Marine Rigging Guide K3.book(08BF135 Set-Up.fm) - sub.honda.se · Cooling system Forced water circulation by impeller pump with thermostat Ignition system MicroComputer programmed

IMPORTANCE OF PROPER SET-UP, INSTALLATION, AND PRE-DELIVERY SERVICE

For Your Customer’s SafetyProper set-up, installation and pre-delivery service are essential to the customer’s safety and the reliability of the outboard motor. Any error or oversight made during assembly can result in faulty operation, damage to the outboard motor, or injury to others.

For Your SafetySome of the most important general safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing set-up, installation and pre-delivery service. Only you can decide whether or not you should perform a given task.

IMPORTANT SAFETY PRECAUTIONS• Make sure you have a clear understanding of all basic shop safety practices and that you are

wearing appropriate clothing and safety equipment. When performing set-up, installation and pre-delivery service, 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 protective wear when necessary, for example, gloves or safety shoes. Handling hot or sharp parts can cause severe burns 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 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 engine.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 out of the way.

• Gasoline vapors are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline.

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.

WARNINGImproper service or pre-delivery service can create an unsafe condition that can cause your customer or others to be seriously hurt or killed.Follow the procedures and precautions in this manual and other service materials carefully.

WARNINGFailure to properly follow instructions and precautions can cause you to be seriously hurt or killed.Follow the procedures and precautions in this manual carefully.

Date of Issue: January, 2005© 2001–2005 American Honda Motor Co., Inc. 8-1

8. BF135A/BF150A

UNPACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5PARTS LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6TYPICAL RIGGING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8INSTALLATION HEIGHT RECOMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12TRANSOM DRILLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12STEERING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13BOLTING MOTOR TO TRANSOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14CABLE/ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17THROTTLE CONTROL CABLE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23AVAILABLE ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24FUEL HOSE CONNECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

To ensure proper operation, you must install a PGM-FI panel indicator or a key switch panel with PGM-FI lights. See the Honda Marine Accessories Catalog (MO045) or the iN (Parts>Publications>Marine Accessory).

8

Date of Issue: January, 2005© 2001–2005 American Honda Motor Co., Inc.8-2

8. BF135A/BF150AUNPACKING1. Remove the nine bolts attaching the upper

frame and the nut attaching the engine hanger bracket.

2. Lift up the upper frame slowly with care not to strike the outboard motor. Have an assistant help remove the crate frame. Remove the corrugated cardboard cover.

3. Lift up and remove the corrugated cardboard protector that contains the engine.

4. Slide and remove the corrugated cardboard cover that contains the engine cover.

5. Cut the tie and remove the parts carton from the crate.

6. Remove the vinyl cover then compare the parts to the Parts Listing on page 8-6.

UPPER FRAME

ENGINE HANGER BRACKET

8 mm NUT (2)

WASHER (2)

CORRUGATED CARDBOARD COVER

8 mm BOLTS (9)

LOWER CRATE FRAME

CORRUGATED CARDBOARD COVER (engine cover)

PARTS CARTON

VINYL COVER


8. BF135A/BF150A7. Remove the engine cover from the box. 8. If you have engine hanger T/N

VSB02C000013, it will be necessary to drill two new 1/2 inch holes as shown below.

To order an engine hanger, call the Honda Marine Tool and Equipment Program at(888) 424-6857 and order T/N VSB02C000021.

ENGINE COVER

ENGINE HANGERT/N VSB02C000013

5-7/8 INCH 5-7/8 INCH

DRILL 1/2 IN HOLES

WARNINGUsing this engine hanger improperly or exceeding the weight limit can result in serious injury or death.

• Follow all instruction provided with the tool.• Do exceed the weight limit or try to lift

anything other than the specified engine.• This tool must be securely attached to both

the lifting device and the engine being lifted.• Do not use this tool if damaged or missing

part(s) and repair only with genuine parts.


8. BF135A/BF150A9. Attach the engine hanger special tool only to

the two upper engine hangers. Connect the hooks to the engine hangers with the hook open ends to the inside as shown.

NOTICEUse only the two upper hangers. Attaching the lower engine hanger will damage the engine.

