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Download Honda Marine owners' and operators' manuals. All Honda outboard owners' manuals are free to download. Honda 4 Stroke Workshop Service Repair Manual 4-Stroke 2 hp 5 hp 7.5 hp 8 hp 9.9 hp 15 hp 25 hp 30 hp 35 hp 40 hp 45 hp 50 hp 75 hp 90 hp 115 hp & 130 hp engines. Honda Outboard Motors - Online Shop/Service/Repair Manuals Download 2001-2014 Honda BF/BFP8D, BF/BFP9.9D Outboards Shop Manual This manual covers service and repair.

1. 2004 Honda Outboard Motor Owners Manual
2. 2002 Honda 9.9 Outboard Owners Manual

. Thank you for purchasing This manual covers operation Motor. Information information available at the time of approval for printing. Honda Motor Co., Ltd. Reserves the right to make changes at any time without notice and without incurring No part of this publication This manual should, be considered and should remain with the Outboard Pay special attention.

SAFETY INSTRUCTIONS 2. WARNING LABELS.

COMPONENT IDENTIFICATION 4. INSTALLATION 5. PRE-OPERATION THE ENGINE. STOPPING THE ENGINE. High altitude operation 9. MAINTENANCE 10. TRANSPORTING/STORAGE 11.

TROUBLESHOOTING 12. SPECIFICATIONS 13. WIRING DIAGRAM 14. THIS OWNER’S MANUAL power is properly mounted. To operate the outboard if any passenger while the boat is near any person poisonous carbon monoxide.

Garage or confined flammable and is explosive area with the engine flames or sparks where refueling. CAMSHAFT PULLEY FUEL TANK CAUTION LABEL 0 ESSUYER TOUTE 2. WARNING LABELS FRONT LABEL Check Controler d’huile STARTING CAUTION. DO NOT OPERATE. PULL STARTER k lARD THEN PULL OTEUR VlTESSES AV POINT LABEL. NE PAS FAIRE FONCTIONNER.

TIPER LE LANCEUR RECOIL. COMPONENT ODENTUFICATOON FUEL LINE CONN STARTER GRIP THROTTLE FRICTION ENGINE COVER GEAR LEVEL WATER INTAKE GEAR DRAIN FUEL (FEMALE) KNOB LOCK LEVER BOLT BOLT FUEL TANK TOOL PRIMER BULB LINE CONNECTOR SPARE CONTAINER.

DIPSTICK;;;;;r;-;TTON SPARE SHEAR COTTER TILT LEVER ENGINE DRAIN CLAMP SCREW ENGINE SERIAL. Always list the serial number ordering parts. ANTI-CAVITATION EXHAUST WATER CHECK PINS PINS SCREW NUMBER when PLATE TUBE. INSTALLATION It is your responsibility boat suitable the engine horsepower BFlOO, 7.5 horsepower BF75). Do not exceed the boat manufacturer’s power dation. Damage result.

Installation Position Install at the stern at the center line of the boat. (B) and pull out to remove.

Inserting the rod in the proper hole, twist it down to lock.CAUTION: To prevent the motor or boat, make sure the adjusting rod is locked. With the water INCORRECT CAUSES BOAT TO “PLOW’.

PRE-OPERATION CHECK 1. Check the engine’oil CAUTION: Engine oil is a major factor affecting Non-detergent and low quality Running the engine with insufficient Use Honda 4-stroke oil, or an equiv- alent high detergent, motor oil certified exceed U.S.

Automobile facturer’s requirements Classification. Check the fuel level Check the fuel gauge and refill the tank if the fuel level is low. NOTE: Open the vent knob before removing vent knob is firmly closed, the cap will be difficult Use any regular grade automotive with a pump octane. Check the following Check the propeller, secure and undamaged. Check the stern bracket to be sure the motor is securely Check steering handle operation.

Make sure you have the tool kit and spare parts with you (P. The shear pin, and the cotter pin to be sure they are installed. CAUTION: Damage to the water system may occur if the motor water. Connect the fuel line to the tank and outboard the connectors are securely latched. NOTE: Position the fuel tank so the tank fuel line connector meter (3.3 ft) below the motor fuel line connector.

Do not place the fuel tank more than 2 meters (6.6 ft) away from the motor. Starting 1. Put the shift lever in NEUTRAL.

Align the throttle grip START’ position with the mark on the steering handle. In temperatures below 20” C (68” F) use the choke knob. Pull the starter rope slowly until a resistance is felt, then pull briskly.

NOTE: Do not allow hand. CHOKE the starter grip to snap back. Return KNOB it slowly. The oil pressure indicator above idle speed. If the lamp goes off, stop the engine immediately,.the engine oil level and inspect engine for oil leaks. OIL PRESSURE.INDICATOR 6. After starting, be sure water is flowing CAUTION: If water does not flow engine.

Emergency Starting If the recoil starter is not working spare starter rope in the tool kit. Remove the engine cover.

