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HONDA BF3eA·4eA SPECIFICATIONS SPECIFICATIONS ...................... 1-2 DIMENSIONAL DRAWINGS ......... 1-4 WIRING DIAGRAM ..................... 1-6 1-1 HONDA SPECIFICATIONS DIMENSIONS AND WEIGHTS Descript on code Clnek:l. oil) • 2: With handle ar ttxte..d FRAME - SLAG (long ty ..) 8LAF (long type) •1: 725 (28.51 685 <27.0) 1,266 I,360 (53.5) 1,266 (49.41 1,360 (53.5) 91 kg 88 kg (194.0 lb) 90 kg 92 kg 90.5 kg 1200.0 lb) kg (201.Bibllf206.1 tbl (204.0 lbl {208.4 lbl (204.0 lb) t208.41b) 521 mm f20.6 In) 416 mm (16.4 inl 521 mm f20. 5 In) R GAT T 1-2 R R R GAT R T . ..: Stendard Equipment Accordin to Shaft Length S: Shon Shaft L: Long Shaf According to Control System tl:Tiller Hand'e Conttol R: Remote Control Accotdlr)Q to tilt s stam GAT: Gas-assisted Tilt lwlth gas damper •ssJst function) T: ower trim & tilt (with hydra lic assist funcdon• ENGINE HONDA. BF315A·415A 210 LOWER UNIT -286 x 330mmNo. of (11·1/4x 13.0 in• CIO˘kwl$t! (vi&wed from rear• 1-3 DIMENSIONAL DRAWINGS Remote control type I ): Short shaft type 1-4 885127.0) HONDA. Unl1: mm fin) 370 114.8) g;_ ..N-.. .. HONDA. Tille< handle type[ ): Short shaft type PROPELLER SHAFT 1.059 (41.71 726128.61 ..."' ....N "!M .. .. ;,a.; o4 (oO. 1611 6. 5 mm f0.26 in) 370 114.61 '3·1 in) 11.6 mm (0.461nJ Unit: mm (in) 1-5 CD >..0 f-..c: § 8 iCD •0E2!i!·;;oilE1:..-CDl.. ..!I !..!,. !I ' i .. IJr .. .. ::::ecCa:..-Qc.:Jz-a:-31: I.I J.. HONDA BF35A·4!5A Remote control type .. =:. ..'"""' .. .. • .. r ..::..."l •• ... .• =--· ' - ·····-' ! u,s},•,•, ••[. .. IJIII IJIII .-R "" 1-7 Tiller handle type 1-8 I" IIIII._ FUM " I · ·-·· · nut r ! n l ..ou .. 8T.MinR eiMTCH rn -t": .,. ltot 171 111 ""' ... - ..I 1"1 ""I :ICC iftR COilCOIL ,, .. ... ··..COlUMf HONDABF3!5A·45A ""OIL'--.. ........8'MTCH fl'..,I.NIKPWG I HONDA SERVICE INFORMATION GENERAL SAFETY .................... 2-2 SERVICE RULES ....................... 2-2 SERIAL NUMBER LOCATION ...... 2-2 MAINTENANCE STANDARDS ..... 2-3 TORQUE VALUES ..................... 2-9 SPECIAL TOOLS ....................... 2-11 TROUBLESHOOTING ................. 2-13 CABLE/HARNESS ROUTING ....... 2-22 TUBE ROUTING ........................ 2-32 LUBRICATION .. ll:;.l..llll.ll .............. 2-33 MAINTENANCE SCHEDULE ........ 2-36 2-1 HONDA GENERAL SAFETY Stop the CNliJine. and remove the a.park plug capa 11nd i nition hy before seMolng the Outboard motor. If the motor must be running to do some wo"<, mllke sure the area l6 well ventilated. Never run the engine in a closed area; the exhau$1 contains ..sonous carbon monoxide gas. Gasoline is extremety fl•mmtlble and it eJtQ.Iosive under certain conditions. Do not smoke or aUow flames or &parits In your wotldng area. SERVICE RULES 1. Use gt.nuine Honda or Hortd.&•recommended parts and lubricants or tMir equivalent&. Parts that do not meet Honda's de. y Di•ragm adjustment Vatve QOicM removal!inataJt.tion 2.5 x 12 mm, 2.5 x 18 mm, 2.5 x 20 mm apring: Dill 2.2 X 3S X 7 mtn Wttf)f $NI inf'telarion SPECIAL TOOLS 5. 21. 07780-0010800 Vatve seat reconditioning IN Valve Hit reconditioning EX Attechment, 52 x 55 mm Anechmtnt, 62 .l< 68 mm Attachment. 24 x 26 mm 14. Inner driver, 35 mm 15. Pilot, 25 mm 16. Pilot.. 22 mm Oil Mil -*iver 07746-0010400 07746-0010500 07746-0010700 07746-0030400 07746-0040600 07746-0041000 07746-0010001 -....8 2-1 1 HONDA 40. Oil fite1 wrend't 4\, End nut wteneh 42. 56 mm lock nut wrench4$. Ring geer holder 44. Vertica\ shaft ..dtr 45. Propeller shaft holder 46. Beatingrace puller 47. Propeller $htf1 rttnovtK•a. Vertical sh ft gtugt 49. -ing height o•-50. Backlash inspecdon ett1ehmem 51. Tnt prope11er ' 07HAA-PJ70100 071.PA-ZV30100 071.PA-ZV30200 07LPil-ZV30100 07LP8-ZV30200 07LPil-ZV30900 07LPC-ZV 0100 07LPC-ZV30200 071.PJ-ZV30100 071.PJ-ZV30200 071.PJ-ZV30300 071.PZ-ZV30100 07LP2-ZV50100 OU titerreplacement ea:se tnd nut r.movalf.nstlhtJon Puhef rotor. 45 mm kN:k nut removallinattlt.atJon Flywt'l.-. 22 mm lock nut removt...l/ltl.tttlletion Venlcal &haft Jock nut r .movallinstalla11on FOfwerd ..:tr b ekl"h insp4Jction Vtrticel &haft, gear Clst outer race removal fl'to.... , theft hold" auembty r..movel Vtrtk:aJ shatt shim &Cijustment Forwerd !if.ll" thim .nt Forward gear bacltf11h 1ntpection For test or;.eratlctl In water tank. ==·=>901===-· 0 ote===::::J ® & ® 2-12 HONDA. TROUBLESHOOTING ENGINE No fuel in the tlnk for colapsed or s:Mnched Fua.l OK liM.• Ch&ek for clogged fuil t.tnk breathet holoe: Close t le tank end open the Fuel flows freely. with fuel ' •t.ct:fode. weak ape1kPuU the re oil starter oncl c.heck for NoIPifks. CAUTION:Do not cheek near the pluo Of od SPilk vont knob, list n for hlu.• Check for air leaks PMt the !>rimerbulb. •Soute.zethe primer butb end be awethat the fuel lt rtec.htng the carburetor.• Check tor dogged fuel fitter and connector. ·Check for clogged Ctrbvrttor port/nozzle. rtttltt the engine.• tt lkCesaivefy wet, chtek the car- b ....... ... floodj,ng, If O.oln ... - system fauUv IP. 12·14• plug hole. Tum the ttart.H swltc:tl on and check 11 Remove the all spar\C plugs. 2t Shitt into n utraJ gear •lld open the throttlu fully. 3t Install a compr sslon Qauge in one of the IPtfk plug holes. 4• 01)«'1te the st•rter motor un il the hlghe1t reading is obtained. 5) IN1•1 the OCWT'Ipfenion oauge in the otNt sp.arlc. plug hole .net repeat the step 31. 2-13 • CMckfor loose cylind r head.• Check fOt d.$m.eigt(f cvtin"Cti<>n Ptobable cauM Cheek the bmtfY tw· itsm miNik fOt connection When a problem OCCUI"'. disconnect th bettery, No good Replace tho eng1no Engine do•• not stopvltcotlty. when the key twkeh is Turns. Repairor repl.llce the with • new one .net startor motor. keyawitcft or ttwttf Che_<=k lnakl4 or the""il'nt. 2-15 HONDA D. ENGINE DOES NOT RUN SMOOTHLY Engrne $tarts but nopJ soon. Poor 11 Wet fouled soarit otuQ cauftd hom excessive choke application-----Stan tho cn;lne 2) Feutty lptrk plug 3) Carbut610r Nyn hron}zation wiTh the chollt fulvopen and th.t throt· tie fulty ttoted. ----.Clean. t ditl st. or n:l)tace. mlsadjutt.cl ----.Ad)U$1 property, 41 Carbufttor pilot screw/stop aerew misadiur.ed -----Adjoat prOI)tfty.SJ CtftlurtiOf ttow circuit.. whh ctitt ----.Ovethoul. 61 Overltowed carbuletor Drain ttle ctrburetot and prim• .ogain. It stl• not good. overhaul tho carouret.or. 7) Seoond•ry air euc ed caused from damlged c•tutetor insu&ator gasbt 2• Throttle cable misadjusted 3) Propeller mlsmetehed Adiu:Wt properly. Select CONtcl Qtopefler,4) Engine ov.me.ta. eng.."" oM PfH$ure drops abnotmatty. (Warning tYatem functions.J SJ Fsutty sptrk piug -----Clean. edjutt. or 61 Oogged futl flhef 71 W&ter/dlrt in carburetor 8} Incorrect valve timing repllc:.. -------...Replooo. -----.Or•ln the CH'tr• buretor. Overhaul ii it is still no good.----.Reirm:afll the timing bolt. mlsedfulted prOC)Ot1y. 2) C1ogged delh pot checkvalve 31 Throt le ctbte aruc:k with aalt Replace. 41 C11burt10f throtdc shaft not moYft smoothly. conee1 .._ .... fRev4fimlter functions when over-revving.) 2) PropeU.n e..;ceuively worn eplaca. 3) Propeller dompet rubber alippory----RepŁtce. 4) lmprQiMrty inttelled outboerd engJne (incorfe.ct transom height,titt angle. etc., 2-16 HONDA BF3BA·4!5A • OIL PRESSURE TEST H Che-ck the ar..gl.!wt oil le\lel (P. 3·21. 2• R.,nQve ti'MI 4 x 8 mm screw •nd oil pressure awh<:h. 31 lnltllll the I)I"Mture gtvge atteohmtnt ($J>e˘i.al toot) on me oil pressure eeuge that has a se..t. calibrated to a maximum ot 7-10 kgiCI"n* f89.6-142.2 pa11 sate s.nd on the ovt· board motor. 41 Remove the ptOpoller and set the out.,.,.rd motOt Inewater t..k or apply watef to the outbot.rd motor with the rinsing pk.tog, and .stan the eng.ine. 5) Measure the oH ptessore when h.e temperat\lft reaches ao•c l21&.o•FI 1.5kg/cm1 1.21.3paU min. 81Ifthe oil pressure it; lea than \M spec.ification. et'leclt the oil .. rot0f6 •nd body for wear. ?I Cklan the oil pressure .switch threads aod apply liquid aealant CTHAEE BONO 1215or CQu1velent) to the thraacls. iighte-n the oll switch to the &pt:cifi.O torque. 2-17 HONDA. E. ALERT S YSTEM 3,000 min..1 frpm• warning horn sounds and tpm drops while running. sound NOLOil p essure I:Jmp (grecnl is OFF NO"TE: Intermittent ·..·-.-..,. ___, trim• Remote conuol lever Jeans excessively lex-.. OK cessive throttle engfe).-Return remote control NOTE: No problem if the oil preuure l&mp No PfOblem if the overheat la"'P n estarting the h t soak at high turns o f after idl- YES turns off when the engine speed is tu:rns On who Solowsd down suddenly. but turns engine after the on after idlin for 1 or 2 minutes. temperature. but YES ing fOt • minute. Stop me eoglne anlh <-NGed)ustment. Reploee. Cheek the dutch dimpletdlttch G. ASSIST TILT LOAD (Gas aubted tv.Ml CMc:lc fricdonl other than of the Check for srictlng by Sift •nd aaaa.t tit. clean if neceiNry. OK • Oo not dittlQflmble the assist 2-19 i' HONDA H. DOES NOT HOLD THE ASSIST TILT I Gao anisted type} OK I. POWER TRIM & TILT DOES NOT MOVE !Power 1rim & tilt type} Ooea not aound. volt· NG1 OK optrldon•chtck oo si gle Cheek the tift switc:h for NG OK Check the circuft breaker NG 01(Clleek fOf ahort circuit in NG _..,..., (chod< on eir'ljl9 Chof11o(repiKc•. Replace tho tilt ttlav. circuit a mature and brush. 2-20 HONDA. J. DOES NOT HOLD THE POWER TRIM & TILT (Power trim & tilt tYpe I Opens. lea s. Raplac. the wer rimJtilt. 2-21 HONDA CABLE/HARNESS ROUTING (Remote control/Power trim & till type) 1101 (Ill POMR TILT RE1A Y WIRE !81 REMOTE SOLENOID REMOTE CHOKE SOLENOID 2P CONNECTOR 2-22 (Remote controi/Powe< trim & tit type) (11) STAim!R MAONETlC SW1TCH POWER TilT RnAYWIM 2-23 l8)1miUlA MCllflER GROUND CABlŁ (1) STARTER MAGNŁTIC SWITCH OROUNO NEUTRAL SWITQI HONDA BF3!5A·4!5A 121 POWER TRIM. CAIILE WIRE HARNESS (Remote control/Power trim & tilt type) 117]I'ULSER COiL 4PCONNECTOR 13ei iii!GULATOR/ [1351..ECT1FIER(341POWE.. TILT RELAY( 1331 POWBI TILT SWITCH ( 1321 COt UNIT [!311 STARTER MAGNETIC SWITCH t (301TAIM CONTROL UNIT (1281POWl. TILT SWITCHt 1281MGULATOII/RECTIFIER t 127] T1llM CONT1101.. UNIT ( HONDA (41 CHAAGIHG131COl UNIT J1191 CHA..OING COIL ]120)CONT..OL CABLE ){211 THERMO SWITCH 161PULSER COIL l 12.21 OIL I'MSSUI'IE SWITCH J 1231GROUND CABLE }1241CONT..OL CABLE )(25) BATTERY CABL Y ] 1261CONT'AOt. CABLE 2-24 HONDA (Remote control/Power trim & tilt type) IBJ TO PULSER 171 TO CABLE 111 TO EXCrTŁ11 COIL 1191 CONNECTOR BRACKET A 1181 TO CONT"RDL CAIII.E 1111 CONTROl CABLE 116) 8ATTEIIY CAlli.Ł 121 TO CONT!IOI. IIIAC1tŁT A 131 COl UNIT 191 CDI UNIT 1121 TO 1GN1T10N COIL NO. 3 1131 TO PULSER COIL 2-25 HONDA BF315A•415A (Remote control/Gas assisted type) (301 TO PULSER COIL 2-26 (111 REGULATOR/ [REcnFIER r (101 CDI UNIT l (91 STARTER MAONEnC SWITCH : :;..:.: ...,.. -11•.":":::::-- 181 REGUUTOII/C ) I11 CHARGING COIL ] 12) CONTIIOL CABU ) (31 THERMO SWITCH l l41 OIL PfiESSURE SWITCH l !51 GROUND CABLE ) (51 CHARGING COIL ; m 8ATTERY CABLE (18) UNfT CASE (21) TO ICMT10N CDIL NO. 3 TO PIJI.SEJI COl. (.231 BATTERY CABLE HONDA (Remote control/Power trim & tilt type) (1) TRIM CONTROL UNIT/ POWER TILT RELAY GROUND CABLE (Power trim & tit type) (21 POWfR TRIM 8t lll MOTOR (1) TRIM CONTROL UNIT TRIM ANGLE SENSOR 2-27 (Tiller handle type) 111 REGUlATORIIIECTIFPWIRE (1 11 Ctlt UNIT WIRECONfoiECTORS (10) INDICATOR WIRE 181 ST AliTER SWITCH WIRE (23) REOUI.A TORI l' RECTIF1ŁR (221 CDI UNIT [ !21) STARTER MAONET1C SWITCH r (20) REGULATORI r RECTIFIER 4P CONNECTOR ..o;r----c:<::)---Cr­ ..---cc:::J---0. -G·.· ..-t HONDA. IGNITION COIL 2 IGNITION Ctl!L 3 )!121 CHAAOING COIL J (131 STARTER SWITCHl 1141 1NDICATOR LAMP ::;-·:.:.=::::>Cc:::J=•l>--•-;(161 Oil PIIE&SURE SWITCH ==....-Jl1n GROUND CABLŁ t:::l ...ow..t.."'-J(18J STARTERSWITCH J f191 8A TTEAY CABU 2-28 HONDA BF:ii5A·415A ITiller handle type) 181 191 TO P\JLSER con. TO INDICA TOR LAMP 111 TO EXCITER COIL/Tr 1211 CONNECTOR 1111 eltŁT A 1201 TO INDICATOR LAMP 1181 INDICATOR LAMP -E 131COt UNIT 141 TO EMERGENCY STOP SWITCH 171 CDI UNIT CASE [101 1111PULUR COIL WIAŁ 1121 GROUND C 8LE 1141 TO IGNITION COIL NO. 3 BATTERY C BLE EMERGUICY STOP SWITCH 2-29 HONDA (TJier handle type) [7) [51 THROTTlE CA8LE [6) STARTER SWITCH [1) EMERGENCY STOP SWITCH WIRE [4( EMERGENCY STOP SWITCH WIRE THROTTLE CA8LE 131 EMERGENCY[4) EMERGENCY STOP STOPSWTTCH SWITCH WIRE 2-30 (Remote conuol tYpel (II INDICATOR (81 THROTTLE 171 SWITCH 181 EMERGEN Y STOP SWITCH COMBINAnON 141 WARMN lPow• trim lr S ITCH BUZZ!R tilttyp• only) .... : .. •• (71 151 REMOTE COfiTROL BUB COM81NAT10N S ITCH 151 REMOTE CONTROL CA81.E B •2: •1: Powtr trkn/tllt $witch wire 1outing wlth remote control levwr !UU e.s shown by A. "'2: Power trtm/titt switch wire routlf'lg wtth temote control lever let •• shOwn by 8. 2-31 HONDA BF315A•415A 121 eontrol type only) (31 SOUHOIO WARNING BUZZER 121 POWŁR TIIIM • TILT SWITc.t (Remote control type only) II HONDA TUBE ROUTING ,., 3.6 x 46 mm FUEL T\JBE 13, IBFC5A onlyl 131 INSTALL PIPE IBF45A onlyl l&l 5.3 x 170 mm FUEL TUBE 3.6 x 60 mm FUEl T E (8f45A onlyl (191 5.3. es mm RJŁ1. TUllE FllTBI 1181 011. 2-32 LUBRICATION Wipetile outskt• of the enwine with • cloth dipped In oiL ..Y' marine anticorrosion graa.u to the folktwing pam: 2-33 HONDA. 2-34 IHier handle type only) 2-35 HONDA. BF31SA •41SA HONDA MAINTENANCE SCHEDULE SERVICE PEAIOO (21at ev.tY lndiclted FIRST MONTH EVERY EVERY YEAfl EVERY r. ope,r•dng l'lol.lr iftw. EACH USE OA tMONTHS OA 2 YlAAS Rtf• to p..ge wli::I4'"'Cfcon'tH fn.t. 20HRS OR100HRS 200HRS 3-2 Check tor war« 3-< Ef'll!liiiiW oil fiUJ Idling 11·2 0 0 3-7 6·l20 Cablecon-Oood<-0 0 NOTE. (1)Lubricate mM& fr..ncy when ua&d in aolt wtttf. (2) For profeuional commereiat us•, log hou11 of operation to determine proper maintenance intervals. 2-36 HONDA. MAINTENANCE ENGINE OIL .................................. 3·2 OIL FILTER .................. ................. 3-3 GEAR OIL .................................... 3-4 SPARK PLUGS ••.......•.....••.....•......• 3-4 VALVE CLEARANCE ..••......•....•...... 3-5 FUEL STRAINER ..••......•......•....•.... 3-7 FUEl TANK STRAINER ................... 3-B CARBURETOR .............................. 3-8 CARBURETOR SYNCHRONIZATION ..••••••.•..•..•.•..• 3-9 ACCELERATION DEVICE/ DIAPHRAGM ADJUSTMENT ....•....• 3-10 THROTTLE ADJUSTMENT (REMOTE CONTROL TYPE) ............. 3·11 THROTTLE ADJUSTMENT (TILLER HANDLE TYPE) .................. 3-12 SHIFT ROO ADJUSTMENT ......•...... 3-14 CHOKE KNOB ROO ADJUSTMENT •..•......•..••....••..••••.. 3-15 REMOTE CHOKE SOLENOID ADJUSTMENT !REMOTE CONTROL TYPE! ....••••.•.•. 3-15 TIMING BELT ............................... 3-16 POWER TILT OIL !POWER TRIM &. TILT TYPE! ••...••.... 3-19 I 3-1 ENGINE OIL a. INSPECTION Used motor oil mey cauH lkln oaneer 11repntedty left in contact wtth the akin for prolonged perlodt. Atthough ttU t. unlkely W"'a... you handle used oil on a cWty bMis. It It: stll advisabM to thoroughty wash your hends with .aap end water u eoon as poeeible afterhoncllng used oil. Place the shop towel undeJ the oil fitter wMn removltlg the oi! filter. 1) Remove the engine eover &nO oil level ga.JQ.e. 2) ln$trt tM oil &evet gauge into the oil tiUer neck. 31 Cllec::k the oil level shown on the oit level gauge; If ne1r or below the lower level matk, flU to the U;p r level merk with the recommended oil. Engine oil capaelty 2.0 t (2.11 us qt, 1. 76 Imp qt) Rec()ml"((!tnded engine oil SAE1OW·30/40 engine oil or equivalent. API Service classffica· tlough the drai·n plug bolt hole until it starts flow· ing out through theoil check bolt hole. RciMtaUand tighten the &il c-heek bolt and drttin plug bolt securety. G..ar oil capacitY 0.52l (0.550us qt, 0.468 Imp Qt.l Recommended geat oil SAE#90 Hypoid ge-ar onorequivalent, AP1 Service Classification IGL-4 orGL-!) rf the water i$ mht•d in the oit. check the gasket and water sea' fOf damage and check t.he gsat e•stl for tightening. SPARK PLUGS 1) R movetheengine cover and spark plug caps. 2) CJean any dirt from around the $park plug beses. 3) Uteasparkplug wrench to r•n•ove tht 1-sMrk plugs. 4i Via.u.elly inspect the sp.erit plug. Discard the plugs if the in· su1etors arecracked or ctlipped. 51 Aemovecubon orother depo.sita withastiff wire bi'U$h. 61 Measure the plug gap withawlre-wpefeelergauge. 7) Make $ure thesealing washet' isir\ gOod condition. 8) Install the plug fingertight to seat the washer, the-n tighten withaplug wr nch tan atkJitlonal 1/2 turn Ifanewplugl to compreu the seating wa.sller. tf you are reusing a plug, tighten l/8-114 tum etterth.e plug seats. ty ti9hten.d p4ug c.n become very hot and POSSlbJy dam.ge the engine-• 3-4 HONDA IIF315A ·45A (1I OIL CHECK B LT DIIAIN PLUG BOLT (1 I IWARK Pt.UG WRENCH 0.6-0.7mm (0.0 4-0.0281nl VALVE CLEARANCE Vatvectewenoe Inspection and t;diu$tment mu:tt be performed wnh the engine cokt. 1t Remove tho engine cover. 21 Move t'M shift .. ver to "N" position. 31 Remove tht four 8 X 25 mrn ftltlge bOllS tnd thrt• 8 mm plein w&...httt from tile flyw'heel cover. 4t Rtmovt the flywheel covt1. 3-5 HONDA. 51 Remove tht seven e • 35 mm hnge botu ond ey!W'Idor head cover. 6) Attach the special tool to the pulsar rotOf u shown. and altgn the "T'" mar1t on the pulser rotor with the "Tt" mark on the cylinder held. So sure that the "T" mark on tM nvwhoeel aligns wfttl the ..,... mark on the tngioe hanger mountlnQ boas this time fwhich tndic::t1es tl\tt me No. 1 p.iston Ia M tho top dead ..tet of its corroresaion atrokel. With the No. 1 piston at tMt09 dead cent.,. of thecompression atroke. measure the int•ke and eJChavst v•tw C:itlrtncu. TOOL: se mm Lodenut WNftCh 07U'A-ZII30200 7 J Loo.en the valve ad'IUI'ting screw ioc:lt nut and tum the lld­juating screw to obtain the specified int•k• end exhaust valve cJurance. 8) Hold the adju:Jt!ng t rew. and Ughtefl the lock nut. 8) Recheck valve clearence after tightening the lock nut. TORQUE: 23 N., (2.3 18.8 ft4bl HONDA 1Ol Af1., tdjuating the intakeand •.Mutt vetv. CINr"anOCS ot the No. 1 eyt;nder. turn the putser 120° further andaJi;gnth8 "2•..·niart wtth the "'Tf"' ..'*on the cylinder head (wh..h lndle-ates that the No. 2 piston ;. at the t p dconttr of rts com"reulon stro«e). th•n adju t t.he intake tnd tJChlust valve cklarances. RntUv. tun'l the pul.ser o or 120° further end ttngn e ..3... mark wi h the "Tt" mark on tt\e cylinOe.