Honda Workshop For Bf5 Maintenance Manual

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W16EPR-U (DENSO) BPR5ES (NGK)
0.028 0.031 in (0.7 0.8 mm)
49 Spark Plug Service
SERVICING YOUR OUTBOARD MOTOR
SPARK PLUG WRENCHSEALING WASHER SIDE ELECTRODE
0.028 0.031 in
(0.7 0.8 mm) New plug Plug needing
replacement
INSULATOR
Incorrect spark plug can cause
engine damage. RECOMMENDED SPARK PLUGS:
Measure the spark plug electrode
gap with a wire-type feeler gauge.
Correct the gap, if necessary, by
carefully bending the side
electrode.
The gap should be:
Remove the spark plug with a
spark plug wrench and screwdriver
supplied in the tool kit. Disconnect the spark plug cap
from the spark plug. Unlock and remove the engine
cover (p. ).Inspect the spark plug. Replace it
if the electrode is worn, or if the
insulator is cracked or chipped.
1.
2.
3.4. 5.
43
11/03/07 16:35:35 31ZV1660_050 
						

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3.2 US gal (12 L)
50REFUELING
Portable Fuel Tank
SERVICING YOUR OUTBOARD MOTOR
OOPPEENN
FUEL GAUGEVENT KNOB
FUEL FILLER CAP
PRESSURE RELIEF TAB
A loose spark plug can overheat
and damage the engine.
Overtightening the spark plug can
damage the threads in the cylinder
head. Af ter the spark plug seats, tighten
with a spark plug wrench supplied
in the tool kit to compress the
sealing washer.
If reinstalling the used spark plug,
tighten 1/8 1/4 turn after the
spark plug seats.
If installing new spark plug,
tighten 1/2 turn after the spark
plug seats.
Attach the spark plug cap.
Install and lock the engine cover. Install the spark plug caref ully, by
hand, to avoid cross-threading.Turn the vent knob
counterclockwise all the way to
open the vent.
Turn the f uel f iller cap
counterclockwise so that it touches
the pressure relief tab. If you do not anticipate cycling
through at least one complete tank of
f uel within a 30 day period, we
recommend adding Honda Marine
Fuel Stabilizer each time you ref uel.
Remove the fuel tank from the boat
for refueling. FUEL TANK CAPACITY:
Check the f uel gauge and ref ill the
tank when necessary. 7.
8.
9. 6.1.
2.
11/03/17 14:39:59 31ZV1660_051 
						

							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.
51
SERVICING YOUR OUTBOARD MOTOR
PRESSURE RELIEF TABFUEL FILLER CAP
PRESSSAFE FILL LEVEL
FUEL FILLER CAP
VENT KNOB
CCLLOOSSEE
Fuel can damage paint and plastic.
Be caref ul not to spill f uel when
f illing your f uel tank. Damage
caused by spilled f uel is not covered
under warranty. Press down the pressure relief tab,
and then turn the f uel f iller cap 1/4
counterclockwise. Release the
pressure relief tab. Wait to relieve
pressure.
The f uel f iller cap will lock again.
Press down the pressure relief tab,
and turn counterclockwise to
remove the f uel f iller cap.Af ter ref ueling, install the cap and
tighten it until you hear it click. Close
the vent by turning the vent knob
clockwise all the way, and return the
f uel tank to the boat.
Ref uel in a well-ventilated area. Fill
the tank to the SAFE FILL LEVEL
line.Never ref ill the f uel tank inside a
building where gasoline f umes may
reach f lames or sparks. Keep
gasoline away f rom appliance pilot
lights, barbecues, electric appliances,
power tools, etc.
Spilled f uel is not only a f ire hazard,
it causes environmental damage.
Wipe up spills immediately. 3.
4.
11/03/17 10:53:28 31ZV1660_052 
						

							52 FUEL RECOMMENDATIONS
SERVICING YOUR OUTBOARD MOTOR
Use unleaded gasoline with a pump
octane rating of 86 or higher.
Your outboard motor is certified to
operate on unleaded gasoline.
Unleaded gasoline produces f ewer
engine and spark plug deposits and
extends exhaust system life.
Never use stale or contaminated
gasoline or an oil/gasoline mixture.
Avoid getting dirt or water in the f uel
tank.
You may use unleaded gasoline
containing no more than 10% ethanol
(E10) or 5% methanol by volume. In
addition, methanol must contain
cosolvents and corrosion inhibitors.
Use of fuels with content of ethanol
or methanol greater than shown
above may cause starting and/or
performance problems. It may also
damage metal, rubber, and plastic
parts of the fuel system.Engine damage or performance
problems that result from using a fuel
with percentages of ethanol or
methanol greater than shown above
are not covered under warranty.
If your outboard motor will be used
on an inf requent or intermittent basis,
please ref er to the f uel section of the
STORAGE chapter (p. ) f or
additional information regarding fuel
deterioration.61
11/03/07 16:36:09 31ZV1660_053 
						