Remove the recoil starter by removing the three 6 mm bolts. Wind the spare rope clockwise CAUTION: Keep clear of moving parts. Gear Shifting The engine has 3 gears: FORWARD, indicator at the base of the gear shift lever aligns with the letters F, N, or R on the engine case to show the gear that has been selected. Turn the throttle grip to SHIFT to decrease engine speed before moving the gear shift lever. Steering To turn to the right, swing the steering handle to the left. To turn to the left, swing the handle to the right. Boats equipped steering wheel are controlled For smooth steering, adjust the steering friction felt when turning.

In the same way as a car. NOTE: passengers and equipment be distributed to balance the boat evenly from side to side and parallel to the water from front to back. Open at a steady friction speed control. Tilting the Motor Tilt the motor to prevent the propeller when the boat is beached or stopped in shallow water. Stop the engine and put the shift lever into NEUTRAL. Pull the tilt lever toward raise the engine to either the 32.5” or 72” tilt position. Don’t allow the motor to strike against the pier or other boats.

CAUTION: avoid damaging the motor, never use it as a handle for lif- ting or moving the boat. Battery Charging and Lighting The DC receptacle provides a 12 V, 60 W current for 12 V battery and lighting. The circuit removing the engine cover.

An electrical plug for the DC receptacle your charging or lighting Batteries cigarettes away. STOPPING THE ENGONE 1. Turn the throttle grip to SHIFT and move the shift lever to NEUTRAL. Push the stop button High altitude operation At high altitude, the standard ly rich. Performance will decrease, High altitude performance main fuel jet in the carburetor always operate. Periodic maintenance and adjustment best operating condition.

Shut off the engine before performing engine must be run, contains poisonous carbon monoxide CAUTION: If the engine must be run, make sure there is water at least 4 inches above the cavitation plate, otherwise cooling water, and the engine will overheat. Tool kit and spare parts The following tools and spare parts are supplied with the outboard maintenance, adjustment, The tool kit and oil bottle Spare shear pins and cotter pins are located on the stern bracket. TOOL KIT 9 x 12 mm WRENCH 10 x 12 mm WRENCH 8 mm WRENCH lzLz-30. Engine Oil Change Drain the oil while the engine draining. Remove the engine cover.Remove the drain screw and filler cap, and drain the oil. Reinstall the drain screw.

Fill the crankcase with the recommended level with the dipstick the 800 cc mark. Gear Oil Check/Change Oil Level Check Check the oil level when engine is in the vertical screw and see if oil flows out. If no oil comes out, fill through hole until the oil starts to flow out through water in the oil, the water will flow out first when the drain screw is removed, or the oil will be a milky color. Spark Plug Service Recommended spark plug: DR-5HS (NGK), XlGFSR-U 1. Remove the engine cover. Remove the spark plug cap. Use the wrench supplied 4.

Visually inspect the spark plug. Discard it if the insulator ped. Clean the spark plug with a wire brush if it is to be reused. Cleaning and Flushing After each use in salt water or dirty outboard motor. Wash the outside of the outboard 2. Flush the cooling system, outboard motor. Attach a hose from a fresh water faucet to the flush kit hose coupler.

Lubrication Wipe the outside of the engine anti-corrosion grease to the following CLAMP SCREWS SWIVEL CASE TILT LINKAGE NOTE: Apply anti-corrosion penetrate. With a cloth dipped parts: THROTTLE CABLE SHIFT SHAFT HANDLE PIVOT PROPELLER pivot surfaces in oil. Apply marine PIVOT PIVOT ’. Shear Pin Change A shear pin is used to protect the propeller when the propeller strikes an obstruction.

Remove the cotter pin, the propeller 2. Remove the broken shear pin and replace it with a new one.

Install the propeller, 4. Fuel strainer replacement The fuel strainer is located or sediment accumulated starting. To prevent engine ((SERVICE PERIOD)) Every Gasoline is flammable smoke or allow flames or sparks near the outboard fuel. Always work in a well-ventilated Be sure that any fuel drained from the outboard container.

Remove the clamps to the motor. Turn the fuel tank primer bulb, and check Contact an authorized accumulated in the fuel strainer. CARBURETOR used to close the fuel tubes. Vent knob for leaks.

Honda dealer if you find excessive Connect the fuel tank line to the ON position. Servicing a Submerged Motor A submerged motor must be serviced immediately the water in order to minimize If there is a Honda immediately to the dealer. Remove the engine cover, and rinse the motor with fresh water to remove salt water, sand, mud, etc. TRANSPORTING/STORAGE 1. Disconnect the fuel line and install the cap on the engine fuel inlet.

Firmly close the fuel cap vent knob. FUEL LINE COb.iNECTbk 2. Loosen the carburetor container. After draining, Be careful not to spill fuel.

Fuel vapor or spilled fuel may ignite. CAUTION: In cold weather, pump, pull the recoil starter several times to flush the water out. To carry, hold the motor handle and engine cover lock lever as shown engine cover. Transport and store the motor here, with the steering handle raised. Vertical transport or storage: Attach the stern bracket to a stand. Horizontal transport (steering handle side of the motor).

TROUBLESHOOTONG Engine Will Not Start: 1. Is the shift lever in neutral?

