Honda 75 Outboard Motor Manual

							Spark Plug Service 
Recommended spark plug: DR-5HS (NGK), XlGFSR-U (ND) 
1. Remove the engine cover. 
2. Remove the spark plug cap. 
3. Use the wrench supplied in the tool kit to remove the spark plug. 
4. Visually inspect the spark plug. Discard it if the insulator is cracked or chip- 
ped. Clean the spark plug with a wire brush if it is to be reused. 
5. Measure the plug gap with a feeler gauge. 
The gap should be 0.6-0.7 mm (0.024-0.028 in). Correct as necessary by 
bending the side electrode. 
6. Attach the plug washer. Thread the plug in by hand to prevent 
cross-threading. 
7. Tighten a new spark plug l/2 turn with the wrench to compress the washer. 
If you are reusing a plug, it should only take l/8-1/4 turn after the plug 
seats. 
8. Reinstall the engine cover. 
CAUTION: 
l The spark plug must be securely tightened. An improperly tightened plug 
can become very hot and possibly damage the engine. 
l Never use a spark plug with an improper heat range. 
/ 
WRENCH+ PLUG GAP 
0.6-0.7 mm 
(0.024-0.028 in) 
29  
						

							Cleaning and Flushing 
After each use in salt water or dirty water, thoroughly clean and flush the 
outboard motor. 
1. Wash the outside of the outboard motor with clean, fresh water. 
2. Flush the cooling system, using the Honda flush kit supplied with the 
outboard motor. 
a. Attach a hose from a fresh water faucet to the flush kit hose coupler. 
b. Remove the propeller, and clip the flush kit rubber fitting over the water 
intake as shown. 
c. Turn on the fresh water supply to the hose. 
d. Start the engi’ne and run in neutral for 10 minutes. 
l For safety, the propeller must be removed. 
l Be sure the outboard motor is securely mounted, and do not leave it 
unattended while running. 
CAUTION: Running the engine without water can cause serious engine 
damage due to overheating. Be sure that water flows from the water 
check tube while the engine is running. If not, stop the engine and 
determine the cause of the problem. 
KIT 
WAiER 
HOSE 
30  
						

							Lubrication 
Wipe the outside of the engine with a cloth dipped in oil. Apply marine 
anti-corrosion grease to the following parts: 
CLAMP SCREWS 
SWIVEL CASE 
TILT LINKAGE 
NOTE: Apply anti-corrosion oil to 
penetrate. 
THROTTLE CABLE AND PIVOT 
SHIFT SHAFT AND PIVOT 
HANDLE PIVOT ’ 
\’ 
PROPELLER SHAFT  
/ 
pivot surfaces where grease cannot 
31  
						

							Shear Pin Change 
A shear pin is used to protect the propeller and drive mechanism from damage 
when the propeller strikes an obstruction. 
1. Remove the cotter pin, the propeller cap, and the propeller. 
2. Remove the broken shear pin and replace it with a new one. 
3. Install the propeller, then install the propeller cap finger tight. 
4. Install a new cotter pin, and spread the ends as shown in the illustration. 
COTTER 
PIN 
PIN 
J I SPARE SHEAR PINS 
AND COTTER PINS 
COTTER 
PIN 
‘PROiELLER 
CAP 
32  
						

							Fuel strainer replacement 
The fuel strainer is located between the fuel pump and the carburetor. Water 
or sediment accumulated in the fuel strainer can cause loss of power or hard 
starting. To prevent engine malfuction, replace the fuel strainer regularly. 
((SERVICE PERIOD)) Every 200 operating hours or every one year. 
l Gasoline is flammable and explosive under certain conditions. Do not 
smoke or allow flames or sparks near the outboard motor while draining 
fuel. 
l Always work in a well-ventilated area. 
l Be sure that any fuel drained from the outboard motor is stored in a safe 
container. 
l Wipe up any spilled gasoline at once. 
1. Disconnect the fuel tank line from the motor. 
2. Remove the engine cover, and remove the fuel strainer. 
NOTE: Before removing the strainer, place clamps on the fuel tubes on 
each side of the strainer to prevent fuel leakage. 
3. Install the new fuel strainer with the arrow mark pointing toward the 
carburetor. 
NOTE: Fuel flow will be impeded if the strainer is installed backward. 
. 
33  
						

