Honda Outboard Service Manual (EN)

Setup Manual

PREFACE CONTENTS This manual covers the construction, function and serving procedures for the Honda BF135A•BF150A outboard motors. SPECIFICATIONS 1 SERVICE INFORMATION 2 All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice. MAINTENANCE 3 ENGINE COVER/COVER LOCK 4 No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and tables.

PROGRAMMED-FUEL INJECTION 5 ALTERNATOR 6 As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to the outboard motor, other property, or the environment. NOTICE ENGINE REMOVAL/INSTALLATION 7 THERMOSTAT/RELIEF VALVE/FLUSH VALVE 8 SAFETY MESSAGES CRANKSHAFT PULLEY/CAM CHAIN 9 Your safety, and the safety of others, are very important. To help you make informed decisions, we have provided safety messages and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing these outboard motors. You must use your own good judgment.

CYLINDER HEAD/VALVES 10 OIL PUMP/FLYWHEEL 11 CRANKCASE/BALANCER 12 You will find important safety information in a variety of forms, including: CYLINDER BLOCK/CRANKSHAFT/PISTONS 13 Safety Labels –– on the engine cover. PROPELLER/GEAR CASE/EXTENSION CASE/ OIL CASE 14 Safety messages –– Preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. MOUNTING CASE/STERN BRACKET/SWIVEL CASE/POWER TRIM/TILT ASSEMBLY 15 STEERING ROD/REMOTE CONTROL BOX 16 These signal words mean: DANGER You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions.

CABLES/SHIFT LINK BRACKET/SHIFT ARM/ NEUTRAL SWITCH 17 ELECTRICAL EQUIPMENT 18 WARNING You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions. OPERATION 19 SYSTEM DIAGRAM/WIRING DIAGRAM 20 21 CAUTION You CAN be HURT if you don't follow instructions. Instructions –– how to service this outboard motor correctly and safely. 21 Honda Motor Co., Ltd. Service Publications Office Date of lssue: November, 2003 © Honda Motor Co., Ltd.

Стр. 1

Index Ch1-5

INDEX 1. SPECIFICATIONS ........................................................ 1-1 1.SPECIFICATIONS .................................................. 1-1 2.DIMENSIONAL DRAWINGS.................................. 1-4 3. MAINTENANCE ............................................................ 3-1 1.MAINTENANCE SCHEDULE ................................ 3-1 2.ENGINE OIL............................................................ 3-2 3.OIL FILTER .............................................................. 3-3 4.GEAR CASE OIL .................................................... 3-4 5.SPARK PLUGS ......................................................

3-6 6.VALVE CLEARANCE .............................................. 3-9 7.FUEL STRAINER (LOW PRESSURE SIDE) ........ 3-15 8.FUEL STRAINER (HIGH PRESSURE SIDE) ........ 3-18 9.WATER SEPARATOR with WATER LEVEL SENSOR .............................................................. 3-19 10. IDLING .................................................................. 3-22 11. SHIFT CONTROL CABLE .................................... 3-24 12. THROTTLE CONTROL CABLE/ THROTTLE LINK .................................................. 3-26 13. REMOTE CONTROL LEVER FRICTION .............. 3-28 14. ALTERNATOR BELT ............................................ 3-28 2.

SERVICE INFORMATION ............................................ 2-1 1.THE IMPORTANCE OF PROPER SERVICING ...... 2-1 2.IMPORTANT SAFETY PRECAUTIONS ................ 2-1 3.SERVICE RULES .................................................... 2-2 4.SYMBOLS USED IN THIS MANUAL .................... 2-2 5.SERIAL NUMBER LOCATIONS ............................ 2-2 6.MAINTENANCE STANDARDS .............................. 2-3 7.TORQUE VALUES .................................................. 2-7 8.SPECIAL TOOLS .................................................. 2-10 9.TROUBLESHOOTING .......................................... 2-14 a.