Is there fuel in the fuel tank? Is the fuel cap knob turned to ON? Is the fuel system primed by squeezing the primer bulb?. Item output Full throttle range 1 Enaine tvoe riisolacement Valve tappet clearance Soark olua aao Starter system Ignition system Lubrication system Specified Oil capacity 1 D.C. Output Cooling system Exhaust system 1 Soark luas Fuel pump Fuel Tank capacity Steering equipment Tilt angle Angle. WIRING DIAGRAM Component Identification I SP 1 Spark Plug Ignition Coil ’ Engine Stop button 1 FW Fly Wheel 1 Neutral Switch Wire color 1 BI 1 Bu BllW Black Yellow Blue Green Brown White Oranae Black/White. OPTIONAL PARTS GEAR EMERGENCY ENGINE STOP SWITCH ENGINE COVER VERTICAL STARTER.

WARRANTY SERWOCE Owner Satisfaction Your satisfaction and goodwill Honda warranty details are explained Normally, any problems dealer’s service department. Been handled to your action: Discuss your problem complaints can be quickly already been reviewed the dealership or the General If your problem still has not been resolved Power. Current customer service contact information: Your owner's manual was written to cover most of the questions you might ask about your Honda. Any questions not answered in the owner's manual can be answered by your Honda dealer.

If your dealer doesn't have an immediate answer, they should be able to get it for you.

. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Keep this owner’s manual handy, so you can refer to it at any time. This owner’s manual is considered a permanent part of the outboard motor and should remain with the outboard motor if resold. Congratulations on your selection of a Honda outboard motor. We are certain you will be pleased with your purchase of one of the finest outboard motors on the market.

We want to help you get the best results from your new outboard motor and to operate it safely. INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this outboard motor safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. OUTBOARD MOTOR SAFETY IMPORTANT SAFETY INFORMATION SAFETY LABEL LOCATIONS CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES COMPONENT AND CONTROL LOCATIONS CONTROLS Side-Mount Type Ignition Switch Switch Clip and Emergency Stop Switch Gearshift/Throttle Control Lever Fast Idle Lever Panel-Mount Type Ignition Switch Switch Clip and Emergency Stop Switch Fast Idle Button. CONTENTS INDICATORS Alternator (ACG) Indicator Programmed Fuel Injection (PGM-FI) Indicator.

29 Oil Pressure Indicator Overheating Indicator Cooling System Indicator OTHER FEATURES Water Separator Buzzer Overrev Limiter Anodes Fuel Priming Bulb BEFORE OPERATION ARE YOU READY TO GET UNDER WAY? IS YOUR OUTBOARD MOTOR READY TO GO?. SERVICING YOUR OUTBOARD MOTOR THE IMPORTANCE OF MAINTENANCE MAINTENANCE SAFETY TOOL KIT and OWNER’S MANUAL SPARE EMERGENCY STOP SWITCH CLIP (optional equipment) MAINTENANCE SCHEDULE TRIM TAB ADJUSTMENT MANUAL RELIEF VALVE ENGINE COVER REMOVAL AND INSTALLATION Engine Oil Level Check Engine Oil Change Oil Filter Change Engine Oil Recommendations Lubrication Points. CONTENTS TRANSPORTING WITH OUTBOARD MOTOR INSTALLED ON BOAT WITH OUTBOARD MOTOR REMOVED FROM BOAT TAKING CARE OF UNEXPECTED PROBLEMS. 85 FUSES Electric Starter Will Not Operate Battery Will Not Charge Fuse Replacement OIL PRESSURE INDICATOR GOES OFF AND ENGINE SPEED IS LIMITED. Understand the use of all controls. Stop the engine immediately if anyone falls overboard, and do not run the engine while the boat is near anyone in the water.

Always stop the engine if you must leave the controls for any reason. OUTBOARD MOTOR SAFETY Refuel With Care Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a well- ventilated area, with the engine stopped. Never smoke near gasoline, and keep other flames and sparks away. Refuel carefully to avoid spilling fuel. OUTBOARD MOTOR SAFETY SAFETY LABEL LOCATIONS The labels shown here contain important safety information.

Please read them carefully. These labels are considered permanent parts of your outboard motor. If a label comes off or becomes hard to read, contact an authorized Honda Marine servicing dealer for a replacement.

