is considered a
permanent part of your outboard motor. If the label comes off or becomes hard to read, contact an authorized Honda
marine dealer for a replacement.
9
04/04/01 16:31:47 31ZY6600_011

CONTROLS AND FEATURES

CONTROL AND FEATURE IDENTIFICATION CODES
Model BF135A BF150A

Type LA XA XCA LA XA XCA

20.0 in (508 mm)

Transom Height
25.0 in (635 mm)

Standard Rotating Propeller Shaft

Counterrotating Propeller Shaft

Power Trim/Tilt

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

TYPE CODE (example)

X C A

Destination
A: America
Rotating direction of propeller shaft
C: Counterrotating propeller shaft
None: Standard rotating propeller shaft
Transom Height
L: 20.0 in (508 mm), X: 25.0 in (635 mm)

10
04/04/01 16:31:56 31ZY6600_012

CONTROLS AND FEATURES

COMPONENT AND CONTROL LOCATIONS

ENGINE COVER OIL FILLER CAP
SPARK PLUG
(under cover POWER TILT
and/or coil) SWITCH

ENGINE COVER
LATCH
OIL LEVEL DIPSTICK

FLUSH PORT
CONNECTOR
TILT LOCK
COOLING SYSTEM LEVER
STERN INDICATOR
BRACKET
ANODE ENGINE OIL FRAME SERIAL
DRAIN BOLT NUMBER
MANUAL
RELIEF VALVE (inside cover)
GEAR OIL
ANODE LEVEL PLUG

ANTIVENTILATION
ANODE PLATE COOLING WATER
INTAKE PORT
EXHAUST PORT/WATER
OUTLET PORT
TRIM TAB GEAR OIL DRAIN/FILL PLUG
PROPELLER
(optional equipment)

11
04/04/01 16:32:03 31ZY6600_013

CONTROLS AND FEATURES

Remote Controls (optional equipment)

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

GEARSHIFT/THROTTLE GEARSHIFT/THROTTLE
CONTROL LEVER NEUTRAL RELEASE CONTROL LEVER
LEVER
NEUTRAL
OIL PRESSURE RELEASE
INDICATOR LEVER

OVERHEAT
POWER TRIM/TILT INDICATOR
SWITCH

FAST IDLE
LEVER POWER TRIM/TILT
SPARE SWITCH SWITCH
CLIP
IGNITION
BUZZER SWITCH
(inside) FAST IDLE
BUTTON
EMERGENCY
CONTROL LEVER STOP SWITCH
FRICTION ADJUSTER

LANYARD SWITCH CLIP

12
04/04/01 16:32:10 31ZY6600_014

CONTROLS AND FEATURES

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

GEARSHIFT/THROTTLE
CONTROL LEVER GEARSHIFT/THROTTLE
CONTROL LEVERS
POWER TRIM/TILT
SWITCH (RIGHT)

POWER
TRIM/TILT POWER TRIM/TILT
SWITCH SWITCH (LEFT)

FAST IDLE
BUTTON FAST IDLE
BUTTON
CONTROL PANEL (for TOP-MOUNT DUAL type)
(for PANEL/TOP-MOUNT type)
OIL PRESSURE
INDICATOR
BUZZER
IGNITION OVERHEAT
SWITCH INDICATOR

SWITCH CLIP EMERGENCY

STOP SWITCH
LANYARD

13
04/04/01 16:32:20 31ZY6600_015

CONTROLS AND FEATURES

Trim Meter Tachometer Digital Speedometer

(optional equipment) (optional equipment) (optional equipment)

Digital Tachometer
(optional equipment)

14
04/04/01 16:32:28 31ZY6600_016

CONTROLS AND FEATURES

CONTROLS Turning the ignition switch key to the The ignition switch can be used to
START position operates the starter start the engine only when the control
Side Mount Type motor. The key automatically returns lever (p. 17 ) is in the N (neutral)
to the ON position when released position, and the switch clip is in the
Ignition Switch from the START position. emergency stop switch.

Turning the ignition switch to the

ON START OFF position stops the engine.
OFF
IGNITION
SWITCH

The ignition switch controls the

ignition system and starter motor.

15
04/04/01 16:32:38 31ZY6600_017

CONTROLS AND FEATURES

Switch Clip and Emergency Stop The switch clip must be inserted in Gearshif t/Throttle Control
Switch the emergency stop switch in order Lever
for the engine to start and run. The
EMERGENCY lanyard must be attached to the CONTROL LEVER
STOP SWITCH operator’s PFD (Personal Flotation
Device) or worn around the wrist as
shown.

When used as described, the

emergency stop switch and lanyard
system stops the engine if the
operator falls away from the controls. NEUTRAL RELEASE
LEVER
A spare switch clip is stored in a slot
LANYARD in the control housing (optional The gearshift/throttle control lever
SWITCH CLIP equipment). controls engine speed and selects F
(forward), N (neutral), or R (reverse)
gears.

LANYARD
SWITCH CLIP

SPARE SWITCH CLIP

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04/04/01 16:32:45 31ZY6600_018

CONTROLS AND FEATURES

Moving the control lever 30° from N

(neutral) selects the gear, and further
movement increases engine speed. N (NEUTRAL)
30° 30°
F (FORWARD) R (REVERSE)
The control lever automatically locks
SHIFT SHIFT
itself in the N (neutral) position. To
move the lever out of the N (neutral)
MINIMUM
position, you must squeeze the MINIMUM
neutral release lever on the underside THROTTLE OPENING
of the lever handle. MAXIMUM
THROTTLE OPENING
A friction adjuster near the base of
the control lever(s) adjusts the
operating resistance of the control MAXIMUM
lever(s). Refer to p. 45 .

Less friction allows easier control

lever movement. More friction helps
to hold a steady throttle setting while
GEARSHIFT/THROTTLE
cruising. CONTROL LEVER

17
04/04/01 16:32:55 31ZY6600_019

CONTROLS AND FEATURES

Fast Idle Lever N (neutral) Panel-Mount Type

MAXIMUM FAST IDLE Ignition Switch
ON START

LOWEST POSITION OFF

FAST IDLE LEVER IGNITION

SWITCH KEY

The fast idle lever is only needed for The fast idle lever will not move The ignition switch controls the
starting carbureted outboard models. unless the remote control lever is in ignition system and starter motor.
The BF135A and BF150A models the N (neutral) position. Conversely,
use programmed fuel injection so, the remote control lever will not
this lever will not be needed for move unless the fast idle lever is in
starting. the lowest position.

After the engine starts and if the Lower the fast idle lever to the
outside temperature is below 41°F lowest position to decrease the fast
(5°C), the fast idle lever can be used idle.
to accelerate engine warm up.

18
04/04/01 16:33:06 31ZY6600_020

CONTROLS AND FEATURES

Turning the ignition switch key to the Switch Clip and Emergency Stop The switch clip must be inserted in
START position operates the starter Switch the emergency stop switch in order
motor. The key automatically returns EMERGENCY
for the engine to start and run. The
to the ON position when released STOP SWITCH lanyard must be attached to the
from the START position. operator’s PFD (Personal Flotation
Device) or worn around the wrist as
The ignition switch can be used to shown.
start the engine only when the control
lever (p. 21 ) is in the N (neutral) When used as described, the
position, and the switch clip is in the emergency stop switch and lanyard
emergency stop switch. system stops the engine if the
operator falls away from the controls.
Turning the ignition switch to the
OFF position stops the engine. SWITCH CLIP A spare switch clip (optional
LANYARD
equipment) can be stored in the tool
bag.

LANYARD
SPARE SWITCH CLIP
SWITCH CLIP (optional equipment)

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04/04/01 16:33:14 31ZY6600_021

CONTROLS AND FEATURES

Fast Idle Button It is necessary to position the control Gearshif t/Throttle Control
lever in N (neutral) to push in the fast Lever
N (neutral) idle button.
F (forward) CONTROL LEVER
R (reverse)

Pull up NEUTRAL RELEASE

NEUTRAL
RELEASE LEVER
CONTROL
LEVER LEVER

Push
The gearshift/throttle control lever
FAST IDLE BUTTON controls engine speed and selects F
(forward), N (neutral), or R (reverse)
gears.
By moving the control lever forward
or reverse when the fast idle button is
pushed in, the throttle opening will
be increased without engaging the
gears.

20
04/04/01 16:33:21 31ZY6600_022

CONTROLS AND FEATURES

Moving the control lever 35° from N

(neutral) selects the gear, and further
movement increases engine speed.
N (NEUTRAL)
The control lever automatically locks
itself in the N (neutral) position. To 35° 35°
move the lever out of the N (neutral) F (FORWARD) R (REVERSE)
position, you must squeeze the SHIFT SHIFT
neutral release lever on the underside
of the lever handle. MINIMUM
MINIMUM
A friction adjuster near the base of THROTTLE OPENING
the control lever adjusts the operating THROTTLE OPENING
resistance of the control lever. Refer
to p. 46 . MAXIMUM
Less friction allows easier control
lever movement. More friction helps
to hold a steady throttle setting while MAXIMUM
cruising.

GEARSHIFT/THROTTLE
CONTROL LEVER

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04/04/01 16:33:31 31ZY6600_023

CONTROLS AND FEATURES

Top-Mount Type Turning the ignition switch key to the Switch Clip and Emergency Stop
START position operates the starter Switch
Ignition Switch motor. The key automatically returns
to the ON position when released EMERGENCY
START from the START position. STOP
ON SWITCH
The ignition switch can be used to
start the engine only when the control
OFF lever (p. 24 ) is in the N (neutral)
position, and the switch clip is in the
emergency stop switch.

Turning the ignition switch to the

OFF position stops the engine.
IGNITION SWITCH CLIP
SWITCH LANYARD
KEY

The ignition switch controls the

ignition system and starter motor.

LANYARD

SWITCH CLIP

22
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CONTROLS AND FEATURES

The switch clip must be inserted in Fast Idle Button Gearshif t/Throttle Control
the emergency stop switch in order Lever
for the engine to start and run. The N (neutral)
SINGLE TYPE
lanyard must be attached to the F (forward)
operator’s PFD (Personal Flotation R (reverse)
Device) or worn around the wrist as
shown. CONTROL
LEVER
When used as described, the
emergency stop switch and lanyard
system stops the engine if the
operator falls away from the controls. CONTROL
LEVER DUAL TYPE
A spare switch clip (optional
equipment) can be stored in the tool
bag. Push

FAST IDLE BUTTON

By moving the control lever forward
or reverse when the fast idle button is
pushed in, the throttle opening will CONTROL
be increased without engaging the LEVERS
gears.
SPARE SWITCH CLIP The gearshift/throttle control lever
(optional equipment) It is necessary to position the control controls engine speed and selects F
lever in N (neutral) to push in the fast (forward), N (neutral), or R (reverse)
idle button. gears.

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CONTROLS AND FEATURES

Moving the control lever 35° from N

(neutral) selects the gear, and further N (NEUTRAL)
movement increases engine speed.
35° 35°
A friction adjuster inside the control F (FORWARD) R (REVERSE)
box adjusts the operating resistance SHIFT SHIFT
of the control lever(s). Refer to
p. 46 .
MINIMUM THROTTLE OPENING
Less friction allows easier control
lever movement. More friction helps MINIMUM
to hold a steady throttle setting while THROTTLE OPENING MAXIMUM
cruising.

MAXIMUM

GEARSHIFT/THROTTLE CONTROL LEVER

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CONTROLS AND FEATURES

Common Controls The power trim/tilt switch is located

on the control lever. It is a rocker
Power Trim/Tilt Switch switch with UP and DN (down)
positions for changing the angle of
(side-mount type) (top-mount type) the outboard motor.

SINGLE TYPE You can use the power trim/tilt

POWER TRIM/TILT SWITCH
switch anytime whether the boat is
underway, stopped, or the ignition
CONTROL switch is in the OFF position. It is
POWER LEVER necessary for the ignition switch to
TRIM/TILT be in the ON position for the trim
SWITCH CONTROL
LEVER meter to indicate the motor angle.