							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.
53 Fuel Filter Inspection and
Replacement
SERVICING YOUR OUTBOARD MOTOR
UNLOCK ENGINE COVER LOCK LEVER
The f uel f ilter is located under the
engine cover, on the right side of the
engine.
Water or sediment accumulation in
the f ilter can cause loss of power or
hard starting. To prevent engine
malf unction, inspect the f ilter and
replace when necessary.
Unlock and remove the engine
cover f or access to the f uel pump
f ilter.
Inspect the f ilter f or water and/or
sediment accumulation.
If the f ilter is OK, reinstall it. If
water and/or sediment are present,
replace the f ilter as described in
the f ollowing steps. Always
replace the f ilter at the scheduled
replacement interval (p. ).Disconnect the fuel hose connector
from the outboard motor, and
place commercially available hose
clips on the f uel hoses on each side
of the f ilter to prevent f uel leakage
when the f uel hoses are
disconnected.
1.
2.3.
42
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							54
SERVICING YOUR OUTBOARD MOTOR
HOSE CLAMPSFUEL FILTER
FUEL HOSE
FUEL HOSEARROW
(Fuel Flow Direction)FUEL FILTER
HOSE CLAMPS
Remove the fuel hoses from the
used f ilter, and discard the f ilter.
To ease hose removal, release the
hose clamps by squeezing the
clamp ends together with pliers
while pulling of f the hoses. Connect the f uel hoses to the f uel
f ilter securely with the hose
clamps. Remove the fuel hose
clips used to close the f uel hoses. Install the new f ilter on the f uel
hoses, with the f uel f low arrow
pointing toward the fuel pump as
shown. Fuel flow will be impeded
if the f ilter is installed backward.Install and lock the engine cover.
4. 5.
6.Securely connect the fuel hose
connector to the outboard motor
(ref er to page ).
Prime the engine using the priming
bulb (p. ). Check for fuel leaks.
Repair any f uel leaks if necessary.
If loss of power or hard starting are
found to be caused by excessive
water or sediment accumulation in
the f uel f ilter, inspect the f uel tank.
Clean the f uel tank and tank f ilter if
necessary. It may be necessary to
drain the f uel tank completely and
ref ill with f resh gasoline. 7.
8.
9.26
27
11/03/07 16:36:39 31ZV1660_055 
						

							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.
55 Portable Fuel Tank and Tank
Filter Cleaning
SERVICING YOUR OUTBOARD MOTOR
FUEL HOSE
(standard equipment)
Fuel Tank
Empty the portable fuel tank into an
approved gasoline container. Use a
f unnel to avoid spilling f uel. Rinse
the fuel tank with nonflammable
solvent to remove any accumulated
sediment.
11/03/07 16:36:48 31ZV1660_056 
						

							56Anode Replacement Recoil Starter Rope Inspection
SERVICING YOUR OUTBOARD MOTOR
ANODE
BOLT
RECOIL STARTER ROPE 5 mm SCREWS (4)
FUEL TANK FILTER JOINT
(Fuel Hose Connector)CONNECTOR
GASKET
FUEL TANK
FILTERFuel Tank Filter
Painting or coating the anodes will
def eat their purpose and will lead to
rust and corrosion damage to the
outboard motor. The anodes must be
exposed to the water in order to
protect the outboard motor. Replace the anode when it has been
reduced to about half its original size,
or if it is crumbling. The anode is located on the
antiventilation plate. It is made of a
sacrif icial material that helps to
protect the outboard motor from
corrosion. Inspect the recoil starter rope, and
replace it if it becomes f rayed.
Always keep the emergency starter
rope on the boat in case the recoil
starter rope f ails.
Reinstall the f ilter and hose
connector in the fuel tank. Tighten
the f our 5 mm screws securely. Clean the f ilter in nonf lammable
solvent. Inspect the f uel tank f ilter
and the connector gasket. Replace
them if damaged. Remove the four 5 mm screws
using a f lat screwdriver, then
remove the fuel hose connector
and f uel tank f ilter f rom the tank. 1.
2.
3.
11/03/07 16:37:03 31ZV1660_057 
						

							57 Propeller and Shear Pin
Replacement
SERVICING YOUR OUTBOARD MOTOR
PROPELLER CAP
SHEAR PIN COTTER PIN
RemovalRemove the cotter pin, the
propeller cap, and the propeller.
Remove the broken shear pin and
replace it with a new one.
Operating the outboard motor at
higher altitudes will reduce available
power. This may require decreasing
the propeller pitch to maintain correct
engine RPM. The propeller blades may have sharp
edges, so wear heavy gloves to
protect your hands. Ashearpinisusedtoprotectthe
propeller and drive mechanism from
damage when the propeller strikes an
obstruction.
Before replacing the propeller or the
shear pin, remove the emergency
stop switch clip f rom the emergency
stop switch to prevent any possibility
of the engine being started while you
are working with the propeller.1.
2.
11/03/07 16:37:14 31ZV1660_058 
						

							58
SERVICING YOUR OUTBOARD MOTOR
COTTER PIN
InstallationSpare shear pins and cotter pins are
provided in the engine compartment
(p. ).
Install the shear pin and the
propeller, then install the propeller
cap finger tight.
Use a Honda Genuine stainless
steel cotter pin or equivalent cotter
pin and bend the pin ends as
shown. Be sure to replace the cotter pin
with a new one. 1.
2.40
11/03/07 16:37:22 31ZV1660_059