CONTROLS AND FEATURES CONTROL AND FEATURE IDENTIFICATION CODES Model Type 20.0 in (508 mm) Transom Height 25.0 in (635 mm) Standard Rotating Propeller Shaft Counterrotating Propeller Shaft Power Trim/Tilt Refer to this chart for an explanation of the Type Codes used in this manual to identify control and feature applications. TYPE CODE (example) Destination A: America. COMPONENT AND CONTROL LOCATIONS ENGINE COVER LATCH STERN BRACKET MANUAL RELIEF VALVE ANODE ENGINE COVER SPARK PLUG (under cover and/or coil) OIL LEVEL DIPSTICK FLUSH PORT CONNECTOR COOLING SYSTEM INDICATOR ANODE ENGINE OIL DRAIN BOLT (inside cover) ANODE ANTIVENTILATION PLATE EXHAUST PORT/WATER OUTLET PORT PROPELLER. CONTROLS AND FEATURES Remote Controls (optional equipment) (SIDE-MOUNT REMOTE CONTROL) GEARSHIFT/THROTTLE CONTROL LEVER POWER TRIM/TILT SWITCH SPARE SWITCH CLIP BUZZER (inside) CONTROL LEVER FRICTION ADJUSTER LANYARD (PANEL-MOUNT REMOTE CONTROL) GEARSHIFT/THROTTLE CONTROL LEVER NEUTRAL RELEASE LEVER OIL PRESSURE INDICATOR LIGHT OVERHEAT INDICATOR LIGHT FAST IDLE POWER TRIM/TILT. (SINGLE TOP-MOUNT REMOTE CONTROL) GEARSHIFT/THROTTLE CONTROL LEVER POWER TRIM/TILT SWITCH FAST IDLE BUTTON CONTROL PANEL (for PANEL/TOP-MOUNT type) BUZZER IGNITION SWITCH SWITCH CLIP LANYARD (DUAL TOP-MOUNT REMOTE CONTROL) POWER TRIM/TILT SWITCH (RIGHT) POWER TRIM/TILT SWITCH (LEFT) (for TOP-MOUNT DUAL type) OIL PRESSURE INDICATOR LIGHT OVERHEAT. CONTROLS AND FEATURES Trim Meter (optional equipment) Tachometer (optional equipment) Digital Speedometer (optional equipment) Digital Tachometer (optional equipment).

CONTROLS Side-Mount Type Ignition Switch START IGNITION SWITCH The ignition switch controls the ignition system and starter motor. Turning the ignition switch key to the START position operates the starter motor.

The key automatically returns to the ON position when released from the START position. CONTROLS AND FEATURES Switch Clip and Emergency Stop Switch EMERGENCY STOP SWITCH LANYARD SWITCH CLIP LANYARD SWITCH CLIP The switch clip must be inserted in the emergency stop switch in order for the engine to start and run. The lanyard must be attached to the operator’s PFD (Personal Flotation Device) or worn around the wrist as shown.

Moving the control lever 30° from N (neutral) selects the gear, and further movement increases engine speed. The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle.

CONTROLS AND FEATURES Fast Idle Lever N (neutral) The fast idle lever is only needed for starting carbureted outboard models. The BF135A and BF150A models use programmed fuel injection so, this lever will not be needed for starting. After the engine starts and if the outside temperature is below 41°F (5°C), the fast idle lever can be used to accelerate engine warm up. Turning the ignition switch key to the START position operates the starter motor.

The key automatically returns to the ON position when released from the START position. The ignition switch can be used to start the engine only when the control lever (p. CONTROLS AND FEATURES Fast Idle Button N (neutral) F (forward) R (reverse) NEUTRAL RELEASE CONTROL LEVER LEVER Push FAST IDLE BUTTON By moving the control lever forward or reverse when the fast idle button is pushed in, the throttle opening will be increased without engaging the gears. Moving the control lever 35° from N (neutral) selects the gear, and further movement increases engine speed. The control lever automatically locks itself in the N (neutral) position. To move the lever out of the N (neutral) position, you must squeeze the neutral release lever on the underside of the lever handle. CONTROLS AND FEATURES Top-Mount Type Ignition Switch START IGNITION SWITCH The ignition switch controls the ignition system and starter motor.

Turning the ignition switch key to the START position operates the starter motor. The key automatically returns to the ON position when released from the START position. The switch clip must be inserted in the emergency stop switch in order for the engine to start and run.

The lanyard must be attached to the operator’s PFD (Personal Flotation Device) or worn around the wrist as shown. When used as described, the emergency stop switch and lanyard system stops the engine if the operator falls away from the controls. CONTROLS AND FEATURES Moving the control lever 35° from N (neutral) selects the gear, and further movement increases engine speed.

A friction adjuster inside the control box adjusts the operating resistance of the control lever(s). Refer to Less friction allows easier control lever movement. You can use the power trim/tilt switch anytime whether the boat is underway, stopped, or the ignition switch is in the OFF position. It is necessary for the ignition switch to be in the ON position for the trim meter to indicate the motor angle. The tilt lock lever is used to support the outboard motor in the fully-raised position.

When the boat is to be moored for a long time, tilt the outboard motor as far as it will go. Then move the tilt. TRIM METER The trim meter has a range of 16° and indicates the trim angle of the outboard motor. Refer to the trim meter when using the power trim/tilt switch to achieve the best performance from the boat. The tachometer shows engine speed in revolutions per minute. Refer to the tachometer when using the throttle and power trim/tilt controls to achieve the best performance from the boat.

Digital Tachometer (optional equipment) Digital Tachometer includes the following functions. INDICATORS Alternator (ACG) Indicator ACG INDICATOR The ACG indicator turns on and the buzzer sounds in one-second intervals when the charging system is faulty. Programmed Fuel Injection (PGM-FI) Indicator PGM-FI INDICATOR When the engine control system detects an PGM-FI malfunction, the PGM-FI indicator turns on and the buzzer sounds at one-second intervals. CONTROLS AND FEATURES When the oil pressure indicator is lit, oil pressure is OK. If oil pressure becomes low, the indicator will go off, and the engine protection system will limit engine speed. Refer to TAKING CARE OF UNEXPECTED PROBLEMS, from All models are equipped with a buzzer that sounds a steady tone when the green light goes off.