Trim the outboard motor to obtain

(panel-mount type) the best performance and stability
DUAL TYPE (p. 48 ).
POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH
CONTROL LEVER (LEFT) (RIGHT) Tilt the outboard motor for shallow
water operation, beaching, launching,
or mooring.

For dual mount outboards, tilt them

up at the same time.

CONTROL
LEVERS

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CONTROLS AND FEATURES

Power Tilt Switch Manual Relief Valve Tilt Lock Lever

MANUAL RELIEF VALVE FREE

LOCK

POWER MANUAL
POWER TILT SWITCH (To f ix) (To release) TILT LOCK LEVER

The power tilt switch is located on The tilt lock lever is used to support
the engine pan. It is a rocker switch the outboard motor in the fully-raised
with UP and DN (down) positions position.
for changing the angle of the
outboard motor. The outboard motor can be tilted When the boat is to be moored for a
manually after opening the manual long time, tilt the outboard motor as
The power tilt switch will operate relief valve. This allows the outboard far as it will go. Then move the tilt
without turning the ignition switch motor to be tilted when no battery is lock lever to the LOCK position, and
ON. connected. gently lower the outboard motor until
the lever contacts the stern bracket.
This switch is used with the engine
stopped to raise the outboard motor
for mooring, trailering or
maintenance.
26
04/04/01 16:34:29 31ZY6600_028

CONTROLS AND FEATURES

Engine Cover Latch Trim Tab INSTRUMENTS

TIGHTENING Trim Meter

BOLT (optional equipment)

UNLOCK

TRIM TAB
ENGINE COVER LATCH

The engine cover latch fastens the The trim tab compensates for TRIM METER
engine cover to the outboard motor. ‘‘torque steer,’’ which is a reaction of
the outboard motor to propeller The trim meter has a range of 4° to
rotation. 16° and indicates the trim angle of
the outboard motor.
If uncompensated, torque steer would
make the outboard motor tend to turn Refer to the trim meter when using
to one side. the power trim/tilt switch to achieve
the best performance from the boat.
When the trim tab is correctly
adjusted (p. 57 ), steering effort is
equal in either direction.
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CONTROLS AND FEATURES

Tachometer Digital Tachometer Digital Speedometer

(optional equipment) (optional equipment) (optional equipment)

TACHOMETER
The tachometer shows engine speed Digital Tachometer includes the Digital Speedometer includes the
in revolutions per minute. following functions. following functions.
Tachometer Speedometer
Refer to the tachometer when using Hour Meter Fuel level Meter
the throttle and power trim/tilt Trim Meter Volt Meter
controls to achieve the best Oil pressure Indicator Tripmeter
performance from the boat. Overheat Indicator Fuel Integration Meter
ACG Indicator Fuel Economy Meter
PGM-FI Indicator Fuel Flow Meter
Refer to the Operation Guide Water Separator Indicator
included with each Digital Refer to the Operation Guide
Tachometer for operation included with each Digital
information. Speedometer for operation
information.
28
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CONTROLS AND FEATURES

INDICATORS Programmed Fuel Injection Oil Pressure Indicator

(PGM-FI) Indicator
Alternator (ACG) Indicator PGM-FI INDICATOR
(side-mount type)

ACG INDICATOR (GREEN)

BUZZER

When the engine control system

detects an PGM-FI malfunction, the (panel-mount/top-mount types)
The ACG indicator turns on and the PGM-FI indicator turns on and the
buzzer sounds in one-second buzzer sounds at one-second (GREEN)
intervals when the charging system is intervals.
faulty.
Under normal conditions when the
ignition key is turned on the
following will occur:
1. Both the PGM-FI indicator and
ACG indicator will turn on.
2. The buzzer will beep twice.
3. The PGM-FI indicator will turn BUZZER
off shortly after the second beep.
4. The ACG indicator will turn off
after the engine starts.
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04/04/01 16:35:15 31ZY6600_031

CONTROLS AND FEATURES

When the oil pressure indicator is lit, Overheat Indicator When the alert triggers, the overheat
oil pressure is OK. indicator comes on and the buzzer
(side-mount type) (RED) sounds a steady tone as the engine
If oil pressure becomes low, the speed is reduced to 1,800 rpm. If the
indicator will go off, and the engine condition persists for another 20
protection system will limit engine seconds, the engine shuts off. Refer
speed. Refer to TAKING CARE OF to TAKING CARE OF
UNEXPECTED PROBLEMS, from UNEXPECTED PROBLEMS, from
p. 92 . p. 94 .
BUZZER
All models are equipped with a All models are equipped with a
buzzer that sounds when the oil buzzer that sounds a steady tone
pressure indicator goes off. when the red light comes on.
(panel-mount/top-mount types)
Low oil pressure indicates that the Engine overheating may be the result
engine oil level is low, or that there is (RED) of clogged water intakes.
a problem with the engine lubrication
system.

BUZZER

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CONTROLS AND FEATURES

Cooling System Indicator OTHER FEATURES Overrev Limiter

COOLING SYSTEM INDICATOR
Water Separator Buzzer The engine is equipped with an
overrev limiter to prevent the
The water separator buzzer sounds a possibility of mechanical damage
rapid, repeating signal when water from excessive engine speed.
has accumulated in the water
separator. The overrev limiter may be activated
during operation, limiting engine
speed, if the outboard motor is
trimmed or tilted excessively, or
when propeller ventilation occurs
Water should flow from the cooling during a sharp turn.
system indicator while the engine is
running. This shows that water is If the overrev limiter is activated,
circulating through the cooling check the trim angle of the outboard
system. motor.

If water stops flowing while the Check to see if the correct propeller
engine is running, it indicates a is installed.
cooling system problem, such as
clogged water intakes, which will WATER SEPARATOR
cause engine overheating.

The cooling system indicator

discharge port can also become
plugged.

31
04/04/01 16:35:41 31ZY6600_033

CONTROLS AND FEATURES

Anodes Fuel Priming Bulb

UP
OUTLET END
(motor)

PRIMING BULB
ANODE ANODE
(each side) (stern bracket)
INLET END (tank)

The anodes are made of a sacrificial A priming bulb is built into the fuel
material that helps to protect the hose that connects the fuel tank to the
outboard motor from corrosion. outboard motor.

There are two anodes on the gear Before starting the engine, hold the
case, one on the stern bracket, and priming bulb up in the direction of
two small anodes in the water the arrow, then squeeze the priming
passages of the engine block. bulb until it feels firm. This will
ensure that fuel is supplied to the
engine (p. 35 ).

32
04/04/01 16:35:54 31ZY6600_034

BEFORE OPERATION
ARE YOU READY TO GET Safety
UNDER WAY?
Always wear a PFD (Personal Improperly maintaining
Your safety is your responsibility. A Flotation Device) while on the boat. this outboard motor, or
little time spent in preparation will failing to correct a problem
significantly reduce your risk of Attach the emergency stop switch before operation, can cause
injury. lanyard securely to your PFD or to a malfunction in which you
your wrist. could be seriously hurt or
Knowledge killed.
IS YOUR OUTBOARD
Read and understand this manual. MOTOR READY TO GO? Always perform a
Know what the controls do and how preoperation inspection
to operate them. For your safety, and to maximize the before each operation, and
service life of your equipment, it is correct any problem.
Familiarize yourself with the very important to take a few
outboard motor and its operation moments before you operate the
before you get under way. Know outboard motor to check its condition. Before beginning your preoperation
what to do in case of emergencies. Be sure to take care of any problem checks, be sure the ignition switch is
you find, or have your authorized in the OFF position.
Familiarize yourself with all laws Honda marine dealer correct it,
and regulations relating to boating before you operate the outboard
and the use of outboard motors. motor.

33
04/04/01 16:36:07 31ZY6600_035

BEFORE OPERATION

Safety Inspection Maintenance Inspection Check the water separator for

water contamination (p. 74 ).
Look around the outboard motor Check the engine oil level (p. 60 ).
for signs of oil or gasoline leaks. Running the engine with a low oil
level can cause engine damage.
Check that the fuel hose is
undamaged and properly Check to be sure the propeller is
connected. undamaged, and the castle nut is
secured with the cotter pin (p. 77 ).
Wipe up any spills before starting
the engine. Check that the anodes are securely
attached to the gear case (p. 76 )
Check the stern bracket to be sure and are not excessively worn. The
the outboard motor is securely anodes help to protect the outboard
installed. motor from corrosion.

Check that all controls are Make sure the tool kit is onboard
operating properly. (p. 55 ). Replace any missing items.

Replace any damaged parts. Check the fuel level in the fuel
tank (p. 69 ).
Check that all fasteners are in
place and securely tightened. Check that the battery fluid is
between the upper and lower levels,
and the battery leads are connected
securely.

34
04/04/01 16:36:20 31ZY6600_036

OPERATION
SAFE OPERATING BREAK-IN PROCEDURE Next 60 minutes:
PRECAUTIONS Run the engine up to a maximum of
Break-in period: 10 hours 4,000 to 5,000 rpm, which is about
To safely realize the full potential of 50% to 80% of maximum throttle
this outboard motor, you need a Proper break-in operation allows the opening.
complete understanding of its moving parts to wear in smoothly for
operation and a certain amount of best performance and long service Short full-throttle bursts are OK, but
practice with its controls. life. do not operate the engine
continuously at full throttle.
Before operating the outboard motor First 15 minutes:
for the first time, please review the Run the engine at trolling speed. Use For boats that plane easily, bring the
IMPORTANT SAFETY the minimum throttle opening boat up on plane, and then reduce the
INFORMATION on page 7 and the necessary to operate the boat at a safe throttle opening to the recommended
chapter titled BEFORE OPERATION. trolling speed. rpm range.

For your safety, avoid starting or Next 45 minutes: Next 8 hours:

operating the engine in an enclosed Run the engine up to a maximum of Do not run the engine at full throttle
area. Your engine’s exhaust contains 2,000 to 3,000 rpm, which is about for more than 5 minutes at a time.
poisonous carbon monoxide gas 10% to 30% of maximum throttle
which can collect rapidly in an opening.
enclosed area and cause illness or
death.

35
04/04/01 16:36:31 31ZY6600_037

OPERATION

FUEL PRIMING

UP
Gasoline is highly
OUTLET END flammable and explosive.
(motor)
You can be burned or
seriously injured when
handling fuel.
PRIMING BULB
Stop the engine and keep
heat, sparks, and flame
INLET END away.
(tank) Handle fuel only
outdoors.
Hold the priming bulb up in the Wipe up spills
direction of the arrow, then squeeze immediately.
the priming bulb several times until it
feels firm, indicating that fuel has
reached the engine.

Check to be sure there are no fuel

leaks before starting the engine.

Do not squeeze the priming bulb

when the engine is running.

36
04/04/01 16:36:42 31ZY6600_038

OPERATION

STARTING THE ENGINE The engine will not start or run,

unless the clip is in the switch.
Side Mount Type
The emergency stop switch clip N (neutral)
EMERGENCY and lanyard system is a safety
STOP SWITCH
device that will stop the engine if
you fall away from the controls
while operating the boat.

Always attach the lanyard to your CONTROL

PFD, or to your wrist, before LEVER
starting the engine.

SWITCH CLIP
LANYARD

1. Put the emergency stop switch clip 2. Set the control lever in the N
in the emergency stop switch, and (neutral) position.
attach the lanyard to your PFD
(Personal Flotation Device) or to The engine will not start if the F
your wrist, as shown. (forward) or R (reverse) gears are
engaged.

37
04/04/01 16:36:51 31ZY6600_039

OPERATION

ON
OFF START
Using the electric starter f or more
than 5 seconds at a time will
overheat the starter motor and can
LOWEST
damage it.
POSITION
Turning the ignition switch key to
the START position while the
engine is running can damage the
starter motor and f lywheel.
IGNITION SWITCH KEY
FAST IDLE RANGE

3. Leave the fast idle lever in the 4. Turn the ignition switch key to the
OFF (fully lowered) position. START position and hold it there
until the engine starts.
Fast idle lever cannot be raised
unless the control lever is in the N When the engine starts, release the
(neutral) position. key, allowing it to return to the ON
position.
The control lever cannot be moved
away from the N (neutral) position If the engine fails to start within 5
unless the fast idle lever is lowered. seconds, release the key and wait
at least 10 seconds before
operating the starter again.

