Honda Outboard Service Workshop and Repair Manual BF15D BF20D

BF15D.BFZOD Paper Book Part No. 66ZYOOO PREFACE This manual covers the construction, function and servicing procedures of the Honda BF15D, BF20D Outboard Motors. All information contained in this manual is based on the latest product information available at the time of print- ing. We reserve the right to make changes at anytime without notice. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic, mechanical, photocopying, record- ing, or otherwise, without prior written permission of the publisher. This includes text, figures, and tables. As you read this manual, you will find information that is preceded by alNOTlcE symbol. The purpose of this mes- sage is to help prevent damage to the outboard motor, other property, or the environment. SAFETY MESSAGES 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. You will find important safety information in a variety of forms, including: Safety Messages -- preceded by a safety alert A symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions. ! 1. You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions. You CAN be HURT if you don't follow instructions. CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE PROPELLEWGEAR CASElEXTENSION CASE ENGINE COVERS FUEL SYSTEM RECOIL STARTER ENG I N E R EM OVA LANSTALLATION FLYWHEEMIMING BELT CYLINDER HEADNALVESIOIL PUMP CRAN KCASWCRAN KSH AFT/PISTON OIL CASElSTERN BRACKETBWIVEL CASE SHIFT MECHANISM STEERING ROD/REMOTE CONTROL BOX TILLER HANDLE Instructions -- how to service this outboard motor ELECTRICAL EQUIPMENT correctly and safely. WIRING DIAGRAMS Honda Motor Co., Ltd Service Publication Office Date of Issue: July 2002 0 Honda Motor Co., Ltd.

INDEX BF15DmBF20D 1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 . SPECIFICATIONS ...................................................... 1-1 1 . SPECIFICATIONS ................................................... 1-1 2 . DIMENSIONAL DRAWINGS ................................... 1-4 SERVICE INFORMATION .......................................... 2-1 1 . THE IMPORTANCE OF PROPER SERVICING ..... 2-1 2 . IMPORTANT SAFETY PRECAUTIONS ................. 2-1 3 . SYMBOLS USED IN THIS MANUAL ...................... 2-2 4 . SERIAL NUMBER LOCATIONS ............................. 2-2 5 . MAINTENANCE STANDARDS ............................... 2-3 6 . TORQUE VALUES ................................................ 2-6 7 . SPECIAL TOOLS .................................................. 2-9 8 . TROUBLESHOOTING ........................................... 2-11 9 . CABLE & HARNESS ROUTING ............................ 2-29 10 . LUBRICATION POINTS ........................................ 2-41 MAINTENANCE .......................................................... 3-1 1 . MAINTENANCE SCHEDULE .................................. 3-1 2 . ENGINE OIL .............................................. 3 . OIL FILTER CARTRIDGE ......................... 4 . GEAR CASE OIL ......................................... 5 . SPARK PLUG .......................................................... 3-6 8 . FUEL FILTER ........ ......................................... 3-11 12 . TIMING BELT ........................................................ 3-15 13 . CRANKCASE BREATHER .................................... 3-19 14 . EXHAUST EMISSION (Bodensee model) ............. 3-19 PROPELLEWGEAR CASElEXTENSlON CASE ....... 4-1 1 . PROPELLER ........................................................... 4-2 2 . PROPELLER SHAFT HOLDER .............................. 4-3 3 . GEAR CASE ASSEMBLY ...................... 4 . WATER PUMP ........ 5 . VERTICAL SHAFT/BEVEL GEAR ......... .......................................... 4-1 1 6 . WATER PUMP HOUSING ...................................... 4-21 7 . GEAR CASEIANODENVATER SCREEN ................ 4-27 8 . EXTENSION CASE ................................................. 4-28 9 . EXHAUST CHAMBER COVER . ENGINE COVERS ....................................................... 5-1 1 . ENGINE COVER ..................................................... 5-1 2 . LEFT ENGINE UNDER COVER ............................. 5-2 3 . RIGHT ENGINE UNDER COVER ........................... 5-3 FUEL SYSTEM ........................................................... 6-1 1 . SILENCER/CARBURETOR ................................... 6-2 2 . CHOKE CABLE ....................................................... 6-17 3 . FUEL PUMP/FUEL FILTER .................................... 6-18 4 . FUEL TANK ............................................................. 6-21 RECOIL STARTER ..................................................... 7-1 1 . NEUTRAL START CABLE ...................................... 7-1 2 . RECOIL STARTER ................................................. 7-2 3 . STARTER CASE B .................................................. 7-10 ENGINE REMOVAUINSTALLATION ........................ 8-1 1 . ENGINE REMOVAL ................................................ 8-1 2 . ENGINE INSTALLATION ........................................ 8-6 FLYWHEEVTIMINGBELT ......................................... 9-1 1 . FLYWHEEUCOILS ................................................. 9-2 2 . TIMING BELT/PULLEYS ......................................... 9-8 10 . CYLINDER HEADNALVESIOIL PUMP ..................... 10-1 1 . CYLINDER HEAD REMOVAL ................................. 10-2 2 . OIL PUMP ............................................................... 10-5 3 . CYLINDER HEAD DISASSEMBLY ......................... 10-8 4 . VALVE SEAT REFACING ....................... 10-14 5 . CYLINDER HEAD ASSEMBLY ........... 1016 6 . CYLINDER HEAD INSTALLATION ............................ 1@18 11 . CRANKCASE/CRANKSHAFT/PISTON ..................... 11-1 1 . THERMOSTATNVATERJACKET .......................... 11-2 2 OIL STRAINER ...................... 11-8 3 . PISTON ............... ...................... 11-9 4 . CRANKSHAFT/CYLINDERBLOCK ......................... 11-15 12.OIL CAWSTERN BRACKETKWIVEL CASE ......... 12-1 1 . OIL CASE ............................. ...................... 12-2 2 . FRICTION ADJUST ...................... 12-4 3 MOUNT FRAME ...................... 12-6 4 . STERN BRACKET .................................. 12-7 5 . SWIVEL CASE ........................................................ 12-1 1 . ... . ..... 13 .SHIFT LINKAGE ........................................................ 13-1 1 . SHIFT ARMnHROTTLE ARM ................................ 13-2 2 . SHIFT LEVER ......................................................... 13-3 3 . SHIFT SHAFT ......................................................... 13-4 14 . STEERING ROD/REMOTE CONTROL BOX ............. 14-1 1 . STEERING ROD ..................................................... 14-1 3 . CONTROL BOX WIRE HARNESS ......................... 14-4 2 . REMOTE CONTROL CABLE .......................... 4 . REMOTE CONTROL BOX .............................. 15.TILLER HANDLE ....................................................... 15-1 1 . TILLER HANDLE .................................................... 15-2 2 . TILLER HANDLE BRACKET ...................... 15-6 3 . THROTTLE GRIP ............................. 4 . STARTER SWITCH .............. 5 . EMARGENCY STOP SWlTC 16 . ELECTRICAL EQUIPMENT ....................................... 16-1 1 . STARTER MOTOR .......................... ...... 16-1 2 . STARTER CABLE (Type with 12A c ...... 16-13 3 . CHARGE WIRE (Type with6A charge coil) ............. 16-17 4 . NEUTRAL SWITCH/INDICATOR ........................... 16-20 5 . IGNITION CONTRO 6 . CONNECTOR BRACKET A .................................. 16-24 7 . IGNITION COIL ......... ...................... 16-27 8 . REGULATOR/RECTI 17 .WIRING DIAGRAMS .................................................. 17-1