Cooling System Indicator COOLING SYSTEM INDICATOR Water should flow from the cooling system indicator while the engine is running. This shows that water is circulating through the cooling system. If water stops flowing while the engine is running, it indicates a cooling system problem, such as clogged water intakes, which will cause engine overheating. CONTROLS AND FEATURES Anodes ANODE ANODE (each side) (stern bracket) The anodes are made of a sacrificial material that helps to protect the outboard motor from corrosion. There are two anodes on the gear case, one on the stern bracket, and two small anodes in the water passages of the engine block. Safety Always wear a PFD (Personal Flotation Device) while on the boat.

Attach the emergency stop switch lanyard securely to your PFD or to your wrist. IS YOUR OUTBOARD. BEFORE OPERATION Safety Inspection Look around the outboard motor for signs of oil or gasoline leaks. Check that the fuel hose is undamaged and properly connected. Wipe up any spills before starting the engine. Check the stern bracket to be sure the outboard motor is securely installed. First 15 minutes: Run the engine at trolling speed.

Use the minimum throttle opening necessary to operate the boat at a safe trolling speed. Next 45 minutes: Run the engine up to a maximum of 2,000 to 3,000 rpm, which is about 10% to 30% of maximum throttle opening. OPERATION FUEL PRIMING OUTLET END (motor) PRIMING BULB INLET END (tank) Hold the priming bulb up in the direction of the arrow, then squeeze the priming bulb several times until it feels firm, indicating that fuel has reached the engine. Check to be sure there are no fuel leaks before starting the engine. The emergency stop switch clip and lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat. Always attach the lanyard to your PFD, or to your wrist, before starting the engine. OPERATION LOWEST POSITION FAST IDLE RANGE Leave the fast idle lever in the OFF (fully lowered) position.

Fast idle lever cannot be raised unless the control lever is in the N (neutral) position. The control lever cannot be moved away from the N (neutral) position unless the fast idle lever is lowered. MAXIMUM FAST IDLE FAST IDLE RANGE Before getting under way, allow the engine to warm up sufficiently to ensure good performance. Above 41°F (5°C), warm up the engine for 2 or 3 minutes. Below 41°F (5°C), warm up the engine for at least 10 minutes at 2,000 rpm. The emergency stop switch clip and lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat. Always attach the lanyard to your PFD, or to your wrist, before starting the engine.

START IGNITION SWITCH Turn the ignition switch key to the START position and hold it there until the engine starts. When the engine starts, release the key, allowing it to return to the ON position. If the engine fails to start within 5 seconds, release the key and wait at least 10 seconds before operating the starter again. The emergency stop switch clip and lanyard system is a safety device that will stop the engine if you fall away from the controls while operating the boat. Always attach the lanyard to your PFD, or to your wrist, before starting the engine.

N (neutral) CONTROL LEVER Set the control lever in the N (neutral) position. The engine will not start if the F (forward) or R (reverse) gears are engaged. START IGNITION SWITCH Turn the ignition switch key to the START position and hold it there until the engine starts.

OPERATION N (neutral) CONTROL LEVER FAST IDLE BUTTON Before getting under way, allow the engine to warm up sufficiently to ensure good performance. Above 41°F (5°C), warm up the engine for 2 or 3 minutes. Below 41°F (5°C), warm up the engine for at least 10 minutes at 2,000 rpm. To stop the engine in an emergency, pull the clip out of the emergency stop switch by pulling the lanyard.

We suggest that you stop the engine this way occasionally to verify that the emergency stop switch is operating properly. Normal Engine Stopping Side-Mount Type N (neutral). Panel-Mount/Top-Mount Types IGNITION SWITCH KEY Turn the ignition switch key to the OFF position. When the boat is not in use, remove and store the ignition switch key and the emergency stop switch clip and lanyard.

GEARSHIFT AND THROTTLE OPERATION. Panel-Mount Type N (neutral) F (forward) R (reverse) NEUTRAL RELEASE LEVER CONTROL LEVER Top-Mount Type N (neutral) F (forward) R (reverse) CONTROL LEVER To shift gears, move the control lever to select F (forward), N (neutral) and R (reverse) gears. The control lever cannot be moved from the N (neutral) position unless the neutral release lever is squeezed. Top-Mount Type TO INCREASE FRICTION TO DECREASE FRICTION CONTROL LEVER FRICTION ADJUSTER Adjust the control lever friction adjuster so the control lever will hold a constant throttle setting while cruising.

STEERING Steer the boat in the same manner as an automobile. You can use the power trim/tilt switch at any time, whether the boat is under way or stopped. Press the UP or DN (down) side of the switch to adjust the angle of the outboard motor. OPERATION Side-Mount Type POWER TRIM/TILT SWITCH Panel-Mount Type POWER TRIM/TILT SWITCH Top-Mount Type (single type) POWER TRIM/TILT SWITCH (dual type) POWER TRIM/TILT SWITCH (LEFT) (RIGHT) MOTOR MOTOR TRIMMED TOO TRIMMED TOO HIGH MOTOR TRIMMED CORRECTLY BOW TOO LOW DUE TO 1. LAUNCHING To raise the outboard motor out of the water while the engine is stopped and the boat is moored, or for maximum clearance when beaching or launching, use the power tilt switch on the engine pan to tilt the. OPERATION POWER TILT SWITCH TILT LOCK LEVER (Lock position) STERN BRACKET Do not attempt to use the power tilt switch to tilt the outboard motor down while the tilt lock lever is in the lock position.