38
04/04/01 16:37:02 31ZY6600_040

OPERATION

6. If the fast idle lever was used to

warm up the engine, gradually
MAXIMUM FAST IDLE If the engine is not properly lower the lever as the engine
warmed-up bef ore raising the engine warms up.
FAST IDLE
RANGE speed, the buzzer and overheat
indicator may activate, and the When the fast idle lever is fully
engine speed will be automatically lowered, the control lever can be
reduced. moved away from the N (neutral)
position.
During the warm-up period, check
the oil pressure indicator (p. 29 ),
overheat indicator (p. 29 ), and
cooling system indicator (p. 30 ).

5. Before getting under way, allow If the indicators show any

the engine to warm up sufficiently abnormal condition, immediately
to ensure good performance. stop the engine and determine the
cause of the problem. Refer to
Above 41°F (5°C), warm up the TAKING CARE OF
engine for 2 or 3 minutes. UNEXPECTED PROBLEMS
from p. 85 .
Below 41°F (5°C), warm up the
engine for at least 10 minutes at
2,000 rpm. Raise the fast idle lever
to achieve approximately 2,000
rpm.

39
04/04/01 16:37:10 31ZY6600_041

OPERATION

Panel-Mount Type The engine will not start or run,

EMERGENCY STOP
unless the clip is in the switch. N (neutral)
SWITCH
The emergency stop switch clip
and lanyard system is a safety
device that will stop the engine if
you fall away from the controls
while operating the boat.
CONTROL
Always attach the lanyard to your LEVER
PFD, or to your wrist, before
starting the engine.
SWITCH CLIP LANYARD

1. Put the emergency stop switch clip 2. Set the control lever in the N
in the emergency stop switch, and (neutral) position.
attach the lanyard to your PFD
(Personal Flotation Device) or to The engine will not start if the F
your wrist, as shown. (forward) or R (reverse) gears are
engaged.

40
04/04/01 16:37:21 31ZY6600_042

OPERATION

START N (neutral)
ON
Using the electric starter f or more
than 5 seconds at a time will
overheat the starter motor and can
OFF
damage it.

Turning the ignition switch key to

the START position while the
IGNITION
engine is running can damage the CONTROL
starter motor and f lywheel. LEVER
SWITCH
KEY
FAST IDLE BUTTON

3. Turn the ignition switch key to the 4. Before getting under way, allow
START position and hold it there the engine to warm up sufficiently
until the engine starts. to ensure good performance.

When the engine starts, release the Above 41°F (5°C), warm up the
key, allowing it to return to the ON engine for 2 or 3 minutes.
position.
Below 41°F (5°C), warm up the
If the engine fails to start within 5 engine for at least 10 minutes at
seconds, release the key and wait 2,000 rpm. Push the fast idle
at least 10 seconds before button then move the control lever
operating the starter again. forward or reverse to open the
throttle and achieve approximately
2,000 rpm.
41
04/04/01 16:37:32 31ZY6600_043

OPERATION

Top-Mount Type The engine will not start or run,

unless the clip is in the switch.
EMERGENCY STOP
If the engine is not properly SWITCH
warmed-up bef ore raising the engine The emergency stop switch clip
speed, the buzzer and overheat and lanyard system is a safety
indicator may activate, and the device that will stop the engine if
engine speed will be automatically you fall away from the controls
reduced. while operating the boat.

During the warm-up period, check Always attach the lanyard to your
the oil pressure indicator (p. 29 ), PFD, or to your wrist, before
overheat indicator (p. 29 ), and starting the engine.
cooling system indicator (p. 30 ). SWITCH CLIP LANYARD

If the indicators show any 1. Put the switch clip in the

abnormal condition, immediately emergency stop switch, and attach
stop the engine and determine the the lanyard to your PFD (Personal
cause of the problem. Refer to Flotation Device) or to your wrist,
TAKING CARE OF as shown.
UNEXPECTED PROBLEMS
from p. 85 .

5. If the fast idle control was used to

warm up the engine, gradually
return the control lever to the N
(neutral) position as the engine
warms up.

42
04/04/01 16:37:41 31ZY6600_044

OPERATION

START
N (neutral) ON Using the electric starter f or more
than 5 seconds at a time will
overheat the starter motor and can
OFF damage it.

Turning the ignition switch key to

the START position while the
CONTROL engine is running can damage the
LEVER IGNITION starter motor and f lywheel.
SWITCH
KEY

2. Set the control lever in the N 3. Turn the ignition switch key to the
(neutral) position. START position and hold it there
until the engine starts.
The engine will not start if the F
(forward) or R (reverse) gears are When the engine starts, release the
engaged. key, allowing it to return to the ON
position.

If the engine fails to start within 5

seconds, release the key and wait
at least 10 seconds before
operating the starter again.

43
04/04/01 16:37:55 31ZY6600_045

OPERATION
N (neutral) STOPPING THE ENGINE
If the engine is not properly Emergency Engine Stopping
warmed-up bef ore raising the engine
speed, the buzzer and overheat Side Mount Type
CONTROL indicator may activate, and the
EMERGENCY
LEVER engine speed will be automatically STOP SWITCH
reduced.
LANYARD
During the warm-up period, check
the oil pressure indicator (p. 29 ),
overheat indicator (p. 29 ), and
FAST IDLE BUTTON
cooling system indicator (p. 30 ).
PULL
4. Before getting under way, allow If the indicators show any
the engine to warm up sufficiently abnormal condition, immediately SWITCH CLIP
to ensure good performance. stop the engine and determine the
cause of the problem. Refer to Panel Mount/Top Mount Types
Above 41°F (5°C), warm up the TAKING CARE OF
engine for 2 or 3 minutes. UNEXPECTED PROBLEMS EMERGENCY
STOP SWITCH CONTROL PANEL
from p. 85 .
Below 41°F (5°C), warm up the LANYARD
engine for at least 10 minutes at 5. If the fast idle control was used to PULL
2,000 rpm. Push the fast idle warm up the engine, gradually
button then move the control lever return the control lever to the N
forward or reverse to open the (neutral) position as the engine
throttle and achieve approximately warms up.
2,000 rpm. SWITCH CLIP

44
04/04/01 16:38:04 31ZY6600_046

OPERATION

To stop the engine in an emergency, Normal Engine Stopping Top Mount Type
pull the clip out of the emergency
stop switch by pulling the lanyard. Side Mount Type N (neutral)
N (neutral)
We suggest that you stop the engine
this way occasionally to verify that
the emergency stop switch is
operating properly.
CONTROL
LEVER CONTROL
LEVER

1. Move the control lever(s) to the N

Panel Mount Type (neutral) position.
N (neutral)

CONTROL
LEVER

45
04/04/01 16:38:15 31ZY6600_047

OPERATION

Side Mount Type 3. When the boat is not in use, GEARSHIFT AND
remove and store the ignition THROTTLE OPERATION
switch key and the emergency stop
switch clip and lanyard. Side Mount Type
CONTROL LEVER

OFF

IGNITION
SWITCH KEY
NEUTRAL
RELEASE LEVER
Panel Mount/Top Mount Types
N (neutral)

OFF

F (forward)
R (reverse)
IGNITION
SWITCH KEY

2. Turn the ignition switch key to the

OFF position.

46
04/04/01 16:38:26 31ZY6600_048

OPERATION

Panel Mount Type To shift gears, move the control lever Side Mount Type
to select F (forward), N (neutral) and
R (reverse) gears.
N (neutral)
F (forward) The control lever cannot be moved
R (reverse) TO INCREASE
from the N (neutral) position unless FRICTION
the neutral release lever is squeezed
(side-mount/panel-mount types).
NEUTRAL
RELEASE Moving the control lever beyond the
LEVER gear selection range increases engine CONTROL
CONTROL LEVER TO DECREASE
LEVER speed. FRICTION
FRICTION
ADJUSTER

Top Mount Type Panel-Mount Type

N (neutral)
F (forward) CONTROL LEVER
R (reverse) FRICTION ADJUSTER

TO INCREASE
FRICTION

CONTROL
LEVER
TO DECREASE
FRICTION

47
04/04/01 16:38:33 31ZY6600_049

OPERATION

Top Mount Type STEERING

Steer the boat in the same manner as
an automobile.

TO INCREASE
FRICTION

TO DECREASE
FRICTION

CONTROL LEVER
FRICTION ADJUSTER

Adjust the control lever friction

adjuster so the control lever will hold
a constant throttle setting while
cruising.

48
04/04/01 16:38:46 31ZY6600_050

OPERATION

CRUISING motor. antiventilation plate is level with the

water.
Engine Speed Trim
When cruising into a high wind, trim
For best fuel economy, limit the Use the power trim/tilt switch to trim the outboard motor down slightly to
throttle opening to 80%. Use the the outboard motor for the best level the boat and improve stability.
throttle friction control (p. 47 , 48 ) performance and stability. With a tail wind, trim the outboard
to help you hold a steady speed. motor up slightly.
You can use the power trim/tilt
For rough water conditions or large switch at any time, whether the boat
waves, slow down to prevent the is under way or stopped. Excessive trim/tilt angle during
propeller from rising out of the water. operation can cause propeller
Press the UP or DN (down) side of ventilation, overheating, and water
The engine is equipped with an the switch to adjust the angle of the pump damage.
overrev limiter to prevent the outboard motor.
possibility of mechanical damage
from excessive engine speed. Refer to the trim meter (p. 27 ) for an
indication of whether the motor is
If, for example, the outboard motor trimmed high or low.
is tilted excessively, or propeller
ventilation occurs during a sharp turn, It is necessary to trim the angle of the
the engine may overrev, activating outboard motor to compensate for
the overrev limiter. changes in boat load, weight
distribution, water conditions, or
If engine speed becomes unstable at propeller selection.
high speed due to activation of the
overrev limiter, reduce speed and Under normal conditions, the boat
check the trim angle of the outboard will perform best when the
49
04/04/01 16:39:00 31ZY6600_051

OPERATION

Side Mount Type Top Mount Type MOTOR MOTOR

(single type) TRIMMED TOO TRIMMED TOO
LOW HIGH
POWER TRIM/TILT SWITCH
POWER TRIM/TILT SWITCH

MOTOR TRIMMED
CORRECTLY

BOW TOO LOW DUE TO

Panel Mount Type (dual type) 1. LOAD IN THE FRONT
2. MOTOR TRIMMED TOO LOW
POWER TRIM/TILT SWITCH POWER TRIM/TILT SWITCH
(LEFT) (RIGHT)

BOW TOO HIGH DUE TO

1. LOAD IN THE REAR
2. MOTOR TRIMMED TOO HIGH

50
04/04/01 16:39:11 31ZY6600_052

OPERATION

If steering effort is not equal in both SHALLOW WATER MOORING, BEACHING,

directions, adjust the trim tab to OPERATION LAUNCHING
compensate for ‘‘torque steer,’’
which is the reaction of the outboard When operating in shallow water, use To raise the outboard motor out of
motor to propeller rotation. the power trim/tilt switch (p. 50 ) to the water while the engine is stopped
tilt the outboard motor, so the and the boat is moored, or for
TIGHTENING BOLT propeller and gear case won’t hit the maximum clearance when beaching
bottom. or launching, use the power tilt
switch on the engine pan to tilt the
Proceed at low speed, and monitor outboard motor as far as it will go,
water flow from the cooling system move the tilt lock lever to the LOCK
indicator (p. 30 ) to be sure the position, then gently lower the
outboard motor is not tilted so high outboard motor until the lever
that the water intakes are out of the contacts the stern bracket.
water.
TRIM TAB To lower the outboard motor, tilt up,
move the tilt lock lever to the FREE
Adjust the trim tab with the engine An excessive trim/tilt angle during position, then lower the outboard
stopped. Loosen the bolt above the operation can cause propeller motor to the desired position.
trim tab, turn the trim tab, then ventilation, overheating, and water
tighten the bolt securely. pump damage. This type of damage
is not covered by the Distributor’s
When the trim tab is correctly Limited Warranty.
adjusted, steering effort will be equal
in both directions.