-head twhlc.:h lndieates that the No. 3 pi ton lt at the top dead center ofcompre.ssion stroktl. then ldjutt the 1nteltolnod. TlVa • the 111ndetd earbu"etor.Perform tM aame adiustment on the No. 1 ll'd No. 2 etrburetOI"'. 3-8 {1)fUEL JOINT HONDA. CARBURETOR SYNCHRONIZATION Start the engine and allow it to warm up to normal operating temperatuffl. 11Place th& outbOard motOf oo 3 lev.. $urfacc and move the shJft lever to "N" position. 2J Remove tht three 5 x 10 mm plugs from the lnuke pott of each cylinder. 3) Attach the vacuum gauge ..pten.. to each plug holes. Connect the vacuum gauge tubes to the adapters. Connect the vacuum gauge No. 1 tube to the No. 1 carburetor adaptor. vacuum gauge No. 2 ttlbB to the No. 2 earturetor adaptor, and the No. 3 tube to the No. 3 c8fbvfetor adeptor ptopel1y. 07404-0030001 4•Stan th& engine 3nd check the standa1d idle speed lp.ege 3-8).51 Chec:l( tNt the vacuum gap between the cylinders is 20 mmHg or below. Vacuum gap 61 If the v•cuum gap is more than 20 tnmHg, adju:st H fo&lowt. 3-9 HONDA BF35A·415A VACUUM G UGE 07404-0030001 1 ADAPTER ADAPTER HONDA. 71 Wtth th voteuum 01 the No. 3 carburetor being the St.1nd9fd, turn the No. t and ... 2 cart>urttor adjusting screws so thal the vacuum gap between th No. 1 an No. 2 carburetors Is 20 mmHg or below. Sn&Pthe e-ngine several tfmcs <1M be suro thatthe va oum ofth• No. 1 and No.2 carburetors is the$&me 8S that ofthe No. 3 carburetor. 111 THROTTLE STOP SCREW 8) Remove the special tool from thoe intake manffo' and install the 5 x 10 mm pfugs. 9) Aft r &djustment. readju$t the tdlll'\g $pee If the clearance is more than t mm (0.04 in}, readjust bv turning the linkage pivot. Remote control cab .. *gth adjustment: RemOte control cable length adjustment MUĄ"1 be performed after adjustfng me throttle rod. 1) Mov• the remote control s-.hJft lever to the "N.' J)O$itlon. 3-11 !11THROTTLE ARM HONDA. 121 THROTTLE CAM REMOTE CONTROL BOX 2) Cheek tt\lt the two reference matk& oo thi ttvonle cam f2l REFERENCE align with the centEtt o1 the roller. If they do not align, adjust ea follows. HONDA ISF315A·4SA 31 Remove the 6 mm toclt pin end 6 mm plain waeMrs from ttlt eh.ift pivot, ancJ O.taoll the shift pivot from the thrott5e trm, 4t L.oosen the shift pivot lock nut and adjust by tuming the Jhift pivot. After adjustme t. tighten the lock nut a d anach the shiftpivot to the thtottt. -.rm. 5) AMnOVe the remote comrol housing 8 11nd C tP. 14-41. 81 Move the •emote control atllftlever to the fUll openposition 1nd be sure that the linkarm tolnt i.. in contact with the 5 x 16 mm hex. bolt. If it is not. tighten tl'lt 5 )I 16 mm hex. bott until It contacts me link arm ioint. THROTTLŁ ADJUSTMENT (TILLER HANDLE TYPE) Thrott .. ctb.. ad]ut1rnent: 1) Move the throttle grip to the full open poaltkwl and be sura that the throttle arm eonttc:u the stopper of the throttle e;ebR brecket. 2) Itthe ttvonle arm doU no1 contact the atoppet. toosen the cable lock nut end tdfuat by turning th• ..fiutting 3-12 8 "'"' .... ThrottlerOd tength edjuttment: The throttle rod length adjustment mvst be performed after ad­justing the thronle ctb'e. 1 I Mev& the shih lever to the ''F" position. 2) Turn the thronle grip to tM fuU-open pos.ftion, an.d confirm that the thronie arm contacts the fuU•OI>tn position stopper of the throttfe cable bfacket. (P. 3-121 HONDA. liiF315A •4!1A 31 8e ture that the catburetor throttle lever contacts the full open position ttOQper on the carburetor side. 4) If thecarburetor throttle .... don notconta<:1tne ttOPI>tr, loosen the tock nut and adjust the thronle rod length by turning the llnkao-pivot. After ..jultment, tighten the lock nut secuteJy. 5) Chtck that the throttle lever moves the entire tenge from the fully open position to the fully closed posiUon without binding. Then, move the carburetor throttltt lever to the full9 ol)fn poaition and be sure that there is cklerance of 1 mm (0.04 in) or less between the throtde lever and the full open poaition stopper. 8) If the dNranoe ts more than 1 mm (0.04 In), readJust by tumi"9 th-e linkage pjvot. 7) Tum the thtottle grip to the fuUy ciOMd position and align tile .,..,•• mark on the ttMrlng handle with the throttl..t mark id.. posltJon. 8e sure that the two teferenct marks on the thtottle cam align wfth the C.ntlf of the roller. If they do not align, looMn the Jock nut on the elostd pos.. tlon si'f the a"ist $pt1ng lfl !Smm with the groove in the throttle eem. NUT 2• Stt the pr..Ktion of the assist pl•te on the nook of the nstst soring and align the flat •urfac. ot the: thronle cern with the "A" point of the as.5ist sprino. Then. eaa.em.Mt whh the colLar and tighten the ..... lnst.,l the d1ro«te rod wfttl the linkage pivot facing t.ht thronle cem. HONDA CHOKE KNOB ROD a. DISASSEMBlY/REASSEMBlY 1) Remove the engine cover IP. 4-2) end 1ilencer OO'\Itr IP. 5·2). 2) Disconnect the tlvott.. rod from tl\ronle erm. 3• Of•connect d'le r11m011 choke solenoid 2P coml&ctor (Remote conuol type onlyt, • 16 mm C:OU.AR (17) 6 mm PLAIN WASHER 121 (131 8 a 12 mm SH FU''""' IOLT (Remote control ._only) CHOKE SOLENOID BODY STAY IA.emott oontrol type My) HONDA • CHOKE KNOB ROD DtSASSEMBL V/REASSEMBL V: 1) Pull the chok.. knob. then push it whl'e hokfing the choke knob rod. Pull up the choke knob rod and discon..ct it from the choke knob and choke arm A. 2) To reinstall me choke knob rod, set it on the choke arm A, puSh the choke knob, and connect the choke knob rod to the choke knob. Pull the choke knob as tun as it goes. • CHOKE ROD DISASSEMBLV: Hold the choke roct and push down the linkaoe bllShing to remove it from the rod. AEASSEMBL V: 11 Connect the chOke rod to the C4tburetor choke, thin con· nect It to the choke ann. Be aurc that the choke rod Is connected H shown. 2) Push the linkage bushing up and set the linkage bushing onthe chotoMn the 8 x 12mm SH flange bOh IAemote comrot type only), 5) S*ide the remote choke solenoid rearwtrd, detach the rod ioint from the plunger rod. and remove the rod from the ehoke trm B (Remote contrOl type ontvt. EH OitOOMeC't the breather tube. OiseoMeC1 tho fu•l rube C ltOd 6.3 x GS mm fuel tube. Removt the 6 .. 2S mmflange bolt, five G x S2 mrn flange bolU end the two 6 mm cap nut&. Re-move tht carburetor a..bly hom the engine, 131 CAABUFIETOR ASSEMBLY l11 1NTAilE MAMfOI.D 121 BRŁA ntEFI PACKING TUBE 6x !51 AJEL TUBE CLAMP (111 FUEL TUBE C FUEL HONDA BF35A·4!5A b. DISASSEMBL Y/REASSEI"'ILY • FUEL UNE 1) Remove the cal1>ur•t0f assembly (p. 5·31. Parts mer1ted with "• 1:" cen be disassembled anCI ff'!&s...mbtt.td with the cttrburetor mounted on th.e ifame. •1: 3.5. 155 •1: 115) RJEL TUBE 114) 6.3 X FUEL 1•1 ..\ 3 WAY .JOINT·---­ PIPE •1; (10( DASHPOT CHECK VALVE INSTALLATION: P. 15-5 3.5 x 45 mm FUEL TUBE 131 IB.. 181 5.3x 170 mm FUEL TUBE •1: (9) FUEL TUBE 0 IBF36A: 3.6 x 70 mm FUEL TUBE! 5-4 • DASHPOT CHECK VALVE/FUEl TUBE ClAMP A INSTAllATION BF45A. lnstaft the das,p01 check valve so that ·..·· m1rk is toward tile eorbutttor tide. Clamp tho lutl tubes with the fuel tube cl•mp A 01 thown. BF35A: !t'ltt•lt the dathpot check valve so that "c:>" mlrk it tOwlrd the engine under cover side. Clamp tho futl tubes with the fuel tube c:ltmp A IIJ lihc>w11. 5-5 FUELTUBE CLAMP A (1) FUEL TU8E D HONDA. BF315A ·415A 121 CAMUAETDA"t-' (8) """" MARK 141 J.s • eo ...., FUEL TUBE 111 (51 DASHPOT CHECK VALVE 3.6 X 70 mm FUEl 121 CHf.CKVALVE HONDA • THROTTlE CAM/CHOKE ARM • The throttle camJchoek lrtn Cbn be dis.atsembiOd end tNIMmbltd with the carburetol MOul'lted of"l the frtmt!. 1• Remove tl'\e engine cover I.P. ..2). 12 N•m 11.2 1<0----------161 THROTT1.E Of'INEII CAM OPENER CAM COI.LAR • THROTTLE CAM REASSEMBLY: 1• Align the ··A·· potnt of ttl• f&Sist s.prlng whh the groove ln the thronle eam. 2) Set the projection of the assist plate on the hook of theauist spring and elign the ftat surface of the throttle cam wtth 1he "B" point of 1he -•• l'lot•·n..n.1he-lnd ttglt-1he belt. 5-6 ASSIST PLATE Ill HOOK 151 THROTTLE CAM fiŁTURH 8PIIING 171 6.7 & 12.5 x 24 mmCOLLAR HONDA • MANIFOLD 1 t RemOve tN carburetor ..Y tP. 5-3}. 16mm BOLT 121 (3} 8 x 16 mm MOLLER 161 (B) I TAKE MANIFOLO )191 A OOE M AL 1101 6 • 1B mm SCREW place. If ex:c&ssively deteriorated. Remove the throttiO liM rod with care not to btnd 115)SIL!'NCioR PLATE HONDA • CARBURETOR GASK T..NSULATOR REASSEMBLY' Note the installation direction. 11 WTAKE MANIFOt.O (1) CARBURETOR GASKET 121 [31 &x 16mm ROI.LER 121 141 CARBURETOR INSULATOR • THROTTLE UNK ROD REASSEMBLY: lntrtttll t.. throttle llnk u>cf withth• "UP" mark at the cemer of the rod facing up. 5-8 • CARBURETOR Remove me df-'n screw and drain the Clltburetor beforedlu... mbllnQ. Gltolnt 5I exttemefy flammable and ta uplotlve undercert-.ln condtdona. Do not smoke or allow f"me' Of epa"'• In the area. 1• Remove the manifold IP. 5-7t. 1131 CAft8UIIETOR BODY •1.2 (121 CARIIURE TORIIODY #3 ChKk 101 worn velve or weak spring befor. m.tenation. 191-1 FLOAT \lALilE 191-2F OAT Chotek for emooth movement after installadon. e. INSPECTION • FLOAT LE.VEL HEIGHT Whh 1he ea,butttOt in an upright potltlon, meaautt the distance between the fiOrat op 3nct th.e eatburetor body whent.,.. flo.-t just conttctl the float valve. StW..d '""'' ""9rt If the hight 1• out of lpecification. replace the floet. Cheek the ftoet ooeratkln. 5-9 HONDA ln.suecc for wear or dilmage before lntttU.. ton. with compressed 181 DRAIN SCREW 171 Instill SO that the dJtm ICIIW tacH to the pilot t:ctew akle. HONDA FUEL PUMP /FUEL STRAINER a. OISASSEMBL Y /REASSEMBLY 1) Remove the engine eover. (1 ) 5.3 x 65 mm (2) FUEL TUBE C FU TUB 3) FUEL TUBE 8 1111 TUBE CUP 810131 Not the in t•llatK.n direction. (10)·1 UP 171 FUEL STRAINER RETAINER 5-10 is the fuel pump rwi1h the hole FUEL ... Pt)MPSIDE 121 ARROW MARK [41 FUEL STllAINER HONDA. [5[ STRAINER RETAINER • FUEL STRAINER INSTAU.ATION: Install the fuel strainer so that "˘:'" mark side and align the proJeCtion on the fuel str$1 in the retainer secor e-ly. 5-1 1 FUEL TUBE a. DISASSEMBLY/REASSEMBLY Before installing thefueltubes, check for deterk>ultion or damage. Replace if necessary. 1) Remove the starter motor (P. 16-71. 21 Aernovetht'! elecuic parts {P. 16-121. 111 TUBE CLf> 812 5-12 (2) TUBE CUP HONDA BF315A·4!1A ECTORA (4) FVŁ1. 8 lSI 6 mm COLLAR FUEL TANK (MODEL WITH FUEL TANK) a. DISASSEMBLY/REASSEMBLY 112! INLET VALVE 110! FUEL REASSEMBLY: Cheek for cracks and deterioration. Replace 1f neceaaary. 113! PRIMER • INLET/OUTLET VALVE INSTALLATION Install with care not to interchange theinlet valve with the outlet valvl!l. lnstaU the primary valve so that .._.,mart< is on the t-ngine side. 5-13 HONDA. {5) OunET VALVE TUBE CUP BAND 20 mm 12) 25 I (6.6 US gol, 5.5 Imp goll REASSEMBLY: Clean the tank of djn Of dust accumulation and assemble. (1) 1NLET VALVE 16! FUEL TANK SlOE (5) PRIMARY VALVE 14) .....MARK (3) ENGINE SIDE HONDA FL YWHEEUTIMING BELT FLYWHEEL .............................. 6-2 TIMING BELT ........................... 6-3 I 6-1 HONDA FLYWHEEL a. DISASSEMBlY/REASSEMBLY 1• Remove the engine cover 4nd the COl unit cover, and disconnect the chargtng coil wires and tile exdter coil connector. FLYWHEEL COVER 112] UNDER CASE GROMMETC41 [1 11 COLlAR 141 CDC UNIT COVER • FLYWHEEL REMOVAL/INSTALLATION Do not hit the flywheel with a h.ammer. Remove/install me flywhHI usin9 the sp•cial tool. TOOL' Ring gUr holder 07LPB-ZV30100 6-2 TIMING BELT/PULLEY a. DISASSEMBL YIREASSEMBL Y 1) Remove the flywheel (P. 6.-2:) and dlsconnect the putse-r coli conneetor. (1) TMINO BaT TENSIONER CAP 1 0N·m11 3.0 k.g·m. 94.0ft·lb1 (12) TIMING BELT A JUSTING SPRING 1111 1101 PULSER COil CONNECTOR 6-3 131 HONDA BF3SA·415A Che<:k tl\at the: belt is not wom or er&Ckel TOOl: 56 mm k>ck nut wrench 07lPA-ZV30200 2) tnstal tnt dmlng belt gu1de *te, 25 • 14mm woodruff key, 1ndthe dmJng p.ufley on thecrankahl'h (p.tQt 6-3). 3) Att•chtheapec..l tool to the pulser rotor, ltld .t.nthe "T"'' mark on thepulse. rotor withte-"Tt" n'\flrlc on the cylinder hcod by tuming the pulser rotor counterclockwise linthenortNI rotatingdirectk>n ofthe c•mlhett), • Do n trotate the pWMr rotor cklck•tte •.4) AligntM ··e·• rnwkon thetinW'tg pull@vwilntM "I" m.nt.., ..., __ _5) Move the..belt tensioner to m. position of s.ladtenlngct. t.l\ •nd install the bett on the tim•ng pulley aide first. then in1t1ll on lho polser rotor. 6• Arter instilling the timing beh.. ctltcl< etch mark for proper alignment. ln•u•lt th• timing belt guide plate .:.nd 48 mm tock nut on the crankahlft.Note the lnstalletlon directionof the llmlogbGtt 7) Titghttn the 48 mm lodr:: l'liJtusing the ped-' tool with e.re nottomove tnemarb out of af.gnment. TOAQUŁ: 130 N•m 113.0 .. 94.0ft-lbl TOOLS: 156 mm loclr nut WfWldl fling""' holdor 07lPA-ZV30200 07lP8-ZV30100 81 A her tlght'tning thelock nut, a d:jut. t the tlmlno bth tentlon (page3·161. 6-5 HONDA HONDA ENGINE REMOVAL/ INSTALLATION REMOVAL ................................ 7-2 INSTALLATION ......................... 7-7 I 7-1 HONDA REMOVAL 1) Sel tl-.e adiu..ulng rod in Ule second hole from the rear of the stem bracket as shown. 2) Movo the shift .ver to the "N" position, ..oosen the loci< n.vt end &dj '-'sting nvt eonl'lecting the shift rod A and B.and dis· conn&et the shift rods. 3) Remove the four 8 x 25 mm hex. bOtt$ and the left/right lower mount housings, end dtJc.ot.neet the ground cable from the left side of the extension case assembly. 4) Remove the two 12 x 162 mm hex. botu a.nd the left/right lower mount rubbers 6) Remove the 5 x 30 mm/5 x 45 mm screws. six screw riv et$ and th6 undtlf cover. 6) Remove thtl tef'l 8 x35 mrnhex. bolt$ and the extension case assembly. 7} Remove the oil pan (P. 12·2). 131 5 x 7 x 39 mm 121 S mm PLAIN WASHI:R (2) AI1 9-3 HONDA. 10JI85mm 84.6-86.6 mm 13.33-3.37 ... HONDA. OIL PUMP 1) Re-move the cvtinder head assembly (P. 9-2). After assembling tM oi1 pump ond before installing it on the cylinder head, pour apprO..;imetely 5 e-c (0.3 cu int of oll 1nto the oi.t ..mp body. 141 58 x 25 mm PUMP COVER D-RING D-RING !21 OIL PUMP COVER Do n forget to install. A.pply I<)Ck tJg..nt. 13 N•m (1.3kg-m, 9.4 it·lbl 191 14mmSEAUNG WA HER REUEF VALIll; SPRING 1111 AB.IEF VA VE 9-4 DISASSEMBLY /REASSEMBLY 1) Remove the cylinder head assembly CP.S..2L 126) OIL SŁAL (30x42l( (Apply greeN bet_..n theHps.J 9-5 Oo not contuse with the intake valv . VALVE HEAD DIAMETBI: 141 VALVE ADJUSTING SCREW (6) 12 N•m C1.2 ko·m, 8. 7 ft-lbl 11 11 CAMSHAfT HOLDER No. 3 REASSEM81.Y: P. 9·6 INSPEC ION: P. 9·9 • VALVE COTTER DISASSEMBLY/ EASSEMBLY: Use the speclat tool to compress the spring and install the con era. Make sure the coners seat in the groove properly. TOOL: V•lve spring Con'lpfUSOf 07757-0010000 • FUEL PUMP LIFTER REASSEMBLY: lnstaU the futf puml) lifter from lnslde of the cyRnder head. Do not forget to install. • ROCKER ARM SHAFT REASSEMBLY: Take cate not to int•rehenge the exhaust side rocker arm shaft with that of the mtah side. mstall the rocker arm shaft that h.as th& hole in It onthe e)(l\aust aide and the rocker arm shaft with the cutout init on the intake si<'e. • CAM HOLDER. No. 2/No. 3 REASSEMBLY: Install with the number of cam holdtf facing the puber rotor side. FUEL PUMP LIF'reR 111 PULSER ROTOR SIDE HONDA BF315A ·4BA 131 HOLE HOLDER 9-6 • ROCKER ARM/ROCKER ARM SPRING/ROCKER ARM COLLAR IIEAS2MBLY: Note tile lns1.tlllt..n dk"eetlon as shown. • 6 x 70 mm/6 x 35 mm FLANGE BOLT RE.USEMBLY: Tighten the IIDht 6 w 70 mm.ttwo 6 x 35 mm flan;e boltl to the sptclfltd torq..o tn the numbered seql10nce thown in the drawing. 9-7 HONDA 151 EX HONDA BF315A·415A INSPECTION • VALVE SPRING FREE LENGTH Measurtthefree length of the valve springs. • VALVE STEM O.D. Inspect oaeh v-alve for feceirregularitie , ending or abno mal $ttm wear. Replace the valve if necu$br . Measure and rtcord each valvestem 0.0. 5.45 mm .0.2\ 5 in) IN 5.42 mm ..0.213 in) EX • VALVE GUIDE I.D. Meas re andrecord each valve guide 1.0. • GUIDE-TO-STEM CLEARANCE Subtract each valve stem 0.0. fTom'!he corres onding guide clearance. IN 0.06rnm 10.0024 inJ 0.1 o mm 1_0.00 in) 0.07 mm (0.003 in• • VALVESEATWIOTH Measur the vaJ e seat width. 2.0 mm !0.0 in) 13.96 mm (0.649 1n) HONDA. • ROCKER ARM SHAFT 0.0. Measure the 0.0. of the ro er erm $haft. • ROCKER ARM 1.0. Mea&Ure the 1.0. of the rocker arm. 14.05 mm «0.553 int Also check the rocker arm . ipper surface for any we r or scraches. • ROCKER ARM SHAFT·TO·ROCKER ARM CLEARANCE HONDA. • CAM HEIGHT Measure tt\8 cam heigh\. IN EX 34.708 mm (1 .3865 in) 34.163 mm 11.3682 lnl • CAMSHAFT JOURNAL 0.0. Me4sure the camsMft 0.0. 22.93 mm {0.9 3 in) • CAMSHAFT RUNOUT • CAMSHAFT AXIAL CLEARANCE Measure the camshaft axial runout before removing the cvli.nder 1\ead f om the cvtinder block. Loosen the valve adjusting IO(;k nuts and back off the valve adjusting screws before inspect on. 0.3 mm 10.012 in) Install the new camshaft and recheck the axial clearance. If it exceeds the service limit, teplace the cylinder head. 9-10 • CAMSHAFT OIL CLEARANCE l) .t pl&$tlgauge axialty on each camshaM journal. 2) tn5tall the ettmshafe holders, No. 1, 2, 3 and4,and each 8 x 14 mm dowel pins. 3) Tighten the 6 x 70 mm flenge bolts and 6 x 35 mm flange bolts to the specified torque. TORQUf: 6 x 70 mm !Iango boha 14N·m t1.4kg-m. 10.1 fHbl 6 x 36 mm flenp boiU 12 Nom {1.2 kg-m. 8. 7 fl-lbl o not rotate the e:twmwhi..tight.nngbofts.ltght.., in· ner botts fif$C. then outer side wfth the same torque value. 4} Remove the camshaft holOer No. 1, 2, 3 and 4, and check the width of each plastigauge u..ing a scale. Me.sure the width 8\ it$ wlde$t point. 0.08 mm (0.003 in} 61 Install a new cam$haft &nd mea!lure the oil cteartmce. If \tie oil clearance still axcesdt> the servfctt limit, reolace the cylinder head. • CYLINDER HEAD Remove carbon dtpo$ltS from thecombustion chamber. Cltan off env ..skat materiel from the cytinder head surface. Check the spark p.. holes end veNe 1reas for cr&eks. Check the cylinder head for warp ge with •straight edge and a feeler gauge. 9-11 111 PLASTIGAUGE HONDA. BF315A·4SA 6x35121 HONDA. • PUMP BODY I.D. 50.20 mm t1 .976 inl • INNER ROTOR· TO·OUTER ROTOR CI.EARANCE 111 0.20 mm f0.0079 in) • OUTER ROTOR· TO-BODY CLEARANj;E., • OUTER ROTOR HEIGHT SER ICE UMIT 0.26 mm 10.0102 in) 16.93 mm (0.667 in) • PUMP BODY DEPTH 17.09 mm (0.673 in) 9-12 HONDA. BF315A·415A • PUMP END CI.EARANCE 0.1 mm (0.004 in) 9-13 HONDA BF315A·45A VALVE GUIDE REPLACEMENT 1) Chill the rep..ce..nt valve guides in the freezer sectionof a retriQeUJtor fOt about an hour. 2) Drive tile valve guide out of the cotnbiSStfon eh..mber slcje U$lng a valve guide driver fapecial tool). be cw.tu1 not to 3) Remove the new vatve guides from the refrigerator one at a time as needed. 