Marine Rigging Guide K3.book(09BF200 Set-Up.fm) - sub.honda.se · Let the engine and exhaust system cool before working in those areas. Injury from moving parts. If the instruction

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. 9-1

9. BF200A/BF225A

UNPACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4PARTS LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5TYPICAL RIGGING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8INSTALLATION HEIGHT RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12TRANSOM DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12STEERING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13BOLTING MOTOR TO TRANSOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15DUAL MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16REMOTE CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16THROTTLE CABLE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20AVAILABLE ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22FUEL HOSE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22

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).

9

Date of Issue: January, 2005© 2001–2005 American Honda Motor Co., Inc.9-2

9. BF200A/BF225AUNPACKINGWear heavy gloves during unpacking to protect hands from the sharp edges and burrs on the steel crate frame.1. Remove the eight bolts attaching the upper

frame and the four nuts attaching the engine hanger bracket.

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

3. Lift and remove the corrugated cardboard protector that contains the engine, then slide and remove the corrugated cardboard protector that contains the engine cover.

4. Cut the tie and remove the parts carton from the crate. Compare the parts to the parts list on page 9-5.

5. Remove the engine hanger brackets from the engine hangers. Remove clear plastic chaf guards.

NUT (4)8 mm BOLT (8)

UPPER FRAME

CORRUGATED CARDBOARD COVER

PARTS CARTON

CORRUGATED CARDBOARD PROTECTORS

CHAF GUARD (2)

ENGINE HANGER

ENGINE HANGER ENGINE HANGER BACKET (2)


9. BF200A/BF225A6. Attach engine hanger, T/N VSB02C000021, only to the two upper engine hangers. As necessary,

use clean protective pads between the anchors and the engine belt cover 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 crane. This type of crane may tend to tip when the boom is extended and the engine is lifted to the installation height.

Before each use, inspect the sling and all fasteners and attachments for damage or defects. Additional inspections should be performed during sling use. Damaged or defective slings must be immediately removed from service.

FLANGE NUT (4)

LOWER CRATE FRAME

The lower engine hanger is used for power head removal. Do not lift outboard using this hanger.

LIFT POINTS

PLASTIC COVERS(Remove covers before installing the engine cover.)

Lift the motor with the crate frame still attached. With the crate frame upright and the lower crate frame resting on the floor, remove the crate frame from the motor by removing the four flange nuts.

NOTICEBefore installing the engine cover, remove the plastic covers from the air intake mouths of the engine to prevent damage to the engine.

ENGINE HANGERT/N VSB02C000021 (NEW) OR T/N VSB02C000013


9. BF200A/BF225ASPECIFICATIONS

ENGINE

LOWER UNIT

Model BF200A BF225A

Type Water cooled 4-stroke, S.O.H.C., 60° V6

Water cooled 4-stroke, S.O.H.C., 60° V6, VTEC

Displacement 3,471 cm³ (211.7 cu in)Bore x stroke 89 x 93 mm (3.5 x 3.7 in)Full throttle range 5,000–6,000 rpm 5,000–6,000 rpmRated horsepower (full throttle range) 200 HP @ 5,500 rpm 225 HP @ 5,500 rpm

Maximum torque 217.7 lb-ft @ 4,000 rpmCompression ratio 9.4:1Fuel consumption ratio 303 g (10.7 oz.) / kWh

Cooling system Forced water circulation by impeller pump with thermostatIgnition system MicroComputer programmedIgnition timing 10° at 650 rpm B.T.D.C.Spark plug IZFR6F 11 (NGK)Fuel supply system Programmed fuel injectionFuel injection system Electronic controlFuel injection nozzle Pintle typeFuel Unleaded gasoline with a pump octane rating of 86 or higherFuel pump Electric and mechanical plunger typeLubrication system Pressure lubrication by trochoid pump

Lubrication capacity 7.6 liter (8.0 US qt)7.8 liter (8.2 US qt) with oil filter replacement

Recommended oil SAE 10W-30, API Service classification SG, SH, SJStarter system Electric starterBattery system 1040 MCA (800 CCA, 110 AH) minimum (engine only)Stopping system Primary circuit groundExhaust system Thru-hub type

Model BF200A BF225AClutch Dog clutch (forward-neutral-reverse)Gear ratio 1.86:1 (15/28)Reduction type Spiral bevel gearGear case oil capacity 1.17 liter (1.24 US qt)Recommended gear case oil SAE 90, API Service classification GL4 or GL5