Damage to the power tilt system may occur. THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble-free operation.

It will also help reduce air pollution. Improperly maintaining this outboard motor, or failure to correct a problem before operation, can cause a malfunction in which you could be seriously hurt or killed. SERVICING YOUR OUTBOARD MOTOR MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

Failure to properly follow maintenance instructions and precautions can cause. SCREWDRIVER HANDLE The tool kit can be used for simple maintenance procedures and emergency repairs. Keep these items on the boat, so they will always be available if you need them.

If your tool kit needs replacement, it is not available as a kit and each item must be ordered individually. SERVICING YOUR OUTBOARD MOTOR MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD ITEM Perform at every indicated month or operating hour interval, whichever comes first.

Engine oil Check level Change Gear case oil Change Engine oil filter Replace ACG belt Check-adjust Throttle linkage Check-adjust Idling speed Check-adjust. REGULAR SERVICE PERIOD ITEM Perform at every indicated month or operating hour interval, whichever comes first. Fuel filter Check (Low pressure side) Replace Fuel filter Replace (High pressure side) Thermostat Check Fuel line Check Replace Battery and cable Check level-tightness connection Bolts and Nuts Check-tightness. TRIM TAB If less effort is required to make right turns, move the back of the trim tab right. Adjust the trim tab in small increments, and retest steering effort with the boat evenly loaded and running at cruising speed. MANUAL RELIEF VALVE MANUAL RELIEF VALVE The outboard motor can be tilted manually after opening the manual relief valve.

This feature enables the outboard motor to be tilted or lowered when no battery is connected. For manual tilting, use a screwdriver to turn the valve counterclockwise 1 or 2 turns.

2004 Honda Outboard Motor Owners Manual

SERVICING YOUR OUTBOARD MOTOR Engine Oil Level Check Check the engine oil level with the engine stopped and the outboard motor in the vertical position. Unlock and remove the engine cover (p.

Remove the dipstick and wipe it clean. UPPER LIMIT LOWER LIMIT. DRAIN PLUG COVER GUIDE DRAIN PLUG COVER GUIDE Set the drain plug cover under the guide. SERVICING YOUR OUTBOARD MOTOR SEALING WASHER GUIDE DRAIN PLUG COVER Place a suitable container below the oil drain guide to catch the used oil, then remove the oil filler cap and the drain plug. SERVICING YOUR OUTBOARD MOTOR Install the oil drain plug cover.

Push the lever of the oil drain plug cover in the direction pointed by the arrow mark of ‘‘LOCK’’, and install the oil drain plug cover so that the locking lug securely sets on the projection of the under cover. Clean the oil filter mounting base, and coat the rubber seal of the new oil filter with clean engine oil. Use only a genuine Honda oil f ilter or a f ilter of equivalent quality specif ied f or your model.

Using the wrong f ilter, or a non- Honda f ilter which is not of equivalent quality, may cause. SERVICING YOUR OUTBOARD MOTOR Lubrication Points Apply marine anticorrosion grease to the following parts: Lubrication interval: After the first 20 hours or 1 month, then every 100 hours or 6 months. (Refer to the maintenance schedule page Apply anticorrosion oil to pivot surf aces where grease cannot penetrate. ENGINE COVER LOCK CABLE (LEFT SIDE) ENGINE COVER LOCK CABLE (RIGHT SIDE) SWIVEL SHAFT SERVICING YOUR OUTBOARD MOTOR THROTTLE ARM/ SHIFT ARM/PIVOT PLATE/NEUTRAL SWITCH/CLICK ENGINE COVER CABLE (FRONT) ARM ROLLER SWIVEL CASE UPPER CYLINDER BUSH/COLLAR PIN/BUSH ENGINE COVER LOCK COVER LOCK BOLTS LEVER/OPEN SHAFT TILT LOCK LEVER TILT SHAFT THREAD.

SERVICING YOUR OUTBOARD MOTOR Spark Plug Service RECOMMENDED SPARK PLUGS: IZFR6K11 (NGK) SKJ20DR-M11 (DENSO) Incorrect spark plugs can cause engine damage. This outboard motor uses spark plugs that have an iridium coated center electrode.

Be sure to observe the following when servicing the spark plugs. Remove the two mud guard clips from the upper part of the under cover grommet. To remove the mud guard clips, raise the inner part of each mud guard clip with a screwdriver, then pull out the clips.

Do not try to remove the mud guard clip with f orce without raising the inner part of the mud guard clip. SERVICING YOUR OUTBOARD MOTOR Remove the ignition coil by pulling it up slightly. Do not strike or drop the ignition coil, or it may be damaged and require replacement. 19 mm EYE SPARK PLUG WRENCH WRENCH Remove the spark plugs with a spark plug wrench and 19 mm wrench. Insert the mud guard clips with the inner part raised off, then push in the inner part securely until they click. REFUELING Check the fuel level and refill if neccessary. Do not fill the fuel tank above the UPPER LIMIT.