ENGINE····························································· 2-14 HARD STARTING ············································· 2-14 CYLINDER COMPRESSION TEST··················· 2-15 ENGINE DOES NOT RUN SMOOTHLY ·········· 2-16 b. IGNITION (POWER) SYSTEM ························· 2-20 ENGINE DOES NOT START ···························· 2-20 FUSE LOAD CHART········································· 2-21 FUSE BOX CONNECTION TABLE··················· 2-22 c. STARTER SYSTEM ·········································· 2-23 ENGINE DOES NOT START ·····························2-23 d.

IGNITION SYSTEM·········································· 2-25 ENGINE IS HARD TO START ·························· 2-25 e. FUEL SYSTEM ················································· 2-28 ENGINE IS HARD TO START ·························· 2-28 f. CHARGING SYSTEM······································· 2-30 BATTERY UNDER CHARGED·························· 2-30 ACG INDICATOR LINE INSPECTION ·············· 2-31 g.

ALERT SYSTEM ··············································· 2-32 OIL ALERT SYSTEM ········································ 2-32 OVERHEAT ALERT SYSTEM··························· 2-32 ALTERNATOR WARNING SYSTEM················ 2-32 FULL WATER (IN WATER SEPARATOR) WARNING SYSTEM········································· 2-32 MIL WARNING SYSTEM ································· 2-32 WARNING SYSTEM········································· 2-32 WARNING BUZZER SOUNDS CONTINUOUSLY·············································· 2-33 OIL PRESSURE INSPECTION·························· 2-35 INTERMITTENT PROLONGED SOUND OF WARNING BUZZER KEEPS SOUNDING········ 2-37 INTERMITTENT SHORT SOUND OF WARNING BUZZER KEEPS SOUNDING········ 2-38 h.

SHIFT MECHANISM ········································ 2-39 i. POWER TRIM/TILT ASSEMBLY ······················ 2-40 POWER TRIM/TILT ASSEMBLY DOES NOT MOVE························································2-40 POWER TRIM/TILT ASSEMBLY DOES NOT HOLD························································ 2-41 POWER TRIM/TILT MOTOR DOES NOT MOVE······················································· 2-42 POWER TRIM/TILT ASSEMBLY QUICK REFERENCE CHART········································· 2-43 CHECK POINT ·················································· 2-44 10. CABLE/HARNESS ROUTING .............................. 2-45 11.

TUBE ROUTING .................................................. 2-66 12. LUBRICATION ...................................................... 2-77 4. ENGINE COVER/COVER LOCK .................................. 4-1 1.ENGINE COVER .................................................... 4-2 2.FRONT SEPARATE COVER.................................... 4-7 3.L./R. ENGINE UNDER COVERS ............................ 4-9 4.UNDER COVER FRONT BRACKET/ L./R. SIDE COVER BRACKETS ............................ 4-20 5. PROGRAMMED-FUEL INJECTION ............................ 5-1 1.SERVICE PRECAUTIONS ...................................... 5-2 2.CIRCUIT DIAGRAM................................................

5-3 3.VACUUM CONNECTIONS .................................... 5-5 4.PARTS LOCATION/ ECM TERMINAL LAYOUT .................................... 5-6 5.TROUBLESHOOTING .......................................... 5-11 6.TROUBLESHOOTING WITH HDS TESTER ........................................................ 5-13 a. TROUBLESHOOTING GUIDE BY DTC············ 5-15 b.

TROUBLESHOOTING ······································ 5-18 MIL DOES NOT COME ON······························ 5-18 MIL COMES ON BUT DTC CODE DOES NOT APPEAR ···························································· 5-21 ALERT SYSTEM INITIAL OPERATION IS FAULTY····························································· 5-23 NEUTRAL SWITCH MALFUNCTION ·············· 5-26 TACHOMETER MALFUNCTION······················ 5-27 ECM TROUBLESHOOTING ····························· 5-28 MAP SENSOR TROUBLESHOOTING············· 5-28 CKP SENSOR TROUBLESHOOTING ·············· 5-30 ECT SENSOR 1 TROUBLESHOOTING ··········· 5-33 TP SENSOR TROUBLESHOOTING················· 5-34 CMP SENSOR TROUBLESHOOTING ············· 5-36 IAT SENSOR TROUBLESHOOTING················ 5-38 BARO SENSOR TROUBLESHOOTING··········· 5-39 IAC VALVE TROUBLESHOOTING ··················· 5-41 VTEC SOLENOID VALVE TROUBLESHOOTING ······································ 5-42 KNOCK SENSOR TROUBLESHOOTING ········ 5-43 A/F SENSOR HEATER TROUBLE- SHOOTING ······················································· 5-44 A/F SENSOR TROUBLESHOOTING················ 5-49 ECT SENSOR 2 TROUBLESHOOTING ··········· 5-51 ECT SENSOR 3 TROUBLESHOOTING ··········· 5-52

