Honda BF20A/BF25A Outboards OEM Service & Repair Manual

Paper book Part No. 66ZV700 HONDA BF2OAe25A This manual covers the construction, function and servicing procedures of the Honda BFZOAIBF25A outboard motors. Careful observance of these instructions will result in bet- ter, safer service work. Illustrations in this manual are based primarily on the BF25A LRS. ALL INFORMATION, ILLUSTRATIONS, Dl- RECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OFFICE CONTENTS 1 SPECIFICATIONS SERVICE INFORMATION MAINTENANCE ENGINE COVERITHROTTLEICHOKE FUEL SYSTEM SWIVEL CASE ELECTRICAL EQUIPMENT OPERATION WIRING DIAGRAM 1 BF30 SUPPLEMENT 1 Data of Issue April 1994 @ HONDA MOTOR CO., LTD. Page: I - Honda BF2OA-BF25A, BF25D-BF3OD Outboard Motors Shop Manual - http:llwww.ReadManuals.Com

SOME PARTS OF CHANGES Publication No. BF2OA. BF25A 66ZV700 HONDA SHOP MANUAL NEWS OUTBOARD MOTOR PAGE I OF 2 BF2OA BF25A Power Equipment I CHANGE LOCATIONS P.12-21 8. BACKLASH ADJUSTMENT @FORWARD GEAR News No. P/P-o36 BEFORE MODIFICATION Issue Date se~tember '94 3) Turn the vertical shaft right and left while pressing it down with approximately 5 kg (11.0 lb) of force and measure the backlash. Standard 1 0.10-0.29 rnm (0.004-0.01 1 in) 4) If the backlash is too large, increase the forward gear shim thickness and recheck the backlash. If the backlash is too small, decrease the forward gear shim thickness and recheck the backlash. P. 12-22 @REVERSE GEAR 3) Turn the vertical shaft right and left while pressing it down with approximately 5 kg (1 1 .O lb) of force and measure the backlash. 1 Standard 1 0-10 - 0,39 mm (0.004 - 0.01 5 in) 1 AFTER MODIFICATION Turn the vertical shaft right and left while pressing it down with approximately 5 kg (11.0 lb) of force and measure the backlash. 17.43*' Backlash =Dial Gauges measures x - 23*2 *I The pinion gear radious of pitch circle *2 The special tools (07MGJ-0010100) lever-length Standard 1 0.10-0.29 mm (0.004-0.01 1 in) 4) If the backlash is too large, increase the forward gear shim thickness and recheck the backlash. If the backlash is too small, decrease the forward gear shim thickness and recheck the backlash. 3) Turn the vertical shaft right and left while pressing it down with approximately 5 kg (1 1.0 lb) of force and measure the backlash. 17.43 Backlash =Dial Gauges measures x 7 Service limit 4) If the backlash is too large, increase the reverse gear shim thickness and recheck the backlash. If the backlash is too small, decrease the reverse gear shim thickness and recheck the backlash. 0.30 mrn (0.01 2 in) Standard 1 0.10-0.39 mm (0.004-0.01 5 in) 4) If the backlash is too large, increase the reverse gear shim thickness and recheck the backlash. If the backlash is too small, decrease the reverse gear shim thickness and recheck the backlash. WGt1- 0.40 mm (0.016 in) 1 HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS Page: 2 - Honda BF2OA-BF25A, BF25D-BF3OD Outboard Motors Shop Manual - http:l/www.ReadManuals.Com

HONDA OUTBOARD MOTOR BF2OA BF25A SOME PARTS OF CHANGES SHOP MANUAL NEWS Publication No. BF2OA BF25A 66ZV700 Power Equipment CHANGE LOCATIONS The part numbers of the pin driver, 4mm and the special tool illustrations have been corrected as follows~ News No. PIP432 *Pin driver , 4mm .. . laue Date Auaust -94 BEFORE MODIFICATION -. . - *Special tool illustrations AFTER .MODIFICATION HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS Page: 3 - Honda BF2OA-BF25A, BF25D-BF3OD Outboard Motors Shop Manual - http:l/www.ReadManuals.Com

