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Honda BF5A - page 1
00X31-ZV1-6500 BF5A 31ZV1650 00X31-ZV1-6500 2eY1 100.2009.07 Printed in Japan N BF5AK0 P ANTONE 288 CVC DIC F101 BLA CK Includes US and Canadian Models ...
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Honda BF5A - page 2
− The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Keep this Owner’s Manual handy, so you can ref er to it at any time. This Owner’s Manua l is cons idere d a perma nent par t of the outboa rd motor a nd should rem ain wit h the outboar d motor ...
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Honda BF5A - page 3
1 INTRODUCTION Congratul ations on your sele ction of a Honda outboar d motor. We are cert ain you will be plea sed with your purchas e of one of the f inest outboard motor s on the marke t. We want to help you ge t the be st resul ts f rom your new outboard motor and to operate it saf ely. This manual conta ins inf ormati on on how to do that; ple ...
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Honda BF5A - page 4
− − − − − − 2 A FEW WORDS ABOUT SAFETY INTRODUCTION Saf ety Mess ages Saf ety Headings Saf ety Labels Saf ety Section Instructions I MPORT AN T SAFET Y I NFORM AT I ON . O UTB O A R D M O TO R S A F E TY. Your saf ety and t he saf ety of othe rs are ve ry import ant. And us ing this outboard m otor saf ely is an im portant responsibilit ...
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Honda BF5A - page 5
3 CONTENTS ................................... OUTBOARD MOTOR SAFETY . 6 ................ IMPORTANT SAFETY INFORMATION . 6 ................................ SAFETY LABEL LOCATIONS . 8 .................................. CONTROLS AND FEATURES . 11 CONTROL AND FEATURE ................................ IDENTIFICATION CODES . 11 .... COMPONENT AND CONTROL ...
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Honda BF5A - page 6
4 CONTENTS ................................................................ OPERATION . 25 .................... SAFE OPERATING PRECAUTIONS . 25 ....................................... BREAK-IN PROCEDURE . 25 ..................... TRANSOM ANGLE ADJUSTMENT . 25 ....................................... PORTABLE FUEL TANK . 26 .......................... ...
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Honda BF5A - page 7
5 CONTENTS .................................................................... STORAGE . 58 ................................... STORAGE PREPARATION . 58 .......................................... Cleani ng and Flushing . 58 ........................................................................ Fuel . 60 .......................................... ...
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Honda BF5A - page 8
6 IMPORTANT SAFETY INFORMATION Operator Responsibility OUTBOARD MOTOR SAFETY It is the operator’s responsibility to provide the ne cess ary saf eguards to prote ct people and prope rty. Know how to stop the e ngine quickly in case of emergency. Underst and the use of all controls. Attach the emergency stop switch lanyard securely to the op erator ...
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Honda BF5A - page 9
7 Carbon Monoxide Hazard Ref uel With Care OUTBOARD MOTOR SAFETY Gasoline is extremely f lammable, and gas oline vapor can e xplode. Ref uel outdoors, in a well - ventilated area, with the engine stopped. Ne ver smoke nea r gasoline, an d keep other f lames and sparks awa y. Remove any porta ble f uel tank f rom the boat f or ref ueling. Keep the p ...
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Honda BF5A - page 10
US, Puert o R ico, and US V irg in Islands T y pes 8 SAFETY LABEL LOCATIONS OUTBOARD MOTOR SAFETY FUEL TA NK The labels sh own here con tain important saf ety inf ormation. P lease read them caref ully. These labels are con sidered perma nent part s of your outboard motor . If a label c omes of f or become s hard to rea d, contac t an authoriz ed H ...
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Honda BF5A - page 11
GASOLINE FL AMMABLE DANGER GAZOLINE INFLAMMABL E DANGEREUX CAUTION DANGER KEEP TOTALLY CLOSED W HEN NOT IN USE. KEEP AWAY F ROM HEAT, SPARKS, AND OPEN FLAM E. ‘‘SECURE ABOVE DECK IN WELL VENTILATED AREA.’’ ‘‘DO NOT USE FOR LONG TER M FUEL STORAGE .’’ HARMFUL OR F ATAL IF SWALLOW ED. KEEP OUT OF REACH OF CHILDREN. IF SWALLOWED, DO NO ...
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Honda BF5A - page 12
Gasoline is harmful or fatal if swallowed. Keep the fuel tank out of reach of children. Honda outboard motor is designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the outboard motor. Failure to do s o could result in personal injury or equipment damage. Gasol ...
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Honda BF5A - page 13
11 CONTROL AND FEATURE IDENTIFICATION CODES CONTROLS AND FEATURES Shaf t Length Type Model S L S: Short Shaf t L: Long Sha f t BF5A BF5A is provided w ith the f ollowing types accord ing to t he shaf t leng th. Shaf t Length Ref er to this cha rt f or an explana tion of the Type Code s used in this manual to ide ntif y control and feature applica t ...