Стр. 2

Ch5-10

EOP SWITCH (HIGH PRESSURE SIDE) TROUBLESHOOTING ······································ 5-54 ECT SENSOR 4 TROUBLESHOOTING ··········· 5-55 7.TROUBLESHOOTING WITHOUT HDS TESTER ........................................................5-57 a. TROUBLESHOOTING GUIDE·························· 5-59 b.

TROUBLESHOOTING ······································ 5-61 MIL DOES NOT COME ON······························ 5-61 MIL ON BUT MIL DOES NOT BLINK WITH SCS CIRCUIT SHORTED·································· 5-64 ALERT SYSTEM INITIAL OPERATION IS FAULTY····························································· 5-66 NEUTRAL SWITCH MALFUNCTION ·············· 5-70 TACHOMETER MALFUNCTION······················ 5-70 MAP SENSOR TROUBLESHOOTING············· 5-71 CKP SENSOR TROUBLESHOOTING ·············· 5-72 ECT SENSOR 1 TROUBLESHOOTING ··········· 5-74 TP SENSOR TROUBLESHOOTING················· 5-75 CMP SENSOR TROUBLESHOOTING ············· 5-77 IAT SENSOR TROUBLESHOOTING················ 5-78 BARO SENSOR TROUBLESHOOTING··········· 5-80 IAC VALVE TROUBLESHOOTING ··················· 5-81 VTEC SOLENOID VALVE TROUBLE- SHOOTING ······················································· 5-82 KNOCK SENSOR TROUBLESHOOTING ········ 5-83 ECT SENSOR 2 TROUBLESHOOTING ··········· 5-84 ECT SENSOR 3 TROUBLESHOOTING ··········· 5-86 EOP SWITCH (HIGH PRESSURE SIDE) TROUBLESHOOTING ······································ 5-87 ECT SENSOR 4 TROUBLESHOOTING ··········· 5-89 A/F SENSOR HEATER TROUBLE- SHOOTING ······················································· 5-90 A/F SENSOR TROUBLESHOOTING················ 5-92 8.IDLE CONTROL SYSTEM ....................................

5-93 TROUBLESHOOTING ······································ 5-93 IDLE ADJUSTING SCREW ADJUSTMENT ················································· 5-94 THROTTLE BODY INSPECTION/ CLEANING························································ 5-95 IAC VALVE REPLACEMENT····························· 5-95 9.FUEL SUPPLY SYSTEM ......................................

5-96 TROUBLESHOOTING ······································ 5-96 PGM-FI MAIN RELAY HARNESS INSPECTION····················································· 5-97 INJECTOR HARNESS INSPECTION ············· 5-100 HOW TO RELIEVE FUEL PRESSURE············ 5-102 FUEL PRESSURE MEASUREMENT·············· 5-102 FUEL LINE INSPECTION································ 5-104 FUEL INJECTOR INSPECTION······················ 5-105 PRESSURE REGULATOR INSPECTION········ 5-106 FUEL PUMP (HIGH PRESSURE SIDE) INSPECTION··················································· 5-107 10. IAB (INTAKE AIR BYPASS) CONTROL SYSTEM ............................................................

5-109 IAB CONTROL VALVE INSPECTION ············· 5-109 SHUTTER VALVE DIAPHRAGM INSPECTION··················································· 5-110 11. VAPOR SEPARATOR/FUEL PUMP (HIGH PRESSURE SIDE ).............................................. 5-111 12. SILENCER CASE/THROTTLE BODY/ INTAKE MANIFOLD .......................................... 5-128 13. FUEL INJECTOR/PRESSURE REGULATOR...... 5-136 14. FUEL PUMP (LOW PRESSURE SIDE) .............. 5-142 15. FUEL STRAINER (LOW PRESSURE SIDE)/ WATER SEPARATOR.......................................... 5-144 16. EOP (ENGINE OIL PRESSURE) SWITCH (HIGH PRESSURE SIDE) .............................................. 5-146 17.