Refer to TRIM TAB ADJUSTMENT,

P. 58.
51
04/04/01 16:39:19 31ZY6600_053

OPERATION

For manual tilting, use a screwdriver

POWER TILT SWITCH to turn the valve counterclockwise 1
Do not attempt to use the power tilt or 2 turns. Close the valve firmly
switch to tilt the outboard motor after positioning the engine.
down while the tilt lock lever is in the
lock position. Damage to the power Be sure the valve is closed before
tilt system may occur. operating the outboard motor. If the
MANUAL RELIEF VALVE valve is not closed, the outboard
motor will tilt up when operated in
reverse.

TILT LOCK LEVER

(Lock position)
POWER MANUAL
FREE (To f ix) (To release)

The outboard motor can also be tilted

LOCK manually after opening the manual
relief valve. This feature enables the
outboard motor to be tilted or
lowered when no battery is connected.
STERN BRACKET

52
04/04/01 16:39:29 31ZY6600_054

SERVICING YOUR OUTBOARD MOTOR

THE IMPORTANCE OF To help you properly care for your Remember that your authorized
MAINTENANCE outboard motor, the following pages Honda marine dealer knows your
include a maintenance schedule, outboard motor best and is fully
Good maintenance is essential for routine inspection procedures, and equipped to maintain and repair it.
safe, economical, and trouble-free simple maintenance procedures using
operation. It will also help reduce air basic hand tools. Other service tasks To ensure the best quality and
pollution. that are more difficult, or require reliability, use only new, genuine
special tools, are best handled by Honda parts or their equivalents for
professionals and are normally repair and replacement.
performed by a Honda technician or
Improperly maintaining other qualified mechanic. Maintenance, replacement, or
this outboard motor, or repair of the emission control
failure to correct a problem The maintenance schedule applies to devices and systems may be
before operation, can cause normal operating conditions. If you performed by any marine engine
a malfunction in which you operate your outboard motor under repair establishment or individual,
could be seriously hurt or unusual conditions, consult an using parts that are ‘‘certified’’ to
killed. authorized Honda marine dealer for EPA standards.
recommendations applicable to your
Always follow the individual needs and use.
inspection and
maintenance
recommendations and
schedules in this owner’s
manual.

53
04/04/01 16:39:41 31ZY6600_055

SERVICING YOUR OUTBOARD MOTOR

MAINTENANCE SAFETY Safety Precautions Read the instructions before you

begin, and make sure you have the
Some of the most important safety Make sure the engine is off before tools and skills required.
precautions follow. However, we you begin any maintenance or
cannot warn you of every repairs. This will eliminate several To reduce the possibility of fire or
conceivable hazard that can arise in potential hazards: explosion, be careful when
performing maintenance. Only you working around gasoline. Use only
can decide whether or not you should Carbon monoxide poisoning a nonflammable solvent, not
perform a given task. from engine exhaust. gasoline, to clean parts. Keep
Be sure there is adequate cigarettes, sparks, and flames away
ventilation whenever you from all fuel-related parts.
operate the engine.
Failure to properly follow Wear gloves when handling the
maintenance instructions Burns from hot parts. propeller to protect your hands
and precautions can cause Let the engine and exhaust from sharp edges.
you to be seriously hurt or system cool before touching.
killed.
Injury from moving parts.
Always follow the Do not run the engine unless
procedures and instructed to do so.
precautions in the owner’s
manual.

54
04/04/01 16:39:48 31ZY6600_056

SERVICING YOUR OUTBOARD MOTOR

TOOL KIT and OWNER’S MANUAL SPARE EMERGENCY STOP

SWITCH CLIP
(optional equipment)
14 17 mm WRENCH 19 mm EYE WRENCH

10 12 mm WRENCH SPARK PLUG WRENCH

8 mm WRENCH 16 17 mm BOX WRENCH

OIL CHECK
SCREWDRIVER
PLIERS
FLAT SCREWDRIVER
TOOL BAG
OWNER’S MANUAL PHILLIPS
SCREWDRIVER 6 mm HEX. WRENCH

SCREWDRIVER HANDLE FUSE PULLER

The tool kit can be used for simple maintenance procedures and emergency Always carry a spare emergency stop
repairs. Keep these items on the boat, so they will always be available if you switch clip onboard. The spare clip
need them. may either be stored in the tool bag
or in an easily accessible location on
If your tool kit needs replacement, it is not available as a kit and each item the boat.
must be ordered individually.

55
04/04/01 16:40:01 31ZY6600_057

SERVICING YOUR OUTBOARD MOTOR

MAINTENANCE SCHEDULE
REGULAR SERVICE PERIOD (3)
First month Every 6 months Every year Every 2 years
ITEM Perform at every indicated month or Each use After use or or or or
operating hour interval, whichever 20 hrs. 100 hrs. 200 hrs. 400 hrs.
comes first.
Engine oil Check level
Change
Gear case oil Change (2) (2)
Engine oil filter Replace (2)
ACG belt Check-adjust (2)
Throttle linkage Check-adjust (2) (2)
Idle speed Check-adjust (2) (2)
Valve clearance Check-adjust (2)
Spark plug Check
Clean (2) (2)
Replace
Propeller and Cotter pin Check
Anode Check
Lubrication Grease (1) (1)
Water separator Check

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

(2) These items should be serviced by an authorized Honda marine dealer, unless you have the proper tools and are mechanically proficient.
Refer to the Honda shop manual for service procedures.
(3) For professional/commercial use, log hours of operation to determine proper maintenance intervals.

56
04/04/01 16:40:13 31ZY6600_058

SERVICING YOUR OUTBOARD MOTOR

REGULAR SERVICE PERIOD (3)

First month Every 6 months Every year Every 2 years
ITEM Perform at every indicated month or Each use After use or or or or
operating hour interval, whichever 20 hrs. 100 hrs. 200 hrs. 400 hrs.
comes first.
Fuel filter Check
(Low pressure side) Replace
Fuel filter Replace (2)
(High pressure side)
Thermostat Check (2)
Fuel line Check
Replace Every 2 years (If necessary) (2)
Battery and cable Check level-tightness
connection
Bolts and Nuts Check-tightness (2) (2)
Crankcase breather tube Check (2)
Cooling water passages Clean (4)
Water pump Check (2)

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

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

57
04/04/01 16:40:23 31ZY6600_059

SERVICING YOUR OUTBOARD MOTOR

TRIM TAB ADJUSTMENT

The trim tab compensates for
‘‘torque steer’’ which is a reaction of
TIGHTENING BOLT TIGHTENING BOLT
the outboard motor to propeller LEFT RIGHT
rotation.

If uncompensated, torque steer would

make the outboard motor tend to turn
to one side.

When the trim tab is correctly

adjusted, steering effort is equal in
either direction. TRIM TAB
TRIM TAB
If steering effort is unequal, loosen
the trim tab bolt and adjust the angle
of the trim tab. Retighten the trim tab
bolt securely. If less effort is required to make left If less effort is required to make right
turns, move the back of the trim tab turns, move the back of the trim tab
left. right.

Adjust the trim tab in small

increments, and retest steering effort
with the boat evenly loaded and
running at cruising speed.

58
04/04/01 16:40:32 31ZY6600_060

SERVICING YOUR OUTBOARD MOTOR

MANUAL RELIEF VALVE ENGINE COVER REMOVAL To remove the engine cover, pull the
MANUAL RELIEF VALVE AND INSTALLATION engine cover latch to the unlocked
position, then lift the engine cover
straight up from the outboard motor.

To install the engine cover, place the

cover on the outboard motor, and
push down evenly.
POWER MANUAL UNLOCK
(To f ix) (To release)

The outboard motor can be tilted

manually after opening the manual ENGINE COVER LATCH
relief valve. This feature enables the
outboard motor to be tilted or
lowered when no battery is connected.

For manual tilting, use a screwdriver

to turn the valve counterclockwise 1
or 2 turns. Close the valve firmly
after positioning the outboard motor.

Be sure the valve is closed before

operating the outboard motor. If the
valve is not closed, the outboard The engine cover latch fastens the
motor will tilt up when operated in engine cover to the outboard motor.
reverse.
59
04/04/01 16:40:48 31ZY6600_061

SERVICING YOUR OUTBOARD MOTOR

Engine Oil Level Check OIL FILLER CAP Engine Oil Change
Check the engine oil level with the An engine oil evacuation device may
engine stopped and the outboard be used to remove the engine oil.
motor in the vertical position.
Drain the used oil while the engine is
1. Unlock and remove the engine warm. Warm oil drains quickly and
cover (p. 59 ). completely.

2. Remove the dipstick and wipe it 1. Unlock and remove the engine
clean. cover (p. 59 ).
DRAIN PLUG COVER
4. If the oil level is low, remove the
UPPER
oil filler cap, and add oil to reach
LIMIT the upper limit mark shown on the
dipstick. Use the oil recommended
on p. 63 .

LOWER
LIMIT Running the engine with a low oil
level can cause engine damage.
LEVER
OIL LEVEL DIPSTICK
5. Install the oil filler cap and tighten
3. Insert the dipstick all the way in, it securely. Do not overtighten. 2. Push the drain plug cover lever
then remove it and check the oil and remove the cover while
level shown on the dipstick. 6. Install and lock the engine cover. pulling the cover backward at an
angle.
60
04/04/01 16:40:58 31ZY6600_062

SERVICING YOUR OUTBOARD MOTOR

DRAIN PLUG COVER SEALING WASHER

GUIDE DRAIN BOLT Improper disposal of engine oil

can be harmf ul to the environment.
If you change your own oil, please
dispose of the used oil properly.
DRAIN Put it in a sealed container, and
PLUG take it to a recycling center. Do
COVER not throw it in the trash, pour it on
the ground or down a drain.
DRAIN PLUG COVER
GUIDE

DRAIN PLUG COVER 4. Place a suitable container below

the oil drain guide to catch the
used oil, then remove the oil filler
cap and the drain plug.

5. Allow the used oil to drain

completely. Use a new sealing
washer then reinstall the engine oil UNDER COVER PUSH LEVER
GUIDE
drain plug, and tighten it securely.

3. Set the drain plug cover under the

guide.
LOCKING LUG PROJECTION
61
04/04/01 16:41:11 31ZY6600_063

SERVICING YOUR OUTBOARD MOTOR

6. Install the oil drain plug cover. Oil Filter Change FILTER WRENCH, 65 mm
Push the lever of the oil drain plug
cover in the direction pointed by 1. Drain the engine oil, and reinstall OIL FILTER
the arrow mark of ‘‘LOCK’’, and the drain plug and oil drain cover
install the oil drain plug cover so (see Engine Oil Change on p. 60 ).
that the locking lug securely sets
on the projection of the under 2. Tilt the outboard motor, and place
cover. a suitable container below the oil
drain guide to catch the used oil.
7. With the outboard motor in a
vertical position, fill to the upper 3. Use a suitable tool to remove the
limit mark on the dipstick (p. 60 ) oil filter, and throughly drain the
with the recommended oil. filter into the used oil container.
Engine oil refill capacity:
Without oil filter change: OIL DRAIN GUIDE
6.9 US qt (6.5 )
With oil filter change:
7.1 US qt (6.7 )

8. Install the oil filler cap and tighten

it securely.

9. Install and lock the engine cover.

RUBBER SEAL

62
04/04/01 16:41:26 31ZY6600_064

SERVICING YOUR OUTBOARD MOTOR

4. Clean the oil filter mounting base, 7. Start the engine and check for Engine Oil Recommendations
and coat the rubber seal of the new leaks (be sure the water level is at
oil filter with clean engine oil. least 2 inches above the Oil is a major factor affecting
antiventilation plate). performance and service life. Use
4-stroke automotive detergent oil.
Use only a genuine Honda oil
f ilter or a f ilter of equivalent Running the outboard motor SAE Viscosity Grade
quality specif ied f or your model. without suf f icient cooling water
Using the wrong f ilter, or a non- will damage the water pump and
Honda f ilter which is not of overheat the engine.
equivalent quality, may cause
engine damage. 8. Stop the engine, and check the oil
level as described on page 59 . If
5. Screw on the new filter by hand necessary, add oil to bring the oil AMBIENT TEMPERATURE

until it contacts the engine, then level to the upper limit mark on the
use a suitable tool to tighten the dipstick. SAE 10W-30 is recommended for
filter an additional 7/8 turn. general use.