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Honda BF5A - page 14
12 COMPONENT AND CONTROL LOCATIONS CONTROLS AND FEATURES ANODE SPARK PLUG THROTTLE GRIP CHOKE KNOB FUEL HOSE CONNECT OR (MA LE) TRANSO M ANGLE ADJUST ING ROD PROP ELLER GEARSHIF T LEVER THROTTLE FRIC TION KNOB COOLING SY STEM INDICAT OR WATER INTA KE PORT (each si de) OIL PRE SSURE INDICAT OR WASH S CREW (FLU SH SCREW) STEERING FRIC TION BOLT EMERG ...
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Honda BF5A - page 15
13 Portable Fuel Tank CONTROLS AND FEATURES VENT KNO B FUEL GAUG E PRIM ING BULB FUEL HOSE FUEL HOSE C ONNEC TOR (FEM ALE) FUEL TA NK FUEL FILLER C AP 09/06/15 14:44:40 31ZV1650_014 ...
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Honda BF5A - page 16
14 CONTROLS Choke Knob Emergency Stop Switch Clip and Emergency Stop Switch CONTROLS AND FEATURES EMERGEN CY STOP SWITCH EMERGEN CY STOP SWITCH CLIP PUSH EMERGEN CY STOP SWI TCH LANYARD EMERGEN CY STOP SWI TCH CLIP CHOKE KNOB O O N N O O F F F F EMERGEN CY STOP SWI TCH LANYARD The choke knob opens and clos es the choke valve i n the carbure tor. Th ...
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Honda BF5A - page 17
15 Throttle Grip Throttle Friction Knob Gearshif t Lever CONTROLS AND FEATURES INDEX MARK T T O O D D E E C C R R E E A A S S E E F F R R I I C C T T I I O O N N T T O O I I N N C C R R E E A A S S E E F F R R I I C C T T I I O O N N THROTTLE GRIP THROTTLE FRIC TION KNOB R (reverse) N( n e u t r a l ) F( f o r w a r d ) GEARSHIF T LEVER The gearsh ...
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Honda BF5A - page 18
16 Engine Cover Lock Lever Transom An gle Adjust ing Rod Starter Grip CONTROLS AND FEATURES UNLOCK TRANSO M ANGLE ADJUST ING ROD ENGINE C OVER LOC K LEVER STARTER GR IP Directio n to pull The engine cove r lock lever f aste ns the engine c over to the outboar d motor. The trans om angle adjus ting rod adjust s the trans om angle of the outboard mot ...
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Honda BF5A - page 19
17 INSTRUMENTS Steering Friction Bolt Tilt Lever Fuel Gauge CONTROLS AND FEATURES STEERING FR ICTION BOLT T T O O D D E E C C R R E E A A S S E E F F R R I I C C T T I I O O N N T T O O I I N N C C R R E E A A S S E E F F R R I I C C T T I I O O N N ENGI NE COVER G RIP TILT LEVER FUEL FILLER C AP FUEL GAUG E Less f rictio n allows the outb oard mot ...
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Honda BF5A - page 20
18 INDICATORS Oil Pressure Indicator Cooling System Indicato r OTHER FEATURES Rev Limiter CONTROLS AND FEATURES COOL ING SYS TEM I NDICATOR OIL PRE SSURE INDI CATOR TA KIN G CARE OF U NEX PECT ED PROBLEMS Wate r should f low f rom the c ooling syste m indicat or while the engine i s running. This shows t hat water i s circ ulating t hrough the cool ...
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Honda BF5A - page 21
19 Portable Fuel Tank Anode Fuel Filler Cap Vent Knob CONTROLS AND FEATURES ANODE VENT K NOB CLOS E O O P P E E N N FUEL FILLER C AP The anode is ma de of a sacri f icial material that helps to protect the outboard mot or f rom corrosion. There is a n anode on the antiventilatio n plate. The po rtable f uel tank has a capacity of US gal ( L) and ha ...
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Honda BF5A - page 22
20 Fuel Priming Bulb CONTROLS AND FEATURES UP OUTLET END (motor s ide) PRIM ING BULB INLET END (tank side ) A priming bulb is built into th e f uel hose that c onnects the f uel ta nk to the outboard m otor. Bef ore start ing the engine, hold the priming bu lb up in the direction of the arrow, then squeeze the p riming bulb u ntil it f eels f irm. ...
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Honda BF5A - page 23
− − − − 17.1 in (434 mm) 22.1 in (561 mm) 21 POWER REQUIREMENTS INSTALLATION POSI TION INSTALLATION CENTER LIN E ANTIV ENTILATION PLATE IDLE POR T 02 i n (0 50 mm) M M O O T T O O R R T T R R A A N N S S O O M M H H E E I I G G H H T T B B O O A A T T T T R R A A N N S S O O M M H H E E I I G G H H T T Correct and secure installation is ess ...
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Honda BF5A - page 24
22 TRANSOM ANGLE ADJUSTMENT ATTACHMENT INSTALLATION SAFET Y ROPE CLAMP SCRE WS STERN BRACKE T WATER LEVEL FULLY TR IM/ TILT DOWN 5.9 in (150 mm) or more IDLE POR T If the outb oard motor is installed too low, the boat w ill squat a nd be hard to plane, an d the motor will spray water that may enter th e boat. It will tend to por poise, a nd high-sp ...