Model BF15D TY Pe SH SHS SR LH LHS LR 640 mm (25.2 in) 650 mm 640 mm (25.6 in) (25.2 in) Overall height Dry weight (With propeller mounted) Operating weight Transom height Transom angle 1,110 mm (43.7 in) 1,240 mm (48.8 in) 46.5 kg 50.0 kg 50.5 kg 49.5 kg 53.0 kg 52.0 kg (103 Ib) (110 Ib) (111 Ib) (109 Ib) (117 Ib) (115 Ib) 47.9 kg 51.4 kg 51.9 kg 50.9 kg 54.4 kg 53.4 kg (106 Ib) (113 Ib) (114 Ib) (112 Ib) (120 Ib) (118 Ib) 433 mm (1 7.0 in) 563 mm (22.2 in) 5 stage adjustment (4" , 8" , 12" , 16" , 20" ) Tilting angle 71 " 72" Swivel angle 45" right and left 640 mm (25.2 in) 650 mm (25.6 in) 47.9 kg (106 Ib) 51.4 kg 51.9 kg 50.9 kg 54.4 kg 53.4 kg (113 Ib) (114 Ib) (112 Ib) (120 Ib) (118 Ib) 433 mm (17.0 in) 563 mm (22.2 in) 1 SPECIFICATIONS 1. SPECIFICATIONS 2. DIMENSIONAL DRAWINGS 1. SPECIFICATIONS DIMENSIONS AND WEIGHTS BF15D Description Code I BALJ Overall length 650 mm (25.6 in) Overall width BF20D Model BF20D Description Code BAMJ SH I SHS I SR 1 LH 1 LHS I LR Overall length 650 mm (25.6 in) 350mm (13.8 in1 Overall width Overall heiaht 1.110 mm (43.7 in) I 1.240 mm (48.8 in) Dry weight 52.0 kg 1 E;k? I (1151b) 46.5 kg 50.0 kg (103 Ib) I (110 Ib) Operating weight Transom height Transom anale 71 I 72" Tilting angle Swivel angle 45" right and left 1 -I