OIL FILTER TIGHTENING The SAE oil viscosity and service

TORQUE: classification are in the API label on
16 lbf·ft (22 N·m , 2.2 kgf·m) the oil container. Honda recommends
that you use API SERVICE category
6. Return the outboard motor to the SG, SH or SJ oil with the ‘‘starburst’’
vertical position, and fill the certification mark displayed on the
crankcase with the specified container.
amount (p. 63 ) of the
recommended oil.

63
04/04/01 16:41:36 31ZY6600_065

SERVICING YOUR OUTBOARD MOTOR

Lubrication Points THROTTLE LINK/

Apply marine anticorrosion grease to PIVOT/PLATE THROTTLE ROD/LINK TILT BRACKET
the following parts:

Lubrication interval:
After the first 20 hours or 1 month, then
every 100 hours or 6 months. (Refer to
the maintenance schedule page 56 ).
ENGINE COVER BRACKET TILT SHAFT

Apply anticorrosion oil to pivot

surf aces where grease cannot penetrate.

PTT THRUST RECEIVER

PROPELLER SHAFT SWIVEL CASE

Apply Honda Marine Corrosion Inhibitor (or equivalent) to all areas under the engine cover and any exposed metal
surfaces except the belts.
64
04/04/01 16:41:41 31ZY6600_066

SERVICING YOUR OUTBOARD MOTOR

THROTTLE ARM/
SHIFT ARM/PIVOT
ENGINE COVER PLATE/NEUTRAL
LOCK CABLE SWITCH/CLICK ENGINE COVER ENGINE COVER LOCK
CABLE (FRONT) LEVER/OPEN SHAFT COVER LOCK BOLTS
(LEFT SIDE) ARM ROLLER

TILT LOCK LEVER

ENGINE COVER
LOCK CABLE
(RIGHT SIDE)

SWIVEL SHAFT TILT SHAFT THREAD

SWIVEL CASE UPPER CYLINDER

BUSH/COLLAR PIN/BUSH

65
04/04/01 16:41:54 31ZY6600_067

SERVICING YOUR OUTBOARD MOTOR

Spark Plug Service Do not adjust the spark plug gap.

If the gap is out of specification,
RECOMMENDED SPARK PLUGS: replace the spark plug with a new UNDER
COVER
IZFR6K11 (NGK) one. GROMMET
SKJ20DR-M11 (DENSO) MUD
1. Disconnect the battery negative GUARD
( ) terminal. CLIP
Incorrect spark plugs can cause
engine damage. 2. Unlock and remove the engine UNDER
COVER
cover (p. 59 ).
This outboard motor uses spark plugs
that have an iridium coated center
electrode. Be sure to observe the
following when servicing the spark MUD GUARD CLIP (2)
plugs.
Do not clean the spark plugs. If an
electrode is contaminated with
accumulated objects or dirt,
replace the spark plug with a new
one.
Use only a ‘‘wire-type feeler
gauge’’ to check the spark plug
gap if necessary. To prevent
damaging the iridium coating of MUD GUARD CLIP
the center electrode, never use a
‘‘leaf-type feeler gauge.’’ IDLE PORT
UNDER COVER GROMMET

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04/04/01 16:42:04 31ZY6600_068

SERVICING YOUR OUTBOARD MOTOR

3. Remove the two mud guard clips SPARK PLUG COVER IGNITION COIL
from the upper part of the under
cover grommet.
To remove the mud guard clips, BOLT
raise the inner part of each mud
guard clip with a screwdriver, then
pull out the clips.

Do not try to remove the mud guard

clip with f orce without raising the
inner part of the mud guard clip.
Otherwise, it can damage the mud BOLTS WIRE CONNECTOR
guard clip and/or under cover.
5. Remove the two bolts with the 6 6. Use a 6 mm hex. wrench to
4. Fold down the upper part of the mm hex wrench, and remove the remove the bolt holding the
under cover grommet without spark plug cover. ignition coil. Move the ignition
removing it from the idle port. coil to a position that allows
removal of the wire connector
easily.

7. Disconnect the wire connector

from the ignition coil by pushing
on the lock tab and pulling on the
connector. Pull on the plastic
connector, not the wires.

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04/04/01 16:42:17 31ZY6600_069

SERVICING YOUR OUTBOARD MOTOR

8. Remove the ignition coil by 12. Install the spark plugs carefully,
pulling it up slightly. 0.039 0.051 in by hand, to avoid cross-threading.
(1.00 1.30 mm)
13. After each spark plug seats, tighten
Do not strike or drop the ignition with a spark plug wrench supplied
coil, or it may be damaged and in the tool kit to compress the
require replacement. sealing washer.
SEALING
WASHER If reinstalling used spark plugs,
tighten 1/8 - 1/4 turn after the
spark plugs seat.

10. Inspect the spark plugs. Replace If installing new spark plugs,
them if the electrodes are worn, or tighten 1/2 turn after the spark
if the insulators are cracked or plugs seat.
chipped.

19 mm EYE
11. Measure the spark plug electrode Loose spark plugs can overheat
SPARK PLUG WRENCH gap with a wire-type feeler gauge. and damage the engine.
WRENCH The gap should be 0.039 0.051 Overtightening the spark plugs
inches (1.00 1.30 mm). If the can damage the threads in the
9. Remove the spark plugs with a gap is out of the specification, cylinder head.
spark plug wrench and 19 mm replace the plug with a new one.
wrench. Never try to readjust the gap.

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SERVICING YOUR OUTBOARD MOTOR

14. Push the wire connector onto the UNDER COVER REFUELING
ignition coil. Make sure it locks in MUD
GROMMET
place. GUARD Check the fuel level and refill if
15. Install the ignition coil. Reinstall CLIP neccessary. Do not fill the fuel tank
the bolt. above the UPPER LIMIT. Refer to
16. Repeat this procedure for the other the boat manufacturer’s instructions.
three spark plugs. UNDER COVER
17. Reinstall the covers. When
reinstalling the covers, make sure
not to jam the wire harnesses
between the covers and engine
case.

Mud guard clip installation:

Press the under cover grommet and
under cover and be sure that they
adhere closely to each other.
Insert the mud guard clips with the
inner part raised off, then push in
the inner part securely until they
click.

69
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SERVICING YOUR OUTBOARD MOTOR

Never refill the fuel tank inside a FUEL RECOMMENDATIONS

building where gasoline fumes may
Gasoline is highly reach flames or sparks. Keep Use unleaded gasoline with a pump
flammable and explosive. gasoline away from appliance pilot octane rating of 86 or higher.
lights, barbecues, electric appliances,
You can be burned or power tools, etc. Your outboard motor is certified to
seriously injured when operate on unleaded gasoline.
handling fuel. Spilled fuel is not only a fire hazard, Unleaded gasoline produces fewer
Stop the engine and keep it causes environmental damage. engine and spark plug deposits and
heat, sparks, and flame Wipe up spills immediately. extends exhaust system life.
away.
Handle fuel only Never use stale or contaminated
outdoors. gasoline or an oil/gasoline mixture.
Wipe up spills Avoid getting dirt or water in the fuel
immediately. tank.

Occasionally you may hear a light

‘‘spark knock’’ or ‘‘pinging’’
(metallic rapping noise) while
operating under heavy loads. This is
no cause for concern.

If spark knock or pinging occurs at a

steady engine speed, under normal
load, change brands of gasoline. If
spark knock or pinging persists, see
an authorized Honda marine dealer.

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04/04/01 16:42:51 31ZY6600_072

SERVICING YOUR OUTBOARD MOTOR

Fuel Filter Inspection and

Replacement
Running the engine with persistent Gasoline is highly
spark knock or pinging can cause The fuel filter (inside the strainer flammable and explosive.
engine damage. cup) is located below the engine oil
filter. You can be burned or
Running the engine with persistent seriously injured when
spark knock or pinging is misuse, Water or sediment accumulated in handling fuel.
and the Distributor’s Limited the filter can cause loss of power or Stop the engine and keep
Warranty does not cover parts hard starting. To prevent engine heat, sparks, and flame
damaged by misuse. malfunction, inspect the filter and away.
replace when necessary. Handle fuel only
outdoors.
Wipe up spills
immediately.

71
04/04/01 16:43:00 31ZY6600_073

SERVICING YOUR OUTBOARD MOTOR

FUEL HOSES
SCREW (3)

UNLOCK

ENGINE COVER LATCH FUEL FILTER SUSPENSION STRAP

(inside strainer cup)

1. Remove the engine cover. 2. Looking through the translucent 3. Remove the suspension strap from
strainer cup, check the fuel filter the strainer bracket, then remove
for water accumulation or the strainer assembly from the
sediment. strap.
Before removing the fuel filter, to
prevent fuel leakage, place fuel
hose clamps on the fuel hoses on
each side of the fuel filter.

72
04/04/01 16:43:10 31ZY6600_074

SERVICING YOUR OUTBOARD MOTOR

4. Remove the three screws and FUEL FILTER STRAINER 9. Prime the engine using the priming
separate the fuel strainer cup from BRACKET bulb (refer to page 36 ). Check for
the strainer body. fuel leaks. Repair any fuel leaks if
necessary.
5. Thoroughly clean the strainer cup,
and replace with a new fuel filter. If loss of power or hard starting are
found to be caused by excessive
6. Reassemble the strainer body and water or sediment accumulation in
the cup. the fuel filter, inspect the fuel tank.
STRAINER TIGHTENING
TORQUE: Clean the fuel tank and tank filter if
2.5 lbf·ft (3.4 N·m , 0.35 kgf·m) necessary. It may be necessary to
drain the fuel tank completely and
7. Reinstall the strainer in the original SUSPENSION refill with fresh gasoline.
position. ALIGNMENT STRAP
POSITION
STRAINER
CUP
7. Align the center of suspension
strap with the screw position and
install the fuel filter assembly.

8. Reinstall the strainer in the original

position.

73
04/04/01 16:43:23 31ZY6600_075

SERVICING YOUR OUTBOARD MOTOR

Water Separator Inspection and FUEL TUBES

Service SCREW (3)
Gasoline is highly
flammable and explosive.

You can be burned or

seriously injured when
handling fuel.
Stop the engine and keep
heat, sparks, and flame
away.
Handle fuel only
outdoors. SUSPENSION STRAP
WATER SEPARATOR Wipe up spills
immediately. 1. Remove the engine cover (see
The water separator is located beside page 59 ).
the oil level dipstick. Water
accumulation in the water separator 2. Remove the suspension strap from
can cause loss of power or hard the water separator bracket, then
starting. Check the water separator remove the separator assembly
periodically. Clean it or consult with from the strap.
an authorized Honda outboard motor During removal of the separator
dealer for cleaning. assembly, take care not to damage
the wire harness with the separator
bracket.

3. Pinch the fuel tubes with tube clips

to prevent fuel leakage.
74
04/04/01 16:43:33 31ZY6600_076

SERVICING YOUR OUTBOARD MOTOR

WATER SEPARATOR 9. Squeeze and release the priming

BRACKET bulb to fill the vapor separator, and
CUP WATER check for leaks.
SEPARATOR
O-RING If the buzzer sounds or water or
sediment accumulation are found to
be caused by excessive water or
sediment accumulation in the fuel
filter, inspect the fuel tank.

Clean the fuel tank and tank filter if

SUSPENSION necessary. It may be necessary to
STRAP drain the fuel tank completely and
BOWL SUSPENSION refill with fresh gasoline.
BOWL
STRAP ALIGNMENT
POSITION
4. Remove the three screws and 7. Align the center of suspension
separate the bowl from the body. strap with the screw position and
install the water separator
5. Thoroughly clean the bowl. assembly.