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Honda BF5A - page 25
Improperly maintaining this outboard motor or failing to correct a problem before operation can cause a malfunction in which you could be seriously hurt or killed. Always perform a pre- operation inspection before each operation, and correct any problem. 23 ARE YOU READY TO GET UNDERWAY? Saf ety Knowledge IS YOUR OUTBOARD MOTOR READY TO GO? BEFORE ...
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Honda BF5A - page 26
24 Saf ety Inspection Maintenance Inspection BEFORE OPERATION Look around the outboar d motor f or signs of oil or gasoli ne leaks . If you are us ing the portabl e f uel tank, ma ke sure it is in good conditio n and properly secured in the boat (p. ). Check that the f uel hose is undamage d and proper ly connected (p . ). Wipe up an y spills bef o ...
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Honda BF5A - page 27
25 SAFE OPERATING PRECAUTIONS BREAK-IN PROCEDURE TRANSOM ANGLE ADJUSTMENT OPERATION TRANSO M ANGLE ADJUST ING ROD TO CHANG E TO LOCK UNLOC KED POSI TION LOCKED POSITION I MPORT AN T SAFET Y I NFORM AT I ON BEFORE OPERAT I ON . To saf ely realize the f ull po tential of this outboa rd motor, you need a comple te underst anding of its operat ion and ...
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Honda BF5A - page 28
Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Wipe up spills immediately. Handle fuel only outdoors. Stop the engine and keep heat, sparks, and flame away. 26 PORTABLE FUEL TANK FUEL HOSE CONNECTIONS OPERATION FUEL HOSE C ONNEC TOR (FUEL TANK S IDE) (OUTBOA RD MOTOR SID E) FUEL HOSE C ONNEC T ...
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Honda BF5A - page 29
27 FUEL PRIMING STARTING THE ENGINE OPERATION OUTLET END (motor s ide) PRIM ING BULB INLET END (tank side ) UP EMERG ENCY STO P SWI TCH CLI P EMERGEN CY STOP SWITCH EMERGEN CY STOP SWI TCH LANYARD The engine wi ll not start or run unless the e mergenc y stop swit ch clip is in the emergency stop switch. Hold the priming bulb u p in the direction of ...
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Honda BF5A - page 30
28 OPERATION MARK N (neut ral) GEARSHIF T LEVER CHOKE KNOB O O F F F F O O N N THROTTLE GRIP Check the p osition of the gearshif t lever. It must b e in the N (neutral) position f o r starting. The engine wi ll not start i f the gearshif t lever is in the F (f orward) or R (reve rse) pos ition. Align the START position with the mar k f or star ting ...
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Honda BF5A - page 31
29 EMERGENCY STARTING OPERATION UNLOCK ENGINE C OVER LOC K LEVER Directio n to pull STARTER GR IP T AK I N G CARE OF U NEX PECT ED PROBLEM S If the recoil st arter i s inoperat ive, you can sta rt the engine m anuall y using the emergency starter rope sup plied with the too l kit. Unlock and remove t he engine cover. Pull the starter grip ligh tly ...
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Honda BF5A - page 32
− 30 OPERATION EMERGEN CY STAR TER ROPE 6 mm CAP NUTS FLYWHEEL C OVER 6 mm FLANG E BOLTS T AK I N G CARE OF U NEX PECT ED PROBLEM S, Pull the emergency starter rope slowly un til resistance is f elt, then pull bris kly. Keep aw ay f rom moving parts while pulling the rope. If necessary, rewind the ro pe and pull agai n. If the engine does not sta ...
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Honda BF5A - page 33
Exposed moving parts can cause injury. Do not operate the outboard motor without the engine cover. Use extre me care when installing the engine cover. 31 OPERATION If it was necessary to remove th e emer gency stop s witch la nyard f rom you to perf orm the emer gency st arting pr ocedure , be sure the lany ard is attached securely to operato r bef ...
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Honda BF5A - page 34
32 STOPPING THE ENGINE Emergency Engine Sto pping Normal Eng ine Stopping OPERATION EMERG ENCY STO P SWI TCH GEARSHIF T LEVER PUSH EMERG ENCY STO P SWI TCH EMERGEN CY STOP SWITCH LANYARD PULL EMERGEN CY STOP SWI TCH CLIP THROTTLE GRIP N (neut ral) Move the thro ttle grip to the slowest speed and gearsh if t lev er to the N (neu tral) position. To s ...
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Honda BF5A - page 35
33 GEARSHIFTING AND THROTTLE OPERATION OPERATION GEARSHIF T LEVER T T O O D D E E C C R R E E A A S S E E F F R R I I C C T T I I O O N N T T O O I I N N C C R R E E A A S S E E F F R R I I C C T T I I O O N N THROTTLE GRIP R (reverse) N (neutral) F( f o r w a r d ) THROTTLE FRIC TION KNOB To shif t gears, turn the throttle grip to the SLOW positio ...
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Honda BF5A - page 36
34 STEERING OPERATION STEERING FR ICTION BOLT T T O O D D E E C C R R E E A A S S E E F F R R I I C C T T I I O O N N T T O O I I N N C C R R E E A A S S E E F F R R I I C C T T I I O O N N Steer by mov ing the tiller hand le opposite the di recti on you want the boat to turn. Use the steering f rictio n bolt to help hold a stea dy course while cr ...