4)ll1$tall the new valve guides from the valve sp,ing .:side of the cylinder head. Drive each valve guide as shown. 61 After Installation.. inspect the valve guide for damage. Raplace the 9Uide H damaged. • VALVE GUIDE REAMING 1) Co81 the reamer and vai"Ve guM;Ie with cutting oiL 2) Rotottt the reamer c..kwit through the valve guide the full length of the reamer. 3) C0t1dnue to rotate th• '"mtr c..wist while removing i't from the vatve guide. 4t Thtoughly clean the cylinder head to remove any cutting re•idu•. 5t Check the vaJve guide bore; it should be straight. round and centered in the vatve guide, insert the valve end check operation. Ifthe valve does not operate smoothly, the guide may have been bent during lnstallat1on. Replace the velve guide ff it is bent or damaged. 61 Check the Valve Guide-to-Stem Clettrence. See page 9-8. ORrvER. 6. 5 m on42-00101 o (11 VALVE GUIDŁ RE MER 07984-2000001 @ @ 0 X 111 COAIIECT (2) INCORRECT 9-14 VALVE SEAT RECONDITIONING 1 • Thoroughly clean the comb\l$tion ch&mbers and valve seats to remove carbon deposits. Apply 3 llgM co.. of Pruul:m Slue coml)<)und or erasable felt-tipped marter ink to the valve faces. 2) ln$en the valves, and then lift them and snap them closed against ..ir &eatsseveral time$. Be sure: the vatve doe$ fi.Ot roune on the seat. The transfered marking compound will show any area of the $t8t that I$ not concentric. 3) Us.lng a 45° cuner, remove enough material to produce a smooth and concenttic seat. Turn the cutter clockwise. never oounterefOckwl:se. Continue to turn the cutter as you lift it from the valve seat. 41 Use the 30°-32° end 60° cutters to nerrow end .Ojust the valve seat so that n contacts the mfddle of the volvo tace. The 30°-32° cutter removes materiaJ from the top edge. The 60° cutter rtmoves material lrom thot bonom edge. Be sure that the width of the finished valve seat is within $1)E!.ifie&tion. 9-15 HONDA BF3!5A·415A 111 CUTTER HOU>EII 07781-0010101 121 VALVE SEAT CUTTERS 13! IN: 07780-0014100 937.5 EX: 07780-0014000 030.0 !41 1N: 07780-0012900 4133.0EX: 07780-0012200 30.0 [51 IN: 07780-0010800 ˘33.0 EX: 07780-0010300 o29.o I11CONTA T TOO HIGH 121 CONTACT TOO LOW • VALVE SEAT WIDTH 2.0 mm (0.08 in) !0.049-0.001 int 5) M&ko a light pas$ w1ttl 45° cutter to remove anv P'0$$1ble burt& at the edges of the seat. 6) After rtsuttac·J"g thO seats, inspect for even valve seating. Apply Prussian Blue compound or eraseb.. fett-lipped marker ink to the vafvt faceĄ. lnsttrt the vlllvvs. and then lift them and snap them closed agamst thelf seats several times. Be sure the vaive does not rotate on the seat. The SCjting surface. as shown by the transfered marking com· pound. shou'd 1'\ave good contact all the way 3rouncl. 7) lap tile valves into their seats, usi:ng a hand valve lapper and lapping compound (comme(cially available). J • Check valve cleatal'lce after reassembly. 9-16 HONDA 0.91&-1.25 mm !0.037-0.049 In) HONDA BLO K/CRANKSHAFT/ PIST N CRANKCASE ........................... 10·2 CYLINDER BLOCK/ CRANKSHAFT ......................... 1 0-6 PISTON . .. .. . ... .. . .. . . .. . . . . . ... . . . . . . . . . 1 0-8 INSPECTION ............................ 1 0·9 BEARING SELECTION ............. ... 1 0-13 I 10-1 CRANKCASE a. DISASSEMBLY/REASSEMBLY 1• R4move the engine (P.7-2) 2t Remove the cyfinder head (P.9-2t 111 11.. (1 11 10-2 (91 HONDA 121 . P. 1D-4 Apply locking agent and tighten to the specified torque. Mark the alignment position on the botl.$ and crankcase, then additionally tighten goo•go . T RQUE: 28N•m i2.8 te.g·m, 20.2 ft·lbl. then add.. tionally tighten 90°... REA SEMBLY:• Use care not to damage the bearings.• Make sure the k>cf<.lng lug on each bearing fits In the ooteh in the crank· e.ase. Remove/install the oil fitter using the special 1001. S.fore installation, ooat the O·ring with the engin.e oil and the threaded po11too of the cylmder block with Three Bond #13238 or equiva· lent. 22 mm 181 DIS SSEMBI. Y/ REASSEMBLY: P. 1..3 WRENCH 07HAA-PJ70100 REPl C MENT: P. 3·3 TORQUE: 5.6 ft·lbl 92 N•m (9.2 kg·m, 66.5 ft·lbl b. INSPECTION • 8 x 96 mm FLANGE BOLT Moasuro bolt length. tf not within service limit, replece the bott. • 6005 RADIAL BAll BEARING DISASSEMBLy, Remove the 6005 radial ball bearing using the special tool. TOOL' Bearing remover, 25 mm 07936-ZV10000 RE SSEMBLy, lnsttll the 6005 r•dia.l ball bearing using the sp•ei•l tool.s. TOOL ' H.-da A Anechment. 42 x 47 mm Pilot, 25 mm • CRANKCASE RE SSEMBLy, on4 -001oooo 07746-0010300 07746-0040600 8ef0t'e ln.sulletion. appjy Three Bond #1141C or equivaktntto the position ..own in the drawing. 10-3 HONDA BF3!5A·415A reo. 111 93.5-94.6 mm (3.68-3.72 .. , PILOT, 25 mm on4s0408oo • 8 x 95 mm/6 x 40 mm FLANGE SOL T REASSEMBt. Y: Tighten the eight 8 x 96 mm flange bolts and tM ten 6 x 40 mm flange bolts to the $peclfled torque in the numbeted 58· quence shown In the drawing. After tightening the 8 x 9& mm flange bolts to the specified torq..Je, mark the alignment posi· tion on the botts and crankcase, then tighten the botts addi­ tionaHy 90°""..0• TORQUE: 8 x 95 nvn fl•nge bott 28 N·m 12.8 kg-m, 20.2 ft-lb). then additionally tighttn goo•:o . 6 x 40 mm f"ngt bott 11 N-m (1.1 k..m.S.Oft•ll) • 22 mm LOCK NUT DISA.SSEMBLY/REASSEM81.Y: 1) Hold the crankShaft using the special tool whtn remov· ingiinstalling the 22 mmlock nut. 2) Aemove the 22 mm lock nut by using the foflowing special tools. TOOLS: Lock nut wrench 07916-7600000 R.,9 gear hokfer 07LPB-ZV30100 3) On installation, ntplaee thelook nut with a new one. fns:tell the 22 mm lock nut using the spcei41 tool. TOOl.: Lock nut wr.,..ch 07918-7500000 HONDA 18 B x 95 181 RINO GEAR HOLDŁ11 07LPB-ZV30100 10-4 ., After lnstellation, stake the lock nut by using the dMt inthe crankshaft. • PRIMARY DRIVE GEAR DISASSEMBLY: R•move the prtmewy cklve 9Nl vsfng the 5\7.... ..1•r. 10-5 111 PRIMARY DRIVE GEAR HONDA BF315A·415A HONDA. CYLINDER BLOCK/CRANKSHAFT a. OISASSEMBL Y /REASSEMBLY 1) Remove ths etankcase (p, 10·2). 191OIL SEAL !50 X 70 x 81 ( ppl'f grease between ""'fip•.l REASSEMBLY: P. 171 Molybdenumdisulfide oil Apply oil to the mating surface with the crankAA,th. Do not apply oil to thV rnatin9 surface with the cylinder block. 151 • Make suJe the locking lug on each bearing tits in the notch in the connecting rod and connecting rod cap. 10-6 131 • Use care not to damage th.e beatings.• Make sure the locking lug en •ach be•rlng fits in the notch in the cylinder block. Position the piston "IN" m&rk on t.. intak.e vtttve side and the "f'' mark toward the up skle. • !41·2 INT KE HONDA • CONNECTING ROD CAP REAS$EMIU.Y: lnstall tM connecti"U rodcaps ,..igning the merka of the con­necting rodt •nd eepa. • THRUST BEARING REASSOMIL Y: Install with the grooved ..de toward the cranka.hth. 111 CAANICSHNT 141''t" MARK ROO "ZVS" MARK • PISTON/CONNECTING ROD (21 CONNECTING REASSEMBLY: Assembl• to thtt "t" mark on the piston polntt In tl. ume dlrectkmu "ZV6" matk on the connecting rod. 10-7 PISTON a. DISASSEMBLY/REASSEMBLY . AftOf W\stal6ng ........ end c:onnecrinil ·-in the..block. MCut• 1he rocls to the Ctrishtft. 1101 181 SQ.aet the side raiJ ond o•ps at lem 20 mm 40.8 in• apan. Ill Set on end of the cJi,p Into the groove in the piston tnd wotk tM other tnd •round In the groove uAng a pair of nMde-pfiefs.tnntll to thet the end OIP does not fe.ce thot notch in tht piston. 161-1 CUP 10-8 HONDA. 11 I ARKING rnomng.facing up.• Staggat 1Mring .. gaps 1 0° lpart. INSPECTION Fo' pi.stons, aankshaft. and cylit\der inspection. measure the followtng. If needed, replace them. • PISTON SKIRT 0.0. Mt3$ure and record the piston 0.0. at a. point 10 mm i0.4 in) from the bottom. and 90° to the piston pin bore. • PISTON PIN HOLE 1.0. • PISTON PIN 0.0. 1 7.994-1 8.0 0 mm (0.7084-0.70 6 inl 69.91 0 mm i2. 7524 in) 17.96 mm (0. 707 in) 17.954 mm 10.7068 inl • CONNECTING ROO SMALL END 1.0. 10-9 18.05 mm (0.71 1 in) 10.4 in) ..-, I HONDA HONDA • PISTON RING WIDTH • PISTON RING SIDE CLEARANCE • CYLINDER I.D. TOP SECOND 0.96 mm {0.038 in I 1.160 mm (0.0467 in) TOP SECOND OIL (0.0022-0.0055 inl 0.1 mm 10.004 in) 0.1 mm t0.004 in) 0.16 mm 10.006 inl Me&$ureand record thecylinder 1.0. at thre&14vtls in both X end.Y axis. Take the maximum reading to determine the cylinder wear. 70.06 mm (2. 758 inl • PISTON· TO-CYLINDER CLEARANCE 0.09 mm (0.0035 in• 10-10 HONDA • PISTON RING END GAP TOP SECOND 0.8 mm 10.03 int 0.95 mm (0.037 in) 1.0 mm (0.04 in) • CRANKSHAFT MAIN JOURNAL O.D. • CRANKPIN O.D. 37.976-38.0 mm (1 .4951 -1.4961 in! 39.95 mm (1 .572 int 37.94 mm (1.494 1n) • CONNECTING ROD BIG END OIL CLEARANCE 11 Clean all oil from tile etankpin and connecting tod bearmg surfaces. 2) fltace a piece of plastigauge on the crankpin, install the con· necting od and cap and tighten thP. nvh:. TO QUE: 28 N·m ( .8 kg-m. 20.2 ft-lbl 10-11 0.3 mm 10.012 in) HONDA 3) Remove the connecting rod and meas.ute the plestigauge. 0.08 mm (0.003 in) • CONNECTING ROO BIG END AXIAL CLEARANCE Ma.as:ure the tlterances with 8 fMier gauge. • CRANKSHAFT SIDE CLEARANCE Measure the clearances with a feeler gauge. 0.05-0.3 mm 0.45 mm 10.018 in) (0.0019-0.01 2 in) 10-12 BEARING SELECTION a. MAIN BEARING H Record the crankshaft ..in joumat 0.0. code numbers 101' me.esure the main joumal O.OJ. 2) Record the crankcase 1.0. code .'lUmbers. 3) Cross reference the cas.. and journal codes to determine the replacement bearing eofor code. STANDARD OIL CLEARANCE 0.020-0.038 mm (0.0008-0.001 s inl Ctrieuti.O. &4e M... A o-....,1:.'1 ........ ....... ........ CI•IQ....t!O.O. 4011 ODtb:O.(Oljl 0J)lii3.00Yrl O.Cl4t'.OOO!I Mw ""'"' RED PINK YELL(IW GREEN G.OOiiO.COQll.O Leu hi 0-..... Ya.LOW Gilt EN tiii()WN ...().OXlll ....... Marl!. •C.oo8(•0.0000-YEllOW GFIEEN 9ROWN !!lACK BLACKGREEN BWE-G.Q}C(..O.ooet> REASSEMBLY: Make s.u.-e the focking lug on each ..aring fits in the notch in the be.&ring sadd&e. Becareful not to damage the bearings. 10-13 121 IDEHTIRCATION COl. OR HONDA 111 LOCKING LUG b. CONNECTING ROD BEARING 1) Record the <;tenkpin 0.0. code letters lor measure the crankpin journal 0.0.) 2• Record the conrMtcting rod 1.0. eode letters or measure the1.0. wfth the bearing cap installed without bearing inserts. 3) Crou-refeutnce the erankl)ln and rod codes to determine the replacement bearing color. MttkA ""...... ·O.O:Z*O.«KKIl "'"' ......0.00610.o!XI'I '""*' P>NK YtUOW GREŁN OROYffl vru.ow GIIUN """WN SLACI< ..... ..... ... GRW< BLACK REASSEMBLY: Be careful not to damage the bearings. Mtke wre the l«k.lng lug on each bearh\g fits into the notCh in the connecting rod. 10-14 CONNECTING I.D.COOELETTEAS 121 1 HONDA I!SF315A • 415A 111 LOC1<1NO WG IDENTIRCATION COLOR c. PRIMARY DRIVE GEAR 1) Recor the riSiJht end rw ber of the l)limery drive gear 1.0. number. 2t O tetmine tile primary rive gear J.D. color and select the proper primary dffve geor by refen11\g to the primary drive gear 1.0. number. HONDA. BF315A·4!5A 1 I 11 I PRIMARY ORlVE ClEAR 1.0. 10-15 HONDA PROPELLER/GEAR CASE/ EXTENSION CASE PROPELLER/PROPELLER SHAFT HOLDER ASSEMBLY .................. PROPELLER SHAFT/PROPELLER SHAFT HOLDER ........................ GEAR CASE ASSEMBLY ............. WATER PUMP ........................... VERTICAL SHAFT/BEVEL GEAR ... WATER SCREEN ........................ SHIM SELECTION ...................... SHIM POSITION ........................ EXTENSION CASE/ UNDER COVER .......................... 11-2 11-5 11-9 11-10 11-12 11-16 11-1 7 11-21 11-24 11-1 PROPELLER/PROPELLER SHAFT HOLDER ASSEMBLY a. REMOVAL 1111 PROPŁUŁR SHAFT HOLDER ASSEMBLY REMOVAL: Remove the propeller shaft holckr assembly using the special tool. PROPELLER SHAFT REMOVER 071.PC-ZV30200 191 4.0mm SPRfT PIN (11 REVERSE GEAR SHIM A..o (8) 16 mm CASTLE NUT 17) 17 mm WASHER 11-2 HONDABF3t!SA·415A 121 GEAR CASE REMOVAL: Bend down the claw washer tab end remove the endnut using the soeelal tool. WRENCH 07LPA-ZV30100 b. INSTALLATION 1) lostaU the propeller sh.aft holder as.sembly with the "UP" mark faeing upward. 2) lnstaU tM claw washef and by aUgning it cutout and the tab of with the projection and the !JI'Oove ot tht:t ge.. C8$&. 3) Apply grease to the end nut. Set the gear case end nut in the g1f.8r c.. with the "OFF" mark' or1 tt"' uear case end nut facing out. Tum the end nut counterclockwise when the end nut con­tacts tt\C thrc.dod portfof'l in the gear co.se. then tighten the nut by turning it clockwise by hand. • Tighten the end nut with care not to ruin the thread$. Tighten the nut » full as it goe-.s by hand, then tighten it further to tl'\e specified torque of 70 ·.. N·m (7 ,0 '3.. kg..m, 50.6 •t'·.. ft. lb) u$ing lhtspecial tool. TOOl'End nut wrench 07LPA-ZV30100 11-3 (1) GEAR CASE END ENONliT WRENCH 07lPA-ZV30100 HONDA (1) PROPELLER SHA" HOLDER ASSEMBlY HONDA. BF315A ·415A 4t Checkto seewhether the claw wa&her tab and the eoeclal tools to the gear case s1Cfe end drive out the needle bearing. INSTALLATION: Drive in the needle bearing from tha propeller aide uaing the $1)CCI-..(·0.0121--Q.lOt-0.0)1;)-A 0.36t3 {0.0141 ·-0.05(11(l021 -0..1010..- • t0.0241 • How to reed ahlm eektction table 0..15f).OOII -OlS 10.0101 -331)1101% - o.2SIU1 1 1.0 1.00 CO.olSI ..0.0351 When the engagement merk. on the 9t.ar eaaevel gear (page 11-1 21 -Propel.ler shatt/propell&f $hlh hotcl.er (J)3ge t1·5• -Ptopeller/propeller shaft holder assembly (page 1 1·2) 1t Hold the prOpeller shaft $eeurety with the special toot as shown. Pfopellef atYft ho'der 07..P8-ZV30 00 2) Set the $peeial tool on the vertical sheft as shown and attach the tij) of the di..l gauge to me 'Peeial toot. TOOL'Bacldashin.. eU.Chm.m 07LPJ-ZV30300 3) Tum the vertical shaft right •nd left whRe l)l'essing it down with approximately 5 kg C1 1.0 lb) offorce and meawre the Ncklash. 41 If th& backlash is toolarge, increase the tocwarcf gear shim thickness and recheck the backlash. If the bacting C. 21 Screw U.,.lodt nut$ and eye ends mote than 8 mm (0.3 inl onto the thread of the remote control cable and tlohten the loek nut 1«:urelv to hold the pivot. APP'V m•rlne gr ase to the hote ot tne ve end. 31 lmot.ll the thlft control cable bv •hgr,ing the groove of the control Clble with the cable guide plate. Th..n connect the eye end to tht ahih &rm pfn u$lng the two washers: end 6 mm lock pin. 4) Install the Clblo clamp spacerand throttle contr.. cabfe by allonlng tt'lt groove with the cable guide p4ate, Then con· nect the evt '"d 10 the ttwottle arm pin ut.lng tht two wa.hert end 6 mm lodepin. SJ Aointt.e" the housing C a.nd t:ighten the SCUIWI. TORQUE: 2 N•m 10.2 k..·m. 1.4ft•lbl 111 CONTROL CABI.E 161 LOCK NUT REMOTE CONTROL HOUSING C 131 CABLE GUIDE PL TE 14-9 HONDA. • OliTBOARD MOTOR SIDE 111 eNG..E COVER 11 Remove the engine cover, 2) Remove the four botu. two washers. and sep rate ces,e. 111 sa>ARATE CASE 3) Pass the control box wire harness and conltol c..bles through the groi'I'Hnet 8$ $hOwn. 4) Attach the Cbble plate to tha control cables by aligning the groove with the cable plate. and then install them to the case. 141 5) Screw the shift pivot on o the threaded portion of the throt· 111 LOCK NUT ti-e and shift eab)e ess..wn. 12) SHIFT PIVOT CON ROL CABLE 14-10 6) Make sure th.at tho '-hiftlink on the outboard motor "de t1> inthe neutral poS-ition tN), and thet the eontrollevur at the remote eontroJ box &-ide is in the neutral position ..N). 7) Apply m.:n e grease to the pins of the shift pivot. 8) Co nect the control cables to tile shift link end thronie arm using 6 mm wnl,ers and lock pins as shown. Tighten the loci( nuts securely. 9) Connect the remote control wire harneu to the outboard motor side wire harness and set the connector to the holder. 10t Secure th(t remote control wire harness with the harness clip. 11 l Rein&t..l the separate case and tighten the bOlts sec rely. CONTROL CABLE LENGTH ADJUSTMENT • THROTTLE CONTROL CABLE 1) DisconneCt the throttlecontrol cable from the throme erm. 2) Mo.. the throttle a m to the fulty-open position until It touchesthe stopper and check that the carburetor throttle lever touches the stQC)C)er at the futtv·open position. 31 tf no, di con ect the throttte rod frOm the throttle cam, loosen the foc:k nut and adjust the rod length by turningthe linkage pivot. 4) After adju tment tighten the lock nut securely and conn.ct the thrOttl• rodto the thfottls c:.m. S) Reconnt:e:t the throttle co trol cable to the throttle a m and set to remote control lever tothe "N" position. 6) Check that the cont&r of the pivot roiJer ali ns with the index marks on the throttle cam. 7t If no, discon ect the throttle control cable, k>osen the Jock nut and turn the pJvot $haft. 14-1 1 {1) CARBUReTOR THROTTLE LEVER [81 UNK.t.GE PIVOT FUU.POSIT104'4 {3) ntROTTLEARM I11 IMI!X MAIIKS OTROUER (31 THROTTLE CAM 8) After adjustment tlghten the lock nut securely and re.. n.ect the thronlc conttol c.abl e. 9) Move the remote control lever end checkthat control lever moves smoothly and that the ccuburator throttle 1ever moves smoothly without binding from the fully-open to the fully--tlo$ed position. • SHIFT CONTROL CABI.E 11 Disconne.ct the shift contr.. cM>Ie from the Shift arm. Set tM shift in "R" and visualty inspect that the cltck roller .. in the center of the g(oove on the $hift link B at the lR) me.k. 111 CLICK ROLLER 2) If no, SooMn the lock nut and tum the adjusting nut, separate the shift rods A and B. 3) Push the shift rod 8 to hs lowest position. Turn t'hol lock nut untM the distance from top of the shift rod 8 is 8 mm (0.3 in• and then tum the adju$ting nut of shlh rod Bin &S required. 4) Tighten the lock nut SOC\Ueiy. 5) Reconneet:the shift control cable and set the remotQ con-­trol lever to the neutral position INI. 6) Checkthatthe cJtek. roller sltt in the (NI groove of the shift link 8. 7) If no, djsconnect the shift pivot. loosen dle lock nut, and tum d'le shift pivot as required. 81 Tighten the tock nut secur..v and reconnect the $1\ift pivot. 9t After 1he edjustment ensure that the shift lever opefatea correctly. 1Ot Reinstalt the outboard motor cover. 