Lift the motor up with the crate frame base still attached. As necessary, use clean protective pads between the anchors and the silencer duct or other related parts.Use an overhead gantry type crane with a lift capacity of at least 2000 lbs. Do not use an automotive type telescoping hydraulic hoist. This type of hoist may tend to tip when the boom is extended and the engine is lifted to the installation height.

The lower engine hanger is used for power head removal/installation.

With the crate frame base resting on the floor, remove the crate frame from the motor by removing the four flange nuts.

ENGINE HANGERT/N VSB02C000021

UPPERENGINEHANGER (2)

LOWER ENGINE HANGER

CRATEFRAMEBASE


8. BF135A/BF150ASPECIFICATIONSENGINE

LOWER UNIT

Model BF135A BF150AType Water cooled, 4-stroke, D.O.H.C., 4-cylinder Water cooled 4-stroke, D.O.H.C., VTEC, 4-cylinder

Displacement 2,354 cm³ (143.6 cu. in.)Bore x stroke 87 x 99 mm (3.4 x 3.9 in)Full throttle range 5,000–6,000 rpm 5,000–6,000 rpmRated horsepower 135 HP @ 5,500 rpm 150 HP @ 5,500 rpmMaximum torque 145 lb-ft @ 4,000 rpm 149 lb-ft @ 4,000Compression ratio 9.6:1Fuel consumption 348 g (12.3 oz.) / kWh 337 g (11.9 oz.) / kWhCooling system Forced water circulation by impeller pump with thermostatIgnition system MicroComputer programmedIgnition timing 0° ± 2° at 750 rpm B.T.D.C. Spark plug IZFR6K11 (NGK)Fuel supply system Programmed fuel injectionFuel injection system Electronic controlFuel injection nozzle Pintle typeFuel pipe Steel pipe and rubber tubesLubricating system Pressure lubrication by trochoid pump

Oil capacity 6.5 liter (6.9 US qt) at oil change6.7 liter (7.1 US qt) with oil filter replacement

Recommended oil SAE 10W-30, API Service classification SG, SH, SJStarting system Electric starterBattery system 809 MCA (622 CCA, 80 AH) minimum (engine only)Stopping system Ignition primary circuit groundFuel used Automotive unleaded gasoline (minimum 86 pump octane)Optional fuel tank capacity 25 liters (6.6 US gal)

Fuel pump Electric and mechanical plunger typeExhaust system Thru-hub type

Clutch Dog clutch (forward-neutral-reverse)Gear ratio 2.14:1 (30/14)Reduction type Spiral bevel gearGear case oil capacity .98 liters (1.04 US qt)Recommended gear case oil SAE 90, API Service classification GL4 or GL5

Propeller

Number of bladesDiameter x pitch Optional part

Rotating direction Clockwise (viewed from rear) LA and XA typesCounterclockwise (viewed from rear) XCA types

Driving system Spline


8. BF135A/BF150APARTS LISTING

(1) Model year specific. See iN>eMall>Helm for owner’s manual listings.

REF. NO. DESCRIPTION

BF135A BF150APART NO. REMARKS

LA XA XCA LA XA XCA1 6 wire PGM-FI panel harness,

16 feet1 1 1 1 1 1 32185-ZY6-000

Use with Ref. 2

2 PGM-FI panel assembly 1 1 1 1 1 1 N/A

3 5 x 40 mm pan-head screw 4 4 4 4 4 4 93500-05040-1B

4 5 mm flange nut 4 4 4 4 4 4 94050-05020

5 5 mm plain washer 4 4 4 4 4 4 94103-05200

6 5 mm lock washer 4 4 4 4 4 4 90501-ZW5-U00

7 Cable clamp F 1 1 1 1 1 1 30569-895-000

8 Remote control cable grommet 1 1 1 1 1 1 40105-ZY6-000

9 Undercase grommet band 1 1 1 1 1 1 40119-ZY3-003

10 18 mm castle nut 1 1 1 1 1 1 90301-ZW1-B00

Propeller Installation

11 Propeller thrust washer 1 1 1 1 1 1 90506-ZY3-000

12 Propeller washer 1 1 1 1 1 1 90512-ZY3-000

13 4.0 mm split pin 1 1 1 1 1 1 90758-ZW1-B00

14 Tool kit 1 1 1 1 1 1 Not available as kit

15 12 x 119 mm hex bolt 6 6 6 6 6 6 90129-ZW1-010Engine

Installation(only 4 bolts are

required)