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Honda BF5A - page 37
35 CRUISING Engine Speed Transom Angle OPERATION CORRECT GIVE S MAXIMUM PERFO RMANCE Transom Angle ( Cruising) MOTOR AN GLE ADJUST ED TOO LOW MOTOR AN GLE ADJUST ED TOO HIGH ROUGH WAVES MOTOR AN GLE ADJUST ED CORRECT LY Exces sive trans om angle during operation ca n cause prope ller venti lation, ove rheating, and water pump d amage. T his type of ...
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Honda BF5A - page 38
36 SHALLOW WATER OPERATION OPERATION 18° ENGI NE COVER G RIP Do not use t he tiller hand le as a lever to raise the outboard motor. Applying excessive f orce t o the t iller handle can d amage it. An exces sive til t angle d uring operation ca n cause prope ller venti lation, ove rheating, and water pump d amage. T his type of damage is not covere ...
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Honda BF5A - page 39
37 MOORING, BEACHING, LAUNCHING OPERATION 38°, 58° (whe n mooring) ENGI NE COVER G RIP TILT LEVER To return the outboard mo tor to the normal ope rating posi tion, rais e the outboard slig htly by pulling on th e engine co ver grip, then pull th e tilt lever t o releas e the outboar d, then slowly lowe r the outboar d motor. Bef ore tilting up , ...
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Honda BF5A - page 40
Improperly maintaining this outboard motor or failure to c orrect a problem before operation can cause a malfunction in which you could be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this Owner’s Manual. 38 THE IMPORTANCE OF MAINTENANCE Maintena nce, replacement, or repair of the emissio ...
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Honda BF5A - page 41
− − − Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in the Owner’s Manual. 39 MAINTENANCE SAFETY Saf ety Precautions Burns f rom hot p arts. Injury f rom movi ng parts. Carbon monoxide poisoni ng f rom engine exhaust. SERVICING Y ...
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Honda BF5A - page 42
× 40 TOOL KIT AND EMERGENCY STARTER ROPE SERVICING YOUR O UTBOARD MOTOR 10 12 mm WRENCH PLIERS TOOL BAG FLAT SCREWDRIVER PHILIPS SCREWDRIVER 8 mm WRENCH SPARE SPARK PLUG COTTER PINS SHEAR PINS WATER MOUTH NUT SPARK PLUG WRENCH SPARE EMERGENCY STOP SWITCH CLIP WATER MOUTH SEAT WATER HOSE CONNECTOR EMERGEN CY STAR TER ROPE FLUSH K IT The f ollowing ...
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Honda BF5A - page 43
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 41 MAINTENANCE SCHEDULE SERVICING YOUR O UTBOARD MOTOR Distributor’ s Limited W arranty Lubrica te more frequently when used in sa lt wate r. These items should be service d by an authoriz ed Honda Marine deale r, unless you ha ve the proper tools a nd are me chanic ally prof ici ...
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Honda BF5A - page 44
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 42 SERVICING YOUR O UTBOARD MOTOR Perform at every indicate d month or operating hour inter val, whichever comes f irst. REGULAR SERVICE PERIOD First month or 20 hrs. (2) Af ter us e (4) Every 6 months or 100 hrs. (2) Every 2 years (If necessary) (2) ITEM Every year or 200 hrs. (2) (2) (2) Each use Fuel t ...
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Honda BF5A - page 45
43 ENGINE COVER REMOVAL AND INSTALLATION Engine Oil Level Check SERVICING YOUR O UTBOARD MOTOR ENGINE C OVER LOC K LEVER UNLOCK OIL FILLER C AP/DIP STICK OIL FILLER CAP /DIPSTIC K UPPER LIMIT LOWER LIMIT Running the engi ne with a low oi l level can cau se engine d ama ge. Check the engine oi l level with the engine st opped and the outboard motor ...
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Honda BF5A - page 46
44 Engine Oil Chan ge SERVICING YOUR O UTBOARD MOTOR DRAIN BO LT Improper d isposal of engi ne oil can be harmf ul to the env ironment. If you change y our own oil, ple ase dispose of the used oil properly. Put it in a seal ed container, and tak e it to a recycling cen ter. Do not discard it in a trash bin, dump it on the ground, or pour it down a ...
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Honda BF5A - page 47
AMBIENT TEMPERATURE 4.8 lbf·ft (6.5 N·m , 0.66 kgf·m) 45 Engine Oil Recomm endations Gear Case Oil Level Check SERVICING YOUR O UTBOARD MOTOR GEAR OIL LEVEL SCR EW GEAR OIL DRAIN/FI LL SCREW Oil is a major f actor af f ectin g perf ormance a nd service li f e. Use 4-str oke deterge nt oil. Check the gear case o il level with the engine st opped ...
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Honda BF5A - page 48
46 Gear Case Oil Chan ge SERVICING YOUR O UTBOARD MOTOR If no oil f lows f rom the oil level hole , add the recommend ed oil (p. ) f ollowing th e procedure d escribed in Gear Case Oi l Change. Change th e gear case oil with the engine st opped and the outboard motor in the ve rtica l position. Allow the used oi l to drain completely, then in stall ...