Refer to the boat manufacturer’s instructions. SERVICING YOUR OUTBOARD MOTOR 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. Never refill the fuel tank inside a building where gasoline fumes may reach flames or sparks.

Running the engine with persistent spark knock or pinging can cause engine damage. Running the engine with persistent spark knock or pinging is misuse, and the Distributor’s Limited Warranty does not cover parts damaged by misuse. SERVICING YOUR OUTBOARD MOTOR Fuel Filter Inspection and Replacement The fuel filter (inside the strainer. SERVICING YOUR OUTBOARD MOTOR UNLOCK ENGINE COVER LATCH Remove the engine cover. FUEL FILTER (inside strainer cup) Looking through the translucent strainer cup, check the fuel filter for water accumulation or sediment. FUEL HOSES SCREW (3) SUSPENSION STRAP Remove the suspension strap from the strainer bracket, then remove the strainer assembly from the strap.

Remove the three screws and separate the fuel strainer cup from the strainer body. Thoroughly clean the strainer cup, and replace with a new fuel filter. Reassemble the strainer body and the cup. STRAINER TIGHTENING TORQUE: 2.5 lbfft (3.4 Nm, 0.35 kgfm) Reinstall the strainer in the original position. SERVICING YOUR OUTBOARD MOTOR Water Separator Inspection and Service WATER SEPARATOR The water separator is located beside the oil level dipstick.

Water accumulation in the water separator can cause loss of power or hard starting. Check the water separator periodically. Clean it or consult with an authorized Honda outboard motor dealer for cleaning. O-RING WATER SUSPENSION SEPARATOR STRAP Remove the three screws and separate the water separator cup from the body. Thoroughly clean the water separator cup. Reassemble the water separator body and the cup. TIGHTENING TORQUE: 2.5 lbfft (3.4 Nm, 0.35 kgfm) SERVICING YOUR OUTBOARD MOTOR WATER SEPARATOR BRACKET.

SERVICING YOUR OUTBOARD MOTOR Anode Replacement ANODE ANODE (stern bracket) (each side) The anodes are located on each side of the gearcase. They are made of a sacrificial material that helps to protect the outboard motor from corrosion.

Replace the anodes when they have been reduced to about half their original size, or if they are crumbling. Propeller Replacement Before replacing the propeller, remove the clip from the engine stop switch to prevent any possibility of the engine being started while you are working with the propeller. The propeller blades may have sharp edges, so wear heavy gloves to protect your hands.

STORAGE STORAGE PREPARATION Proper storage preparation is essential for keeping your outboard motor troublefree and looking good. The following steps will help to keep rust and corrosion from impairing your outboard motor’s function and appearance, and will make the engine easier to start when you use the outboard motor again.

FLUSH PORT WATER HOSE CONNECTOR WATER HOSE JOINT (Commercially available) Screw the water hose into the flush port connector. EXHAUST PORT Turn on the fresh water supply and flush the outboard motor for at least 10 minutes. After flushing, remove the garden hose adapter, and install the flush port cap. STORAGE Fuel Gasoline will oxidize and deteriorate in storage. Old gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your fuel tank and vapor separator deteriorates during storage, you may need to have the vapor separator and other fuel system components serviced or replaced. Unhook the drain hose from the front bracket clamp.

Set the end of the hose toward the outside of the engine undercase. Loosen the vapor separator drain screw. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. HOIST HOOKS Attach the hoist hooks to the lifting eyes. Disconnect the outboard motor from the boat, hoist the outboard motor, and move it to the storage area.

After the outboard motor is placed in storage and disconnected from the hoist, install the engine cover. OUTBOARD MOTOR STAND If the outboard motor will be removed from the boat for storage, we recommend storing it vertically by mounting it on a stand. PROTECTOR If it is necessary to store the outboard motor horizontally as shown, drain the vapor separator (p. Use a motor support bar to prevent the outboard motor from moving while trailering the boat. Refer to the manufacturer’s instructions for using a motor support bar. MOTOR SUPPORT BAR (commercially available). ENGINE WILL NOT START Check emergency stop switch clip.

Check control positions. TAKING CARE OF UNEXPECTED PROBLEMS Possible Cause Clip not inserted in stop switch. Control lever not in neutral position. Fast idle lever raised (side-mount type).

Correction Insert clip in stop switch. Shift to neutral. Check fuel. Possible Cause Out of fuel. Fuel hose not primed. Fuel filter or fuel tank filter clogged. Bad fuel; boat stored without treating or draining gasoline, or refueled with bad gasoline.

Correction Refuel (p. Squeeze priming bulb (p. Replace fuel filters (p. ENGINE WILL NOT START (continued) Check battery.

Remove and inspect spark plugs. Use starting procedure (p.

If engine still will not start then take outboard motor to an authorized Honda marine dealer, or refer to the shop manual. TAKING CARE OF UNEXPECTED PROBLEMS Possible Cause Battery connections loose. Possible Cause Fast idle lever raised (side-mount type). Fuel hose not primed. Fuel filter or fuel tank clogged. Bad fuel; boat stored without treating or draining gasoline, or refueled with bad fuel. Correction Leave fast idle lever OFF (p.