16 12 mm plain washer (large) 6 6 6 6 6 6 90552-ZV5-000

17 12 mm plain washer (small) 12 12 12 12 12 12 90559-ZV5-000

18 12 mm self-locking nut 6 6 6 6 6 6 90308-ZW1-003

19 Remote control cable plate 1 1 1 1 1 1 17877-ZY6-000

20 6 x 16 mm hex bolt 1 1 1 1 1 1 90127-ZV4-000

21 6 mm plain washer 1 1 1 1 1 1 90506-ZV4-000

22 Front separate cover 1 1 1 1 1 1 40151-ZY6-000ZA Includes 3 collars 6.5 x 9 x 5 mm

P/N 91553-ZY6-000

23 6 x 17 mm special bolt 1 1 1 1 1 1 90111-ZY3-000

24 6 x 25 mm pan-head screw 3 3 3 3 3 3 93500-06025-4J

25 Fuel tube assembly 1 1 1 1 1 1 17700-ZY3-000 Fuel Line Connection26 12.5 mm tube clip band 1 1 1 1 1 1 17704-ZV4-010

27 Cable tie 5 5 5 5 5 5 –

28 Cable pivot assembly 2 2 2 2 2 2 –

29 Steering link rod 1 1 1 1 1 1 53238-ZW1-010

SteeringConnection

30 3/8-24 UNF bolt 1 1 1 1 1 1 90105-ZW1-000

31 Collar 1 1 1 1 1 1 91560-ZV5-000

32 3/8-24 self lock nut 2 2 2 2 2 2 90307-ZV5-003

33 10 mm washer 3 3 3 3 3 3 90514-ZV4-000

34 Gear case cover 1 1 41102-ZY3-710ZA

35 Emission hang tag (CARB 3 stars)

1 1 1 1 1 1 N/A

Give to Customer36 Instruction (CARB) 1 1 1 1 1 1 N/A

37 Owner’s Manual 1 1 1 1 1 1 (1)


8. BF135A/BF150A

BLACKWHITE36

35

37


8. BF135A/BF150ATYPICAL RIGGING TABLES

• Add throttle and shift cables to all remote models. • Water separating filters are recommended on all permanent fuel tank applications. • Add a propeller to BF40A models and larger.• A dual cable steering kit is available for BF135A/BF150A. See the Honda Marine

Accessories Catalog (MO045) for all available accessories including propellers, control boxes, harness extensions, key switch panels, gauges and gauge harnesses.

• Fuel-injected models must have PGM-FI light indicators, either panel or switch units.

Side Mount Control Box24800-ZY3-010Includes 16.5 ft main harness.

Main Harness32205-ZY6-020AH 20 ft. (20 wire)32205-ZY6-025AH 25 ft. (20 wire)32205-ZY6-030AH 30 ft. (20 wire)32500-ZY6-050AHR 50 ft. (23 wire)

Key SwitchComes with the control box.

PGM-FI Light Panel and Harness32340-ZW7-000AHUsed as optional warning light panel where necessary.

GaugesAnalog or digital gauges; 6-pin PGM-FI harness will supply information.

Gauge HarnessUse brand-specific harness.


8. BF135A/BF150A Flush Mount Control Box06240-ZW7-U00 Premium Flush Type

Main Harness (optional)32205-ZY6-020AH 20 ft. (20 wire)32205-ZY6-025AH 25 ft. (20 wire)32205-ZY6-030AH 30 ft. (20 wire)32500-ZY6-050AHR 50 ft. (23 wire)

Single Engine Key Switch Panel36452-ZW7-100AH or 36452-ZW7-100AHRIncludes all 4 warning lights, emergency stop switch.