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Honda BF5A - page 49
0.11 US qt (0.10 L) 4.8 lbf·ft (6.5 N·m, 0.66 kgf·m) 4.8 lbf·ft (6.5 N·m, 0.66 kgf·m) 47 SERVICING YOUR O UTBOARD MOTOR GEAR OIL BOTTLE GEAR OIL CAPACITY: OIL LEVEL SCREW TORQUE: OIL DRAIN SCREW TORQUE: Add oil through t he oil dra in hole until it f lows out the oil le vel hole, then install th e oil level screw. Remove the pump ada pter and ...
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Honda BF5A - page 50
48 Lubrication Points SERVICING YOUR O UTBOARD MOTOR PROPELLER SHAFT CLAMP SCREWS SWIVEL CASE THROTTLE CABLE AND PIVOT SHIFT SHAFT AND PIVOT TILLER HANDLE PIVOT TILT RELEASE LEVER AND REVERSE LOCK ROD TRANSOM ANGLE ADJUSTING ROD ENGINE COVER LOCK LEVER T o prevent corrosion, apply anticorrosion oil to pivot surf aces whe re grease cannot penetrate ...
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Honda BF5A - page 51
− − − − W16EPR-U (DENSO) BPR5ES (NGK) 0.028 0.031 in (0.7 0.8 mm) 49 Spark Plug Service SERVICING YOUR O UTBOARD MOTOR SPARK PLUG W RENCH SEAL ING WASH ER SIDE ELECTR ODE 0.028 0.031 in (0.7 0.8 mm) Incorrect spark plug can c ause engine damage. RECOMMENDED SPARK PLUGS: Unlock and remove t he engine cover (p. ). Disconne ct the s park plug ...
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Honda BF5A - page 52
− 3.2 US gal (12 L) 50 REFUELING Portable Fuel Tank SERVICING YOUR O UTBOARD MOTOR VENT KNO B CLOS E O O P P E E N N FUEL GAUG E SAFE F ILL LEVEL FUEL F ILLER CAP A loose s park plug can overheat and damage the engine. Overtighte ning the spark plug c an dam a ge t he t h re a ds in t he c y l i nde r head. Fuel can damage paint and plastic. Be c ...
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Honda BF5A - page 53
Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. 51 FUEL RECOMMENDATIONS SERVICING YOUR O UTBOARD MOTOR Use unleaded gasoline with a pump octane rati ng of 86 or higher. Never ref ill th ...
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Honda BF5A - page 54
Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. 52 Fuel Filter Inspection and Replacement SERVICING YOUR O UTBOARD MOTOR UNLOCK ENGINE C OVER LOC K LEVER The f uel f ilter is located un ...
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Honda BF5A - page 55
53 SERVICING YOUR O UTBOARD MOTOR HOSE CLAM PS FUEL F ILTER FUEL HOSE FUEL HOSE ARROW (Fuel Fl ow Directio n) FUEL F ILTER HOSE CLAM PS Remove the f uel hoses f rom the used f ilter, and discard the f ilter. To ease ho se removal, release the hose clamps by squeezing the clamp ends together with pliers while pulling of f the hoses. Connect the f ue ...
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Honda BF5A - page 56
Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. 54 Portable Fuel Tank and Tan k Filter Cleaning SERVICING YOUR O UTBOARD MOTOR FUEL HOSE Fuel Tank Empty the portabl e f uel tank into a ...
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Honda BF5A - page 57
55 Anode Replacement Recoil Starter Rope Inspection SERVICING YOUR O UTBOARD MOTOR FILTER O-RING TANK FILTER JOIN T (Fue l Hose Connect or) ANODE BOLT RECOI L START ER ROPE Fuel T ank Fil t er Painting or coati ng the anodes will def eat their purpose and will lead to rust and corrosion damage to the outboard motor. T he anod es mus t be expose d t ...
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Honda BF5A - page 58
56 Propeller and Shear Pin Replacement SERVICING YOUR O UTBOARD MOTOR PROP ELLER CAP SHEAR PIN COTTER PIN Removal Remove the cotter pin, the propell er cap, and the pr opeller . Remove the broke n shear pin and repla ce it with a new one. Operat ing the outboa rd motor a t higher altitud es will reduce available power. T his may requ ire decreasing ...
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Honda BF5A - page 59
57 SERVICING YOUR O UTBOARD MOTOR COTTER PIN In s ta lla ti on Spare shear pins and co tter pins are provided in the e ngine compar tment (p. ). Insta ll the she ar pin and the propell er, then ins tall the prope ller cap f inger tight. Use a Honda Genuine s tainles s steel cotter pin o r equivalen t cotter pin and bend t he pin ends as shown. Be s ...
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Honda BF5A - page 60
58 STORAGE PREPARATION Cleaning and Flushing STORAGE WATER HOSE WATER HOSE CONN ECTOR Cl eaning Fl ushing W it h t he H ond a Wa ter H ose Conn ect or Proper stor age prepa ration is esse ntial f or keeping your outboa rd motor tr ouble-f ree a nd looking good. The f o llowing steps will help to keep rust and corro sion f rom impairing your outboar ...
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Honda BF5A - page 61
59 STORAG E ANTIV ENTILATION P LATE Fl ushing W it hout t he Hond a Wa ter H ose Conn ect or Running the engine without good water circ ulation c an cause overheati ng and water pump damage. Distributor’ s Limited W arranty It is nece ssar y to run the e ngine during the f lushing proce dure. For saf ety, rem ove the propell er f rom the outboard ...