							4. Remove the clamps used to close the fuel tubes. Connect the fuel tank line 
to the motor. Turn the fuel tank vent knob to the ON position, pump the 
primer bulb, and check for leaks. 
Contact an authorized Honda dealer if you find excessive water or sediment 
accumulated in the fuel strainer. 
FUEL STRAINER 
The arrow mark indicates 
the fuel flow direction. 
CARBURETOR 
34  
						

							Servicing a Submerged Motor 
A submerged motor must be serviced immediately after it is recovered from 
the water in order to minimize corrosion. 
If there is a Honda outboard motor dealership nearby, take the motor 
immediately to the dealer. If you are far from a dealership, proceed as 
follows: 
1. Remove the engine cover, and rinse the motor with fresh water to remove 
salt water, sand, mud, etc. 
2. Loosen the carburetor drain screw (p. 36), drain the contents of the 
carburetor into a suitable container, then retighten the drain screw. 
3. Change the engine oil (p. 27). If there was-water in the engine crankcase, or 
the used engine oil showed’signs of water contamination, then a second 
engine oil change should be performed after running the engine for l/2 
hour. 
4. Remove the spark plugs. While pressing the engine stop button, pull the 
recoil starter several times to completely expel water from the cylinders. 
CAUTION: 
l When cranking the engine with an open ignition circuit (spark plugs 
removed from the ignition circuit), keep the engine stop button 
depressed to prevent electrical damage to the ignition system. 
l If the motor was running when it submerged, there may be mechanical 
damage, such as bent connecting rods. If the engine binds when cranked, 
do not attempt to run the motor until it has been repaired. 
5. Pour a teaspoon of engine oil. into each spark plug hole, then pull the recoil 
starter several times to lubricate the inside of the cylinders. Reinstall the 
spark plugs. 
6. Attempt to start the engine. 
l If the engine fails to start, remove the spark plugs, clean and dry the 
electrodes, then reinstall the spark plugs and attempt to start the engine 
again. 
l If the engine starts, and no mechanical damage is evident, continue to 
run the engine for l/2 hour or longer (be sure the water level is at least 4 
inches above the cavitation plate). 
7. As soon as possible, take the motor to a Honda outboard motor dealer for 
inspection and service.  
						

							10. TRANSPORTING/STORAGE 
1. Disconnect the fuel line and install the cap on the engine fuel inlet. Firmly 
close the fuel cap vent knob. 
CAP 
FUEL’INLET 
FUEL LINE COb.iNECTbk 
2. Loosen the carburetor drain screw, and drain the gasoline into a suitable 
container. After draining, retighten the drain screw. 
B Be careful not to spill fuel. Fuel vapor or spilled fuel may ignite. 
CAUTION: In cold weather, to prevent ice from forming inside the water 
pump, pull the recoil starter several times to flush the water out. 
DRAliv SCdEW - 
36  
						

							3. To carry, hold the motor by the carrying handle, or hold by the carrying 
handle and engine cover lock lever as shown here. Do not carry by the 
engine cover. 
4. Transport and store the motor either vertically or horizontally, as shown 
here, with the steering handle raised. 
Vertical transport or storage: Attach the stern bracket to a stand. 
Horizontal transport or storage: Rest the motor on the case protector 
(steering handle side of the motor). 
CAUTION: 
l Any other transport or storage position may cause damage or oil leakage. 
5. Store the outboard motor in a clean, dry area. 
NOTE: Before storing, clean, flush, and lubricate the outboard motor as 
described on pages 30 and 31. 
CASE PROTECTOR 
37.  
						

							1 ‘I. TROUBLESHOOTONG 
Engine Will Not Start: 
1. Is the shift lever in neutral? 
2. Is there fuel in the fuel tank? 
3. Is the fuel cap knob turned to ON? 
4. Is the fuel system primed by squeezing the primer bulb? 
5. Is fuel reaching the carburetor? 
Loosen the carburetor drain screw to see if there is fuel in the carburetor 
float bowl. 
w If any fuel is spilled, make sure the area is dry before testing the 
spark plug or starting the engine. Fuel vapor and spilled fuel may ignite. 
6. Are the spark plugs firing? 
a. Remove and inspect ‘the spark plugs. Clean and dry the plugs, and check 
the electrode gap (p. 29). 
b. Install both spark plugs in their caps, and ground the side electrodes to 
each other or to any engine ground. 
c. Pull the recoil starter briskly, and see if the plugs spark. 
d. If the spark plugs are OK, reinstall them, and try to start the engine. 
Engine Overheats: 
1. Is the water intake screen clogged? 
2. Is the thermostat faulty? 
38