BF15D-BF20D Model BFl5D BF20D Tvpe I Water cooled 4-stroke, overhead valve, vertical twin Ignition system Ignition timing Spark plua Displacement I ' 350 cm3 (21.5 cu. in) CDI 0'12" B.T.D.C. CR5EH-9 (NGK). U16FER9 (DENSO) Bore x stroke I 59 x 64 mm (2.3 x 2.5 in) Oil capacity Recommended oil Starting system Rated horsepower Maximum torque 1 .O e (1.06 US qt, 0.88 Imp qt) at oil change 1.3 e (1.37 US qt, 1.14 Imp qt) with oil filter replacement SAE 1 OW-30, API Service classification SG/SH/SJ SH, LH Type: Recoil starter SHS, SR, LHS, LR Type: Electric starter and recoil starter 11 .O kW (15 PS) 25.2 N.m (2.6 kgf.m, 18.8 Ibf.ft) at 3.500 min-I (rpm) Fuel used Fuel tank capacity Fuel pump 14.7 kW (20 PS) at 5.500 min-l (ram) Automotive unleaded gasoline (minimum 86 pump octane) Steel tank: 13 e (3.43 US gal, 2.86 Imp gal) Plastic tank: 12 e (3.17 US gal, 2.64 Imp gal) Mechanical plunger type 25.8 N.m (2.6 kgf.m, 18.8 Ibf.ft) at 5,000 min-l (rpm) Model Compression ratio I 9.2: 1 BF15D, BF20D Fuel consumption I 313 g (11 .O oz.)/kWh Clutch Gear ratio Reduction type Gear case oil capacity Prope I le r Number of blades Diameter Cooling system Dog clutch (Forward-neutral-reverse) 0.48 (13/27) Spiral bevel gear 0.285 e (0.27 US qt, 0.23 Imp qt) 4 235 mm (9-1/4 in) I Rotating direction 337 g (11.9 oz.)/kWh Clockwise (viewed from rear) Forced water circulation by impeller pump with thermostat Carburetor I Horizontal butterflv valve type sinale carburetor Lubricating system Forced lubrication by trochoid pump Stopping system L Ignition primary circuit ground Exhaust system I Under water type LOWER UNIT 1 Pitch 203 mm (8.0 in) I -2

BF15DmBF20D Types of Honda BF15D/BF20D Outboard Motors It may be necessary to refer to this chart for reference purposes when reading this manual. BF15D/ BF20D Starting system Charge enrichment 1 Shaft Remote Electric Recoil I Model ~ Type ~ length 1 zr%e ~ control ~ starter ~ starter ~ coil 1 SH S 6A Manual SHS S 12A Automatic SR S 12A Automatic LH L 6A Manual LHS L 12A Automatic LR L 0 12A Automatic S: Short shaft L: Long shaft 13

BF15DmBF20D 2. DEMENSIONAL DRAWINGS Tiller Handle Type .. I I 1 S 1 1,110 (43.7) I 433 (17.0) 1 71" 1 Unit: mm (in) .r; 1-4

I [IITvpe I H T t 1,110(43.7) 1,240(48.8) Unit: rnrn (in) 433 (17.0) 563 (22.2) 1-5

BF15DmBF20D Propeller Shaft Detail Unit: mm (in) t 4 3 (0.12) 6 (0.24)- I k 8 (1.50)J 2o (0'78) I 74 (2.91) 89.5 (3.52) 105.5 (4.15) 1-6

2. SERVICE INFORMATION I BF15DmBF20D 1. THE IMPORTANCE OF PROPER SERVICING 6. TORQUE VALUES 2. IMPORTANT SAFETY PRECAUTIONS 7. SPECIAL TOOLS 3. SYMBOLS USED IN THIS MANUAL 8. TROUBLESHOOTING 4. SERIAL NUMBER LOCATIONS 9. CABLE & HARNESS ROUTING 5. MAINTENANCE STANDARDS 10. LUBRICATION POINTS ! ' . e r v i c i n g can cause an unsafe condition that can lead to serious injury or d e a t h . 7 Follow the procedures and precautions in this shop manual carefully. Some of the most important precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance or repairs. Only you can decide whether or not you should perform a given task. Failure to follow maintenance instructions and precautions can cause you to be seriously hurt or killed. 1 Follow the procedures and precautions in this shop manual carefully. I 2. IMPORTANT SAFETY PRECAUTIONS Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. Protect your eyes by using proper safety glasses, goggles, or face shields any time you hammer, drill, grind, or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe bums or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. Protect yourself and others whenever you have engine-powered equipment up in the air. Any time you lift an outboard motor with a hoist, make sure that the hoist hook is securely attached to the outboard motor. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the Burns from hot parts. Let the engine and exhaust system cool before working in those areas. Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or battery. Use only a nonflammable solvent, not gasoline, to clean parts. Never drain or store gasoline in an open container. Keep all cigarettes, sparks, and flames away from all fuel-related parts. engine. out of the way. 2-1

3. SYMBOLS USED IN THIS MANUAL As you read this manual, you may find the following symbols with the instructions. [S. TOOL] 3 0x0 (0) P. 0-0 : A special tool is required to perform the procedure. : Apply grease. : Apply oil. : Indicates the diameter, length, and quantity of metric flange bolt used. : Indicates the reference page. 4. SERIAL NUMBER LOCATIONS The engine serial number is located on the cylinder block and the frame serial number is located on the stern bracket. Always refer to these numbers when making technical inquiries or ordering parts in order to obtain the correct parts for the outboard motor being serviced. FRAME SERIAL NUMBER \ ENGINE SERIAL NUMBER 2-2

Honda Outboard Service Workshop and Repair Manual BF15D BF20D

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