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Honda BF5A - page 62
60 Fuel STORAG E Ad d ing a Fuel St abil izer Distributor’ s Limited W arranty Depending on the region whe re you operate your outboard , f uel f ormulations may deteriorate and oxidize rapidly. Fuel deteriorati on and oxid ation can oc cur in as littl e as 15 d ays and may cause damage to the carburetor and f uel s ystem . Please check wit h you ...
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Honda BF5A - page 63
Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. 61 STORAG E DRAIN SCREW DRAIN TUBE AIR GUI DE CARBURET OR DRAIN PORT Dr aining t he Fuel Syst em Af ter the f uel has drained f rom the c ...
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Honda BF5A - page 64
−− 62 Engine Oil STORAGE PRECAUTIONS STORAG E CARRYING HANDL E Lif ting the outboard motor by the engine co ver, or using the instal led outboard motor as a handle or lever to move the boat, can damage the outboard motor. Select a well-ventilated storage area. If possible, avoid st orage are as with high humidit y. If your portable f uel tank c ...
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Honda BF5A - page 65
63 REMOVAL FROM STORAGE STORAG E CASE PROT ECTORS BEFORE OPERAT I ON Any other horizontal storage pos ition may cause damage to the outboard motor or oil le akage. Cover the outboard m otor to kee p out dust. Do not use plast ic sheet a s a dust cove r. A nonporous cover w ill trap moisture, promo ting rust and corrosion . Check your outboar d moto ...
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Honda BF5A - page 66
64 WITH OUTBOARD MOTOR INSTALLED ON BOAT WITH OUTBOARD MOTOR REMOVED FROM BOAT TRANSPORTING CARRYING HANDL E MOTOR SUP PORT BAR (commercia lly available) Lif ting the outboard motor by the engine cov er, or using the install ed outboard motor as a handle or lever to move the boat, can damage the outboard motor. If there is in suf f icien t road cle ...
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Honda BF5A - page 67
65 TAKING CARE OF UNEXPECTED PROBLEMS Check emergency stop switch clip. Check contr ol positions . Clip not ins erted i n emerge ncy stop switch. Insert clip in emergency stop switch. Shif t to neutral (p. ). ENGINE WILL NOT START Possible Cause Correction Gears hif t lever not in neutra l position. Choke OFF. Pull choke knob to ON position, unless ...
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Honda BF5A - page 68
66 TAKING CARE OF UNEXPECTED PROBLEMS Correction Possible C ause ENGINE WILL NOT START (conti nued) Check f uel. Out of f uel. Fuel hose not pr imed. Bad f uel; boat store d without treating or drainin g gasoline, or ref ueled with bad gasolin e. Carbure tor malf unction, f uel pump f ailure, ignition malf un ction, stuck valves, etc. Ref u el (p. ...
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Honda BF5A - page 69
67 TAKING CARE OF UNEXPECTED PROBLEMS Correction Possible C ause HARD STARTING OR STALLS AFTER STARTING Check control positions. Choke OFF. Pull choke knob to ON position, unless e ngine is warm (p. ). Check f uel. Throttle grip not in START position. Turn throttle grip to START position (p. ). Fuel vent c losed (port able f uel tank). Fuel hose n ...
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Honda BF5A - page 70
68 TAKING CARE OF UNEXPECTED PROBLEMS HARD STARTING OR STALLS AFTER STARTING (conti nued) Take outboa rd motor t o an authoriz ed Honda Marine de aler , or ref er to the shop ma nual. Faulty ther mostat or wa ter pump. Replac e or repair f aulty components as necessary. ENGINE OVERHEATS Possible Cause Correction Carbure tor malf unction, f uel pump ...
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Honda BF5A - page 71
69 TAKING CARE OF UNEXPECTED PROBLEMS Possible Cau se Correction Take outboa rd motor t o an authoriz ed Honda Marine de aler , or ref er to the shop ma nual. ENGINE WILL NOT DRIVE THE PROPELLER Check shea r pin. Broken shea r pin. Damaged gearsh if t mech anism. Replace shear p in (p. ). Replac e or repair f aulty components as necessary. 2. 1. 56 ...
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Honda BF5A - page 72
70 OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMI TED TAKING CARE OF UNEXPECTED PROBLEMS OIL PRE SSURE INDI CATOR If the throttle is closed suddenly af ter f ull throttle op eration, engin e speed may drop belo w the specif ied idle rpm, a nd that coul d activa te the engine prot ection sys tem momentarily. If low o il pressure activates ...
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Honda BF5A - page 73
71 SUBMERGED MOTOR TAKING CARE OF UNEXPECTED PROBLEMS STARTER GR IP A subme rged outboar d motor mus t be serviced immediately af ter it is recovered f rom th e water in order to minimize corrosion . Remove the e ngine cover, and rinse t he outboard motor wit h f resh water to remove salt water, sand, mud, e tc. Drain the ca rburetor a s descri bed ...