14-12 HONDA SHIFT ROO 11) SHIFT PIVOT LOCK NUT HONDA. THROTTLE BRACKET/SHIFT LEVER/HANDLEBAR (TILLER HANDLE TYPE ONL Yl THROTTLE BRACKET ................. 15·2 SHIFT LEVER ............................ 15-4 HANDLEBAR ............................. 15-5 15-1 HONDA THROTTLE BRACKET a. DISASSEMBLY/REASSEMBLY 1) Re-moved. engine cove• (P. 4·2). 12) 6 K 10.5 x 16 mm DIST NCE [8] THROTTLE BRACKfT ADJUST ENT: P. 3·12 161 6 mm SELF-L CKING NUT (21 mmPt.AIN WASHER 121 • 40 C2l 15-2 • THROTTLE CABLE REASSEM8l Y: 1) Tum the throttle grip to the full open position, then back it off 3 mm (0.1 in) from th6 fully open posnion and tighten the friction bolt. 2> Adju$l the closed $ide Md op...... $id8 of the throttle cables to the length shown in the drawing. 3) Connect t e throttle cab5es to the tlvonle arm. 41Cotmt-et the throttle cables tothe throttle bt&ck.ct. 61 loosen the frictjon ..t and install the 6 x 10.5 lC 16 mm disu..nce colter on t.. throttle cam. 61Ina-tall the throttle cam on the thront. bracket and tighten the 6 x 25 mm flange bott. 7) Install the throttle bracket on the engine under case and tighten the 6 mm self-locking nvts. Install the thronl• fOd. 8) After installing the throtde bracket, ldjust thO throttle (P. 3·12). 11I FRICTION BOLT HONDA BIF3SA ·415A Sx 151 6mm (1] CLOSBl SIDE 46.2-47.2 mm 11.82-1.86 inl .ENSlOE 11) THIIOTTLE ARM 1 1 6 x 10.5 x 16 mm DISTANCE COLlAR (31 THROTTLE CABLŁ 15-3 HONDA. SHIFT LEVER a. DISASSEMBLY/REASSEMBLY 1) Remove the engine cover end separate case tP. 1 5·2) 2t R.tmove the COl unit cover and disconnect the $tarter switch wite connectOfs. 3• Remove the throttle cable brec.ket (P. 15-2) 4) Move me &hih lever to tile "R" posi..ion. 1141 5 mm PLAIN 1131 WASHER NEUTRAL SWlTC>I 2P CQNNECTOR 151 UNDER CASE GROMMET A STOP SWITCH WIRE STARTER CABI.E 15-4 HONDA HANDLEBAR a. DISASSEMBLY/REASSEMBLY 11 Remove the shift •ever (P. 15-4) 21 Disconnect 1hf! indicator lamp 4P connector, wire connector andemergency stop swttch 2P COMectQr. (29110 mm $ŁLI4.0CKIHG NUT !21 !281 HANDt.ESAR P1.A TE (271 HANOLESAR M •witch wir-e U shown. 15-6 111 EMŁAGENCY STOPSWITCH WIRE 121 THROTTU CABLE CCiosed &ide} 131 THROTTlE REEL HONDA ELECTRICAL EQUIPMENT COMPONENT LOCATION ............ 16-2 COl UNIT !IGNITION COIL ............ 16-4 POWER TILT RELAY /TRIM CONTROL UNIT (POWER TRIM & TILT TYPE ONL VI ....................... 16-6 STARTER MOTOR ..................... 16·7 ELECTRIC PARTS ...................... 16-12 INSPECTION ............................. 16· 1 3 16-1 COMPONENT LOCATION 111 120) INSPE·CT ON: 1171 16-2 115) P. 16·13 IN CnON: P. 16-17 and 18 1121 HONDA 161 OIL PRES URE WITCH 191 T IM CON ROL UNIT trim &. dlt type only( TRIM &nL T SWITCH (Power trim & tlitt type only) 1111 POWER TII.T RELAY 1131 • Tlll.ER HANDLE TYPE 131 • REMOTE CONTROL 171 111 THROTTU! SWITCH P. P. 16-21 16-3 HONJ:)A. BF3!1A·415A 121 CDI UNIT/IGNITION COIL a. DISASSEMBLY/REASSEMBLY 1) Remove the engine cover. (3) Refer to CABLEJHARNESS ROUTING (P. 2·22). CASECOLLAR 141 120)POW R TRIM & 111.T SWITCHGROUNDCAI!lf P. (17] 16-4 1181EXCIT R COIL 2PCONNECTOR 114)CONNECTOR BRACKET A HONDA. BI=35A·45A INSTALLATIOfke and ttont cover by aligning tM d&nts in ttle front cover with the projections on the yoke. 16-11 HONDA {3) "A'' POINT ELECTRIC PARTS a. DISASSEMBLY/REASSEMBLY 11 Remove tN engine cover. 21 Remove the starter motor fP. 16-7). 3) Remove t..e COl unit cover and disconnect the stal1:er magnotlc twitch wire connector, surter cablo Uower sidel connector end regvr..uor/rectifier wire connectort. 4} DIKonntc:t the 14P connector and choke solenoid 2P connecnor. rRemote control tvPt only), After ti9f'lt1nlng the band. cut off the exce&a ot 15 mm C0.6 in) frotn e-nd of 131 WIRE (51 RroULATOR/ 151 HONDA. BF315A·41!!1A REC'IlREII NEUTRAl SWITCH 2P OOWE TOII WSTAllATlON: P. 7-8 1..1 P. CONNECTOR CABlE CUP POWERT IM •nl T SWITCH 16-12 P. 1-a INSPECTION • STARTER MAGNETIC SWITCH ASSEMBLY Connect the blacklwhh:e wW• of the aterter switch to thl pochJve t+t terminal of tnt battery and bltck wire to the negative f-1 terminal and check tor continUity. There sOOuld be conllnultv between the Mtmln111, And then th re lhouid be no cootlnulty when disconnecting the b&ttery. • FUSE/FUSE CASE Cheat tM fusefot continuity.Connect the fUM to m. ft.tM ee..e end check the ease for c:ontlnuity. • NEUTRAL SWITCH Att.ec:h the tHtlf &Nd.s to the twO tet!'I'Mrl.als at the: twitchand check few oontinuhy. .r• 5hould be oontinufty whtn 1t141 $witch knob is pu"-d. SWITCH PIJSHEO 16-13 CONTINUITY NO CONTINUITY HONDA 111 FUSE 121B&.OWN FUSE • REGULATOR/RECTIFIER Measure the res.stance between the eonn..tors. Replace tho regulaor if the measurement is 001 of the ..cifiedrange shown in lh4 tablebelow. Checkthe regu\.ator/,.ctifierfor condnultv. The regulator/rectifier is norma1 Htllere is continuity b&tw"n C and A. orC and 8. RECOMMENDED MUL TITESTERS: TH-SHIKOWA Analogue typel SP-1 00 ISANWA Analogue ype) Select the following rtnge. Kowa: R x 100 a Sanwa:kO •POWER TILT RELAY (Power trim & tilt type only I Check the continuity ..tnd re•istanc::e ..twtHtn thtt tenni•'l.tll.. shown ln the table below. 16-14 HONDA 121 SWITCH INP\ITSlOE HONDA Chcttr.th..t thtrt: is batterv vohagu bctweun the prouud cable 81 end the motor output side Glind Bu in the circuit shown to the right. 12) v • POWER TRIM & TILT SWITCH I Power trim & tilt type onlyl Attach the tester leadto each termiNI and check. lex contJnui· tv. There th(lvld he continuity .,.tween the terminals marked with circle in the table below. W/Bl Lb Lg Attach the tester leads tothe trim angle sensor connector and measure the ret.lttance. 16-15 HONDA BF35A·4!5A • TRIM CONTROL UNIT !Power trim & tilt type only) Besure ttte battery ls lfl 90od condlllon before performing this test. 11 Check that the.re is !) :t 0.1 v"' vott.-g.. between me 0 ttnd 81 terminals in the circuit shown to the right. 21 Turn the angle sensor until voltage between Y/Bu and 81 is 3.05 volts. Be •ure thet the butut so..•nds intermittentfy when the switch 1 is turned OFF. Check also that the buz.zetstops sounding when the switch 1 is ON. 12V =.. 131BUZZER 121 TRIMMIOTEJI 111 TRIMU\IIT ':' 1lUM ANGLESENSOR 16-16 HONDA • CDI UNIT IExcept1iler handle type) Mea.-ure tN r•sinenee betweenthe C:Di wnh. terminal• and be sure th11 moa:sut.-nonu confOtm to the ranges shown tn tht t•b141 below. 16-17 PC.E PC2 PC3 11 l COl UNrT IGI -• 1<32 IG3 PS ltl - !XC.E. TH-5H (KOWA Anllogue 1\'l)e) SP-100 (SANWA Analogue 1VP"l Select tilt fOCIOwlng ,.1\Qe . Kowa: R x 100 0 GND DZ ....NDJ HONDA. • COl UNIT (Tiller handle type only) Me.asurt the resistance between the CDI unit tenninals end be surt thilllt m•a:s.urements conform to the ranges s-hown in the table below. COLOR PC1 PC.E 16-18 gJ, PC2 EXCoE. PC3 IPS} Bl (GND}CPC3l CGNDJ IG1 IS WI IG3 -- INO.E. sw.e. RECOMMENDED MUL TITESTERS: TH-6H IKOWA Analogue type) SP-1 00 tSANWA Analogue type• Select ttle follow ng r nge. Kowa; R X 100 0 TH GNO • REMOTE CHOKE SOLENOID (Remote control type only) Mea.sure the resistan e between the terminals. • OIL PRESSURE SWITCH 1) Remo e the oil pressure switch wire. 2) Anach the testat leads tot.. terminal JoiM:end$Witeh body and check for continuity. There should be con inuity. • PULSER COIL Remove the engine co er and di.sconnec t.. pvl$tr coil connector from the right side of the tnvinc (P. 6·3). Attach the tetter lead to each terminal and me sure the resistance betWeen the termi"''!l$. • EXCITER COIL • For excher coli repi&eement, see page 6-2. Measure the resistan e between eaeh termfnelof the exciter coil with the tt.ster. 16-19 111 4x8mm SCREW HONDA. BF3!5A·4!5A HONDA. •CHARGING COIL 12V-6A Measuretho rC$I$tance between e.bch terminal of the charging coil with the tester. •CHARGING COIL 12V-10A (OPTIONAL) Meeth.Jflf tht! r$.SilH80Ctl>e:tw..f:ln each terminal of the charging coil kit with the tester, •IGNITION COIL • For fgnitiOI"' ˘041 rep&eccment. ooc pago 164. MNsurt the retltttne• of the primary coil between the two terminals at the igntion coil. secondary eo41 between the plug wire aod thegreen terminal. (1) Remove the spark plug cap and measure the resistance of t e 16-20 HONDA. BF3E5A·4E5A • SPARK PLUG CAP Measure the resis ance ofthe spark plug cap bytouching one e-st tt lead a:t the wire end of the cap. end the other at the spark plug end. . RECOMMENDED MULTITESTER$: TH-5H fKOWA Analogue type) • STARTER SWITCH (Tiller handle type only) onnect thestarttu •witch 2P connector. attach the tester leads to the 2P connector terminal joints, and PU$h thf:l tt8fter .switch knob. Theswitch is normal if there l.s contil'nJitv whenthe knob iG pu$h.ed. {1) Pu$1\ [11 SPARK PLUG 121 Connect • COMBINATION SWITCH Chf$t;k, for continuity hetwMn tl.. te--minttls wi h the switch in each position. • INDICATOR LAMP A.J)ply 12V of vottag.-to the ar terminal and connect the switches 1, 2. and 3 to the 81. R, and Y terminals rUp&ctivaly. When SW1 is ON: The green lemp shovld tum on. When SW1 and SW3 ore ON: The green lamp should go off. When SW2 is ON: The red lamp thou1<1 1um on. 16-21 • POWER TILT MOTOR I Power trim & tilt type only) • SOLENOID SWITCH IRemote control type only) Attacl'l the tttltf INdl to th• two terminals at the $01enoid swh:ch and cl'!eck for contlnuttv. There ahould be continuity whet!..awltc:h knob It pushed. • THROTTLE SWITCH (Power trim & tilt type only) Auach tht tttttr Jtldl to the two terminets ttt the thtott1e switch and check fOf continuity. Ttlert should be continuity when the switch knob it puthtd. • WARNING BUZZER IRemote control type only) NOTE Connect the block/y1llow tarminel f the warning buzzer to the pO.Sitive t+• terminal of the 12V bantry and the yellow/gtHn terminel to the negtdve (-) terminal of the bantry. The wamtngbllu:tr thoold tound. 16-22 HONDA l.g/81 81/G HONDA. • EMEIIGENCY STOP SWITCH Attach the tener leldt tO the two terminal• of the •mtt.. stop swhch end chec.lt for continuity. an cue tNt the awitch clip is set, there should be continuity when tfle bunon is ptJ!ihed. 16-23 HONDA OPERATION ELECTRICAL SYSTEM ............... 17-2 POWER TRIM & TILT SYSTEM .... 17-10 POWER TRIM & TILT FUNCTION .............................. 17-12 GAS ASSISTED SYSTEM ........... 17-19 CARBURETOR ACCELERATION/ DECELEAA TION SYSTEM .......... 17-22 ELECTRICAL SYSTEM ........ 1. Electronic advance CDJ system The BF3SA • 45A is equipped with the electronic advance maintenZ.ncc free COl system which is excellent in sparking perfor· mance an 111 ENGINE STOP SWITCH (11) 181 PULSER ROTOR 171 MAGNET R ITHYRISTERl 131 IGNmON COIL 121 SPARK PLUG 1) Whenthe flywheel rotates, the eleclric power Qen.eteted at the exciter coil is rcctifisd bythe dOde (0) and charged huo tho lgflition condenser tC) (shown bythe broken fine in the above diagram). The thyriner ISCR) i-$ O..F this time. 2) When the magflet Of1 the pulsar rotor passes thepulser coil, the electric pulser coil sign$1 is e-mitted bythe magneticforce. This signal passes the gate circuit. turns ON the thvrlster, end discharges the etactric charge from the condenser. When the dil'charui'd current flows through the ignition coil primary circuit, h.. voltage is generated inthe secondary circuit and the spark pkJg sparks tshown by the solid line in the above dl-,agram•. 3• Spark advance The 8F35A • 45A Is equipped with the electronic &dvance $p.&rk sys-tem, which JJdvances the ignition timing when tl'w! gate circuit tums ON the thyrlster according to tho tngine speed to obtain the high speed power. 17-2 HONDA BF3EiA·415A <3 cylinc* Ignition system> ThisSVttem Ia OQIIJtpped with the three ignition condtnHrt and ao independent ignidon tystem is proYiOeCI fOr Ueh eytindet. • Billie: c:lrcuh. dlegram 1171 PVLSER 2 17-3 111ENOINE STOP SWITCH D1 141 SCR 1ITHYRISTER 11 181SCR2 ITHYRISTŁR 21 1121 SCR 3 ITHYRISTEA 31 131 IGMTIONCOIL 1 1111IGNITION COIL 3 121SPARK PLUG 1 PWG2 1101Sf' ARK PlUG 3 HONDA ........ 2. Ovatrev limiter The overrev limiter is provided in the COl unit circuit to prevent the overrewing of the engine. Set speed of overrev limiter: 6.600 % 200 min-1 (r.p.m.). 111 Engine 6.600 speed mln-1 (f,p,m,) (3] Aring zone .. (41 Time (TI I11 ENGINE STOP SWITCH [10) MAGNET 17-4 (14[ 191 P\JLSER COIL 181 EHOINE SPEED SIGNAL CIRCUIT [41 SCR JTHYAISTERI (71 FlAME.(HJT CONTROL CIRC\IfT [31 IGNITION COIL (2) SPARKPWG HONDA 1) Getting the engine speed signal from the puhoe.-coil gate clrCt.rit, the flatnt·Out conuol circu;t detects whether it is over or below the set speed. 21 When the speed is over the set speed, the transi.stOf nR) tumsON and short circuits the thYfister (SCRl trigger sjgnal to the ground to flameout. •The obovc procedUfOS ere performed to flameout the No. 2 andNo. 3 cylinders. Stable engine speed while under way is th&feby obtained. 17-5 HONDA. ......... 3. Overheat/oil preaaure alert system The 8F3SA • 4 .A is .ulpped withthe overhoeatloil pressure alert system which J)f'Otteta the engine by eontrolingthe engine speed in the COl ettcuh when th• •noinoe is ovethUt.:i Or 011 pre.s.sure drops.. When a troubie occura. the system stows down the ..ine spe.ct vr•du .. v. •• t Sl\lrl) drop of tile e:naine speed is very dt..erous for tht operator 11 it the boat is bfaked suddenly. Wt-..n the trouble it aolved. it a1so inere&Jt$ the engiM sl)ted slowly and gradutlly. The system is pro'Yided with t'he indit:llOI limPS tnCI buuuer sound (r......ote control type)to indicate the c:&m:e of trouble to the operetOf. 1) Engini tP..(i c:qnuol I 111 141 1518 5 · Alontee. N'niOf OFF (3) lJnder wey HC. speed )12) Alon sensor ON 1111 (10) Steb.. tpeed (a.l preaunt .... li.C.. -(71---S. t apeed: 2.800 min-• (r.p.m.l 191 Trouble occuirtd (IJJ Troub'etolved e.,-..-dOwn bolt stows dOwn Fering and flaming out it repeated electricaDy to control tht ttniint aJMe(l. 1. Engine sp-eed: betow U1e stable speed When the engine •PHd ie boe..w 11'1e stable speed, it increasea to 1he atable $peed according tQ the thtottle angle. 2. Engine &Qeed: obovo a table speed Theengine speed alowa down gradually from the under way speed end stebtlina •t thetlable spefd (approximately 2.800 r.p.rn.l. Then the engine speed doe-& not increase regardless of the throttle anglo. 17-6 HONDA. 21 Warning system Th& warning system sets the time of the tlmer before the engine speed control is s-tarted an(! notifie$ the oper.:.tm of the oil pressure switch/thermo switch operation with the Indicator lamps tLEOI. Item Wilen fautty tho 1amp Green OFF Thermo switch: ON when temperature is above the set temperature Oil Qrt$$Ure $Witch: ON wh•n oil prtuure i$ below tht set pressureRed ON If the PfOduct is the steer(ng handle type. the indicator lamps are installed on the outboard. If the product isthe remote control type, the operetor does not notic& the trouble easily before theengine speed controt is started, tiS M must fre(luently turns back while driving if the indicator lamps are mounted on the outboard. Therefore, the indieetor Lamps are mounted on the remote control box and the buzzer in the remote controf box sounds after the indlCJtor Jamps tum ON (OFFt. 11 8as1c circuit diagram r---It l DIODŁ l2.------. MAJN CONDENSER I lt1( g..LITER 131 I {101 PUI.SŁR COIL 17-7 ..UG .. ------- (131 1141 . .,...,... ....... QIICI.n 19) COl UNIT CONTJIOI. by COMPAIU.T. (171 "1 I I STOOl I I I I I l lJ DmcnoN 181 SWITCH SWITCH HONDA 2) Operation 1. Whw. the o;1 pres.sure switch orthermo switch detects the trouble sig!lal, the comparator circuit compares the condenser discharged voltage curve of the slowing down engine speed standatd voltage circuit with the engine speed voltage sj,g.nal ..nd detects wt.ether the spoed Js 4bove or below the specified speed. 2. Gening the signaf from the comparator, rhe flame-out circuit turns ON/OFF the tr8nslstor (TRI end convots the thyrl$ter gatt. 3. The slowing down engine speed standard voltage stabilizH atthe preset stable engine speed and flaming-out and firing are repeated at this stable engine speele HONDA 11 Basio circuit diagram 121 Ill INOICATOR LAMP ASSEMBLY ILEDI r---------1 RfGULATORJREcnFIEA 1101 r · CHARGING! COIL 181 BAT. I I I 1131I THERMO LAMP llfOlI 171 OIL...UP!LED I L__ r I a, I I 1 I I I I I __J (NOAM LI ..OPEN (oOI (51 OG.PAESSUM $WITCH (NORMAL ClOSE) 1. The direct current svpplled trom the Cf'l.arliJing coil and rectified to the hatfwave by the 'ftCtlntr Rows to the thormo lamp end oil lemp to light. 2. 'T'hl tNtmo •witch turns ON when the temoerature it lbove theHt ttmeerat.Xe and tho current flow$ thrOugh the lamp circuit to light. The alett ON $igJ'Ial is sent to the COl unit when the thermo switd'llt ON. 3. The oil pcessure switch t\.lml5 OFF and the CtMTettt ttows to the oil ....-...p whenthe oil preature is IPPfed to the enginewH1en..nnin9. Whenthe oil pre1.ure drops belowtheNtpre!S$Utt,m. 1witd'l turns ON, the current ftows through tMdiode02 to tMoil Pfes&Ure a witch, and the cu"*""' to theoll lemp is &hut off to tum the lamp OF;F, The alert ON &igl'\lll il sent to tM' COl unit when the twhch It ON. 17-9 HONDA POWER TRIM & TILT SYSTEM The BF35A••SA 1\ts a wpe equipped with \he pow., uim & titt system which hydreunc:alv raise&Bowers the outboard by simpfy on the switel't. "-"1. Power trim & tilt motor drive ayotem The power ulm & tllt switch end powtt till tWitch ere Installed onthe conuol l<.nob ot the remote control box and on tho lett side of tl\o outboard under case. Press on the eitMr orwt of tht&e switches. and th8 teley ectivJtes and control& the rotering direction ot the motor. and the outboiJrd Is rfiMdllowered by the hydreiJik: cylinder. {10) POWER TilT MOTOR __ _ _..------1111 Down ------(12) Up 17-10 111 POWER TIIIM & TILT SWITCH IRfMOTt CONTROL BOX) ___j ------"\ mPOWERTilT RELAY r : ,., L JFU&E 181 BATTERY HONDA 1) Turning tMpowtt trim&: tilt switch Or power tilttwitch ON to the UP aldt, the UP r•lty inthe power tilt relay ec1ivetea, contect point moves in the direction ahown by me tolld line and arrow. el@ctrlc current f'ows tn the .nctton shown by the brobn lint .nc:t .,row, and the motor rotottt ln the normal direction.2• Tumlng tM switch ON to ttw. OOWN side, the reltv Inthe power tift relay aetivatet, cont•et point moves in the d.·octlon shown by the dot line and arrow, and the motor rotates in the rev-erse direction• .