8. BF135A/BF150A R.H. Single Binnacle Mount Control Box06240-ZW5-U40 Premium TypeSingle Binnacle Mount Control SpacerUsed only when the control box handle has interference with the console.06241-ZW5-U00

Main Harness32205-ZY6-020AH 20 ft. (20 wire)32205-ZY6-025AH 25 ft. (20 wire)32205-ZY6-030AH 30 ft. (20 wire)32500-ZY6-050AHR 50 ft. (23 wire)

Single Engine Key Switch Panel36452-ZW7-100AH or 36452-ZW7-100AHRIncludes all 4 warning lights, emergency stop switch.





8. BF135A/BF150A R.H. Dual Binnacle Mount Control Box06240-ZW5-U60 Premium TypeDual Binnacle Mount Control SpacerUsed only when the control box handle has interference with the console.06241-ZW5-U10

Main Harness (two required)32205-ZY6-020AH 20 ft. (20 wire)32205-ZY6-025AH 25 ft. (20 wire)32205-ZY6-030AH 30 ft. (20 wire)32500-ZY6-050AHR 50 ft. (23 wire)

Dual Engine Key Switch Panel (one required)36652-ZW7-100AH or 36652-ZW7-100AHRIncludes all 8 warning lights, emergency stop switch.





8. BF135A/BF150AINSTALLATION HEIGHT RECOMENDATIONS

With the boat loaded, stationary and the motor perpendicular to the water surface, there must be a minimum of 127 mm (5 in) between the water surface and the idle exhaust port. If the motor is mounted lower on the transom, water may enter the exhaust port through wave surge or backwash, potentially causing engine damage.

TRANSOM DRILLINGBefore drilling, check the thickness of the transom, making sure it does not exceed the maximum allowable thickness shown below.

1. Set the outboard motor onto the boat transom and verify the correct installation height.

2. Center the Transom Mount Drill Fixture on the boat transom. Position the Drill Fixture flat against the transom. See also TRANSOM CENTER LINE on page 1-24.Verify no damage will occur when the motor mounting holes are drilled. Look for any structural impediments such as bulkheads, braces, fuel cells, bilge pumps or floor sections before drilling.Ensure there is adequate space for the bolt, washer and transom support plates (if applicable), to bear on a flat surface.The upper bolt holes should be more than 33 mm (1.3 in) from the top of the transom. The lower bolt holes should allow the mounting bolts to contact the upper end of the stern bracket. See also USING THE TRANSOM MOUNT DRILL FIXTURE on page 1-28.

3. Secure the Transom Drill Fixture with clamps to prevent movement

4. Wear safety glasses and drill four holes with a 12.5 mm (1/2 in) drill bit in the upper “C” and lower “D” guides of the Transom Mount Drill Fixture.

Shaft Length

Outboard Transom Height

Workable Boat Transom Height

L type 508 mm (20 in) 483 ~ 508 mm(19 ~ 20 in)

X type 635 mm (25 in) 610 ~ 635 mm(24 ~ 25 in)

IDLE EXHAUST PORT

Maximum Boat Transom Board Thickness85 mm (3.35 in)

TRANSOM MOUNT DRILL FIXTURE 07MPZ-ZV3010D

USE UPPER “C” AND LOWER “D” GUIDES

http://www.in.honda.com/rramdctm/content/paw/pw22/ml.repaw22a.Common_Model_Info.pdf#page=25



8. BF135A/BF150ABracket Dimensions STEERING CONNECTIONS

STEERING SELECTIONA single cable steering system is not recommended for either the BF135A or BF150A.The steering system selection is determined by the particular application. Consult the boat manufacturer or steering system manufacturer for recommendations.Hydraulic steering would be the best choice to improve boat stability, minimize lost motion in the steering system and reduce boat chine walk on high performance boats. A dual cable steering system will help to eliminate steering free play which may cause the outboard motor to move side-to-side slightly at high speeds resulting in chine walk. For further information regarding hydraulic steering or dual cable steering, refer to the hydraulic steering, mechanical steering, or dual cable kit manufacturer's instructions.Steering Recommendations:Bay Star Hydraulic Steering by TeleflexDual Cable Steering Kit P/N 08M61-ZW3-000AHLink Arm Kit P/N 06532-ZY3-U00

STEERING PREPARATIONRemove the cap from the steering/tilt tube prior to installing steering system.