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Honda BF5A - page 74
72 TAKING CARE OF UNEXPECTED PROBLEMS W hen cranking the engine with an open igniti on circui t (spark plug removed f rom the ignition circui t), remove the e mergenc y stop swit ch clip f ro m the emerge ncy stop s witch to preven t possib le da mage to th e ignition s ystem . Reinst all the spark pl ug, and put the emergency stop switch clip into ...
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Honda BF5A - page 75
73 TECHNICAL INFORMATION Serial Number Locations TECHNICAL AND CONSUMER INFORMATION PRODUCT IDE NTIFICAT ION NUMBER ENGI NE SERIAL NUMB ER Engine ser ial number : Product ide ntif ication numbe r: The product ide ntif icati on number is stamped on the swivel case. The engine se rial numbe r is stam ped on the right side of the motor. Record the pro ...
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Honda BF5A - page 76
74 Carburetor Modif ication f or High Altitude Operation TECHNICAL AND CONSUMER INFO RMATION W hen the carburetor has been modif ied f or operation at one of the higher altitude ranges, the air-f uel mixture will be too le an f or operation at a lowe r altitude. Operat ion at altit ud es below the range f or which the carburetor is set may cause th ...
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Honda BF5A - page 77
75 Emission C ontrol Syst em Inf ormation TECHNICAL AND CONSUMER INFO RMATION Source of Emissions Tamper ing and Al t er ing The U.S. and Cal if or nia Cl ean Air Act s The combust ion process pr oduces carbon monoxi de, oxides of nitrogen, and hydroca rbons. Control of hydrocar bons and oxides of nitrogen is very important because, under certain c ...
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Honda BF5A - page 78
76 TECHNICAL AND CONSUMER INFO RMATION Ma inte nance Repl acement Par ts Pr obl ems That M ay Af f ect Emissions A manuf acturer o f an af termarket part assumes the responsibility that the part will no t adversely af f ect emis sion perf ormance . The manuf actur er or rebuil der of the part must certif y that use of the part will not result in a ...
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Honda BF5A - page 79
77 Star Label The Symbol f or Cleaner Marine Engine s: Cleaner Air and Wate r - Better Fuel Economy - Longer Emissio n Warranty - US, Puerto Ri co, and US Virgin Islands TECHNICAL AND CONSUMER INFO RMATION The St ar Label means Cl eaner M ar ine Engine f or healthier lif estyle and en vironment. burns up to 3 0 - 40 percent less gas and oil than co ...
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Honda BF5A - page 80
78 Two Stars Very Low Emission One Star Low Emission Three Stars Ultra Low Emission Four Stars Super Ultra Low Emission TECHNICAL AND CONSUMER INFO RMATION The one-st ar label ide ntif ies engines t hat meet t he Air Resourc es Board’ s Persona l Wate rcraf t and Outboard ma rine engi ne 2001 exhaust em ission standa rds. Engines m eeting the se ...
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Honda BF5A - page 81
− −− ± ± ± − − × ×× BF5A BADS 13.8 in (350 mm) L S 20.7 in (525 mm) 39.6 in (1,005 mm) 44.7 in (1,135 mm) Diaphragm type fuel pump Unleaded gasolin e (86 pump octane or higher) Forward-Neutral-Reverse (dog type) 45° right and left 5 stages (4°,8°,12°,16° ,20°) Underwater exhaust Water cool ing with thermostat ULTRA LOW EMISSIO ...
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Honda BF5A - page 82
− 80 CONSUMER INFORMATION Honda Publications Custom er Service Inf ormation TECHNICAL AND CONSUMER INFO RMATION American Hon da Motor Co ., Inc. Honda Canada Inc. (United States, Puerto Rico , and U.S.Virgin Islands) Accessor y Catal o g Part s Cat al og Shop M anual Cont act i ng Hond a This manua l provides com plete , illustrated parts lists. ...
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Honda BF5A - page 83
81 TECHNICAL AND CONSUMER INFO RMATION Warra n ty C ov erag e Pleas e include the f ollowing inf ormation in your comm unicati on: Model a nd complete s eria l number Date of purchase Name and location of selling dealer Name and location of servicing dealer (if dif f erent) A deta iled des cripti on of your concerns Your new Honda is c overed by th ...
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Honda BF5A - page 84
82 TECHNICAL AND CONSUMER INFO RMATION W arr ant y Ser vice As the owner of a Honda product, your ser vicing dea ler m ay ask you t o authori ze an inspe ction. If the problem i s covere d under warr anty, your deale r will perf orm any warranty repairs f or you at no co st. However, you may be re sponsible f or additiona l non-warra nty charge s. ...
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Honda BF5A - page 85
＊ ＊ ＊ ＊ − 83 War ranty Stateme nts Distributor’s L imited War ranty United states, Puerto Rico and Virgin Islands What Americ an Honda Will Repair or Replace Under Warranty: To Qualif y f o r This Warranty: TECHNICAL AND CONSUMER INFO RMATION The Honda Outboard Mot or must be purchas ed f rom Americ an Honda or a dealer authoriz ed by A ...
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Honda BF5A - page 86
‘‘ ’’ ’ 84 To Obtain Warra nty Service: Exclusions: TECHNICAL AND CONSUMER INFO RMATION Contacting Honda All parts replaced under warranty will be considered as part of the origina l product and any w arrant y on those parts wi ll expire c oincident ally with the ori ginal product warrant y. This warra nty does not extend to the f ollowin ...