1. SPECIFICATIONS 1 1. SPECIFICATIONS 2. DIMENSIONAL DRAWINGS 1. SPECIFICATIONS DIMENSIONS AND WEIGHTS Overall length Model Description code Tv~e *I: 675 mm (26.6 in) *2: 1,005 mm (39.6 in) 1 640 mm (25.2 in) I BF2OA * 1 : With Tiller Handle raised Overall width Overall height Dry weight Operating weight (incld. oil) *2: With Tiller Handle extended BAHL LHS BAHS SRS BAHS SH DIMENSIONS AND WEIGHTS BAHL LRS BAHL LH 380 mm (15.0 in) Overall length BAHS SHS 375 mm (14.8 in) Model Description code Type *I : 675 mm (26.6 in) *2: 1,005 mm (39.6 in) 1,315 rnrn (51.8 in) 72 kg (158.8lb) 74 kg (163.2 lb) 1,190 mrn (46.9 in) 69 kg (152.1lb) 71 kg (1 56.6 lb) 1 640 mrn (25.2 in) 1,315 mm (51.8 in) 71 kg (156.6lb) 73 kg (161 .O lb) 1,190 mm (46.9 in) 70 kg (154.3lb) 72 kg (1 58.8 lb) 1,190 mm (46.9 in) 67 kg (147.7lb) 69 kg (152.1 lb) BF25A 1,315 rnrn (51.8 in) 69 kg (152.1lb) 71 kg (156.6 lb) BAJS SH * 1 : With Tiller Handle raised *2: With Tiller Handle extended Overall width Overall height Dry weight Operating weight (incld. oil) Page: 4 - Honda BF2OA-BF25A, BF25D-BF3OD Outboard Motors Shop Manual - http:l/www.ReadManuals.Com BAJL LH BAJS SHS 380 mm (1 5.0 in) 1,190 mm (46.9 in) 67 kg (147.7 lb) 69 kg (152.1 lb) 375 mm (14.8 in) BAJL LHS 1,190 rnm (46.9 in) 69 kg (152.1 lb) 71 kg (156.6 lb) 1,315 mm (51.8 in) 69 kg (152.1 lb) 71 kg (156.6 lb) 1,315 mm (51.8 in) 71 kg (156.6 lb) 73 kg (161-0 lb) BAJS SRS BAJL LRS 1,190 rnm (46.9 in) 70 kg (I 54.3 lb) 72 kg (158.8 lb) 1,315 mm (51.8 in) 72 kg (1 58.8 lb) 74 kg (163.2 lb)

HONDA 6F2OA*25A FRAME Model Tv~e TYPES OF HONDA BF2OAlBF25A OUTBOARD MOTORS It may be necessary to refer to this chart for reference purposes when reading this manual. BF2OAtBF 25A 1 Swivel angle Models I--- SH 1 LH 1 SHS 552 mm (21.7 in) - -- Transom height 40Â right and left L , S: Short Shaft - 431 mm (1 7.0 in) Transom angle Tilting angle 552 mm (21.7 in) I LHS 1 SRS 431 mm (1 7.0 in) 5 stage adjustment (4O, 8O, 12', 1 Go, 20') 75O 431 mm (1 7.0 in) LRS - - 552 mm (21.7 in) TY P~S s H L H SHS LHS I 1 I I 1 L: Long Shaft H: Tiller Handle R: Remote Control Shaft Length SRS LRS Page: 5 - Honda BF2OA-BF25A, BF25D-BF3OD Outboard Motors Shop Manual - http:l/www.ReadManuals.Com Tiller Handle Short Long Remote Control Electric Starter Recoil Starter