-.....2. Power trim warning system Ttle 8F35A • 45A Ia equipped with the wemlog 1'(1tem which aounds when the 1rlm engle exceeds 20° so that the power trim can be uMd at the safe crul$1ng atagJe. Howev... " the power titt ls used tor the tMintenance and etub:ing inl&haliowa, the wemlng buo:tr does not sound when thettuonle Ingle t& bmw the set angle wJth Chi snih lever in neuttat reverae. Ot IO 11Trimming wntn the throttle swil.ch is OFF (i.t. OWC' the cenaJn set tf'w'Oute angte with the shift tever in forward poahlor\ andfor le'VIltlpo$ltionl. The unit detects tM volt• whfH'l the trim ang.le a.anSOf eXCHCII the certiinset ang ... turns tht translstOf ON Drut OFF at regula1 lnte:rvelt. end sounds the buzzer intemunemly. 2J Tilting whtf' the trvottle $witch ir; ON li.a. under Ihe certain nt throttle angl« with the shift hwttrin neutral. reverse, and/or forwtrd position!. The buzzer does not sound lndependenttv of the trim engle &f!nsor. •The buZ20f 1110 functions for th• oil preuur• eltrt tyotem. When th$ powor tlim wemlnge:yatem and the oil prettuHJ Ą1ttrt ..ystem ooerote simUltaneously, the buzze1 aoundt continuous beep for the alert ot tho oil pressure. POWER TRIM & TILT FUNCTION 11 Powtr r•t hnc;:luding cruisjng in shaUowsl: HvQ'Wic:aftv raiaes!lowers the outboard to the 6tligni-te:d position by prutJng the button. A r. 'Nhtfl l$ not under the large thrutt IUd'l as forcruising in shllows. t'nOOfin;. etc.. Crange of 20°-60• in the drawtng., 2J Powet t11m: Adjuttl me bttanceof the boat while acceleratiOfl or cruising, resulting in improvtd acceleration, maximum #PCOd. oper•· tiont.blllty, at'ld fuel consumption. Require• ltrge lifting I)OWCr <:IS the outboardIll underthe thrust while operatloo h.tt.oye of 0°-20° in me drtwlng.) 3) Revtrtt ..c:k: Maintains the reverse thrust. Wh•n collition with the ObSt:ICICs in th.. weter, it unlocktto absorbthe impact. 4) Shoc,k fthsorhtr: Red·uces the Jmpact when th-e rever-se Jock It reltu.ed. IIIII' [1)lliANSOM JJ.so 17-12 HONDA • !'owe< """ • tilt typo Ill • UP/DOWNrelief: Operates to protect the circuit and tl\e outboard when It Ia eaugl'rt with the ob•tlc:ltt durlr'\Q the full tlh up/down or during operation. Lett side: Down relief velve A.. side: Up relief valve (9) • Pump: Supplies oil co the UP sldt when rotating In nonn...f direction. and to the DOWN aide when routing in revetse direction. 181 • Spool v•tve: Moves to right Ot &eft and switchh the oil flow according to the rotating dW.cdon of the pump. 171 • ..ual v.tve: Op.n.s me clrcutt to dow the manual ooe•ation. when the motOf or pump bec:ome:s fauhy. 17-13 181• Tttermel vetve: 151 131• Shock v.tve; tht oil betweenthe piston end frM pirton anc:t absOtba the •mpact when the outt>Mrd collides wh:h the obttlcles In the wttet Piston • """""' Vlllve: After the colision, oM re.1HHd between the piston liOd fret f)Jtton returns thfough the return v.rve to the upper chwnber end the outboard titts down. Operat& to reteese thl preaure, wtlen the exceufvethrust is applied Of whtft the intemal l)tehUre rises ex.. due to tht change in temperature. HONDA BF315A·415A • Hydraulc cirCuit The motor rotates clockwise whenthe ''UP" side of the oowertrim & tiltswttch l.s prU&ed, and the oilflowsfrom the gear pump to the spoolvaCve. At this oilmovesthe Spool valve to the left and pushes the lettaide check valve open, the oilin the upper chamber of the cylinder returns to the gear pump, oil pre$1UTtln tht oil Pillage A increases further, right side check valve opens. and the oil flows to the lower chamberof the cylinder and pushes tM piston up to aUow the outboard motor to tilt up. Tl\e oil in the upper chamber of the oyllflderpassesthrough the left side check vatve end retlll'nt to tM gear pump.As oilpressure inthe lower chambar ofthe cylinder incr8tlses when the outboard is ltl the fun tilt up position. it is rellevftCI by the up relief valve. (71 LEFT SIDŁ CHECK VAl. VE 17-14 181 SPOOL VALVE 131 UPPŁ11 CHAMBER Of' CYUNDEII LOWER CHAMBER OF CYUNDEII HONDA The motor rotates counterclockwise when the "DOWN" side of the power trim &tilt switch is pt&&&Gd, andthe oil flows from tne gear pumpto the a-pool valve. As thls oU moves the spool valve to the right and pushes the right side check valveopen, the oii in the lower chamber of the cylinder returns to the gear pump, oil pressu'e in the oil paua.. 9increases further. k!ftside check valve opens, and the oil flows to the upper chamber of the cylinder and pushes th·e pi91on down to allow the outbo81d motor to tiJt down. The oil in the lower chamber of the cylinder passes through the right sklc check vatve and return.s to the gear pump, Asoil praasure inthe upper chamber of the cylinder increases when the outboard i.sinthe full tilt down position, itis relieved by the down rEriief valve. 111 MOTOR 121 UPPŁA CHAMBEF OFCYUNDER DOWN AEUEF VALVE 191 OIL PASSAGE B 131 PISTON 171 LEFT SIDE CHECK VALVE 151 RIGHT SIDE CHECK 141 161 SPOOL VALVE LOWER CHAMBER OF CYUNDEA VALVE 17-15 HONDA BF3!5A ·4!5A The manual vtdve opens whe" it I$ turnett COtltlterelockwlse, forming the m&nual pusage to allow an easy manual tilt up Of tilt down ofthe outboard mot01. When the manual vatv& is tj,ghten.cd fully clockwiSe whUe tiltln.g up/down the outboard motor. the manual passage closes and the ootboard motor locks in the po.sition. 111 MANUALVAL VI; 17-16 HONDA The outboard motor is equipped with the sl'w>ek valve tmd rewrn velve to protect It 6nd allow it to cruise at a designated tilt angle. Because the pl$tOn rises: ane1 the oil in the upper chamber of the cylinder is pressured when force Is appUcd to the outboard motor from front whikJ cruising at a designlted tilt '"9"· the shock vaJve o pen$ and the oil fiows between the ftee piston, located under the piston. and the piston to absord the impact and thereby to protect the outboard motor. When the outboa-rd motor is away from the force. the pltton low..n by thlf dead wei!;lht of the out..rd motor and the thrust. The oil between the piston and flee piston flows through the return valve in the piston and enters the upper chamber of the cylinder. 17-17 151 RETURN VAL\11< 121 UPPER C! HONDA. 8F315A·4!SA The outboa-rd motor is equipped with t.. thermal valve to protect it andallow it to cruiseatadesignatedtrim engle, Becausethepistontowersand oilIn the uppercha-mber of the cytlnd&r ispre&sured whenforceis applied•o the outt>oard motorfrom rtat while cruising at a designated trim/tilt angle, the oil flows through thoe r{ght side checJc \lalve and activates the thermalvarve to reiC-aM the oilpressure end the..eby to protect the outbwrd motor. 17-18 (31THERMAL 121 RIGHTVAI.VE CHECK 111 PISTON HONDA GAS ASSISTED SYSTEM • Gu aatbttd dlt type 111 Chock 1101 o• chamber 181 • Shock Ylh,,: Ooenuet to rel.osc the oil betwatfl tile piston and ftee piston 111od absorbs the lmpiC't when tnt outboard colltdlt with the obs.t&des m the weter. 011 chamber I 131 • Check vatve push rod: ()pensfclo$es the ehedt vat..e to raisellowet the piston. 141 SwftcMs to ''LOCK" ot "fREE'• poshlof\, 151 • R.wm..: Ahet tM colision, oH reiNAd from be1ween tM .. a:nd free piston retumt tNough the retum valve to the lJPC)ef c..ambef and the outboard tlhs down. (6) Piston 17-19 When the tilt .lever is in the "LOCK" position, the piston does not move N the c:hange val\le cam is also in the ''LOCK'' position and the oil passagtt closes. When the tilt lever is set ln the "FREE" position. the change valve c•m lifts the check valve pue:h rod and ooens the check. valve, •Multfng In the oil flowing Into the oil passage. When tilting up the outboard motor, the oil in the oil cham..r I enters the oil chembet II and the outboard can be tltted up east. ly because of the nitrogen gas In the nitrogen gas chamber. When tilting down the OU'tboard motor, the oil m the on cho!Y\IM!r II flows to the oU chamber I and the outboard motor low•s by its own we';ght. 171 OIL II CHAMBER HONDA BF3!5A ·41SA !81 OIL CHAMBER I 17-20 HONDA 8F3!5A·415A 8eceutethe piston IOW$r.S ll'ld prellurtt tl\e c:WIIn th• oil Chlmber I when the outboero motor Ia struck with en obtttclt while c:ruitlng, the &hOek vaJvc Of*\* and oil enters betweefl the pl.tton tnd tree piston to tOaorb me collialon impoct. Whtn tht outboard motor is away from the obstacle. the pltton rlset by the dead w•lght of tht outboard motor and the thrust. The oil bttw•en the piston and tht fret piston fklwa through the retum valve In the pf:tton to the oil chamber 1. 131 (51FilEŁ PISTON 141 PISTON SHOCK VALYe 17-21 HONDA. BF3!SA·4!SA CARBURETOR ACCELERATION/DECELERATION SYSTEM Operation • At aooe .. ratlon When tM throttle is openeo qulekty tor tl'la_rp accelflration of the outboard motor from o conn.mt speed. the diaph gm moves to the full t1roke pos.ltkJn at thO Itt engle of the throttle eam, and tM cart>uret·or main wellis pressured In t&n· umeou.clyand the fuel in the wellis discharged thrCHJgh the main nonle by thO olr puah&d by the diaplwagm. When the throttle is opened slowly, he preuuted air is bled tfvough the eJr btttd and air jet not to chsel'\arge the fuel exceulvelv, 151 141 .. 17-22 • • From the set aragleto fuU open HONDA. BF35A·45A Fromthe ope..ation angle where the ·111, ''\ ' . ..".:.. -.. . .} . 'r ; . •..-· . ir The marked section$ contain no changes. They are not covered in this manual. 1 HONDA. BF35A•415A OUTL.INE OF CHANGES •CHANGE LOCATIONS Model Spiral t be Sefl)re change: Tiller handle type :.::.r=r= j.. THROTTLE CABLE (21 BF35A; 1000001 -1005441 8F45A: 1000001 -1013155 OUTLINE OF CHANGES After change: Tiller handle tYPe .::--c:n::=. THROTTLE CABLE 121 .l:b SPIRAL TUBE 8F35A; 1005442 and svbseQvt(lt 8F45A; 1013156 and subs..quenr 2 Before change: POWER TRJMITlLT TYPE POWŁR TRIM(TIL T ASSY. POWER TRIM(TILT MOTORASSY. •415A Ahtt change: POWER TRIM/TIL TVPŁ POWER TRIM/TILT PARTS Ug0 I,J 0 ! 0 • 0 • g• 0 •0 • • HONDA 2. SERVICE INFORMATION BF35A•45A 1. TORQUE VALUES 2. TROUBLESHOOTING A. THE POWER TRIM/TILT DOES NOT MOVE UP OR DOWN 1. TORQUE VALUES B. THE POWER TRIM/TILT DOES NOT HOLT 3. CABLE/HARNESS ROUTING Item • POWER TILTASSEMBLY Motor mount screw M5 X 0.8 6 0.6 4.3Gear pump bolt M5x0.8 5 0.5 3.6 Sp ol vafve cap M22 X 1.0 20 2.0 14.5 Oil cap bolt 15 1.5 10.8 2. TROUBLESHOOTING HONDA BF35A•45A A. THE POWER TRIM/TILT DOES NOT MOVE UP OR DOWN (Power trim &tilt type) NOTE: Be surethat the battery cables are connected. B nery voltage must be 12 V or above. Connect a banery to tha power tilt motor. Does the power tilt. motor Move Faultythe power trim/tilt cylinder, and in· and check the gear pump for smootll 5 HONDA BF35A•45A B. THE POWER TRIM/TILT DOES NOT HOLD (Power trim & tilt type) Cruise test with a 10.. trim angle. Hold Check for oil leaks around the No leaks. power trim/tift cylinder b dy. • Cylinder cap O·ring power trim/tilt cylinder body. · Power tilt motor O·ring • Spool valve cap O·ring Open Close the manual relief valve. Add oil.· • Spool valve O·rings and valves • Manual relief valve Q.rings UpJDown rehef valve assembly • Thermal valve assembl-y • Piston O·,-ing • Pi:::ton ba<:k up ring o Free piston O·ring o Free piston back up ring OK Substituta a known, good piston tha power trim/tilt asscm· Replaoe the odginal piston assem· bly. Replace. 6 3. CABLE/HARNESS ROUTING 7 lliller handle type) l1I STRAP CABlE BAND 121 EMERGENCY STOP SWITCH WIRE NOTE: HONDA BF3SA•4!5A 161 EMERGENCY STOP SWITCHWIRŁ THROTTlŁ CAIIlŁ 10-sldol Move the handfob..r up a.nd dOwn and be sure that the clearance between tne emergency S-top switch wire and bolt (A in the drawing) it. 1mm(0.04 int or more. 12. OIL PAN/PRIMARY GEAR CASE/SWIVEL CASE !;!......:! 1. OIL PAN/MUFFLER DISASSEMBLY I ASSEMBLY Remove the extension case assembly 8 115) Do not rause. (141EXHAUST PIPE GASKET A ASSEMB Y: Do not reuse. (12) •, WATER TUBE ' ' I' I 1 I OIL LEVELDIPSTICK 121 Do not reuse.Alwaysinstall a new gasket. 131 Clean the oil strainer SCfeen withsolvent and check the 5ereen for damage. rsplace If necessary. 16112 mmDRAIN PLUGWASHER 171 181ILPAN.. (91\ 8X20 mm HEX. Bot. T (2) 21 N·m 12.1 kg·m, 15.2ft·lbl 1111 (101 13. GAS ASSISTED/POWER TILT HONDA BF31!5A•45A POWER TILT ASSEMBLY !POWER TRIM & TILT TYPE! 1. POWER TILT ASSEMBLY (POWER TRIM & TILT TYPE) a. DISASSEMBLY/ASSEMBLY ASSEMBLY:Make sure there are no obstructions on the magnets. 191 ASSEMBLY:Visually inspect the commu· tator surface for dust, rust or other damage. tf nocouary, wipe it with a c-lean lint-free cloth. If rusted org used .,;a. KEEP OUT Of REACH OF CHII.DRfN. 1t Place the outboard moorin the verical position. 2} Remove 1he engine cover. 3J Remove the oil dipstickandwipeit clean. 41 Insert;, all the way down the dipstick hole, then pull it out and read the oif level. 5) If the oil levelislow,add the necessary recommended engine oilto bring the oil level to the upper mark on the dipstick. Do not ovarfill. Running the outboard motor without sutfietent cooling waterwill damagethe water pump and ovtfheet the engine.BesUrethat water flows fromthe cooling &yst.-n indicator wt\il• the engine is running. If not, ttop the engine anddeterminethe cause ofthe prob...,. Keep cle1r of moving parts. HONDA BF40A•50A 2. ACCELERATION DEVICE/DIAPHRAGM ASSEMBLY AdJust the acceleration device/diaphragm assembly after adjusting the idle speed (P. 3-8 of the base shop manual 166ZV300)1. 1) Loosen the 6 x 16 mmtorx bolts using the special tools. TOOLS: Torx bit hand._ 07703 -0010300 SerewT30H 07703-0010600 2) Remove the throttle rod hom the throttle cam. 3) Move the throttle cam and hold it in a position where it does not contact the throttle cam roller. •• Move the diaphragm up or down slowly until the clear· anco between the throttle CDm roller and throttle opener cam is 0.2-0.8 mm (0.008 -0.031 in). Whikl hofding the clearance, tighten the 6 x 16 mmtorx bolts using the special tools. TOOLS: Tone bit handle 01703 -0010300 SerowT30H 01703-0010600 Att&eh the throttle rod to the throttle cam. !11 6 x 16 mm T RX BOLT(21 !4) SCREWT30H 01703-0010600 HONDA OUTBOARD MOTOR SOME PARTS OF CHANGES Power Equipment P/P-o87 The met hod ofinst lling the water seal which had been described to the undermentioned shop manual was changed. BF20A/25A 66ZV700 66ZV31l0BF35N45A B 5AI90A 66ZWOOOZ BF115A/130A CHANGE LOCATIONS The liquid appll&d to the circumference of water seals has been changed. INSTALLA110N: • Do not reuse. • Apply greas• to the mating surface and lips of the seats. HONDA MOTOR CO., LTD. SERVICE PUBLICATION OFACE INSTALLATION: • Do not reuse. • Apply grease to the mating surface, circumference and lips ofthe seals. HONDA OUTBOARD MOTOR SOME PARTS OF CHANGES CHANGE LOCATIONS Engine Serial No. Carburetor BF30A 1iBF4 A 1/BfSOA 1 Canadian models only PILOTSCREWWITH LIMITER CAP PILOT SCREW PilOt Screw Opening Honda M torCo.,Ltd. 2001Servk:e Pubrieat o Offtce PILOT SCREW REPLACEMENT Leavethe pi!«screw and limiter cap in place during catburetor cleaninG. RMnovt onty ifnecess.atv tor carburttot repair. Removal of the limiter cap requires br.ating the pilot screw. A new Qltot tctew and limh:er cap mu$t beinstaUtd. 1) When melimiter cap has been broken off, rtmow tht brot:en pilotac... 2• Place e now O.rlng on the replacement pilotaerew, end install it on the certn..retor. 3) Turn tht pilot strew in until itt$ fully seated. then turn the screw out the required number of turns. 30A1 Pitot scrtw BfOMI !BAYI2!lOOJOI•lllm99l opening BfW.Il11AYI 21107400-4) Apply L.ocktlte.. 10 the inside of the limiter ctp, theo install thtetP to Ita rtop prevents the pilot screw from belngrumed eounterclockwlse. Be cereful to •vokl turning the pilot screw while installing the limittt cap. Tt\.e pilotwew must stay at Its ret tb.. ph..nomc..cn ,.--....:Speed uot ..tabh. ..:t7lnt:' -'ltc:'l .:.g:ur.. 4t [( l'* 'P't't>bl.,n. OO˘llr.e <:\9..11\ 'Nlfh rh* p:...ll.'loge of dml': ..fr.t:.. the abe\'e etcp:: {ll to 0} b""v.. beer. l)..t!O:;.(l(!d. Model: BF40/50AY Re: Change of the wiring method for the power trim New H070ii. ,),SS,' ., roW!F!. TlŁ.!' ht•> C'hi'tlf!.. 1.'. c..n ooN:.r/epect!:lC tnotor: OOl:"CI ttx1ng po$..>;; 1on. the motor cord t.c:ndee e.o be FUHed, c<..u.JitiS ddOl'on. gt"Olmet; ..c ..he notor cord ot:.tlet, r<=ducln;) the 11.:-al "..trvtol\;li)Co;o,, <..•)(.) cau.elog ..nrry r;.f WiltJf! contlri'IA..I<;.n 'fhe lf:otor u( tt.e po-... u· !:r"ill'l tllL a.&&Ofl'lbly Cloce not oper;llt;... P:oced.u:e { 1• Oi::;.:u.::oerrOly ehe 11t.':.or accordi.n;il t.o t.bE! .e.er-..ice "'"'''v.. J. ..ne{lolloC.t a.U p.lrt$;, o1.r,::t cer.!!.rm thl\'! there iS r.o inecrno1l ru::;t. or !.ll.lcking of o:he brueh to th!i' boldt't'· {:!. !o eue o! ctt:'l?:Ttditio:.. . .:xcha09"t t.l)e (..h'('(! (.lo'll't$ or th#l m..,tnr .:.r.r.anbly :sccon::ling to the $@!">·1ee III!I'UJns are not foHow.d. All INFORMATIONS,ll.I.USTRAllONS, PIREC· TIONS AND SPECIACATIONS INCLUDED IN THIS PUBUCAllON ARE !lASED ON THf LAT·EST PROOUCT WFORMAllON AVAILABlE AT THE TIME OFAPPROVAL FOR PRINTING.Hondo Co., ltd. RESERVES THE RIGHT TO MAKE CHANGES WITHOUT INCURRING ANYOBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCEO WITHOUT WRITTEN PERMISSION. Honda Motor Co .. Ltd. Service Publications Office .. E:l!t11N' ! I . tHA...."t;... ... . CYl•t.. H-"". b <:P.ANV";;B;.n • ;..TO• ?RC..;ll t R '• A : "',. .. O'rf· .::,.. 1N,J1v o:t p.."'.j'Ticfl:t/1-\Ft :-.. rS·.\'!V! t t\l' r STH:R'!Ntt l\0..1·t,l'MOH (.(•N .., · !Ht:M·:)1.. t;\)I'Jlfl(>l IY>'Io (,:,tV> T..:)GfTtf f.kAC"IWll QlJIPICtiQn hole ton· stantly? YES NO •Oil J)omp i.. h.u.•lly.• Oil passag is dogged.• Oil tl"er ls te.-.llt)'. • Oil pr(l$$UI(l :;lcrt i:; f:mlly. NOTE: No f)IObltm if th" engine r. p. m. dose not t.:xceed 6,300 rnill ' (r. p. mJ. Ovefr'ev limite' is functioning because of unmatching pro..ICf. etc. 2-1 for minutes to cool engine do•wn, then perform the norma1 idling operatiol\. Che k whether the overhnt 11'1mp turns ott. • hermostat Is feul;y. Remove th.. mote,.. I •WMef tuUe i$ c\Qggttl OYd..m;,gl}d. YES 3. MAINTENANCE 1. MAINTENANCE SCHEDULE 1. MAINTENANCE SCHEDULE * Ern..sliion item rot Borden see model. Note: i1l lubrtc:...\a morofroquul"l\\yw"hcn used in$EthWl'l1t:tT. MeruM .... ......... yoear or veedOt 0 E\'fl'V2 v_r_,Of rte«SAry) f2• When operoting in sa't water. turbid or muddy water. tho ongh1e should be flushed with clean water after each us.o. t3) For profHsional commercial use, log hovrs of operatiOtl to dctormlnc propermaintenance inteNaJs. 