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CONTENTS Page 3 5 7 7 SPECIA.L TOOI..S ................................. . ENGINE AND LOWER UNIT REMOVAL AND INSTALLATION ••••••.•.•••.•.••..•.•.••••.•.•.• DISASSEMBLY AND REASSEMBLY •••••••••••••••• 1. Recoil Starter ................ .. .. . . .. ........ . 2. Carburetor • Inlet Manifold 3. 4. Cylinder Head • Camshaft .................. . 11 Cylinder Barrel Piston • Crankshaft • ••.••••.•• s. Electrical(ignition coil, breaker point.s, spark plug a) 16 6. Oil Pump ท Fuel Pump . .. , .••••.••••••••••••• 18 7. Gearcaae • Extension Case ทWater Pump 20 Handlebar 23 .......................•..•........ Stern Bracket ท Swivel Case 25 ........... •...•.. Oil Ca ee 27 ..•....•............•.•....•........ 10. [!) SERVICE DATA 28 ......... ..... ..... , • . • . • • • .. • . .. • 1. Service Data • • • • •• • • • . •••. • • • • • • • . • • . • • . . •. • 28 2. Torque Table 29 .• • • •• • • • • • • • • • • • • . • . • • • • • • • • • • • 3. Lubrication Chart 30 . . . . . . . . . .. . • . . . . . . • . . . . . . . . • 4. Trouble Shooting 31 • • . • • • • • .. . • • • . • • • • • • . • • • . • • • . . • . . . . . . . . . . • . • . • . . . . . . . . • . . 5. Wiring Diagram 33 6. Specific,ations 34 . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . FOREWORD This shop manual is published as a guide for servicing the Honda Marine Engine, model B75 (4-cycle watercooled engine). Many photographs and illustrations are used to clearly describe the details of the respective operation. Reading the manual thoroughly will prepare you to service the engine properl y . August, 1971 HONDA MOTOR CO., LTD. llltVICa DIVISION * Special instruction in the use of this manusl. -1. The disassembly operation is perforo:>ed by first removing those parts preceeded by (Q) followed by the other components in the order of the numbered sequence. Operation nUinbers marked with (') can be disassembled in any order within the same sequence numb.er. -2.. The important operation• are described using the i Uustrations. * Special operational instruction -1. Since all bolts and washers which are exposed on the outboard engine are made of special corrosion resistant material, thoee parts which are intended for use internally should not be used. -2.. Always replace lockwasbers, 0-rings, cotter pi.ns and packings with new items. -3. Sand any bare paint spots with emery paper, wipe clean with thinner, and then repaint. [j] SPECIAL TOOLS Tool No. & Photo Description use 1 07000-92100 Sepcial too.! set 2. 07001-92110 Valve seat cutter set 07001-21601 Valve seat cutter, Inlet and 3 exhaust valve seat 07003-9210 l 07004-92.101 Inlet valve seat flat cutter Ex_haua.t ya\vc scat flat cutter Inlet valve seat top Exhaue,.t valve •eat top 07007-2.1601 Seat cutter holder Valve seat cutter 07997-05101 07051-92101 07046-92101 Seat cutter case P-iston slider alve guide driver Piston installation Valve guide installation and removal Tool No. & Photo 07048-92101 .. 1 1 07048-92105 0706l-92101 I 3 07078-92101 Description Water seal driver Seal driver Use Water seal 6mrn, 14nun installation Coupling seal, 17mm water seal and 6203 bearing installation Clamp screw Clamp screw and staking tool push plate staking Socket wrench, Timing pulley 27tnm lock nut 07790-99911 Toot case • 07008-24001 reamer * 0703J-Z1601 Valve lifter • 07081-00101 Tappet socket wrench guttieVal ve guideValve finishing Valve removal and installation Valve tappet adjustment * 07087-00101 Tappet Lock nut Valve tappet wrench adjustment Note: (•) marked tools are not mcluded in special tool set. :b ENCINI': AND LOWER UNIT l. Lower Unit Removal lever (D Cotter pin ฎshHt rod (D Lower TnOunt bolder " that in the NEUTRAL and REVERSE gear positions the throttle can only be opened hall N way. a. When moving the shift lever from FORWARD to NEUTRAL or REVERSE, the cam on the shift shaft moves in the (A)ท direction. b. As the throttle grip is twisted to open the throttle, the throttle cable moves the arm in the (B) direction. When the shut lever is in the NEUTRAL or REVERSE Fig. 6 N: Neutra.t F': Forward (D Shift ohalt ฎ Cam (!