Squeeze priming bulb (p. HARD STARTING OR STALLS AFTER STARTING (continued) Remove and inspect spark plugs. Take outboard motor to an authorized Honda marine dealer, or refer to the shop manual. ENGINE OVERHEATS Check water intake screens. Take outboard motor to an authorized Honda marine dealer, or refer to the shop manual.

TAKING CARE OF UNEXPECTED PROBLEMS FUSES Electric Starter Will Not Operate The 10A, 15A, and 30A main fuses protect the electric starter relay and related circuits. The 10A main fuse protects the ignition switch and related circuits. If this fuse blows, the engine will not start or run, and the power trim/tilt switch will not activate the trim/tilt mechanism.

FUSE PULLER Use the fuse puller from the tool kit to remove the fuses. If a fuse is blown, install a replacement fuse of the same specified rating. The outboard motor is supplied with spare fuses in the fuse holder. MAIN FUSE RATINGS: 10 A, 15 A, 30A Reinstall the fuse cover and the. TAKING CARE OF UNEXPECTED PROBLEMS Remove the electrical part cover.

Remove the fuse case lid. Remove the old fuse by removing two 5 mm screws. Install a new fuse with the ‘‘90 A’’ mark downward.

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ACG FUSE: 90 A After finishing replacement, install the fuse case lid with its hook toward the engine side. If the engine protection system remains activated after 30 seconds, return to the nearest boat landing, and have the outboard motor inspected by an authorized Honda marine dealer. OVERHEAT INDICATOR COMES ON AND ENGINE. If there is still no water flowing from the cooling system indicator, or if the engine protection system remains activated after 30 seconds, return to the nearest boat landing, and have the outboard motor inspected by an authorized Honda marine dealer. WATER SEPARATOR BUZZER SOUNDS WATER SEPARATOR When the water separator buzzer sounds (a rapid, repeating signal): Check the water separator for water contamination.

If water is accumulated, stop the engine, and clean the water separator following the instructions on page, or consult with an authorized Honda marine dealer. TAKING CARE OF UNEXPECTED PROBLEMS Change the engine oil and oil filter − as described on p. If there was water in the engine crankcase, or if the used engine oil showed signs of water contamination, then a second engine oil change should be performed after running the engine for half an hour. TECHNICAL INFORMATION Serial Number Locations Record the product identification number and engine serial number in the space provided on this page. You will need these numbers when ordering parts, and when making technical or warranty inquiries TECHNICAL AND CONSUMER INFORMATION PRODUCT IDENTIFICATION NUMBER.

TECHNICAL AND CONSUMER INFORMATION Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. You may use gasoline containing up to 5% methanol by volume, as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems.

It may also damage metal, rubber, and plastic parts of your fuel system. TECHNICAL AND CONSUMER INFORMATION Emission Control System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Problems That May Af f ect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Misfiring or backfiring under load. Afterburning (backfiring).

TECHNICAL AND CONSUMER INFORMATION Star Label A Star label was applied to this outboard motor in accordance with the requirements of the California Air Resources Board. The Star Label means Cleaner Marine Engine This engine has been certified as a: The Symbol for Cleaner Marine Engines: Cleaner Air and Water - for healthier lifestyle and environment. TECHNICAL AND CONSUMER INFORMATION The one-star label identifies engines that meet the Air Resources Board’s One Star Personal Watercraft and Outboard marine engine 2001 exhaust emission standards.

Engines meeting these standards have 75% lower emissions than Emission conventional carbureted two-stroke engines. These engines are equivalent to the U.S.EPA’s 2006 standards for marine engines. TECHNICAL AND CONSUMER INFORMATION Specifications MODEL Description Code BARJ Type 33.3 in (845 mm) Overall length Overall width 22.8 in (580 mm) Overall height 65.6 in (1,665 mm) Transom height 20.0 in (508 mm) Weight 478 lbs (217 kg) (without propeller) Rated power 100.7 kW (135 HP) Full throttle range. Specifications MODEL Description Code BANJ Type 33.3 in (845 mm) Overall length Overall width 22.8 in (580 mm) Overall height 65.6 in (1,665 mm) Transom height 20.0 in (508 mm) Weight 478 lbs (217 kg) (without propeller) Rated power 111.9 kW (150 HP) Full throttle range 5,000 6,000 rpm 4 stroke DOHC VTEC in-line 4-cylinder. TECHNICAL AND CONSUMER INFORMATION BF135A/BF150A Tune up Spark plug gap (do not adjust) Idle speed Valve clearance (cold) Other specifications 0.039 0.051 in (1.00 1.30 mm) − − ± 50 rpm Intake: 0.23 ± 0.02 mm Exhaust: 0.30 ± 0.02 mm No other adjustments needed. CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing your outboard motor.

2002 Honda 9.9 Outboard Owners Manual

You may purchase them from your Honda marine dealer. Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician. INDEX Alternator (ACG) Indicator Anodes Replacement ARE YOU READY TO GET UNDER WAY?