3-1 ..urintlflv.ll. wl'l..tt comes firsc. * Enoine o;t Chock IC\ocl Engine O•l filttt BF40A•BF50A Paper Book Part No. 66ZV300U PREFACE This manual covers the construction, function and serv'K:ing procedures of the Honda BF40A•BF50A Outboard motors. For service information which Is not covered in this supplement, please refer to the base shop manual (66ZV300, 66ZV300Z, 66ZV300Y, 66ZV300X, 66ZV300W, 66ZV300V). All information contained in this manual is based on the latest product information available at the time of printing. We rese!Ve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in a retrieval system. or transmlned. In any tonn by any means. electronic, mechanical, photocopying, reoorting, or otherwise, without lhe prior written permission of the publisher. This includes text. figures and tables. Service Publication Office CONTENTS OUT INE OF CHANGES SPECIFICATIONS SERVICE INFORMATION ENGINE COVER/THROTTLE/CHOKE FUEL SYSTEM , CYLINDER HEAONALVE/OIL PUMP J...........x.twR. ..LoC.. .. P.PELLE..EA_R OIL PAN!PRIMARY GEAR CASEJSW1VEL CASE GAS ASSISTED/POWER TILT STEERING ROD!f.lEMOTE CONTROL (REMOTE CONTROL 'TYPE ONLY) OPERATION WIRING DIAGRAM -The marked sections contain no changes. Theyare not covered in this manual. INDEX OUTUNE OFCHANGES ..................................... . BF40A•BF50A 15. THROTTLE BRACKET/SHIFT LEVER! 1. SPECIFICATIONS.......................................... H I. SPECIFICATION$ ........................................ 1·1 2. DIMENSIONAL DRAWINGS ........................ 1-4 2. SERVICE INFORMATION .............................. 2·1 1. MAINTENANCE STANDARDS ..................... 2·1 2. TORQUE VALUES....................................... 2·1 3. SPECIAL TOOLS ......................................... 2·3 4. APPLYING UQUIO SEALANT..................... 2.J 5. TROUBLE SHOOTING................................. 2-4 6. CABLE & HARNESS ROUTING ................... 2·17 7. TUBE ROUTING ........................................... 2·28 3. MAINTENANCE.............................................. 3·1 1. MAINTENANCE SCHEDULE....................... 3·1 2. CARBURETOR SYNCHRONIZATION......... 3·2 3. DASH POT DIAPHRAGM.............................. 3-4 4. THROTTLE UNKAGE ADJUSTMENT......... 3-5 5. SHIFT CABLE ADJUSTMENT (Long Tiller Handle Type)............................. 3-8 6. STEERING FRICTION ADJUSTMENT (long Tiller Handle Type) ............................. 3-8 5. FUEL SYSTEM............................................... 5-1 1. SILENCER COVER ...................................... 5·1 2. CARBURETOR/MANIFOLD REMOVAL....... 5·2 3. CARBURETOR............................................. 5·5 4. CARBURETOR/MANIFOLD INSTALLATION ............................................ 5-22 6. FL YWHEEVfiMING BELT............................. 6-1 1. FLVWHEEL................................................... 6-1 12. OIL PAIIIIPRIMARY GEAR CASE/SWIVEL CASE 12·1 1. STEERING FRICTION LEVER (Long Tiller Handle Type) ............................. 12·1 13. GAS ASSISTED DAMPER ............................. 13·1 1. GAS ASSISTED DAMPER .......................... 13·1 2. POWER TRIM/TILT ASSEMBLY ................. 13·5 HANDLEBAR (TILER HANDLE TYPE ONLY)....................... 15-1 1. LONG TILLER HANDLE ............................... 15-1 16. ELECTRICAL EQUIPMENT ........................... 16-1 1. COl UNIT ...................................................... 16·1 2. POWER COIL ............................................... 16-3 3. ECT (Engine Coolant Tempetature) SENSOR....................................................... 16·3 4. INDICATOR.................................................. 16-4 OUTLINE OF CHANGES [2) After dlange (4) ECT swilch. (5)ECTsensor ECTsensor Installation position dlanged. [5}-1 ECTSENSOR [7) Water hose join! (8)1mer diameter(1.0.)dlanged (81-1 WATŁRHOSE JOWfT (3) Before dlange (.1 ECT SWITCH (11}-1 WATŁR HOSE JOifT I 11 I Analogue cot lri D 1 (2) Aft r change (8) Power trim/tilt assembly method changed. (6}-1OIL PfiE8SURE SWITCH (5]-411ALE CONNECTOR {7]Change to power coH from exc..er coil. (7}-1 POWER COIL 0 (B)o1 50 0 POWER ..T ASSEIIBL Y BF40A•BFSOA [3) Before change (5)-3otL PRESSUR SWITCH (7}-2EX..RCOL (8)o1POWER TIIIIIITILT ASSEMBLY BF40A•BF50A (3) Bef0<8 change (1)11em [6) lnvened1ype (4) Gas assfsled damper (6)-1 GAS ASSlSTEO DAMPER [5}1 GAS ASSlSTEO DAMPER (7) Moon! frame [7)-1 MOUNT FRAME [7)·1 MOUNT FRAME [7)·2 FRICTION PLATE MOUNTING SECTION "" (8}-1 [8..1 STERN BRACKET (7] Friction adjustinglever [2) After change [4}-1STEERlNG FRINCTION STUD INSTALLATION HOLE [4]·2 SWIVEL CASE (S}-1LONG nLLER HANDLE (8) Tiller handle friction lever being added inoonnection with addition of 1he longIiiier hendle type FRICTION PI..ATE [31 Before change [4}-2SWIVELCASE BF40A•BF50A 111 121 After change (31 Before change (4 I Carburetor [4]·1SE [4]-2 SE THIER..IAL VALVE VALVE CHOKE SOLENOiD (REMOTE CONTROL TYPE) [51 Remote control box (61 Choke switch is no longer (6)·1 SWITCH [2) AHerchange (3) Before change [5]-1FUSE HOLDER BRACKET [5}-3REGULATOR/RECTIFIERBRACKET [5)-2 FUSE HOLDER [5)-3REGULA TOR/RECT1FIER BRACKET 1. SPECIFICATIONS BF40A•BFSOA 1. SPECIFICATIONSDIMENSIONS AND WEIGHTS code 370 (14.6in) 1,3 5 mm (53.7 in) 1,2 0 mm (49.6in) 1,365 mm (53.7 in) (49.6 in) Dry weight 95.5.. 89k.. 91 kg 91 "ff,propeller mounted) (3161b (32? lb) (307 ) weight (3171b) (3241b) : I:J?21b) (3091b) (3161b)heighl 521 mm(20.5 In) (16.4in) angle ..ing ngle Swivel angle 5stage adjustment(8', 12', 16'. 20'. 24') -4'-12' -37.5' andleft Types of Honda BF40A Outboard Motors Shah Long Rem te Elecmc P wer Model Type length tillar control starter mmllin assisted till BF40A SH s •. SR -- 1·1 '] -4' -12' Startingenrichm nt • Dry weight ight Tl..lng angle angte Type ' - ..weight .2f>er ting weight Til ing angl LH kg (2161bl SRT 96.5 kg (2131b) 556 in) _ 5 stage adjustment (8', 12·. 16'. 20', 24') 37.5'rightand loft 101 kg (2231b) rMl (55.1 1n)! 1 mm (57.9in) 91 kg(201 lb) 91 kg (201 1b) 93.5kg (2061b) 93.5kg (206 1b) 95.5 kg (211 1b) 5stage adjustment (8', 12·, 16', 20', 24') --· 37.5'rightand left Types of Honda BFSOA Outboard Motors Long Remote Electric Power Gas-StartingModel Type leng h tiller control sta t r trim/tilt assisted enrichment lin BF50A YHT ' YRT 1-2 BF40A•BF50A ENGINE Descri tion code Type Displacement 29.4 kW (40 PS) 36.8 kW (50 PS) at 3,500 min·• (rpm) at4,500 min·• (rpm) 329g (1 1.6 oz.)/kWh Cooling system lgn..ion system lgnrtion timing S ark plug DR7EA (NGK), X22ESR·U (DENSO) Lubricating system St rting system Stop ing system Ignition primary circuH ground LOWER UNIT BF40A, BF 0A Dog clutch (Forward-neu ra..rever e) Pro ller Rotating direction 1·3 BF40A•BF50A 2. DIMENSIONAL DRAWING Unit: mm (in) Tiller Handle Type 1,260 (49.6) (16.4) (31.7) SType (53.7) (20.5) (35.4) (57.9) (21.9) 930 (36.6) ULType (57.9) (2 .5) (39.0) . ....... V ....'-'··-... . _j --··-...... 1------s 3'30(15.35) --j (30.31) 1·4 BF40A•BFSOA Remole Control Type . Unit: mm (in) $Type (49.6) (16.4) (31.7)(53.7) (20.5) (35.4) (57.9) (21.9) (366) Ul Type 622 (57.9) (24.5) (39.0) 1-5 2. SERVICE INFORMATION BF40A•BF50A 2. TORQUE VALUES 6. CABLE & ARNESS ROUTING 3. SPECIAL TOOLS 7. TUBE ROU ING 4. APPLYING LIQUID SEALAN 1. MAINTENANCE STANDARDS Float height Exhau temissionBon ensee typeonly 2. TORQUE VALUES Item Thread dla. x p..ch kgl•m Crankc se cover bott M8 X 1.25 27 2.8 M8 X 1.0 12 1.2 Cylinder head bolt M10 x 1.25 39 4.0 MB x 1.25 28 2.7 Oil strai erbatt 6x1.0 13 1.3 Water tube joint PT1/8 9 0.9 • Gear case Pr peller castle nul M16 x 1.0 1 0.1 Gear case end nut M80x 1.5 69 7.0 Gear case nut (UL type) M10 x 1.25 34 3.5 M8 x 1.25 22 2.2 Gearcase stud (UL type) MlO x 1.25 1.5 0.15 M8 x 1.25 1.3 0.13 Water screen screw Msx 0.8 1 0.1 2-1 NOlA 20 (1) 9 29 (2)20 9 6.5 (3) 0.7 (4) 51 (5) 25 16 1.1 0.9 0.7 Item Thread dia. x pitch 9.5 22 39 54 29 34 4.57 2.2 7 1.3 7 1.3 6.5 Torque Note kgf•m 0.95 6.9 (6) 4.0 29 25 5.5 40 3.0 22 3.5 25 0.45 3.3 0.7 5.1 0.22 1.6 0.7 5.1 0.1 3 0.9 0.7 5.1 0.1 3 0.9 0.65 4.7 Steering friction lever nut (long tiller handle type) • Stern bracket Stern bracket ten side nut • Tiller handle Steering !)racket pivot lock nut Steering bracket pivot nut Steering bracket nut Throttle arm holder boa Throttle grip bolt Under cover screw Cable older bolt Emegen y stop itch nut Connector bracket bolt Throttle cable pivot lock nut • Gas assis ed damper Ti.. lever nut M8 X 0.75 7/8·14UNF M12 X 1.25 M12X 1.25 M10x 1.25 M5x 0.8 MS X 1.0 M5 x0.8 M5 X 1.0 MIS x 1.0 MS X 1.0 M6 X 1.0 MS X 1.0 NOTE: (1): (3): Apply oil to the thread and seating surface. Tighten to the specified torque first. then tighten an add.ionat 90' • 120'. Clean off oil or grease from the cranks aft and flywheel mating surfaces (see page 6-1). Apply oil to the thread and seating surface of the flywheel boll, then tighten them to the specified torque. (4): .. the splij pin cannot be set by tightening the castle nut to the specified torque, tighten the castle nut addi· tionally until the split pin can be set. Donot exceed the maximum torque of 34 N-m (3.5 kgf-, 25 lbfolt). (5): .. the tab of t e washer does not align with t e groove of me gear case end nut by tightening it to the specified torque, tighten the castle nut additionally until the groove aligns with t e tab. Do not exceed the max.. mum torque of 98 N-m (10.0 kgf-m, 72 1bf.ft). Tum the friction lever to the right side fully, and hold it in this position and tighten the friction lever nut to the spe..ied torque. Tighten the stem bracket nut to the specnied torque, then tum.. back to 180 • 210'. 3. SPECIAL TOOLS 07510·30001005x08x t20L 2 Vacuum gauge attachmenl or 5x0Bx50L 0751 0·3000200 CD }Carburetor synchronization 4. APPLYING LIQUID SEALANT Apply liquid sealant to the prtmary gear case gasket and oil pan gasket as follows: • Assemble the crankcase side cover and oil pan the specified time after application of a sealing Example: • Within 90 minules when using Three Bond #121 t. • Within 30 minutes when using Three Bond #1216. • Apply about 1 • 5 mm (0.04 · 0.20 in) width. • Wart for 15 minutes after assembly. Oo not add oil dur· ing this period. • PRIMARY GEAR CASE GASKET 1) Clean the engine and primary gea case mating sur· faces with a degreasing cleaning agent or a clean shop towel (see base shop manual). 2) Apply liquid sealant to the position shown on both side of a new primary gear case gasket • OIL PAN GASKET 1) Clean the engine and oil pan mating surtaces with a degreasing cleaning agent or a clean shop towel (see base shop manual). 2) Apply liquid sealant to the position shown on bolh side of a new primary gear case gasket. Apply 1 • 5 mm (0.04• o.20in) width. Apply 1 • 5 mm (O.Al4 • 0.20 In) width. Applytngaru 5. TROUBLESHOOTING a. ENGINE • Hard Starting BF40A•BF50A 1. Check the in the tan.. No luel in lhe tank Sufficient fuel in the tank 2. loosen the carburetor drain screw --Not re ching the .. • Check tor clogged fuel tank breather hole: Close the tank and open ttoe ventknob, listen for hiss. and check whether fuel reached the carburetor carburetor. Reaching the c rburetor. 3 Remove the spark plugs and check --01)' for wet or fouled electrode. -Wet • Check for air leaks past primer bulb. • Squeeze the primer bulb and be sure that the fuel is reaching the c r· buretor.• Check for clogged fuel filter, fuel tubes and connector. 5·18 and 19). • Clean the electrode and rest rt with the throttle 1/4 open or gradually opening wider. • II excessively wet, check the carbu· retor for flooding. If flooding Is -severe, drain the carburetor and prime again. or check the carburetor float valve for leakage. Nosparkorweak Perform IGNITION SYSTEM trou· Good spark High compressionCheck compressoon of each (See base shop manual). Normal compression 2-4 Low compression .. • Check that the valve clearance is correct. • Check for defective cylinder head gasket, valves or va ve seats. • Check that the cylinder head bolls are correctly tightened. • Check for wom piston, piston rings or cylinder. BF40A•BFSOA • Engine Does Not Run Smoothly Engine starts, but stalls Ins ect: P. 5-t8 a d 19 Isoon. Enrichment) valve. Idle speed Is not stable or stalls. Spark plug launy. (sea base shop manual). Adjust (see base shop m;.;..-;,_1).thr ttle stop screw misedjuated. Cartluretor slow circuit clogged. Overhaul a d clean cartluretor: P. 5·15 thru. 17 Ove flowed ca tluretor. again. If still not good, check the carburetor float valve. and intake manifold mounting mounting bol1s or intake bolts, and/or damaged carbure-manifold bolts. if they are loose. I • Make sure the carburetor nd i insulator are installed correct· ly. Replace the gaskets if Valve clearance misadjusted. Adjust (see base shop manual). I Low c linder compression. head gasket, valves or valve seats. • Check that the cylinder head botts are correctly t ghtened. • Check for worn piston. pisron 2-5 BF40A•BF50A ----! Repl ce: P. 5-15 nd 21..nglne speed does al). Propeller mism tched. peller. S rk plug faulty. (See base shop manual). Clogged 1uel1itter. Replace (see baseshop manual). Wateror deps..s in . . - no good, overhaul the cart>ure- V lve timing inoorrect. base shop manual). Alert sy tem function. . Troubleshooling: P. 2·9. control module fa l P. 16-1. 2·6 BF40A•BF50A b. IGNITION SYSTEM These outboard motors are equipped with an engine overrev limit r which Is provided In the Ignition control module. The overrev lim"er is activated when the engine speed exceeds 6,300 rpm. When activated the sparks are emitted to the No. 1, No. 2 and No. 3 cylinders. The overrev limiter may be activated under sudl conditioos as; light pro· pel!er toad or propeller ventilation. • Hard Starting No spark or weak sparkI Standard plug: DR7EA (NGK), X22ESR.U (DENSO) Plug gap: 0.6 -0.7 mm (0.24 -0.28 in) th spark test again using f--Good spalk I No spark Check that the switch clip is installed on the emergency stop sw..ch correctly. Installed -Diseng ed 4. Disconnect lhe black/red wire of the Good spark emergency s op switch and partorm spai1< test. Nospark Install the clip securely. the emergency stop switch. the power ooil wire connector, and check lor resistance. Resistance: 7.02 -8.58 n Abnormal ----.·..R.e.p.la.ce.lh.e.pow.e.r.co.i.l.========. Normal Go to page 2·8. 2-7 From page 2·7. Disconnect the pulse generator coil wire connector, and check for res stance. No al BF40A•BF50A Abnormal • -·-Replace the p lse generator coil. ' b amaged high ension wire lation. Ch-eck the ignition coil tances (see base shop m nual). Resistance: Normal a. Remove the COl unit and check for Abnormal resi-stance between the terminals (P. 16-1). Normal Nonn l Check the wire harness for short or open drcuit Replace or repair the wire harness. 2-8 Abnonnal BF40A•BF50A c. ALERT SYSTEM Long Tiller Handle 1\IPB: Oil pressure Indicator light (Green) turns OFF while the engine is run· '---the engine and check the oil Is the oil level corr ct? CORRECT LEVEL 2. Start the engine and check the oil pressure light with the engine idling. Does the oil pressure light comes ON? YES N TE: No problem if the oil pressure light comes OFF when the engine speed Is slowed down suddenly. but goes ON after idling for 1 or 2 minutes. LOW LEVEL YES System is OK (oil level was low). NO 4. Check the oil pressure switch (see NO Replace the oil pressu e switch. base shop manual). Is the oil pres- YES ' 5. Check the oil pressure. Is the oil NO normal? .. the COl unit (P. 16·1). or repair the wire harness ij the COl unit is in good condrtion. Clean the oil strainer if necessary. • Check the oil pump. Replace or overhaul the oil pump If necessary. • Check the oil passage lor clogging . Cleanthe oil passage .. neces.o;ary. 2-9 1 whilethe engine indicator light (Red) turns Is running I NO 2. Start the engine and check the cooling system indicator with the engine Idling. Does cooling water constantly flow through the cooling system indicator? YES NOTE:No problem if the overheat Indicator light c mes ON when restarting the engine after hot soak at high temperature, but comes OFF after idling for a few minutes YES NO YES ,... Remove the foreign material and recheck. • Check the discharge port tor clog· ging, clean the discharge port ifnecessary. • Check the water pump for wear or damage. Replace or repair the wat r pump. • Check the water tube for clogging or damage. Clean or replace the watertube if necessary. System Is OK (engine temperaturewas high). 4. Check the thermostat. Is the ther· NOmostat good? YES s. Disconnect the ECT NO --unit(P. 16·1).temperature) sensor 2P connector.Check the overheat indicator light. Does tho overheat inelicator light go YESI _ 6. Check the ECT NOthe ECT sensor in good condition. YES Replaceor repair ..ire 2-10 Replace the ECT sensor. Remote Control Type: 1. Stop the engine and check the i diOil pressure indicator light OFF. Oil pressure indicator lightON. Overheat I dicator light OFF. verheat indicator ON. YES the engine and check YES light wit h the engine idling. the oil pressure light come NO System is OK(oil level was tow). f--------Buzzer stops but oil pressure 011 pressure Indicator light ON but buzzer does ot stop. i dicator light doea not oome ON. 4. Disconnect the oil pressure switch NO · ·-----J..[Check the COl unit (P. 16-1). wire. Doesthe buzzer stop? YES base shop manual). Is the oil pressure switch good? YES NO pressure normal? YES Check the COl unit (P. 16-t). Replaceor repair the wire harness II the COl unit is in good condition. Replace the oil pressure switch. • Check the oil strainer for Clean lhe oil strainer rt necessary. • Check the oil pump. Replace or , overhaul the oil pump if necessary. • Check the oil passage for clogging. Clean the oil passage if necessary. • Replace the oil filter. 2-1 1 2. Stop the engine and check the water intake screen for clogging. Is the water intake screen NO -· YES BF40A•BFSOA ------!fiemove the foreign material and recheck. 3. Start the engine and check NO cooling system indicator with the • Check the discharge port for clogging, clean the discharge port If necessary. • Check the water pump fot wear or damage. Replace or repair the water pump. engine idling. Does cooling water constantly llow through the cooling YES • Check the water tube for clogging or damage. Clean or replace the water tube if necessary. 