Loosely install the hydraulic or mechanical steering cables on the motor before final placement of the motor on the transom.Refer to the steering cable or hydraulic steering manufacturer's instruction manual for handling procedures.

TRANSOM TOP Unit: in (mm)

TRANSOM BOARD TOP

BO

AT T

RA

NSO

M

CEN

TER

CAP


8. BF135A/BF150ABOLTING MOTOR TO TRANSOMApply marine hull sealant to the mounting holes and inside sealing surface of the large washer. Use Hondabond HT (P/N 08718-0001) or equivalent polymer sealant for below waterline use. Adhesives should not be used, as they will result in difficult engine removal or height adjustment. Gel coat damage may also occur when removing/adjusting the engine. With the motor in place against the transom, verify correct motor height. Motor can be raised by using a lower set of mounting holes on the bracket. If the boat transom has molding that prevents the outboard stern bracket from sitting flat against the transom, add a spacer plate or contact the boat manufacturer for information on how to remove the molding.

Attach the motor with marine grade hardware. Use washers under all bolts and nuts. Use additional fender washers against the transom. Use support plates as recommended by the hull manufacturer.

Lubricate the mounting bolt threads with marine grease prior to installing the mounting bolt nut to prevent thread galling and locknut insert damage.

Be sure at least one thread of the bolt is visible beyond the nut when the fasteners are tightened.

NOTICEDo not use an air impact tool to tighten or loosen the transom bolts. Using an air impact tool to tighten or loosen the transom bolts can generate enough heat to damage the bolt threads. The air impact tool can also produce enough tightening torque to damage the boat transom.

Do not scratch the transom bracket when tightening the mounting bolts. Removing paint promotes corrosion and leads to eventual failure of the bracket.

Pay attention to the washers, support plates (if applicable) and boat transom as the nuts are tightened. This is especially important on boats that are being repowered. If the washers and/or support plates (if applicable) are drawn into the transom material, the transom material is weakened and must be inspected and repaired as necessary before the engine is installed.If the transom is found to be soft, water penetration may have occurred and caused the transom material to rot and weaken. Contact the boat manufacturer for boat repair information as needed.

SPACER PLATE

12 mm PLAINWASHER (8)

12 x 119 mmBOLT (4)

12 mmFENDER

WASHER (4)

SUPPORT PLATES (2)[optional (refer to boat

manufacturer)]

12 mm SELF-LOCKING NUT (4)

12 mm WASHER (4)

APPLY SEALANT

(marine grease)

Install with rounded edge/side against painted surface.

PAINTED SURFACE


8. BF135A/BF150ASTEERING LINK ARM INSTALLATIONRemove the bolts and bracket from the steering arm.Discard the hardware indicated and reinstall the 1/4-28 bolts.

The steering link arm must be secured between the steering arm and steering system using the bolt, washers, nuts and collar shown. Both the bolt and self-locking nuts, used at each end of the steering link arm, must be in good condition.Install the bolt, washer and collar into the link arm. Thread the bolt into the steering arm inside hole. Tighten the bolt then tighten the lock nut.Do not use the forward hole.

TORQUE:3/8-24 UNF bolt 22 N•m (16 lb-ft)3/8-24 UNF lock nut 18 N•m (13 lb-ft)

Refer to the steering manufacturer's instructions when tightening the steering link arm 3/8-24 self-locking nut.

The steering link arm to steering system self-locking nut is normally tightened to 8–11 N•m (7–8 ft-lb) then loosened 1/8 turn. The link arm needs to be able to pivot at the steering attaching point. Follow the steering manufacturer's instructions when tightening this nut. The steering link arm must have sufficient thread length when the nut is tightened down and the link arm must have at least two or three threads past the end of the self-locking nut.

Directly after completing the steering installation, verify the following:• Motor turns the proper direction when the

steering wheel is turned right and left. If the steering is reversed, correct as necessary.