ENGINE Mode I 1 cool in^ system 1 Forced water circulation by impeller pump with thermostat 1 -- - Displacement Bore x stroke Rated power 1 Maximum torque Compression ratio Fuel consumption ratio 1 lanition svstem I CDI I -- - 499 cm3 (30.5 cu in) 58 x 63 rnm (2.3 x 2.5 in) 20 HP (14.9 kw)/4,500-5,500 rnin-I (rpm) 3.55 kg-m (25.7 ft-lb)/3,000 min-I (rpm) 1 Fuel tank capacity 1 25 f (6.6 US gal, 5.5 Imp gal) 1 25 HP (18.7 kwl/5,000-6,000 min-I (rpm) 3.59 kg-m (26.0 ft-lb)/4,000 min-I {rpm) Ignition timing Spark plug Carburetor Lubrication system Lubrication capacity Starter system Stopping system Fuel 1 Fuel pump 1 Mechanical plunger type 1 - - - 5-26O B.T.D.C. DR7EA (NGK), X22ESR-U (NIPPONDENSO) Horizontal type, butterfly valve (3 carburetor) Pressure lubrication by trochoid pump 1.9f (2.00 US qt, 1.67 Imp qt) Electric starter or Recoil starter Grounding of primary circuit Regular automotive gasoline (86 pump octane; unleaded preferred) 1 Exhaust system 1 Under water type 1 9.2 : 1 214 g/PSh (7.5 oz/PSh) LOWER UNIT 239 g/PSh (8.4 oz/PSh) Recommended oil SAE 1 OW-30 I 1: Full throttle range. Clutch Gear ratio Reduction Dog clutch (Forward - Neutral- Reverse) 0.48 (13127) Spiral bevel Gear case oil capacity Propeller driving system 1 Spline I 0.29 ((0.307 US qt, 0.255 Imp qt) Propeller No. of blades-Dia, x Pitch Propeller rotating direction Page: 6 - Honda BF20A-BF25A, BF25D-BF30D Outboard Motors Shop Manual - http://www.ReadManuals.Com 3-235 x 305 mm (9-114 x 12.0 in) Clockwise (viewed from rear)

HONDA BFSOAeS5A 2. DIMENSIONAL DRAWINGS Unit: mm (in) Remote control type I I: Short shaft type . .. . Page: 7 - Honda BF20A-BF25A, BF25D-BF30D Outboard Motors Shop Manual - http://www.ReadManuals.Com

HONDA BF80AmSBA Tiller handle type [ I: Short shaft type PROPELLER SHAFT Unit: mm (in) Unit: mrn (in) Page: 8 - Honda BF20A-BF25A, BF25D-BF30D Outboard Motors Shop Manual - http://www.ReadManuals.Com

2. SERVICE INFORMATION 1. GENERAL SAFETY C. ELECTRIC STARTER 2. SERVICE RULES 1 3. SERIAL NUMBER LOCATION 4. MAINTENANCE STANDARDS 5. TORQUE VALUES 6. SPECIAL TOOLS 7. TROUBLESHOOTING I A. HARD STARTING I Cylinder Compression Test (Electric starter type only) D. ENGINE DOES NOT RUN SMOOTHLY E. ALERT SYSTEMS Oil Pressure Test F. SHIFT LEVER 8. CABLEIHARNESS ROUTING 9. TUBE ROUTING 10. LUBRICATION B. IGNITION SYSTEM 11. MAINTENANCE SCHEDULE Spark Test 1. GENERAL SAFETY Pay attention to these symbols and their meanings: Indicates a strong possibility of severe personal injury or death if instructions are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed. Stop the engine, and remove the spark plug caps and ignition key before servicing the outboard motor. If the motor must be running to do some work, make sure the area is welt ventilated. Never run the engine in a closed 1 area; the exhaust contains poisonous carbon monoxide gas. 1 Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in your working area. CAUTION Keep away from rotating or hot parts and high voltage wires when the engine is run with the engine cover off. 2. SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may damage the unit. 2. Use the special tools designed for the product. 3. Install new gaskets, O-rings, etc. when reassembling. 4. When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless a particular sequence is specified. 5. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 6. After reassembly, check all parts for proper installation and operation. 7. Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the female threads and ruin the hole. 8. Use only metric tools when servicing this unit. Metric bolt, nuts and screws are not interchangeable with nonrnetric fasteners. The use of incorrect tools and fasteners will damage the unit. 9. Follow the instructions represented by these symbols when they are used: : Apply oil [s] : Use special tool : ~pply grease 0 x 00) : Indicates the type, length, and number of the flange bolt used. : Indicates the reference page. : Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1 : 11, I Molybdenum disulf ide oil Page: 9 - Honda BF20A-BF25A, BF25D-BF30D Outboard Motors Shop Manual - http://www.ReadManuals.Com

3. SERIAL NUMBER LOCATION The engine serial number is stamped on the cylinder block and the produce identification number is located on the R. stem bracket. Always specify these numbers when inquiring about the engine or when ordering parts in order to obtain the correct parts for outboard motor being serviced. I PRODUCT INDENTIFICATION NUMBER Page: 10 - Honda BF20A-BF25A, BF25D-BF30D Outboard Motors Shop Manual - http://www.ReadManuals.Com

Honda BF20A/BF25A Outboards OEM Service & Repair Manual

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