4. Idle in gear for a few minutes to -YES cool down the engine. Check the is OK (engine temperature was high). overheat indicator light. Does the NO Overheat indicator light ON but buzzer does not stop. 5. Check the thermostat. Is the thermostat good? YES the Jcr (Engine coolant perature) sensor 2P connector. , Check the buzzer. Does the buzzer stop? YES YES ' • Check the thermostat. Replace the thermostat if necessary. 2-12 Buzzer stopsbut overheat -•..fe.--Gr--]CHARGE COIL WIRE -Gr Gr (24) REGULATORIRECnFIER WIRE -Gr Gr ][12) (21)POWERTRIM/TILTRELAYWIRE c=tg ..[23) POWER TRIM/TILT SWITCH WIRE [=t.. c::J [28) COl UNIT WIRE -Lg/81 .. [21) c::J [28) POWER TRIM/TILT RELAY WIRE --w --BATTERY CABLE (MAIN FUSE WIRE) [24) REGULATORIRECnFIER WIRE --w[27) STARTER MAGNETIC SWITCHWIRE BVW-] [12)[16) [-Bl..BI--MAINWIREHARNESSTR1M ANGLE SENSOR WIRE -Lg/81--(C)-Lg/BI- YIBu-cJc:)-Y/Bu- 2-20 •Gas-Assisted Tilt Type: (2]IGNinON PULSE GENERATOR WIRE (11 POWER COIL 181 2P CONNECTOR [161 CH,,RGiE COIL WIRE (8] HIGH TENSION CORD CLAMP (9] No. 1 IGNITION COIL 2 IGNITION COIL 111) No. 3IGNITION COIL [12] MAIN WIRE HARNESS REGULATOR/RECTIFIER WIRE 2-21 [15] MAIN WIRE HARNESS [-··--=-··-] [5)(13) REGULATOMECTIFIEA WIRE =....=8=:..:=) fr2tAGE COILW1RE-W./81-<::))-WIIN-MAJNW1RE HARNESS = = = = = [19)(13) REGULATORIREC'nFIERWIRE --w BATTERY CABLE (MAJN FUSŁWIRE) (20] STARTER MAGNE11CSWITCHWIRE [12) MAIN WIRE HARNESS L.:l BF40A•BF50A [1]CHARGE COILS POWER COIL (8]WIRE HOLDER 8 CAM PULLY WIRE [5] POWER COIL WIRE [6] WIRE HOLDER A 2-22 • Power TrimfTIII Type: TRIM ANGLE ..cNSOR WIRE (14] 14 mm TUBE CLIP protoc oc after cJamp!ng tho [9) WIRE HARNESS CLIP [12) MOTOR CORD BUSHING 2-23 -f.. POWER TRIMITILT SWITCH [5] POWER TRIMITILT RELAY [6) POWER TRIMITIL T SWITCH WIRE (10) TRIM ANGLE SENSOR [8) POWER TRIWTILT MOTOR WIRE •Remote Control Type With Power TrimfTilt: [7) It] INDICATOR R --ec::::J--A -y--ec::::J--y -WIRE BAND EMERGENCY STOP SWITCH [4] R-IGNmON SWITCH CONTROL BOX WIRE HARNESS WARNING BUZZER ·._J 4--«::J--4-POWER TILT SWITCH 13] EMERGENCY SWITCH (1] 1NDICATOR (14) WIRE TIE (8) POWER TRIMfTIL T SWITC TRIWT1LT SWITCH WIRE [5) WARNING BUZZ R 113] REMOTE CONTROL BOX WIRE HARNESS (9] SWITCH WIRE [11) Stali>oard mount POWER TRIMfTILT 2-24 Ahgn the cable tie WTlh the edgeof the controlboxasIshown (1OJ Port mount type •Long Tiller Handle Type: 2-25 (1( SHIFT CABLE BF40A•BF50A •Long Tiller Handle Type: ·: With power trimllia type only See next page tor wteconnection. (1]' POWER TRIM/TILT SWITCH (10) WIRE BAND CLIP (3) [12)1NDICATOR (11) CONNECTOR (10}-1 10 • 20 mm (0.4 • O.B in) After seeuring thewires with wire band clips, cutthe end as pojected length is 10 • 20 mm (0.4 • O.S in), provided that the length is not specified inthe corresponding drawings. 2-26 BF40A•BF50A [2) Clamp thepower trim/tiltswitch wire to the wltecover. Aftersecuring thewir..swith wire band-clips, cutthe end as projected length is about 10 nun (4) POWER TRIM/TILT SWITCH WIRE • POWER TRIM/TILT SWITCH WIRE surethe power trimftilt switch wire doesnotinterfere with the throttle aim and throi· [&) IGNITION SWITCH [71 CONNECTOR COVER B (8) EMERGENCY STOP SWITCH (9) TILLER HANDLE WIRE HARNESS (9}-1 GROMMET ' •Wire Connection IntheLong Tiller Handle: --------(1) WIRE BANO CLIP (3) .--.. [2] (9) Bl 81 } EMERGENCY STOP SWITCH POWERTRIMI'TlLT SWITCH(Po-trlm/IIH typeonly) {''''''''': ..:; (8)COVER B (7JIGNmON SWITCH (8) INDICATOR W/8 ··+WIBI···· ! ;. .W/8 .. Lb ·····•' ! Lb :.r Lb .........:···•,± lg ....... .: ':!·' , .1 j 1/W : : • y ' • • y• . . . : :f Lg ••..• ./ l/ ' :15) CONNECTOACOVER A :j'::f-·t lb ..... ..... ..' 2-27 141 30 mmCONNECTOR COVER TILLER HANDLE WIRE HARNESS BF40A•BF50A 7. TUBE ROUTING [1) TUBE CLIP [27)VINYL TUBE (160 (24) VACUUM TUBE D [20) FUEL PUMP 2-28 [19) OIL TUBE [18) FUEL [4[ [3) AIR VENT TUBE A SETUBE BF40A•B 50A [5) BREATHER TUBE [2) AIR VENT TUBe B [6) SE TUBE B FUEL CONNECTOR [8) FUEL TUBE AIR VENT TUBE D TUBE (100 mm) [12) DASHPOT CHeCK VALVE WATER CHECK TUBE [14) FUEL FILTER [15) AIR VENT TUBE (170 mm) [18) FUeL TUBE B BF40A•BFSOA (1) VACUUM TUBE (3) (3.5 x4S mm) (24) (2] AIR VENT TUBE A AIR VENT TUBE (3) (4.5 x 9<1 mm) (3] TUBECUP B10 (23) 3-WAY JOINT A (2) (22] (5] AIR VENT TUBE C VINYL TUBE (4.5 x 160 mm) (6] VACUUM TUBE (21) (3.5 x 60 mm) AIR VENT TUBE B (20) 3-WAY JOINT B (19) AIR VENT TUBE D FUEL TUBE CLIP FUEL TUBE (17) AIR VENT TUBE (5.3 x 240 mm) (4.5 x 9<1 mm) (13) FUEL TUBE C (16] AIR VENT TUBE (4.5 x 170 mm) FUEL TUBE E (11) TUBE CLIP B10 (5) ..WAYJOlNTA (15] AIR VENT TUBE (4.5 x 170 mm) 2-29 3. MAINTENANCE 2. CARBURETOR SYNCHRONIZATION 3. DASH POT DIAPHRAGM 4. THROTTLE LINKAGE ADJUSTMENT 1. MAINTENANCE SCHEDULE 5. SHIFT CABLE ADJUSTMENT (Long Tiller Handle Type) 6. STEERING FRIC ION ADJUSTMENT (Long Tiller Handle Type) Eac l After First Every6 Every Every ! Refer Perform at every indicated month or operating hour interval, whichever comes first. • Engineoil • Idlingspeed Spark plugs ·-Pr pellerand cotter -Pin..- • --· --· · ... -. ..· • Fuel filler • Fuel line ChangeChange Replace Chec -adjust Chec -adjust Check-adjust Chec-k-adjust Check·adjust Replace Replace Replace Check level-tighten Check-tighten ': Referto the base shop manual. use • Emission related ttems (Bodensoo type and Canadian type) (I) Lubricate more frequentlywhen used in salt water. use monthOf20 Hrs 0 0 (1) months or100 Hrs 0 .,'.. 0 (1) year '2 y ars or I or -Every2 years (if necessary) 0(3) (2) For professional commercial use, l ghoursof operation todetermine pr per maintenance interval. to 3·2 '3·t6 3·5 ' 3-8 ·a-4 -' -8 '$-7 I '5-4 -- (3) Wilenoperating in salt water. turbitor muddy water, the engine should be flushed with dean water after ea h use. 3-1 2. CARBURETOR SYNCHRONIZATION t) Remove the engine cover. 2) Remove the 5 x I 0 mm plugs and sealing washers from the intake manifold of each cylinder. 3) Attach the vacuum gauge adapters to each intake manifold plug hole and connect the vacuum gauge noses to the adapters. • Connect The No. 1 vacuum gauge hose to the No. 1 vacuum gauge adapter. The No. 2 vacuum gauge hose to th No. 2 vacuum gauge adapter. The No. 3 vacuum gauge hose to the No. 3 vacuum gauge adapter. 4) Attach an engine tachometer and restart the engine. • Follow the tachometer manufacturer's instructions. 5) Run the outboard motor in an outboard test tank with the water at least 4 inches above the antlventilation plate. Allow the engine to warm up to nonnal operating temperature (Approx. 10 minutes). Engine exhaust contains poisonous carbon monoxide gas that can cause uncon ciousnes and de th.• If the e gine must be running, make sure the area Is well ventilated. 6) Check the idle speed (See base shop manual). BF40A•BF50A [1] VACUUM GAUGE ADAPTER 5X 0.8X 120L (3) 07510.3000100 or 5 x 0.8X SOL (3) 07510.3000200 [2] VACUUM GAUGE (Commercially available) 3-2 BF40A•BF50A 7) Pinch the SE tubes using commercially available tube clips keeping away from tube protector as shown. 8) Check the Intake manifold vacuum difference between cylinders. Take maximum vacuum differ· ence between each cylinder. It should be 20 mmHg (0.75 lnHg)or less. 9) If the vacuum difference between tile cylinders is not20 mmHg (0.75 inHg) or less, adjus1 as follows. Adjustment: • The No. 3 carburetor is the synchroniuotion base carburetor. This carburetor will not have a synchronization adjusUng screw. Adjust the carburetor to get the least amount ofvacuum difference between the cylinders. As the manifold vacuum difference decreases. the idle speed will become more stable. t) Turn the No. 1 and No. 2 adjusting screws so that the vacuum difference between each cylinder is 20 mmHg (0.75 inHg) or less. 2) After adjustment. check the Idle speed and adjust if necessary by turning the No. 3 carburetor throttle stop screw. 3) Snap the throttle several times and allow tile engine to return to idle. Check to be sure that the vacuum difference between each cylinder stays within 20 mmHg (0.75 inHg) or less. Readjust if necessary. 4) Stop the engine, remove the vacuum gauge, adapters and tube clips. 5) Install the 5 x 10 mm plugs and sealing washer$. 3-3 [3] TUBE CLIP (2) (Commercially available) [2] No.2 C BURETOR ADJUSTING SCREW TUBE 3. DASHPOT DIAPHRAGM Adjust the dashpot diaphragm after adjusting the idle speed (see base shop manual). 1) Remove the engine cover. 2) Remove the thronte rod from the throttle cam. (2)THROTILE ROD 3) Loosen the 6x 16 mm torx bolts using a commercial-(I)ly available torx bit (T30H). TORX BIT T30H 4) Disconnect the vacuum tube from the dashpot ched< 111 VACUUM TUBEvalve. 5) Move the throttle cam in the direction pointed byarrow until the throttle cam roller is set free from the throttle cam and hold the throttle cam. [1) THROTilECAM [2)THROTilECAM ROlLER 6) Move the diaphragm up or down slowly until the clearance between the throttle cam roller and throttle opener cam is 0.2 • 0.8 mm (0.008 • 0.031 in). While holding the clearance, tighten the 6 x t 6 mm torx bolls to the specified torque. TORQUE: 9 N•m(0.9 kgfom, 6.5 lbfoft) 7) Connect the vacuum tube to the dashpot check valve and anach the throtue rod to the throttle cam. 4. THROTILE LINKAGE ADJUSTMENT •Throttle Rod Length Adjustment 1) Remove the lock pin and washer, and disconnect the throttle cable from the throttle arm. 2) Move the throttle arm to the fully open position and be sure that the throttle arm contacts the fully open stopper. 3) Check that the throttle cam Is also at the fully open position and that there is clearance ol 1 mm (0.04 in) or less between the carburetor throttle lever and stop· per on the No. 3 carburetor. 4) If either the throttle arm or throttle cam is not at the fully open position, adjust as tallows. 5) Loosen the throttle rod pivot look nut. detach the throttle rod pivot from the throttle cam, and adjust by tuming the throttle rod pivot 6) Attach the throttle rod pivot to the throUJe cam and tighten the throttle rod pivot lock nut securely. BF40A•BF50A (3) THROTTL.E OPENER CAM [5] THROTTLE CAM T ROTTLE CAM (3) THROTTLE ROD PIVOT [2) LOCK NUT 7) After adjustment, move the throttle cam to the fully open position and be sure that there is clearance of 1 mm (0.04 In) or less between the carburetor throt11e lever and stopper on the No. 3 carburetor. 8) If the clearance is more than 1 mm (0.04 in}, readjust by turning the throttle rod pivot. 9) Adjust the throttle cable. then connect the throttle cable to the throttle arm. • Throttle Cable Length Adjustment Adjust the throttle cable length alter adjusting the throttle rod length. 1} Tum the throttle grip to the fully open position and check that tho throttle arm conY-;!!11!;31he fully openstopper. 2) Return the throttle grip to the fully close position. 3) Pushing the throttle anm lightly (i.e. by the amount of throttle link play) in the direction of arrow, check whether the center of throttle cam roller is at the right side (i.e. adVancing direction) to the reference marks. 3-6 (I) THROTILEARM (5]THROTILEARM (2) 1 mm (0.041n) or tass THROTTlE CABLE (2) THROTTlE CAM ROLLER 4) Adjust as follows. if necessary. 5) Loosen the ShiH pivot loci< nut, remove the 6 mm loci< pin and 6 mm washer, and diS(.'onnect the throttle cable. 6) Turn the throttle grip to the fully open position and hold it in the position using thefriction grip. 7) Remove the throttle rod pWot from the throttte cam. 8) Pulling the throttle cable's shift pivot lightly, turn the shift pivot so that tho throttle cable can be connected smoothly to the thronle arm that is set in the fullyopen pos"ion (i.e. throttle arm is lighUy in oontact with the fully open stopper). 9) Connect the throttle cable to the throttle arm and lighten the shift pivot lock nut securely. 10) Install the thronle rod pivot on the throHie cam. 11) Turn the throttle grip to the fully closed position. Pushing the throttle arm lightly in the direction of arrow, check whether the center of throttle cam roller is at the right side (advancing side) to the reference marks. BF40A•BF50A (3) LOCK NUT [4] 6 mm LOCK PIN SHIFTPIVOT .. i (1) SHIFT PIVOT .....jO' [4) REFERENCE MARKS THROTILEARM [31 THROTTLE CAM 3-7 (1] SHIF LINK B 5. SHIFT CABLE ADJUSTMENT (Long Tiller Handle Type) • Shift Cable Length Adjustment Adjust the shift cable lengm alter adjusting the shift rod adjustment (see base shoP manual). 1) Loosen the shift link pivot lock nut, and remove the 6 mm lock pin and 6mm washer. 2) Disconnect the shift cable from the shift link B and remove the 6 mm washer. 3) Set the shift link Bin the "N' (neutral) position. 4) Set the shift lever in the neutral position. 5) Rotate the shift pivot by the necessary amount until rt will easily insert into the shift link B. 6) Install the 6 mm washer over the pin of the shift pivot and connect to the shift link B using the 6 mm washer and 6 mm lock pin. 7) Tighten lhe shift pivot lock nut securely. 8) Aher adjustment, be sure that the shif1 lever moves smoothly into all positions. 6. STEERING FRICTION ADJUSTMENT (Long Tiller Handle Type) 1) Move the friction adjusting lever to the lett side fully until the friction lever contacts 10 the stopper as shown. 2) Check the starting torque by measuring the starting force using a spring scale at the center of the throttJe gnp as shown. The motorshould start to move with 100 N (10.0 kgf, 22.0lbf). 3) If it does not. loosen the lock nut once. Then, relight· en the self-locking nut to the specmed torque by tum· ing the adjusting lever Ia the left side fully. • Tighten the friction adjusting lever and tighten the lock nul lo the specified torque. TORQUE: 9.5 N'fl'l (0.95 kgf'fl'l, 6.9 IbM!) 4) Recheck the starting force. If the starting forces is less than 100 N (10.0 kgf, 22.0 lbf), check the fric«on discs for contaminated with grease (P. 12·1 ). [1] STOPPER [I] SHIFT LINK B [3] FRICTION ADJUSTING LEVER [4] THROTTLE GRIP BF40A•BF50A 5. FUEL SYSTEM 2. CARBURETOR/MANIFOLD REMOVAL 1. SILENCER COVER a. REMOVAL.JINSTAL.LATION 1) Remove the engine cover. 2) Pull off the breather tube from the silencer cover. 3) Unfasten the SE thermal vatve heater wire from the clamp on the silencer cover. 4) Pull ott tho vinyl tubes from the engine under case. 5) Remove the 6 mm flange bolts, washers and cover nut, then remove Ule silencer cover from the silencer plate. 6) Install the removed parts in the reverse order of removal. (1] COVER NUT.. [6] VINYL TUBE (2) ASSEMBLY: fnsen the vinyl tubes into the holes in lh& engine uncku case as shown. [6}-1 VINYL 5-1 4. CARBURETOR/MANIFOLD INSTALLATION Insert until the white line aligns with the hole edge as shown. (2]·1 BREA ER TUBE (2]·2WHITE UNE [3] 6 mmWASHER (2) 6X40 6 X 25 [4] SE THERMAL VALVE HEATER WIRE (5] SILENCER COVER 2. CARBURETOR/MANIFOLD REMOVAL Gasoline fa highly flammable and expfooiVe. You can be burned or serioosly Injured when han· dllng fuel. • Keep heat, eparka, and flame away. •Handle fuel only outdoors. • Wipe up spills immediately. 1) Remove lhe enginecover. 2) Remove the llywheel cover (P. 6·1). 3) Drain me carburetor by loosening the drain screws. 4) Pull off the breather tube from tho siloncor covor. 5) Remove lhe 14P connector (remote control box wire hames.s or tiller handle main wire hamess) and 2P connector (SE thermal valve heater wire) from lhe connector holders, and disconnect the2P connector. 6) Disconnect the throttle rod from the throHie cam. 5-2 (1) BREATHER TUBE (2]THROTTLEROD BF40A•BFSOA CAM 7) Pinch the fuel tube with a commercially available tube clip and disconnect the fuel lube (No. 1 carburetor suppty line) fromthe fuel pump. 6) Pinch the fuel tube with a commercially available tube clip and diS<:onnect the fuel lube E (No. 2 and 3 carburetor supply line) from the fuel pump. 9) Pull off the vinyl tubes from the engine under case. 10) Pull off the air vent tubes from the engine under case. 5-3 TUBE CLIP (CommorclaHy aval-) [3] FUEL PUMP FUEL PUMP BF40A•BF50A FUEL TUBE E (2) TUBE C IP (Commercially available) (2]ENGINE UNDER CASE (2] ENGINE UNDER CASE 11) Remove the two 6 mm cap nuts and five 6 x 32 mm Hange bO»s. then remove the carburetor and manifold assembly from the crankcase. [1] CARBURETOR/MANIFOLD ASSEMBLY [2] 6 mm CAP NUT (2) (4) 6x32(5) INTAKE MANIFOLD GASKET (3) FUEL TUBE CLAMP 3. CARBURETOR a. SEPARATION Gasoline Is highly flammable and explosive. You can be burned or seriously Injured wnen han· dUng fuel. • Keep heat, sparks, and flanl& .r e•-•1..deteriorat d. 6 x 18 mm SCREW (8) No. 2 CARBURETOR [9] SILENCER PLATE OLLAR (6) 10 N•m(1.0l 28 mm flange botts, two 6 x 40 mm flange bolts and tour 6 mm plain washers, and remove the separator cover. 3) Remove the 14P connector from the connector holder and disconnect the 14P connector. 4) Remove the 6 mm lock pins and 6 mm washers. the disconnect the throttle and shift cabtes. 