• Motor steering angle is equal when steering wheel is turned full right and full left. If the motor steering angles are not equal:

• Corrections can be made at the steering box (refer to the steering box or steering cable manufacturer's instructions).

• Make the steering angles equal as necessary.

The steering mechanism must not come in contact with any part of the boat when the steering wheel is turned full right and full left and at all tilt angles.Correct as necessary and re-check.

BOLT(discard)

WASHER(discard)

BRACKET(discard)

NUT(discard)

1/4-28 STAINLESS BOLT (2)(reinstall and tighten)

3/8-24 UNF BOLT WASHER (3)

COLLAR

(marine grease)

3/8-24 UNF SELF-LOCKINGNUT

3/8-24 UNF STEERING LINK ARMSELF-LOCKING NUT

STEERING ARM

STEERING LINK ARM


8. BF135A/BF150ATIE BAR INSTALLATION (DUAL MOTORS)Dual or multi-motor installations must have a motor center-to-center distance of 660 mm (26 in) minimum. The right and left motors must be well-balanced.1. Install the steering system of choice.2. Install a Honda or a commercially available tie

bar in the steering arm hole (See page 1-29).3. Adjust the toe-in or toe-out.(See page 1-67)

Tie bar P/N 50850-ZV5-000AH (optional part)* Included with Honda tie bar. Tie bar specification is 19 inches minimum and 29 inches maximum.

TIE BAR

3/8-24 UNF HEXHEAD BOLT *

WASHER *

TIE BAR *

BUSHING *3/8-24 UNF SELF-LOCKING NUT *

660 mm (26 in) MINIMUM




8. BF135A/BF150ACABLE/ELECTRICAL CONNECTIONSAfter installing the control cables at the remote control box, install the control cables at the outboard motor.

6 x 16 mm HEX BOLT

FRONT SEPARATE COVER

THROTTLE CONTROL CABLE

SHIFT CONTROL CABLE

CABLE PIVOT ASSEMBLIES

REMOTE CONTROL CABLE PLATE

6 mm WASHER

THROTTLE ARM LINK PIN

6 x 17 mm SPECIAL BOLT

6 x 25 mm PAN-HEAD SCREW (3)

FUEL TUBE

BAND

MAIN WIRE HARNESS

6 WIRE PGM-FI PANEL HARNESS

BATTERY CABLES

SHIFT LINK PIN

REMOTE CONTROL CABLE GROMMETApply silicone spray lubricate to ease installation.


8. BF135A/BF150A1. Pass the battery cable, throttle control cable,

shift control cable, PGM-FI panel and the main wire harness through the front separate cover.

The front separate cover is one piece. All of the cables and harnesses must go through the front separate cover before proceeding. Otherwise all cable and wiring connections will have to be remade.

2. Route the battery cable to the front cover bracket.

Position a white tape mark on the battery cable so it aligns with the edge of the front cover bracket.

3. Connect the engine main wire harness 14P connector to the main wire harness connector, and the 6P connector to the PGM-FI panel wire harness connector, then attach them to the connector holders.

4. Pass the fuel hose, PGM-FI panel wire harness, battery cables, main wire harness and speedometer tube through the grommet.

5. Install the grommet by aligning it with the groove in the front cover bracket.

ALL CABLES, TUBES AND WIRING HARNESSES FROM MOTOR


BATTERY CABLES

FRONT COVER BRACKET

WHITE TAPE MARK

HOLDERS

MAIN WIRE HARNESS

PGM-FI PANEL WIRE HARNESS

BATTERY CABLE

MAIN WIRE HARNESS

FUEL TUBE


REMOTE CONTROL CABLE GROMMET

SHIFT CONTROL CABLE


SPEEDOMETER TUBE

VIEWED FROM OUTSIDE OUTBOARD MOTOR

WATER PRESSURE TUBE (optional part)


8. BF135A/BF150A6. Position the tie-wrap band on the PGM-FI

panel wire harness at the inside of the grommet.