6. Reassemble the water separator 8. Reinstall the water separator in the

bowl, O-ring, and cup. reverse order of removal.
TIGHTENING TORQUE:
2.5 lbf·ft (3.4 N·m , 0.35 kgf·m)

75
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SERVICING YOUR OUTBOARD MOTOR

Anode Replacement
Painting or coating the anodes will
def eat their purpose and will lead to
rust and corrosion damage to the
outboard motor. The anodes must be
exposed to the water in order to
protect the outboard motor.

ANODE ANODE
(each side) (stern bracket)

The anodes are located on each side

of the gearcase. They are made of a
sacrificial material that helps to
protect the outboard motor from
corrosion.

Replace the anodes when they have

been reduced to about half their
original size, or if they are crumbling.

76
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SERVICING YOUR OUTBOARD MOTOR

Propeller Replacement Installation

Before replacing the propeller, 1. Apply marine grade grease to the Install the thrust washer with the
remove the clip from the engine stop propeller shaft and beveled surface grooved side toward the gear case.
switch to prevent any possibility of of the thrust washer.
the engine being started while you Use a genuine Honda cotter pin
are working with the propeller. 2. Install the propeller in the reverse and bend the pin ends as shown.
order of removal.
The propeller blades may have sharp
edges, so wear heavy gloves to
protect your hands.

Operating the outboard motor at

higher altitudes will reduce available
power. This may require decreasing
the propeller pitch to maintain correct
engine RPM.

Removal PROPELLER

1. Remove the cotter pin, unscrew

the castle nut, remove the washer,
then remove the propeller and MARINE GREASE
thrust washer.
COTTER PIN
THRUST WASHER
2. Inspect the propeller shaft for any WASHER
fishing line or debris. CASTLE NUT

77
04/04/01 16:44:01 31ZY6600_079

STORAGE
STORAGE PREPARATION Cleaning
Proper storage preparation is Wash the outside of the outboard
essential for keeping your outboard motor with clean, fresh water, and
motor troublefree and looking good. flush the cooling system as follows.
The following steps will help to keep
rust and corrosion from impairing Flushing With a Garden Hose
your outboard motor’s function and (commercially available)
appearance, and will make the engine
easier to start when you use the
outboard motor again. Do not run the motor when f lushing
the motor with a garden hose or the
Cleaning and Flushing motor may be damaged. FLUSH PORT
CONNECTOR
Thoroughly clean and flush the For safety, remove the emergency 1. Disconnect the flush port
outboard motor with fresh water after stop switch clip so the engine cannot connector.
operation in dirty water or salt water. be started while you are standing near
the propeller.
Touch up any damaged paint, and
coat areas that may rust with Honda
Corrosion Inhibitor, or equivalent.
Lubricate controls with a silicone
spray lubricant.

78
04/04/01 16:44:08 31ZY6600_080

STORAGE

FLUSH PORT WATER HOSE

CONNECTOR

WATER HOSE JOINT

(Commercially available) EXHAUST PORT
2. Screw the garden hose into the 3. Turn on the fresh water supply and
flush port connector. flush the outboard motor for at
least 10 minutes.

4. After flushing, disconnect the

garden hose and reconnect the
flush port connector.

79
04/04/01 16:44:21 31ZY6600_081

STORAGE

Fuel Adding a Fuel Stabilizer The Distributor’s Limited Warranty

When adding a fuel stabilizer, fill the does not cover fuel system damage
Gasoline will oxidize and deteriorate fuel tank with fresh gasoline. If only or engine performance problems
in storage. Old gasoline will cause partially filled, air in the tank will resulting from neglected storage
hard starting, and it leaves gum promote fuel deterioration during preparation.
deposits that clog the fuel system. If storage. If you keep an additional
the gasoline in your fuel tank and container of gasoline for refueling, Draining the Fuel System
vapor separator deteriorates during be sure that it contains only fresh You can avoid fuel deterioration
storage, you may need to have the gasoline. problems by draining the fuel tank
vapor separator and other fuel system and vapor separator.
components serviced or replaced. 1. Drain the vapor separator before
adding fuel stabilizer. FRONT BRACKET CLAMP
The length of time that gasoline can
be left in your fuel tank and vapor 2. Add fuel stabilizer following the
separator without causing functional manufacturer’s instructions.
problems will vary with such factors
as gasoline blend, your storage 3. After adding a fuel stabilizer, run
temperatures, and whether the fuel the engine in water for 10 minutes
tank is partially or completely filled. to be sure that the treated gasoline
The air in a partially filled fuel tank has replaced the untreated gasoline
promotes fuel deterioration. Very in the vapor separator.
warm storage temperatures accelerate
fuel deterioration. Fuel deterioration 4. Turn the engine OFF.
problems may occur within a few
months, or even less if the gasoline
was not fresh when you filled the DRAIN SCREW
fuel tank. DRAIN HOSE
VAPOR SEPARATOR

80
04/04/01 16:44:36 31ZY6600_082

STORAGE

1. Unhook the drain hose from the 4. Tilt the outboard motor up all the Engine Oil
front bracket clamp. way. Leave the outboard motor
tilted up until the gasoline stops 1. Change the engine oil and the oil
2. Set the end of the hose toward the flowing. filter (p. 60 63 ).
outside of the engine undercase.
5. After thoroughly draining, tighten 2. Remove the spark plugs (p. 66 ),
3. Loosen the vapor separator drain the drain screw securely and return and remove the clip from the
screw. the outboard motor to the vertical emergency stop switch.
position.
3. Pour a tablespoon (5 10 cm3) of
6. Clamp the drain hose on the front clean engine oil into each cylinder.
Gasoline is highly bracket clamp.
flammable and explosive. 4. Rotate the engine a few
7. Drain the fuel tank into an revolutions to distribute the oil in
You can be burned or approved gasoline container, or if the cylinders.
seriously injured when you need to store fuel in the fuel
handling fuel. tank, you can extend fuel storage 5. Reinstall the spark plugs (p. 68 ).
Stop the engine and keep life by filling the fuel tank with
heat, sparks, and flame fresh gasoline and adding a fuel
away. stabilizer that is formulated for
Handle fuel only that purpose.
outdoors.
Wipe up spills
immediately.

81
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STORAGE

HOISTING THE OUTBOARD STORAGE PRECAUTIONS

MOTOR HOIST
HOOKS
Select a well-ventilated storage area.
If possible, avoid storage areas with
high humidity.

If storing a container of gasoline,

UNLOCK store it away from any appliance that
operates with a flame, such as a
furnace, water heater, or clothes
dryer. Also avoid any area with a
spark producing electric motor, or
ENGINE COVER LATCH where power tools are operated.

1. Unlock and remove the engine 2. Attach the hoist hooks to the
cover. lifting eyes.

3. Disconnect the outboard motor

from the boat, hoist the outboard
motor, and move it to the storage
area.

4. After the outboard motor is placed

in storage and disconnected from
the hoist, install the engine cover.

82
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STORAGE

REMOVAL FROM STORAGE

Check your outboard motor as
described in the BEFORE
OPERATION chapter of this manual.

If the cylinders were coated with oil

during storage preparation, the
engine may smoke briefly at startup.
This is normal.
PROTECTOR
OUTBOARD MOTOR STAND

If the outboard motor will be If it is necessary to store the outboard

removed from the boat for storage, motor horizontally as shown, drain
we recommend storing it vertically the vapor separator (p. 80 ), and drain
by mounting it on a stand. the engine oil (p. 60 ), before
removing the outboard motor from
the boat.

Rest the motor on a cushion of

protective material.

Cover the outboard motor to keep out

dust. Do not use sheet plastic as a
dust cover. A nonporous cover will
trap moisture, promoting rust and
corrosion.
83
04/04/01 16:45:03 31ZY6600_085

TRANSPORTING
WITH OUTBOARD MOTOR WITH OUTBOARD MOTOR
INSTALLED ON BOAT REMOVED FROM BOAT
When trailering a boat with the Secure the outboard motor in either
outboard motor attached, leave the the vertical or horizontal position
engine in the normal running position, shown on p. 82 83 .
if possible.

Use a motor support bar to prevent

the outboard motor from moving
while trailering the boat. Refer to the
manufacturer’s instructions for using
a motor support bar.

MOTOR SUPPORT BAR

(commercially available)

84
04/04/01 16:45:12 31ZY6600_086

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START Possible Cause Correction

1. Check emergency stop switch Clip not inserted in stop switch. Insert clip in stop switch.
clip.

2. Check control positions. Control lever not in neutral Shift to neutral.

position.

Fast idle lever raised (side-mount Leave fast idle lever OFF (p. 18 ).
type).

85
04/04/01 16:45:24 31ZY6600_087

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START Possible Cause Correction

(continued)

3. Check fuel. Out of fuel. Refuel (p. 69 ).

Fuel hose not primed. Squeeze priming bulb (p. 31 ).

Fuel filter or fuel tank filter Replace fuel filters (p. 71 ).

clogged.

Bad fuel; boat stored without Drain fuel tank and vapor
treating or draining gasoline, or separator (p. 80 ). Refill with fresh
refueled with bad gasoline. gasoline (p. 69 ).

86
04/04/01 16:45:40 31ZY6600_088

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START Possible Cause Correction

(continued)

4. Check battery. Battery connections loose or Clean and tighten battery

corroded. connections.

Battery discharged. Recharge battery.

5. Check fuses. Fuse(s) blown. Replace fuse(s) (p. 90 ).

6. Remove and inspect spark plugs. Spark plugs faulty, fouled or Replace spark plug (p. 66 ).
improperly gapped.

Spark plugs wet with fuel (flooded Dry and reinstall spark plugs. Start
engine). engine with the throttle open.

7. Use starting procedure (p. 37 ), Fuel system malfunction, fuel Replace or repair faulty
if engine still will not start then pump failure, ignition malfunction, components as necessary.
take outboard motor to an stuck valves, starter malfunction,
authorized Honda marine dealer, switch malfunction, or electrical
or refer to the shop manual. problem in the starting circuit, etc.

87
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TAKING CARE OF UNEXPECTED PROBLEMS

HARD STARTING OR STALLS Possible Cause Correction

AFTER STARTING

1. Check control positions. Fast idle lever raised (side-mount Leave fast idle lever OFF (p. 18 ).
type).

2. Check fuel. Fuel hose not primed. Squeeze priming bulb (p. 31 ).
Fuel filter or fuel tank clogged. Replace fuel filters (p. 71 ).

Bad fuel; boat stored without Drain fuel tank and vapor
treating or draining gasoline, or separator (p. 80 ). Refill with fresh
refueled with bad fuel. gasoline (p. 69 ).

88
04/04/01 16:46:07 31ZY6600_090

TAKING CARE OF UNEXPECTED PROBLEMS

HARD STARTING OR STALLS

AFTER STARTING Possible Cause Correction
(continued)

3. Remove and inspect spark plugs. Spark plugs faulty, fouled or Replace spark plug (p. 66 ).
improperly gapped.

4. Take outboard motor to an Fuel system malfunction, fuel Replace or repair faulty
authorized Honda marine dealer, pump failure, ignition malfunction, components as necessary.
or refer to the shop manual. etc.

ENGINE OVERHEATS Possible Cause Correction

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

2. Take outboard motor to an Faulty thermostat or water pump. Replace or repair faulty
authorized Honda marine dealer, components as necessary.
or refer to the shop manual.

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TAKING CARE OF UNEXPECTED PROBLEMS

FUSES Fuse Replacement FUSES (10A, 15A, 30A)

Electric Starter Will Not Main Fuse

Operate
1. With the engine stopped, remove
The 10A, 15A, and 30A main fuses the engine cover.
protect the electric starter relay and
related circuits. 2. Remove the electrical part cover.
SPARE FUSES
The 10A main fuse protects the (10A, 15A, 30A)
ignition switch and related circuits. If
this fuse blows, the engine will not
start or run, and the power trim/tilt
switch will not activate the trim/tilt
mechanism.

Battery Will Not Charge

A 90A ACG fuse protects the FUSE CASE LID
alternator circuit. If the ACG fuse ELECTRICAL PART COVER
blows, the engine will not charge the 3. Remove the fuse case lid.
battery. Refer to p. 91 .

LOCK TAB

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TAKING CARE OF UNEXPECTED PROBLEMS

ACG Fuse FUSE (90A)

FUSE PULLER Never use a f use with a rating

greater than specif ied. Serious
damage to the electrical system could
result.