EOP (ENGINE OIL PRESSURE) SWITCH (LOW PRESSURE SIDE) .............................................. 5-146 18. ECT (ENGINE COOLANT TEMPERATURE) SENSOR 1 .......................................................... 5-147 19. ECT (ENGINE COOLANT TEMPERATURE) SENSOR 2, 3, 4 .................................................. 5-148 20. BARO (BAROMETRIC PRESSURE) SENSOR ..............................................................5-149 21. KNOCK SENSOR................................................ 5-149 22. CMP (CAMSHAFT POSITION) SENSOR .......... 5-149 23. CKP (CRANKSHAFT POSITION) SENSOR ...... 5-150 24. VTEC SOLENOID VALVE.................................... 5-150 25.

VAPOR CHAMBER/CHECK VALVE .................... 5-151 26. EXHAUST MANIFOLD ...................................... 5-152 6. ALTERNATOR .............................................................. 6-1 1.SILENCER DUCT.................................................... 6-2 2.ALTERNATOR ........................................................ 6-5 7. ENGINE REMOVAL/INSTALLATION.......................... 7-1 1.REMOVAL .............................................................. 7-2 2.INSTALLATION ...................................................... 7-6 8. THERMOSTAT/RELIEF VALVE/FLUSH VALVE.......... 8-1 1.THERMOSTAT........................................................

8-2 2.WATER RELIEF TUBE/RELIEF VALVE .................. 8-5 3.FLUSH VALVE ...................................................... 8-10 9. CRANKSHAFT PULLEY/CAM CHAIN ........................ 9-1 1.DISASSEMBLY ...................................................... 9-2 2.ASSEMBLY ............................................................ 9-9 10. CYLINDER HEAD/VALVES........................................ 10-1 1.CYLINDER HEAD COVER REMOVAL.................. 10-2 2.CYLINDER HEAD COVER DISASSEMBLY.......... 10-4 3.CAMSHAFT/ROCKER ARM DISASSEMBLY ...... 10-5 4.CAMSHAFT/ROCKER ARM INSPECTION ........ 10-13 5.CYLINDER HEAD ASSEMBLY REMOVAL ........

10-19 6.CYLINDER HEAD ASSEMBLY DISASSEMBLY .................................................. 10-20 7.CYLINDER HEAD ASSEMBLY INSPECTION .... 10-23 8.VALVE GUIDE REPLACEMENT ........................ 10-26 9.VALVE SEAT RECONDITIONING ...................... 10-28 10. CYLINDER HEAD ASSEMBLY ASSEMBLY ...... 10-30 11. CYLINDER HEAD ASSEMBLY INSTALLATION .................................................. 10-32 12. CAMSHAFT/ROCKER ARM ASSEMBLY .......... 10-34 13. CYLINDER HEAD COVER ASSEMBLY.............. 10-38 14. CYLINDER HEAD COVER INSTALLATION ...... 10-40

Стр. 3

Ch11-20

11. OIL PUMP/FLYWHEEL .............................................. 11-1 1.EOP SWITCH/OIL FILTER FLANGE .................... 11-2 2.OIL PUMP ............................................................ 11-6 3.FLYWHEEL.......................................................... 11-12 16. STEERING ROD/REMOTE CONTROL BOX ............ 16-1 1.STEERING ROD.................................................... 16-1 2.REMOTE CONTROL BOX (OPTIONAL PART) .................................................................... 16-2 3.CONTROL PANEL (OPTIONAL PART) ................ 16-7 4.INSPECTION ........................................................ 16-9 12.