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Honda BF5A - page 87
85 Accessories and Replacement P arts To Qualif y f or This Warranty: What American Honda Will Repair or Re place Under Warranty: TECHNICAL AND CONSUMER INFO RMATION Products Covered by Warrant y: Accessories Replacement Parts Length of Warranty: (f rom date of original retail purchase) Non Commercial Commercial/ Rental Lo cal/State/ Federal Govern ...
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Honda BF5A - page 88
86 Exclusions: To Obtain Warra nty Service: Disclaimer of co nsequential damage a nd limitation of implied warranties: TECHNICAL AND CONSUMER INFO RMATION You must take the Honda Outboa rd Motor product accessory or rep lacement part or th e outboard motor o r boat on which th e accessory or replacemen t part is insta lled, and pr oof of purchase , ...
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Honda BF5A - page 89
87 Emission C ontrol System Warran ty YOUR WARRANTY RIGHTS AND OBLIGATION Calif ornia All States MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE: TECHNICAL AND CONSUMER INFO RMATION Your new Honda outboar d engine compli es with both the U.S. EPA and State of Calif ornia emiss ion regulat ions. Americ an Honda provides the s ame emis sio ...
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Honda BF5A - page 90
88 OWNER’S WARRANTY RESPONSIBILITY: WARRANTY COVERAGE: TECHNICAL AND CONSUMER INFO RMATION Contacting Honda As the outboard engi ne owner, you are res ponsible f or the perf ormance o f the requ ired maintenan ce listed in your owner’s ma nual. Ameri can Honda Motor Co., Inc. recommends th at you retain all r eceipts covering mainte nance on yo ...
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Honda BF5A - page 91
89 TO OBTAIN WARRANTY SERVICE: EXCLUSIONS: DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATION OF IMPLIED WARRANTIES: TECHNICAL AND CONSUMER INFO RMATION may be denied. If th e part in question is not related to the reas on that your engine r equire s repai r, your cla im will not be denied. You must ta ke your Honda out board engine , along wit h yo ...
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Honda BF5A - page 92
＊ ＊ 90 EMISSION CONTROL SYSTEM WARRANTY PARTS: TECHNICAL AND CONSUMER INFO RMATION PARTS DESCRIPTION Carburetor assembly, Throttle body, Fuel injector, Fuel pump, Fuel pressure regulator, T hrottle position sensor, Intake air temperature sen sor, Engine temp erature sensor, Manifold absolute pressure sensor, Idl e air control valve, Baromet ric ...
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Honda BF5A - page 93
91 WARRANTY PERIOD RETAILED ON OR AFTER AP RIL 1, 2005: THIS WARRANTY COVERS Distributor’s Warranty Canada TECHNICAL AND CONSUMER INFO RMATION HONDA CANADA INC., f or and o n behalf of Honda Motor Co. Ltd., Tokyo, J apan, give s the f ollowing written warranty on each new marine product manuf acture d by Honda Motor Co. Ltd., Ja pan, distri buted ...
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Honda BF5A - page 94
92 THIS WARRANTY DOES NOT COVER THE OWNER’S OBLIGATION TO OBTAIN WARRANTY SERVICE TECHNICAL AND CONSUMER INFO RMATION Any repairs req uired as a result of collision, accid ent, stri king any objec t, mis use or la ck of required maintenance; Any repairs required as a result of an y attachments, parts or de vices ins talle d by or repairs done by ...
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Honda BF5A - page 95
93 REPLACEMENT PARTS AND ACCESSORY WARRANTY ENTIRE WRITTEN WARRANTY DISCLAIMER NOTICE TO CONSUMER TECHNICAL AND CONSUMER INFO RMATION New genuine Honda replacement parts or accessories sold to a consume r or ins talle d by an authori zed Honda Mari ne deale r which a re not cove red by the DISTRIBUTORS WARRANTY are warranted f or a period of one ye ...
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Honda BF5A - page 96
94 INDEX ............................................................................ Anode . 19 .............................................................. Replacement . 55 ............. ARE YOU READY TO GET UNDERWAY? . 23 ........................................................... ATTACHMENT . 22 ............................................... ...
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Honda BF5A - page 97
95 INDEX Gear Case Oil ....................................................................... Change . 46 ............................................................... Level Che ck . 45 .. GEARSHIFTING AND THROTTLE OPERATION . 33 .............................................................. Gearshif t Lever . 15 HARD STARTING OR STALLS AFTER .. ...
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Honda BF5A - page 98
96 INDEX .... TAKING CARE OF UNEXPECTED PROBLEMS . 65 .. TECHNICAL AND CONSUMER INFORMATION . 73 ................................... TECHNICAL INFORMATION . 73 ............... THE IMPORTANCE OF MAINTENANCE . 38 .................................................. Throttle Friction Kn ob . 15 ........................................................... ...
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Honda BF5A - page 99
00X31-ZV1-6500 BF5A 31ZV1650 00X31-ZV1-6500 2eY1 100.2009.07 Printed in Japan N BF5AK0 P ANTONE 288 CVC DIC F101 BLA CK Includes US and Canadian Models ...
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