If a blown fuse is found, try to

determine and correct the electrical
problem that caused the blown fuse.
An uncorrected electrical problem
may cause the fuse to blow again.
FUSE CASE LID ‘‘90A’’MARK
If fuses continue to blow, take the SPARE FUSE (90A)
3. Use the fuse puller from the tool outboard motor to an authorized
kit to remove the fuses. If a fuse is Honda marine dealer for inspection Disconnect the battery cable at the
blown, install a replacement fuse and service or refer to the shop battery negative (-) terminal bef ore
of the same specified rating. The manual. replacing the f use.
outboard motor is supplied with Failure to do so may cause a short
spare fuses in the fuse holder. circuit.

MAIN FUSE RATINGS: Replacement

10 A, 15 A, 30A
1. Stop the engine.
4. Reinstall the fuse cover and the
engine cover. 2. Remove the engine cover.

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TAKING CARE OF UNEXPECTED PROBLEMS

3. Remove the electrical part cover. A spare fuse is located on the reverse OIL PRESSURE INDICATOR
side of the fuse case lid and tightened GOES OFF AND ENGINE
4. Remove the fuse case lid. with two 3 mm screws. SPEED IS LIMITED
When the new fuse is set as a spare
5. Remove the old fuse by removing fuse on the reverse side of the fuse Side Mount Type
two 5 mm screws. case lid, set the fuse so that you can (GREEN)
see the ‘‘90 A’’ mark on it.
6. Install a new fuse with the ‘‘90 A’’
mark downward.

ACG FUSE: 90 A
BUZZER
7. After finishing replacement, install
the fuse case lid with its hook
toward the engine side.

8. Be sure to check the fuse case lid Panel Mount/Top Mount Types
is securely locked. (GREEN)

BUZZER

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TAKING CARE OF UNEXPECTED PROBLEMS

Digital Tachometer If the throttle is closed suddenly after OVERHEAT INDICATOR

full throttle operation, engine speed COMES ON AND ENGINE
may drop below the specified idle SPEED IS LIMITED
rpm, and that could activate the
engine protection system Side Mount Type
Normal momentarily. (RED)

Abnormal If low oil pressure activates the

engine protection system, stop the
engine, check the engine oil level
(p. 60 ), and add oil if needed. BUZZER

If oil pressure becomes low, the oil With the engine oil at the
pressure indicator will go off, and the recommended level, restart the
engine protection system limits engine. If the lubrication system is
engine speed. If you are at cruising OK, the oil pressure indicator should
speed, engine speed will decrease come on within 30 seconds, and the Panel Mount/Top Mount Types
automatically. engine will respond normally to (RED)
throttle control lever operation.
The oil pressure indicator is also
equipped with a buzzer that sounds If the engine protection system
when the oil pressure indicator goes remains activated after 30 seconds,
off. return to the nearest boat landing, and
have the outboard motor inspected by
Low oil pressure may be the result of an authorized Honda marine dealer.
a low engine oil level, or there may BUZZER
be a problem with the engine
lubrication system.
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TAKING CARE OF UNEXPECTED PROBLEMS

Digital Tachometer If the engine is stopped after running If water is flowing from the cooling
at full throttle, and then restarted system indicator, continue idling for
soon afterward, that could activate 30 seconds. If the cooling system is
the engine protection system OK, the overheat indicator should go
Normal momentarily. off within 30 seconds, and the engine
will respond normally to throttle
Abnormal COOLING SYSTEM INDICATOR control lever operation.

If there is no water flowing from the

cooling system indicator, stop the
engine, and tilt the outboard motor to
If the engine overheats, the overheat inspect the water intake screens. If
indicator will come on, and the restricted, clean the water intake
engine will stop in 20 seconds after screens, return the outboard motor to
the engine protection system limits the running position, restart the
engine speed. If you are at cruising engine, and check the cooling system
speed, engine speed will decrease indicator again.
automatically.
If overheating activates the engine If there is still no water flowing from
All types are equipped with a buzzer protection system, idle the engine in the cooling system indicator, or if the
that sounds when the overheat neutral, and check the cooling system engine protection system remains
indicator comes on. indicator. activated after 30 seconds, return to
the nearest boat landing, and have the
Engine overheating may be the result outboard motor inspected by an
of restricted water intake screens, or authorized Honda marine dealer.
there may be a problem with the
cooling system thermostat or water
pump.
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TAKING CARE OF UNEXPECTED PROBLEMS

WATER SEPARATOR WATER SEPARATOR SUBMERGED MOTOR

BUZZER SOUNDS INDICATOR
A submerged outboard motor must
Digital Speedometer be serviced immediately after it is
recovered from the water in order to
minimize corrosion.
Normal If there is a Honda marine dealer
nearby, take the motor to the dealer
Abnormal immediately. If you are far from a
dealer, proceed as follows:

WATER SEPARATOR 1. Remove the engine cover, and

rinse the outboard motor with
When the water separator buzzer When the water separator indicator fresh water to remove salt water,
sounds (a rapid, repeating signal): blinks. sand, mud, etc.

Check the water separator for water Check the water separator for water 2. Drain the vapor separator as
contamination. If water is contamination. If water is accumlated, described on p. 80 .
accumulated, stop the engine, and stop the engine, and clean the water
clean the water separator following separator following the instructions
the instructions on page 74 , or on page 74 , or consult with an
consult with an authorized Honda authorized Honda marine dealer.
marine dealer.

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TAKING CARE OF UNEXPECTED PROBLEMS

3. Change the engine oil and oil filter 6. Attempt to start the engine (be sure If the engine fails to start, remove
as described on p. 59 62 . If the water level is at least 2 inches the spark plugs and dry them, then
there was water in the engine above the antiventilation plate). reinstall the spark plugs and
crankcase, or if the used engine oil attempt to start the engine again.
showed signs of water
contamination, then a second If the engine starts, and no
engine oil change should be Running the outboard motor without mechanical damage is evident,
performed after running the engine suf f icient cooling water will damage continue to run the engine for a
for half an hour. the water pump and overheat the half hour or longer. Be sure the
engine. water level is at least two inches
4. Remove the spark plugs (p. 65 ). above the antiventilation plate to
Operate the starter to expel water avoid overheating and water pump
from the engine’s cylinder. damage.

5. Put a teaspoon of engine oil into 7. As soon as possible, take the

each spark plug hole to lubricate outboard motor to an authorized
the inside of the cylinders. Honda marine dealer for
Reinstall the spark plugs. inspection and service.

If the engine was running when it

submerged, there may be
mechanical damage, such as bent
connecting rods. If the engine
binds when cranked, do not
attempt to run the engine until it
has been repaired.

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TECHNICAL AND CONSUMER INFORMATION

TECHNICAL INFORMATION
PRODUCT
Serial Number Locations IDENTIFICATION
NUMBER
Record the product identification
number and engine serial number in
the space provided on this page. You
will need these numbers when
ordering parts, and when making
technical or warranty inquiries
(p. 107 ).

STERN BRACKET ENGINE SERIAL NUMBER

The product identification number is The engine serial number is

stamped on a plate attached on the stamped on the upper right side of
right stern bracket. the motor.

Product identification number: Engine serial number:

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TECHNICAL AND CONSUMER INFORMATION

Oxygenated Fuels The following are the EPA-approved You may use gasoline containing up
percentages of oxygenates: to 10% ethanol by volume. Gasoline
Some conventional gasolines are containing ethanol may be marketed
being blended with alcohol or an ETHANOL: ethyl or grain alcohol; under the name ‘‘Gasohol’’.
ether compound. These gasolines are 10% by volume.
collectively referred to as oxygenated MTBE: Methyl Tertiary Butyl Ether;
fuels. To meet clean air standards, 15% by volume.
some areas of the United States and
Canada use oxygenated fuels to help You may use gasoline containing up
reduce emissions. to 15% MTBE by volume.

If you use an oxygenated fuel, be METHANOL: methyl or wood

sure it is unleaded and meets the alcohol; 5% by volume.
minimum octane rating requirement.

Before using an oxygenated fuel, try

to confirm the fuel’s contents. Some
states/provinces require this
information to be posted on the pump.

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TECHNICAL AND CONSUMER INFORMATION

You may use gasoline containing up If you notice any undesirable Battery
to 5% methanol by volume, as long operating symptoms, try another
as it also contains cosolvents and service station, or switch to another For complete information, refer to
corrosion inhibitors to protect the brand of gasoline. the battery manufacturer’s
fuel system. Gasoline containing instructions.
more than 5% methanol by volume Fuel system damage or performance
may cause starting and/or problems resulting from the use of an Minimum Requirements
performance problems. It may also oxygenated fuel containing more
damage metal, rubber, and plastic than the percentages of oxygenates 12V 80AH
parts of your fuel system. mentioned above are not covered (CCA622)
under warranty.

99
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TECHNICAL AND CONSUMER INFORMATION

Emission Control System various sensors to determine how Tampering and Altering
Information much air is going into the engine. It
then controls how much fuel to inject Tampering with or altering the
Source of Emissions under all operating conditions. emission control system may increase
emissions beyond the legal limit.
The combustion process produces Ignition Timing Control System Among those acts that constitute
carbon monoxide, oxides of nitrogen, tampering are:
and hydrocarbons. Control of The system constantly adjusts the
hydrocarbons and oxides of nitrogen ignition timing, reducing the amount Removal or alteration of any part
is very important because, under of HC, CO and NOx produced. of the intake, fuel, or exhaust
certain conditions, they react to form systems.
photochemical smog when subjected The U.S. and Calif ornia Clean
to sunlight. Carbon monoxide does Air Acts Alterations that would cause the
not react in the same way, but it is engine to operate outside its design
toxic. EPA and California regulations parameters.
require all manufacturers to furnish
Honda utilizes various systems to written instructions describing the
reduce the emissions of carbon operation and maintenance of
monoxide, oxides of nitrogen, and emission control systems.
hydrocarbons.
The following instructions and
PGM-FI System procedures must be followed in order
to keep the emissions from your
The PGM-FI system uses sequential Honda engine within the emission
multiport fuel injection. It has three standards.
subsystems: Air Intake, Engine
Control, and Fuel Control. The
Engine Control Module (ECM) uses
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TECHNICAL AND CONSUMER INFORMATION

Problems That May Af f ect Replacement Parts A manufacturer of an aftermarket

Emissions part assumes the responsibility that
The emission control systems on the part will not adversely affect
If you are aware of any of the your Honda engine were designed, emission performance. The
following symptoms, have your built, and certified to conform with manufacturer or rebuilder of the part
engine inspected and repaired by EPA and California emission must certify that use of the part will
your servicing dealer. regulations. We recommend the use not result in a failure of the engine to
of genuine Honda parts whenever comply with emission regulations.
Hard starting or stalling after you have maintenance done. These
starting. original-design replacement parts are Maintenance
manufactured to the same standards
Rough idle. as the original parts, so you can be Follow the maintenance schedule on
confident of their performance. The p. 55 . Remember that this schedule
Misfiring or backfiring under load. use of replacement parts that are not is based on the assumption that your
of the original design and quality machine will be used for its designed
Afterburning (backfiring). may impair the effectiveness of your purpose. Sustained high-load
emission control system. operation, or use in unusual
Black exhaust smoke or high fuel conditions, will require more
consumption. frequent service.

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TECHNICAL AND CONSUMER INFORMATION

Star Label The Star Label means Cleaner Marine Engine

A Star label was applied to this This engine has been certified as a:
outboard motor in accordance with
the requirements of the California
Air Resources Board.

The Symbol for Cleaner Marine Engines:

Cleaner Air and Water - for healthier lifestyle and environment.

Better Fuel Economy - burns up to 30 - 40 percent less gas and oil than
conventional carbureted two-stroke engines, saving money and resources.

Longer Emission Warranty - protects consumer for worry free operation.

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TECHNICAL AND CONSUMER INFORMATION

The one-star label identifies engines that meet the Air Resources Board’s
One Star Personal Watercraft and Outboard marine engine 2001 exhaust emission
Low standards. Engines meeting these standards have 75% lower emissions than
Emission conventional carbureted two-stroke engines. These engines are equivalent
to the U.S.EPA’s 2006 standards for marine engines.