7. Install the remote control cable plate with the6 x 16 mm hex bolt and 6 mm washer.

8. Install the remote control cables by aligning their grooves in the remote control cable plate slots.

9. Install the cable pivots and lock nuts on the remote control cables.

10. Apply marine grease to the joint hole of the cable pivots and link pins.

11. Adjust the cable pivots until they will attach to the link pins.

12. Put the cable pivot lock plates in the released position.

GROMMET

MAIN WIRE HARNESS

TIE-WRAP BAND


GROMMET

FRONT COVER BRACKET

6 x 16 mm WASHER


6 x 16 mm HEX BOLT

LOCK PLATE (2)

(marine grease)

SHIFT CONTROL CABLE


SHIFT LINK PINTHROTTLE ARM LINK PIN

LOCK NUT (2)

THROTTLE CONTROL CABLE GROOVES

CABLE PIVOT ASSEMBLY (2)


8. BF135A/BF150A13. Install the front separate cover, then tighten

the bolts securely [follow numbers (1) through (4)].

14. The front separate cover prevents the remote control cable grommet from rotating.

15. Make sure the cables, wire harnesses and tubes pass through the grommet securely.

16. Tighten the grommet with the band securely. Make sure the fuel tube is not pinched by the grommet.

SHIFT CONTROL CABLE CONNECTION1. Install a cable pivot on the shift control cable

(see page 8-19).2. Move the control lever to the full Forward "F"

position.3. Then slowly return the control lever to the

Neutral "N" position, and make a mark “A” on the inner cable at the end of the outer cable seal as shown.

4. Move the control lever to the full Reverse "R" position.

5. Then slowly return the control lever to the Neutral "N" position, and make a mark “B” on the inner cable at the end of the outer cable seal as shown.

6. Make a mark “C” at the center between the “A” and “B” marks.

6 x 17 mm SPECIAL BOLT


BAND

REMOTE CONTROL CABLE GROMMET

6 x 25 mm PAN-HEAD SCREW (3)

[1] [2]

[4]

[3]

"N”

"F"MARK “A”

INNER CABLE

OUTER CABLE SEAL

OUTER CABLE

"N'

"R"MARK “B”

OUTER CABLE SEAL

MARK “C”

MARK “A” MARK “B”


8. BF135A/BF150A7. Apply marine grease to the joint hole of the

cable pivot shift link pin.8. Align the mark “C” on the shift control cable to

the edge of the outer cable seal, then install the cable pivot to the shift link pin.

9. Make sure that the cable pivot is in the center of the shift link pin joint hole and adjust by turning the cable pivot, if necessary.

10. If necessary, remove the cable pivot from the shift link pin for adjustment.

11. If necessary, loosen the lock nut and adjust the cable pivot.After adjustment, tighten the lock nut securely and move lock plate into the locked position.

12. Make sure that outboard motor is in the Neutral position; click arm tip aligns with the neutral switch tip and the detent roller of the click arm is set in the groove in the shift arm.

13. After attaching the shift cable to the shift link, check for smooth operation by moving the remote control lever to Forward and Reverse positions.

14. Ensure the shift link moves smoothly and returns to the Neutral detent position when the remote control lever is returned to the Neutral.

NOTICEIf it is hard to shift, turn the propeller shaft. Shifting with force will damage the shift mechanism.

If the shift arm moves smoothly and the Neutral detent aligns, tighten the cable lock nut securely.• If the shift position is not in Neutral position

when the shift lever moves from Forward position to Neutral position, loosen the lock nut of the cable pivot and turn the cable

CABLE PIVOT

(marine grease) LOCK PLATE

LOCK NUT

SHIFT LINK PIN

Center of the shift link pin free play.

SHIFT LINK PIN

LOCK NUT

LOCK PLATE

CABLEPIVOT

GROOVE

CLICK ARM

SHIFT ARM

NEUTRAL SWITCH

Click arm tip aligns with the neutral switch tip.

DETENT ROLLER


8. BF135A/BF150Apivot close to mark “A”. After adjusting, tighten the lock nut.

• If the shift position is not in Neutral when the shift lever moves from Reverse position to Neutral position, loosen the lock nut of the cable pivot and turn the cable pivot close to mark “B”. After adjusting, tighten the lock nut.