CRANKCASE/BALANCER ........................................ 12-1 1.CRANKCASE/BALANCER CASE ASSEMBLY REMOVAL ............................................................ 12-2 2.BALANCER CASE ASSEMBLY DISASSEMBLY .................................................... 12-5 3.INSPECTION ........................................................ 12-6 4.BALANCER CASE ASSEMBLY ASSEMBLY ...... 12-7 5.CRANKCASE/BALANCER CASE ASSEMBLY INSTALLATION .................................................... 12-8 17. CABLES/SHIFT LINK BRACKET/SHIFT ARM/ NEUTRAL SWITCH.................................................... 17-1 1.REMOTE CONTROL CABLE/GROMMET............

17-2 2.SHIFT LINK BRACKET/NEUTRAL SWITCH .............................................................. 17-11 3.SEAL HOLDER.................................................... 17-20 13. CYLINDER BLOCK/CRANKSHAFT/PISTONS.......... 13-1 1.DISASSEMBLY .................................................... 13-2 2.INSPECTION ........................................................ 13-8 3.BEARING SELECTION ...................................... 13-15 4.ASSEMBLY ........................................................ 13-19 18. ELECTRICAL EQUIPMENT ........................................ 18-1 1.STARTER MOTOR................................................

18-1 2.STARTER CABLE................................................ 18-15 3.ECM/PGM-FI MAIN RELAY/FUSE BOX ............ 18-19 4.POWER TILT RELAY/CONNECTOR BRACKET A ........................................................ 18-27 14. PROPELLER/GEAR CASE/EXTENSION CASE/ OIL CASE.................................................................... 14-1 1.PROPELLER .......................................................... 14-2 2.GEAR CASE ASSEMBLY [*1].............................. 14-3 3.WATER PUMP/SHIFT ROD [*1] .......................... 14-7 4.PROPELLER SHAFT HOLDER ASSEMBLY [*1] ................................................

14-17 5.PROPELLER SHAFT/PROPELLER SHAFT HOLDER [*1] ........................................ 14-18 6.VERTICAL SHAFT/BEVEL GEAR [*1]................ 14-27 7.SHIM SELECTION [*1] ...................................... 14-35 8.SHIM POSITION [*1] ........................................ 14-40 9.BACKLASH ADJUSTMENT [*1] ...................... 14-41 10. GEAR CASE ASSEMBLY [*2]............................ 14-42 11. WATER PUMP/SHIFT ROD [*2] ........................ 14-46 12. PROPELLER SHAFT HOLDER ASSEMBLY [*2] ................................................ 14-56 13. PROPELLER SHAFT/PROPELLER SHAFT HOLDER [*2] ........................................ 14-57 14.

VERTICAL SHAFT/BEVEL GEAR [*2]................ 14-68 15. SHIM SELECTION [*2] ...................................... 14-77 16. SHIM POSITION [*2] ........................................ 14-84 17. BACKLASH ADJUSTMENT [*2] ...................... 14-85 18. ANODE METAL/WATER SCREEN .................... 14-88 19. EXTENSION CASE/LOWER RUBBER MOUNT .............................................................. 14-89 20. OIL CASE............................................................ 14-94 19. OPERATION .............................................................. 19-1 1.DOHC (SWING ARM TYPE) + VTEC .................. 19-1 2.CHAIN DRIVE CAM DRIVE SYSTEM ..................

19-2 3.INDEPENDENT CYLINDER HEAD/CYLINDER BLOCK COOLING SYSTEM................................ 19-3 4.AIR/FUEL RATIO O 2 FEEDBACK CONTROL BY A/F SENSOR .................................................. 19-4 20. WIRING DIAGRAM/SYSTEM DIAGRAM ................ 20-1 15. MOUNTING CASE/STERN BRACKET/SWIVEL CASE/POWER TRIM/TILT ASSEMBLY .................... 15-1 1.MOUNTING CASE .............................................. 15-2 2.STERN BRACKET/SWIVEL CASE REMOVAL/INSTALLATION ................................15-10 3.STERN BRACKET/SWIVEL CASE/ POWER TRIM/TILT ASSEMBLY ........................ 15-14 4.POWER TRIM/TILT ASSEMBLY ........................

15-36 5.AIR BLEEDING .................................................. 15-48 6.BLOW PRESSURE INSPECTION ...................... 15-50 7.POWER TILT MOTOR ASSEMBLY.................... 15-53

Стр. 4