The two-star label identifies engines that meet the Air Resources Board’s
Two Stars Personal Watercraft and Outboard marine engine 2004 exhaust emission
Very Low standards. Engines meeting these standards have 20% lower emissions than
Emission One Star-Low Emission engines.

The three-star label identifies engines that meet the Air Resources Board’s
Three Stars Personal Watercraft and Outboard marine engine 2008 exhaust emission
Ultra Low standards or the Sterndrive and inboard marine engine 2003-2008 exhaust
Emission emission standards. Engines meeting these standards have 65% lower
emissions than One Star-Low Emission engines.

The four-star label identifies engines that meet the Air Resources Board’s
Four Stars Sterndrive and Inboard marine engine 2009 exhaust emission standards.
Super Ultra Personal Watercraft and Outboard marine engines may also comply with
Low Emission these standards. Engines meeting these standards have 90% lower
emissions than One Star-Low Emission engines.

Cleaner Watercraft - Get the Facts

1-800-END-SMOG
www.arb.ca.gov
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TECHNICAL AND CONSUMER INFORMATION

Specifications
MODEL BF135A Starter system Electric starter
Description Code BARJ BARJ BASJ Ignition system Fully transistorized, battery ignition
Type LA XA XCA Lubrication system Trochoid pump pressure lubrication
Overall length 33.3 in (845 mm) Specified oil Engine: API standard (SG, SH, SJ)
Overall width 22.8 in (580 mm) SAE 10W-30
Overall height 65.6 in 70.5 in (1,790 mm) Gear case: API standard (GL-4/5) SAE
(1,665 mm) 90 outboard motor gear oil
Transom height 20.0 in 25.0 in (635 mm) Oil capacity Engine: 6.9 US qt (6.5 )
(508 mm) without oil filter change
Weight 478 lbs 485 lbs (220 kg) Gear case: 1.04 US qt (0.98 )
(without propeller) (217 kg) CARB star label ULTRA · LOW EMISSION
Rated power 100.7 kW (135 HP) D.C. output 12V 40A
Full throttle range 5,000 6,000 rpm Cooling system Water cooling with thermostat
Engine type 4 stroke DOHC in-line 4-cylinder Exhaust system Water exhaust
Displacement 143.6 cu-in (2,354 cm ) Spark plugs SKJ20DR-M11 (DENSO)
Spark plug gap 0.039 0.051 in (1.00 1.30 mm) IZFR6K11 (NGK)
(do not adjust) Fuel pump Low pressure side: mechanical type
High pressure side: electrical type
Fuel Automotive unleaded gasoline
(86 pump octane or higher)
Gear change Forward-Neutral-Reverse (dog type)
Steering angle 30° right and left
Transom angle (at 12°) 4° to 16°

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

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TECHNICAL AND CONSUMER INFORMATION

Specifications
MODEL BF150A Starter system Electric starter
Description Code BANJ BANJ BAPJ Ignition system Fully transistorized, battery ignition
Type LA XA XCA Lubrication system Trochoid pump pressure lubrication
Overall length 33.3 in (845 mm) Specified oil Engine: API standard (SG, SH, SJ)
Overall width 22.8 in (580 mm) SAE 10W-30
Overall height 65.6 in 70.5 in (1,790 mm) Gear case: API standard (GL-4/5) SAE
(1,665 mm) 90 outboard motor gear oil
Transom height 20.0 in 25.0 in (635 mm) Oil capacity Engine: 6.9 US qt (6.5 )
(508 mm) without oil filter change
Weight 478 lbs 485 lbs (220 kg) Gear case: 1.04 US qt (0.98 )
(without propeller) (217 kg) CARB star label ULTRA · LOW EMISSION
Rated power 111.9 kW (150 HP) D.C. output 12V 40A
Full throttle range 5,000 6,000 rpm Cooling system Water cooling with thermostat
Engine type 4 stroke DOHC VTEC in-line 4-cylinder Exhaust system Water exhaust
Displacement 143.6 cu-in (2,354 cm ) Spark plugs SKJ20DR-M11 (DENSO)
Spark plug gap 0.039 0.051 in (1.00 1.30 mm) IZFR6K11 (NGK)
(do not adjust) Fuel pump Low pressure side: mechanical type
High pressure side: electrical type
Fuel Automotive unleaded gasoline
(86 pump octane or higher)
Gear change Forward-Neutral-Reverse (dog type)
Steering angle 30° right and left
Transom angle (at 12°) 4° to 16°

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

105
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TECHNICAL AND CONSUMER INFORMATION

BF135A/BF150A Tune up
Spark plug gap (do not adjust) 0.039 0.051 in (1.00 1.30 mm) See page 67
Idle speed 750 50 rpm See shop manual
Valve clearance (cold) Intake: 0.23 0.02 mm See shop manual
Exhaust: 0.30 0.02 mm
Other specifications No other adjustments needed.

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TECHNICAL AND CONSUMER INFORMATION

CONSUMER INFORMATION Customer Service Information Or telephone: (770) 497-6400

Honda Publications Honda Marine dealership personnel When you write or call, please give
are trained professionals. They us this information:
These publications will give you should be able to answer any
additional information for question you may have. If you Model and serial numbers (p. 97 )
maintaining and repairing your encounter a problem that your dealer
outboard motor. You may purchase does not solve to your satisfaction, Name of the dealer who sold the
them from your Honda marine dealer. please discuss it with the dealership’s outboard motor to you
management. The Service Manager
Shop Manual or General Manager can help. Almost Name and address of the dealer
all problems are solved in this way. who services your outboard motor
This manual covers complete
maintenance and overhaul procedures. If you are dissatisfied with the Date of purchase
It is intended to be used by a skilled decision made by the dealership’s
technician. management, contact the Honda Your name, address, and telephone
Marine Customer Relations Office. number
Parts Catalog You can write:
A detailed description of the
This manual provides complete, American Honda Motor Co., Inc. problem
illustrated parts lists. Marine Division
Customer Relations Office
4900 Marconi Drive
Alpharetta, Georgia 30005-8847

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04/04/01 16:50:46 31ZY6600_113

INDEX

Alternator (ACG) Indicator ............................................ 29 Electric Starter Will Not Operate ................................... 90
Anodes ............................................................................ 32 Emission Control System Information ........................ 100
Replacement ............................................................... 76 Engine
ARE YOU READY TO GET UNDER WAY?............. 33 Cover
Latch ....................................................................... 27
Battery ............................................................................ 99 REMOVAL AND INSTALLATION .................... 59
Will Not Charge ......................................................... 90 Oil
BEFORE OPERATION................................................. 33 Change.................................................................... 60
BREAK-IN PROCEDURE ............................................ 35 Filter Change .......................................................... 62
Level Check ........................................................... 60
Common Controls .......................................................... 25 Recommendations .................................................. 63
COMPONENT AND CONTROL LOCATIONS ......... 11
CONSUMER INFORMATION .................................. 107
Honda Publications ...................................................... 107
Customer Service Information ..................................... 107
CONTROLS ................................................................... 15
CONTROLS AND FEATURE IDENTIFICATION
CODES ....................................................................... 10
CONTROLS AND FEATURES ................................... 10
Cooling System Indicator............................................... 31
CRUISING ..................................................................... 49
Customer Service Information ..................................... 107

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

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

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04/04/01 16:50:50 31ZY6600_114

INDEX

Fast Idle Button Ignition Switch

Panel-Mount Type...................................................... 20 Panel Mount Type ...................................................... 18
Top-Mount Type ........................................................ 23 Side Mount Type ........................................................ 15
Fast Idle Lever ................................................................ 18 Top Mount Type ........................................................ 22
Fuel IMPORTANT SAFETY INFORMATION ..................... 7
PRIMING ................................................................... 36 INDICATORS................................................................ 28
Priming Bulb .............................................................. 32 INSTRUMENTS ............................................................ 27
RECOMMENDATIONS ........................................... 70 IS YOUR OUTBOARD MOTOR
Filter Inspection and Replacement ............................. 71 READY TO GO? ....................................................... 33
Fuse Replacement .......................................................... 90
FUSES ............................................................................ 90 Lubrication Points .......................................................... 64

Gearshift/Throttle Control Lever MAINTENANCE SAFETY .......................................... 54

Panel Mount Type ...................................................... 20 MAINTENANCE SCHEDULE .................................... 56
Side Mount Type ........................................................ 16 MANUAL RELIEF VALVE ......................................... 59
Top Mount Type ........................................................ 23 MOORING, BEACHING, LAUNCHING .................... 51
GEARSHIFT AND THROTTLE OPERATION .......... 46
Panel Mount Type ...................................................... 47
Side Mount Type ........................................................ 46
Top Mount Type ........................................................ 47

HOISTING THE OUTBOARD MOTOR ..................... 82

Honda publications....................................................... 107

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04/04/01 16:50:54 31ZY6600_115

INDEX

Oil Pressure Indicator ..................................................... 29 SPARE EMERGENCY STOP SWITCH CLIP

OIL PRESSURE INDICATOR GOES OFF AND (optional equipment) .................................................. 55
ENGINE SPEED IS LIMITED ................................. 92 Specifications ............................................................... 104
OPERATION ................................................................. 35 Star Label ..................................................................... 102
OTHER FEATURES ..................................................... 31 STARTING THE ENGINE ........................................... 37
OUTBOARD MOTOR SAFETY .................................... 7 Panel-Mount Type...................................................... 40
Overheat Indicator .......................................................... 30 Side-Mount Type ....................................................... 37
OVERHEAT INDICATOR COMES ON AND Top-Mount Type ........................................................ 42
ENGINE SPEED IS LIMITED ................................. 95 STEERING..................................................................... 48
Overrev Limiter .............................................................. 31 STOPPING THE ENGINE ............................................ 44
Oxygenated Fuels ........................................................... 98 Emergency Engine Stopping...................................... 44
Normal Engine Stopping............................................ 45
Power Tilt Switch ........................................................... 26 STORAGE ..................................................................... 78
Power Trim/Tilt Switch ................................................. 25 STORAGE PRECAUTIONS......................................... 82
Programmed Fuel Injection (PGM-FI) Indicator ........... 29 STORAGE PREPARATION......................................... 78
Propeller Replacement ................................................... 77 Cleaning and Flushing ............................................... 78
Engine oil ................................................................... 81
REFUELING.................................................................. 69 Fuel ............................................................................. 80
REMOVAL FROM STORAGE .................................... 83 SUBMERGED MOTOR................................................ 95
Switch Clip and Emergency Stop Switch
SAFE OPERATING PRECAUTIONS ......................... 35 Panel-Mount Type...................................................... 19
SAFETY LABEL LOCATIONS ..................................... 9 Side-Mount Type ....................................................... 16
Serial Number Locations................................................ 97 Top-Mount Type ........................................................ 22
SERVICING YOUR OUTBOARD MOTOR ............... 53
SHALLOW WATER OPERATIONS ........................... 51
Spark Plug Service ......................................................... 66

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INDEX

Tachometer (optional equipment) .................................. 28

TAKING CARE OF UNEXPECTED PROBLEMS..... 85
TECHNICAL AND CONSUMER INFORMATION... 97
TECHNICAL INFORMATION .................................... 97
THE IMPORTANCE OF MAINTENANCE ................ 53
Tilt Lock Lever............................................................... 26
TOOL KIT and OWNER’S MANUAL......................... 55
TRANSPORTING ......................................................... 84
WITH OUTBOARD MOTOR INSTALLED
ON BOAT .............................................................. 84
WITH OUTBOARD MOTOR REMOVED
FROM BOAT ........................................................ 84
Trim Meter (optional equipment) .................................. 27
Trim Tab ......................................................................... 27
TRIM TAB ADJUSTMENT ......................................... 58

Water Separator Buzzer ................................................. 31

WATER SEPARATOR BUZZER SOUNDS ............... 95
Water Separator Inspection and Service ........................ 74
WIRING DIAGRAMS......................... Inside Back Cover

115
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MEMO

116