6mm PLAIN WASHER {2) [1] 6mmPLAIN WASHER{2) 14P CONNECTOR 6x28{2) [2]SEPARATOR COVER 6xm, 1.11bMI) [1] INDICATOR [5) EMERGENCY STOP SWITCH BF40A•BF50A IGNITION SWITCH (1] CUTOUT F AT SECTION 15-10 • SHIFT LEVER, SHIFT UNIT, THROTILE ARM [1] 5 mm WASHER (3) [ 1] GUIDE PLATE [20] HOLE CAP (19] 8x50mm SOCKET BOLT (18]8 mmWASHER 15-11 [4] SHIFT GEAR [3] THRO TLE ARM (16] [7]SPRING [6]SHIFT ARM PIN [5]ROLLER [14] BUSHING SHIFT LEVER BUSHING [8] SCREW (2) [12] (2) SHIFT FRAME [15] SHIFT LEVER • Apply grease to the: -roller. shift arm pin and spring. -gear and roller slkling section of the shift gear. -bushing. -gear of the shift arm. • Note the installation direction of the shift arm pin. • Set the roller and shift gear in the neutral position as shown. • Install the shift gear and spring guide assembly with the shift arm set in vertical position as shown. • Apply grease to the pivot point of the throttle arm. • Tighten the 5 x 12 mm hex bolt to the spe<:ified torque. TORQUE: 4.5 Nom (0.45 kgfom, 3.3 lbfoft) 15-12 BF40A•BF50A [2) RO....ER [ ) SHIFT FRAME SIDE SHIF GEAR [3) GUIDEPUTE PIN [51 [6] SPRING HRO E BF40A•BF50A • Apply gr e ase 10 the: -sliding surface of the lever stopper. -sliding surface of the shih lever. -busing. • Position the shift ann in a vertical position to align the Shih unit squaro and shih gear. Install the shift lever. • Install the shift lever by aligning the square of the lever stopper and that of the shift gear. (21 SHIFT LEVER STOPPER (31 SHIFT UNIT 41 x 12mm BOLT [11 HOLE CAP ASHER (2) (7J 8 mm WASHER (61 BUSHING [51 SHIFT LEVER 15-13 • POWER TRIM/TILT SWITCH • Power trim/tilt type only: Install the power till switch so lhat the "UP' mark is at the bracket bolt installation hole side (lower side) as shown. and install the switch grommetnoting the direction. • Power trim/lill type only: Replace lhe wire band with a new one, if it has been cut. After securing the wires wrth a new wire band, cui ttlm, 0.91bM1) • Apply grease to tile sliding surtaces of the cable pivot. • Apply grease tothe pivot point of the throttle arm, then install the throttle rodwith tile two 10 mm washers and 9mmw·clip. • Power trim/tilt type only: Check whether the power tilt wire does notintertere with throttle rod. • Apply grease to the throttle grip installation surtaoe ol the tiller handle and friction disc. Install the friction disc by aligning the grooves ofthe throttle friction disc with the bosses ofthe tiller handle as shown. • Install the throttle cable pin on the cable pivot with the projected length at both ends of the pin equal as shown. switch (3)GROOVE BF40A•BFSOA 9-10 mm (0.35-0.39 in) [3)10 mm WASHER (2) [2) THROTTLE ROD (4) 9mmE-CLIP FRICTION DISC (2) BOSS 8 mm (0.321n) 15-16 • Apply grease to the inside of the throttle grip pipe, inside ofthe friction grip, both onds of the throttle cable pin, handle pipe and both sides of the friction pad. Set the throttle friction pad on the grip pipe. • Install the grip pipe on the tiller handle by slowly turning it clockwise. • Tighten the throttle friction grip against the thro.tt.. fric· lion disc by aligning the cutout of the friction pad with the boss of the friction disc. Tighten the 6 x 12 mm flange bolt securely. • Tum the grip pipe to the fully close position and install the grip rubberby aligning the '&' mark with fully close mark. 15-17 (7) (Inside.) THROTTLE FRICTION GRIP [1) GRIP PIPE [1) BOSS [4) THROTTLE FRI TION PAD [4] GRIP RUBBER 6x12 [3) ".a.• mark •STEERING BRACKET • Instal a new steoring handle busing when .. has been removed. • Apply grease to the inside ol the steering handle bush· ings, boCh ends of the 12 mm thrust washe<. inside olthe cfostance collar and boCh ends ol the wave washer. • Clean off grease on tho threads of the 12 x 80 mm hex. bolt, then dghlen the 12 mm hex. nut to the specified torque. TORQUE:29 Nom (3.0 kgt.m, 22 lbMt) • Hold tho 12 mm hex. nut and tighten the 12 mm lock nut to the specllied torque. TORQUE: 54 Nom (5.5 kgf•m, 40 lbl•ft) [2) 14 nvn WAVE WASHER 54 Nom (S.SIMt) :mmHEX.NUT ..29 N•m (3.0 .gt•m. 22 lt>lolt) [8) 12mm THRUST WASHER 15-18 BF40A•BFSOA (3[ 04ST ANCE COLLAR STEERING BRACKET [6) HEX. BOLT [7)STEERING HANDLE BUSHING (2)Do not "'use. I BF40A•BF50A •TILLER HANDLE WIRE HARNESS • Connect connectors to the wire connectors of the same color, cover the connectorswith the connector covers andsecure them with the harness band clip. • Replace the wire band with a new one, ifit has been cut After securing the connectors and wires with a new wire baro. cut the ero of!he wire baro so the projected endlengthIs10-20 mm (0.4-0.8 in). • Install the tiller handle wire harness by aligning the wire tie wilh the grommet as shown PowerTrim/TiltType: [3) WIRE TIE [5] SWITCH WIRE [14) CONNECTOR COVER A [13) IGNmON SWITCHWIRE [12) [6)WIRE BAND CLIP POWE.R TRIWTILT INDICATOR WIRE [9) 10-20 mm (0.4 -0.8 in) nLLER HANDLE WIRE HARNESS nLLER HANDLE WIRE HARNESS 30 mm CONNECTOR COVER 15-19 BF40A•BF50A Gas Assisted Tilt Type: [t] WIRE BAND CUP (3) [tO) CONNECTOR COVERA [9] IGNITION SWITCH WIRE [8] INDICATOR WIRE (7] 6 x 12 mm BOLT WASHER [2) EMERGENCYSTOP SWITCH WIRE [3) CONNECTOR COVER B [4) TILLER HANDLE WIRE HARNESS [51 30 mmCONNECTOR COVER [6] CONNECTOR BRACKET 15-20 BF40A•BFSOA •CONTROL CABLES, UNDER COVER • Install lhe cable holder as shown noting the IO$lallalion direction andlighten the 6 x 12 mm bolt washer to the specified torque. TORQUE: 0.7 Nom (0.7 kgkn, 5.1 1bMt) • Apply grease to the link pins ol the throttle arm and shift arm, then connect the throttle cable and shift cable. • Set the shift cable by aligning tile groovo olthe cable with the cutout of the mounting point. • Set the throttle cable by aligning the groove with the cutout ol the cableholder. • Route lhe thrOI!Ie and shift cable through the grommet (upper holo: shift cable, lower hole: throttle cable) holesand set the grommet in the case correctly. • Power trim/lilt type onty:Check whether the power tilt switch wire does not interfere wHh the throtde cable. • Tighten the cover screw to the specified torque. TORQUE: 2.2 Nom (0.22 kgkn, 1.6 IbM!) (1) SCREW (6) Z2N-m UNDER (0.221<.gi-m, 1.6 lbfoft) (5) CABLE HOLDER (8) (6] THROTTLE ARM GROMMET (71 SHIFT ARM 15-21 d. INSTALLATION 1) Install the long tiller handle assembly to llle motor. 2) Install the 10 mm washers and lighten the 10 mm self·locking nuts to the specif ied torque. TORQUE: 34 Nom(3.5 kgfom, 25 IbM!) 3) Pass the long tiller handle wire hamess through the under case grommet. and secure it with the wire harness clamp. 4) Set llle oontrol cable setting plate into the groove of me under case. 5) Pass the control cables through the under case grommet and set the control cables by aligning llle groove of the control cable with the cutout of the control cable setting plate. 6) Adjust !he control cables (throttle control cable length: P. 3·6. shift oontrol cable length: P.3·8). 7) Connect the oontrol cables to the shift arm and lllrottle arm with the 6 mm plain washers and 6 mm lock pins [21 SHIFT CABLE [3) THROTTLE CABLE [5) WlRE HARNESS CLAMP [6) SHIFT CABLE [7) 6mm 6 mm LOCK PIN (2) WASHER(4) 15-22 8) Install ohe separator cover with the two 6 x 28 mm !lange bolls and two 6 mm washers and 6 x 40 mm hex. bolls. 9) Tightenthe two 6 x 28 mm ftange bolls and two 6 x 40 mm hex. bolls securely. 1O)Connect the 14P connector of the tiller handle wire harness to the main wire harness and set the 14Pconnector10 the connector holder. 11)After installation check the throttle operation and gear shift operation. 15-23 [3] /a!6 mmPLAIN WASHER(2) 14P CONNECTOR BF40A•BFSOA • 40(2) (2) CONNECTOR HOLDER 16. ELECTRICAL EQUIPMENT 3. E T (Engine Coolant Temperature) SENSOR 2. POWER COIL 4. INDICATOR 1. COl UNIT a. INSPECTION Measure the resistance between the terminal,s and be sure that the measurements conform to the ranges shown in the table below. • Use a tester that is equivalent to or higher than the performance specified; Internal resistance: 20 kCWOC. 9 W.WAC • Be careful not to touCh the melalllc pMof the tester probe with your body, otherwise correct resistance value cannot be obtained. • Reao the tester manufacturer's operation Instructions carefully before operatio n with a tester. Be sure the teste(s battery is fully charged and check the meter before using the tester. • Use a R x 1 scale of an commercially available multi· meter. and meter shows current flowing from negative (-) to posrtive (+). '4 L * 13.... 16-1 1.4·6 1 11 -50 ...• .. I I . -t: · 4S4 ·--- '14(Not used) ·----- 0 BF40A•BF50A18 19 20 .• : i 16-2 2. POWER COIL Disconnect the 2P power coil connector, and measure the resistance between the terminals. • See page 6-1 for the power coil replacement. 3. ECT (Engine Coolant Temperature) SENSOR • The sensor resistance decreases as the coolant tern· perature increases as shown on the right table. 1) Disconnect the 2P connector from the thermo sensor and measure the resistance between the sensor ter· minals at the room temperature. Standard resistance: 1 -5 kO 2) Connect the 2P connector and start the engine and warm up the engine to normal operating temperature. 3) Stop the engine, and disconnect the 2P connector and measure the resistance. Standard resistance: 200 • 400 Q • ECT sensor installation/removal is almost the same as installation/removal of the sermo switch. (See page 8-2 ofthe Base Manual.) "' (,)......wa:.. "' 10 0.1 (1) POWE.R COIL WIRE (1) ECTSENSOR O.O_.!SO 0 50 100 15(/C -so o 100 200 m•F (2] TEMPERATURE 16-3 BF40A•BF50A 4. INDICATOR a. INSPECTION The green indicator should turn on when connecting a 12V ba nery (+) terminal to the Black/yellow terminal and (-) to the Orange terminal. The red indicator should tum on when connecting a 12V battery(+} tenninal to the Black/yellow tenninal and(-) to the Red terminal. • Be sure the battery is in good condition before perform· ing the test. 16-4 BF40A•BF50A Remote controltype withpowertrlml'tllt {Fnme seMI number · ..ETP ,.._,.. ,.(1) . ... ... ..-·-.. -. .IWffCH •••• ii i ..? .... ....y ..: 1<1.... .... i..· ' ....... __.: :: j!! .... fCII'110N) , . • +-..'-----------· -..! .. . i (111ew.. ---.... .. I• V4-=:.-..:Q ' ..m -I [11![IJII'CJIIIIPERn.t IETHENW.1LTSWITCit VAJ.YI:HEATERI II =-- I {tet-2 OENt.. (10)i. lI I(10JINOICATOI'I ________.,__ji •f IIJ l1l ="'' '..1l!!i"tlill ' "" 1401 lUI SEMtOAP'OWŁR T-.TRIE1AY Itt) IIIIIPCIIWDinLT$WfTCH 11\.YW)t(fl ..... 1131OIU..Y[:MJCONNtCTOA8RACUT ::: a i--·X tB..g..ii..il ..•• a..i Hu6t 1'"1 '2S}PUUIA .. CAMPULUY PULSIA -· (30]ECTSENIOR 1>11 OtL .... I!ISUAISWITCH (32) COIL 1 ....K1'\UQ KiHmOM COil 2 .. .... ... --· ......81 ..KP\.00 Remote control type with power trim/lilt 121 1>1 [t) ..A ...._!ftR UGHTINQ • '· I '\ SWI'T'Qt 1 (j;;_·';··· ! ! ' --- (4) ! Frame serial number: } BF40A: After BAY$-3400530 BFSOA:AfterB..7 MAOHEnC COiL......{l:l'V•Io..) ..nA HARNE.a$ C,Q PULLEYPULlER -· OO I2$JCOIUHrT (32)JGNmoHCOL 1 ... .. . . .... . ... ... (34) ·z.:,. l15J..K fGNITlON ..E"..· liEII18·2 (II POWIJt liL T -""""' """"' .. (40 ) (.a] TRIM AHQ .. s•..e..anLTAIU.Y BF40A•BF50ALong tiller handle type withpowertrim/tilt { Frame aerialnumber: } BF40A: Up to BAYS-3400629BF50A: UptoBAZS.340 0006 (') ':'ACMOM na LMnutr·-. ... . )\ ... : : j ! ! .'!" ,,., !'!-( 12Y MAONtTIC = ' • QII:IUND 'ONQ l1U.ffi...,.DU(01-I "'.HntEIOMN. [f)-­IWm:N[f).. "(11)NIUTIW.""""" ....-""'""" (If) (It)(12Y.10A) (21)"""""- (>4) COI UIIIT (31) lwm:Nl.lffil .) ..(7)18-3 l>tJ (.,) '111111A.NGl frrOIIIW!Ant.. TPlll.A : .. ,POWift flLT1-wrJCH .. ,,.,ECT8191SOR)>OJOILPR ESSURE SWITCH(311ICJNmoH COli. 1 ""' I... .. IONmoN COILS ·..·-PLUG Long tiller handle type withpower trlm/1111 {Frameserial number: } BF40A:After BAYS-3400530BF50A:After BAZS-3400007I:IJ [JJ (1) TIWrl MIITIJII .__awm:H .... • .. i J : 1 .........../ 1"": ! : • . . . ··r..1 . 1 Hl • • • • f I .... Q.... a&.... oa • • . ' . ' ' . • , , , .....,....,._ .. .. .. ··-.. a .. !lloio.;;._,.,..1 .. ! I .,.,.."""" (10)"""""" 110)IW!TOI1 1111 (12) r=· g; "' "' . ' - .. :;:. .. -1201IECTIENSOR w ........ ·•· (11)..lA) =. me : I I I , 1 · --• ' • I .. --I -'111) 8··-1 ....' (») . i. . siS :':;.... I . I ....... I . .. -..-..--l u ...... .. u 1"1 ... .. [41) ::o..u: POWI III nLTMl.AY 1>11.............. t'MTCH 18-4 BF40A•BF50ARemote control typewith gas 888lstad tilt l2l..T.\" ll.. Qg oq ftOa I ! ! i ! ! ! • ! I :! PJ .... h i.... & ' ; ail IIITUHARN!SS:j !! : · i ! :: ..i (OPTION)! .... ..,.....t..••••••··-·-1' ......40•..1-·•-•••••••BI••-4C:J f-..--.--. .... CONTIIOL -, ii.... .. : I 1110Ptwm:Ot (11} GRCUID --- CHARGE lUI.......,... -1 .. .. CAMPULLŁY •...__ ('10)KTSIHSOfl.. y 'I YO oo:-• ..I _,.,•.1 .. .. ... lZSJ COlUHfT a J ••• t iB illi..i!HH inod5 •• 1HHit 1001IOHmON COIL 1 .. 18-5 I I I Swm:H I , 1 1 1.!Fl D .1 · «> (1] [11)FUSE 00 """"""lwrTCH (10A) ....···.. n PLUG COIL 2 .... .&PARKPLUG Long tiller handletype with gas assisted tilt If) . [1..FLYWHEEL i : r-nm ..9 go • (14) (1] .. =" c (17]CHAI!GlCOIL(12'V-10A) . ,..., I .. ·I f101 111) (10J..P..O QAOUND ·· -·· -·· -··[I) OleRQENCY1101'1MTCH III ., "'w..w . I II (7)ODC;ITOR...... . .. .. .. •ntiJWM. ORAYv.u.va HUJW:" [1>1l::ifeil?Fl 1221COI UNn .. (-MJ FUSE[f) (lOA)lr..wtni'IN ._..,. .. PUUIA (271I!CT """""'(:ill) OL PAUSIMI!&WITCH y[211tGtr1 1110 N COIL 1 Na.t..... .. PUJQ [011IGHmoN COIL. 2-..13>1No.2..... .. PUJG I'> IIGHtT'ION COIL 3 .... 1(...... CONTENTS BF40A..BF50A Paper Book Part No. 66ZV300T PREFACE This manual covers the construction, function and servicingprocedures of the Power Trim/Tilt Assembly for Honda I SPECIFICATIONSBF40AoSFSOA Outboard motors. For service information which is not covered in this suppl&­ ment, please refer to the bese shop manual (Parts number 66ZV3 0U). Pay anention to these symbols and thelr meaning: f!§lf§NSH Indicates a strong possibility of severe per· sonal lnjury or loss ol llle ll lnstruc11ons are not followed. CAUTION: Indicates a possibility ol personal injury or equipment damage II instructions are not followed. All Inform tion, illustrations, directionsand specifications include in this pu lication are based on the latest prod· uct information availabl at the lime of approval for print· ing. Honda Motor Co., Ltd. reserves the right to make changes without incurring any o ligation whatev r. No part ot this publication may reproduced without written permisston. SE..CE INFORMATION • The marl-j Replace lha power irimltilt switch. 2-5 Ooesno1 til1 up 0 0 -lo 0 -- - 2-6 Does Docsnotholdtin Extended sioo side--0 ---- -- 0 -..-= ---I -I i -f -• -- -- lowet chambEW blow Pf'essure blow presswe --- 0 ---I - --- - BF40A•BF50A Ch..k point Check/repair method See page 2-7 -··· --® Free piton, 0-ring, oil seal @ Oil (ATF) @ Upper cham· ber check valve <].; SpOOl vaJve (w1.1h bu-ill-in upper relief valve) valve ening, ama..Of' torelg!l al. Check the ·ring tor damag&. rcplaoc it ncccssary.Replace the! manual val.. feptace •fnt...essary. a e. repl<"tCC ifMCGssruy. Replace lhe piston rod assembly if naces.-. Check the oil level and add if nee· age, wear or foreign material. Clean and reaasemble the upper or forei..m ateri aL Clean and reassem the spool vaNe prop·eri...Do nei disassemble tho spool va ve. ei1her as 1he upp$r relial a..e, wear or foreign malarial. C an and reassemble the lOwer chambe.....eckvarve property. or forei..mcueriat.Ciean and : reass m the down retiet valve ' propc..y. QO Thermal ICheck the check valve fOt . ingij lightly. Push in aslant. [1) OIL SEAL 0 ®[41Ho4dtn""' shape ·u·. [6] OIL TA..K J SEALING [9] -aJMOT R CORD BRACKETS [8] 0-RING 2.0 X 52.5 mm :_oo not reuse TAPE • POWER TRIMITllT MOTOR After .nstalling the yoke, lighUy tap on the outer sur.. face ol the yOke with a plas·he hammer (lor snug tilting of tt\.o armature bearing). • Remove the burrs al the arma1ure shah with a tine Otnet andbring theOil levct to the lower edge ollhe oil tiller port. Loosely tighcen the oil hole cap. 10) Move the piston rod from the tully compressed posi· tion to the tully extended posmon two or three tirnos by operating the power trim/tilt switch. 11) Push the "UP" side of the power trlm..ltt switch again to extend the piston rod fully. 12) Remove the oil cap bolt and ch&Cl< the oil level. II the level is low. add ATF with a syringe or equivalent tool until ATF llows out ot the oilfiller p0<1. 13) Install the newO·ring on the oil cap and tightltll the oil capto the specitiad lolque. TORQUE: 0.8 N•m (0.08 kgf•m, 0.58 lbf•ft) 14)Wtpe up ATF spilled from lhe cylinder comp. thor· oughly. Operate the power lll..ln switcl> and cl>eck that lhe piston rod moves smoothly. 1 5)Che<:k the blow pressure (P. 13·29). e. UPPER JOINT METAL INSTALLATION 1) Apply LOCTITE® 27t or equivalent to the thread of the piston rod. 2) Install the upper joint metal against the piston rod. 3) Holding the piston rod and tighten the upper joint metal to the specified tOe power trim/till assembly can operate while it is isolated from the outboard motor. Extend the piston rod of 111e power trim/tin assembly fully after operating (moving up and down) the pis· ton rod several times. Check A TF level in the power trim/till assembly oil tank. II must be at the specified level (P. 13-28). Perform the cylinder upper chamber side and lower chamber side blow pressure inspection using the special tools and commercially available pressure gauge. Use the pressure gauge which measures 40 MPa (400 kgflcm'. 5.600 psi) or above with P/F 1/4 thread. • LOWER CHAMBER SIDE BLOW PRESSURE 1) Remove the internal circlip, manual valve and sealing washer from the valve body. Install the special tool (gauge joint body B) and the sealing washer, and tighten the special tool to the specified torque. TORQUE: 1.7 N•m (0.17 kgf•m, 1.2 1bf•ft) • Be sure to remove the manual valve with the piston rod tully extended. or A TF spurts out. • A small amount of A TF flows out after removing the valve. Install the special tool quickly. • Install the sealing washer securely not to let it collapse in the valve body. 2) Attach a commercially available pressure gauge to the spcctal tool that is set in the valve body. 3) Be sure that ATF level in the oil tank is at the speci· tied level (P. 13·28). 13-29 [1] SEALING WASHER BF40A•BF50A (1] For lower chamber side GAUGE JOINT A 070PJ.V150100 {2} For upper chamber side .. GAUGE JOINT B 070PJ-V150200 [2] INTERNAL CIRCLIP (31 1MANUAL I\VALVE [4] Remove. e[6) GAUGE JOINT B 070PJ·V150200 (5) PRESSURE GAUGE (Commercially available) 3) Push the 'ON' s•de of the power trim/tilt switch and oompress tho piston roo fully. 4) Push the ·up· side ot the power lrimlli.. switch again. With the piston rod extended fully, measure the lower chamber btow pressure by reading the pressure gauge. If the blow pressure is out of the specified range, check each part of !he power trim/tilt assembly for oil leakage. tl there is no oil leakage but the blow pressure drops below the specified pressure quickly, the power trim/till motor assembly can be faulty. Replace the motor assembly w"h a new one and measure the blow pressure agaJn. After measuring the lower chamber blow pressure, measure the upper chamber blow pressure. • UPPER CHAMBER BLOW PRESSURE 1) Remove tho special tool (gauge JOint body B) that is for measurement of the lower chamber blow pressure from the valve body. Install tho special toot (gauge joint body A) that is for measurement of the upper chamber blow pressure in the valve body. Tighten the spedal tool to the specified torque. TORQUE: 1.7N•m(0.17kgf•m, 1.2 1bf•lt) • 6e sure to remove the special tool wiU• the piston rod fully extended, or the automatic transmission nuod spurts eu1. A sm. amount ol ATF flows OU1 after romoving the special tool (gauge joint body B). Install !he special tool (gauge joint body A) quickly. Install the seating washer securely not to let .. ool· lapse In the valve body. 2) Attach a oommerciatty available pressure gauge to tho spacl