THROTTLE CONTROL CABLE CONNECTION1. Apply marine grease to the joint hole of the

cable pivot and throttle arm link pin.2. Adjust the cable pivot until it will attach to the

throttle arm link pin.3. Install the cable pivot to the throttle arm link

pin, then tighten the lock nut securely.

4. Move the remote control lever to the full throttle position.

5. Ensure that the throttle arm contacts the throttle arm stopper.

NOTICEIf it is hard to shift, turn the propeller shaft. Shifting with force will damage the shift mechanism.Adjust by turning the cable pivot if necessary.

6. Remove the cable pivot from the control box throttle linkage.

7. At the control box, thread the lock nut all the way onto the cable (no threads showing on the cable past the nut) and thread the cable pivot until it meets the lock nut.

8. After adjustment, recheck and tighten the lock nut securely. Re-install the cable pivot on the control box throttle linkage and lock plate into the locked position.

MARK “C”MARK “A”

ADJUSTABLE RANGE

MARK “B”MARK “C”

ADJUSTABLE RANGE

THROTTLE ARM LINK PINLOCK PLATE

CABLE PIVOT

(marine grease)LOCK NUT


CABLE PIVOT

STOPPER

THROTTLE ARM

LOCK NUT

CABLEPIVOT

LOCK PLATE

NO THREADS VISIBLE HERE

CONTROL BOX END


8. BF135A/BF150ATHROTTLE CONTROL CABLE ADJUSTMENTThe throttle control cable must be adjusted properly to achieve wide-open throttle at the throttle body. Follow these steps to ensure the engine can reach the wide-open throttle position.1. At the control box, thread the lock nut all the

way onto the cable (no threads showing on the cable past the nut) and thread the cable pivot until it meets the lock nut.

2. Move the remote control lever to the “F” (Forward) full open position. Check that the throttle arm is in contact with the full open stopper of the shift link bracket.

3. Check for clearance between the throttle cam of the throttle body and the full open side stopper. The clearance must be 1 mm (0.04 in) or less. If adjustment of the throttle cam is needed, follow the procedure on page 3-27 of the BF135A•BF150A Marine Shop Manual.

LOCK PLATE

NO THREADS VISIBLE HERE

LOCK NUT

CABLE PIVOT

FULL OPEN STOPPER

THROTTLE ARM

SHIFT LINK BRACKET

THROTTLE CAM

STOPPER (FULL OPEN SIDE)

1 mm (0.04 in) OR LESS

http://www.in.honda.com/rramdctm/content/paw/pw95/ml.repaw95a.BF135A_(ALL).pdf#page=114


8. BF135A/BF150AAVAILABLE ACCESSORIESConsult the Honda Marine Accessories Catalog (MO045) or the iN (Parts>Publications>Marine Accessory) for additional information on gauges, instrument harnesses, wiring harnesses, switch panels, and control boxes.

FUEL HOSE CONNECTIONNOTICE

Do not use unlined, worm-type fuel hose clamps. They may cause leaks by damaging the outside of the fuel hose.During operation, check for any fuel or air leaks and repair immediately. If these leaks draw air, the engine fuel pump will malfunction.The primer bulb must be positioned so that the outlet end is higher or can be positioned higher than the inlet end. The arrow on the primer bulb must point upward toward the engine.ENGINE SIDEIf you are unable to properly crimp the band type clamp provided, use a quality lined stainless steel fuel hose clamp.

BOAT SIDEThe fuel hose is 7.5 mm (5/16 in) and the male hose barb is stepped to 12 mm (0.4725 in). The priming bulb hose barbs are 7.5 mm (5/16 in). Ensure the fuel hose is not pinched or crushed as it routes to the boat fuel supply, as this could cause an engine malfunction.Fuel Hose ClampIf the outboard motor fuel hose is going to be connected directly into the boat fuel tank supply hose, secure the hose using a fuel hose clamp type as listed above. Secure the hose joint so that it does not bounce on the boat under deck and become damaged.

Water SeparatorA water separator/fuel filter is recommended between the boat fuel tank and the motor. Remove the hose barb from the boat fuel hose end and connect the fuel hose directly to the water separator/fuel filter outlet and clamp securely.

PRIMERBULBARROW

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