> Throttle arm ฎStopper the shift shaft ia moved in place between the throttle arm and the stopper to limit the stroke of the throttle arm, preventing the throttle to be opened full. • Fuel stop mechanism When the fuel tube connector is removed from the fuel connector on the engine, the fuel stop shaft moves in the (A) direction by the force of the spring and the inter Z. Carburetor • Inlet Manifold • position, a cam at tho end of Linked fuel stop lever moves in the (B) direction. The link shaft forces the stopper to block the fuel flow through the main jet. neengag ing the fuel tube connector into the fuel connector moves the linkages in the opposite direction and allows fuel to flow through the main jet. FueI luhe connecto t Fuel ttop ehaft Fuel c:onnect.or Spring Ft,lel stop rod Fuel •top lever Li n.k • ha.n. o Engine cover (page 5) o Choke, throttle, fuel stop rod l. Ca.rburetor assembly 1'. Float chamber body z. 2'. Z'. Z'. -0 Float z•. Main jet Valve seat z ' . Jet block Cove.r 3. Link shaft 3'. Packing Fig. 10 (j) Float @ Float arm l ip@ Float vo.lve Fig. 9 ''li'11 hrntn.. n".a.rk@!ndC!lC: mDTk -2. Ignition timing "-ท Turn the flywheel in the direction of the arrow abown in lhe figure and obaerve the 1'\g. a? vel gear Engine oil capacity Gear oil capacity 28 Maintenance Standard (0.216"-0. 217 in.) 1.5mm(0.059 in.) Inlet: 0.. lZm.m (0.0047 in.) Exhaust: O.l6mm. (0.0062 in. ) 50.lmm(l.97 in.) 49.8mm(l.96 in. ) 0.6mm(0.023 in.) 0.07mm(0.0027 in.) 0. 3"-0.4mm in. O.l5mm(0.0059 in.) 0.10mm(0.0039 in.) 0.1"-0.Smm 0.8(l. 7 us pt,l.4 Imp.pt) 32 US 0.26 2. Table .9 i E The table below shows the torquing value for the important components. Components Bolt or nut (mm) Torque Value Crankcase 6 (PI. 0) bolt 90"' 120 (6. sr --.8. 68) Cylinder head 8 (Pl. 25) nut 2oo--.2so(I4. 4--. 17.1) Flywheel 12 (Pl. Z5) nut 600"-700(43. 4--.so. 6) Connecting rod 6 (Pl. 0) special 90"'120(6. 51"'8.68) bolt Timing pulley 22 (Pl. 0) special 200"-250(14.4"-17.1) nut Cam Pulley 6 (PI. 0) bolt 90"-120(6. 51"-8.68) Carburetor air guide 6 (Pl. 0) bolt 90"' 120 (6. 51 "'8. 68) Engine mounting 6 (Pl. 0) bolt 90"-120(6. 51"-8. 68) Extension case 8 (Pl. 25) bolt zoo"' 250 (14.4"' 17.1) Gearcase 6(Pl. 0) bo.lt 90"' 120 (6. 51 "'8. 68) Propeller sha!tholder 6 (Pl. 0) bolt 90"-120(6.51"'8.68) Mount rubber(upper, 8 (Pl. 0) nut 2oo--.2S0(14.4"' 17.1) lower, thrust) Stern bracket 6 (Pl. 0) nut 90--.120(6. 51"-8.68) Tilt bolt 8 (Pl. 25) nut 200"-250 (14. 4"' 17. I) Swivel shaft 6 (Pl. 0) bolt 90"' 120(6. 51"-8. 68) 29 30 3. Lubrication Chart A. Grease B. API Standard SD SAE lOW-30 0.8ฃ ( 1. 7 us pt/1.4 I p.pt) Lubrication Record Engine oil Throttle grip H..ndlebar stopper. Friction plate C. API Standard GL-4 SAE 90 Outboard motor gear oil 0.15ฃ(0.32 us pt/0.26 I p.pt) Trouble Probable Causes Engine does 1. Fuel tank empty Refill not start Z. Defective fuel tube Inspect and connector repair 3. Clogged fuel filter " -- 4. Closed pilot screw Adjust carburetor.. ., 5.Clogged carburetor Inspect and " .. repair carburetor 6. Malfunction of fuel stop lever -" - 7. Clogged fuel connector Inspect and 1. Defective spark plug Replace e Z. Improper spark plug gap Adjust gap " to 0.6..0. 7 ... .. rnm(O.oz.. 0.03 in.) ';Ju 3. Electrical leak in high Replace.... tension cord ignition coil .. ...u 4. Defective points Clean and .,...... adjust points 5. Grounding of stop switch Repair or cord "' Pull with ... 1. Insufficient starter pull .. greater force .<:... 0 4. Trouble Trouble Probable Causes Engine runs 2. Water mixed in fuel Drain and for short refill period s 3.Pilot screw opened too far Adjust Frequently ., carburetor .. ., 4. Idling set too low " engine stops -- U) 5. Clogged carburetor Inspect and while ...., running " repair;:1 r.. carburetor6.Fuel pump malfunction Inspect and repair fuel pump 7.Fuel stop .lever alfunction nspect and 1. Grounding of engine stop Inspect and cord repair s 2. Defective high tension cord Replace ., ignition coil .. 3. Defective coil or condenser Replace., defective ';i part u 4. Defective points Adjust or.... ... .. replaceu .. 5. Defective spark plug Replace....,1>1 6. Loose spark plug cap Inspect and repair .. 1. Clogged coo ling water pipe Inspect and ... repair" ..d ..0 (!) Ignition coil @ Spark plug@ Contact breaker assembly @ AC generator ฎ Engine switch MEMO Fig. 49 33 6. ' Items Data. Engine type 4 cycle, 2. cylinder, OHC Total displacement 149cc (9. 09 cu. in. ) Bore and stroke 50 x 38mm (1.38 x 1.50 in. ) Power output 7. 5 ps/ 6, 000 rpm Starting method Recoil starter Ignition method Flywheel magneto Lubrication method Forced lubrication by trochoid pump Cooling method Water cooled Fuel system Diaphragm fuel pump S type: 530 x 315x 945mm Dimension (20. 9 X 12. 4 X 37. 2 in. ) (L x W x H) L type: 530 x 315 x 1, 100mm (20• 9 X 12• 4 X 44 3. 0 in. ) S type: 27. 0 kg (59. 5 lbs)Weight L type: 2.8.9 kg (63. 6 1bs) Transom mounting angle Four mounting angle (3•,s•,t3•, 18ฐ) Tilt angle Two tilt angle (35 •, 70 •j ' S type: 380mm ( 15 in.) Transom height L type: 533mm (2.1 in. ) Reduction ratio 13 : 25 No. of propeller blades x 2. x 2.10mm x 150mm(8. 2.7 x 5. 90 in.) diameter x pitch Clutch Dog type Spark plug NGK D-5H S Tools Engine and lower unit removal and and