Propeller rotating directionClockwise (viewed from rear): LA, XA and XXA typesCounterclockwise (viewed from rear): XCA and XXCA

types


9. BF200A/BF225APARTS LISTING

REF. NO. DESCRIPTION

BF200A BF225APART NO. REMARKS

LA XA XCA

LA XA XCA

XXA

XXC

A

1 Indicator wire harness 1 1 1 1 1 1 1 1 32185-ZW5-0002 Indicator panel assembly 1 1 1 1 1 1 1 1 37206-ZW5-0043 Pan-head screw (5 x 40mm) 4 4 4 4 4 4 4 4 93500-05040-1B

Use withREF. NO. 2

4 Flange nut (5 mm) 4 4 4 4 4 4 4 4 94050-050205 Plain washer (5 mm) 4 4 4 4 4 4 4 4 94103-052006 Lock washer (5 mm) 4 4 4 4 4 4 4 4 90501-ZW5-U007 Band, case grommet (lower) 1 1 1 1 1 1 1 1 40119-ZY3-0038 Undercase grommet A 1 1 1 1 1 1 1 1 40105-ZY3-U009 Propeller castle nut (18 mm) 1 1 1 1 1 1 1 1 90301-ZW1-B00

Propellerinstallation

10 Propeller thrust washer 1 1 1 1 1 1 1 1 90506-ZY3-00011 Propeller washer 1 1 1 1 1 1 1 1 90512-ZY3-00012 Cotter pin (4.0 mm) 1 1 1 1 1 1 1 1 90758-ZW1-B00

13a Wrench (14x17) (open end) 1 1 1 1 1 1 1 1 99001-1417013b Wrench (10x12) (open end) 1 1 1 1 1 1 1 1 99001-1012013c Wrench (8 mm) (open end) 1 1 1 1 1 1 1 1 89203-836-00013d Pliers (135 mm) 1 1 1 1 1 1 1 1 89210-GBJ-J1013e Wrench, hex. (6 mm) 1 1 1 1 1 1 1 1 89221-371-00013f Grip 1 1 1 1 1 1 1 1 99003-3000013g Screwdriver, check bolt 1 1 1 1 1 1 1 1 89301-921-010

13h Screwdriver 3, straight slot (no. 2) 1 1 1 1 1 1 1 1 99003-30000

13i Screwdriver 1, Phillips (no. 2) 1 1 1 1 1 1 1 1 99003-1000013j Wrench, plug 1 1 1 1 1 1 1 1 89216-SF4-00013k Puller, mini fuse 1 1 1 1 1 1 1 1 38235-S04-00313l Wrench, eye (19 mm) 1 1 1 1 1 1 1 1 99006-19000

13m Wrench, box (P16x17) 1 1 1 1 1 1 1 1 99004-1617013n Bag, tool 1 1 1 1 1 1 1 1 89101-ME5-67014 Hex bolt (12 x 119 mm) 4 4 4 4 4 4 4 4 90129-ZW1-010

Outboard motor installation

15 Plain washer (12 mm) 8 8 8 8 8 8 8 8 90559-ZV5-00016 Fender washer (12 mm) 4 4 4 4 4 4 4 4 90552-ZV5-00017 Self-locking nut (12 mm) 4 4 4 4 4 4 4 4 90308-ZW1-00318 Remote control cable plate 1 1 1 1 1 1 1 1 17877-ZY3-00019 Front separate cover 1 1 1 1 1 1 1 1 40151-ZY3-000ZA20 Hex bolt (6 x 25 mm) 2 2 2 2 2 2 2 2 90113-ZV5-000

Use withREF. NO. 1921 Shouldered bolt (6 x 17 mm) 1 1 1 1 1 1 1 1 90111-ZY3-000

22 Shouldered bolt (6 x 37 mm) 2 2 2 2 2 2 2 2 90132-ZY3-00023 Emergency lock clip 1 1 1 1 1 1 1 1 36187-ZV4-651

24 Emission hang tag (CARB 3 stars) 1 1 1 1 1 1 1 1 N/A Give to

customer.25 Instruction (CARB) 1 1 1 1 1 1 1 1 N/A27 Fuel tube assembly 1 1 1 1 1 1 1 1 17700-ZY3-00028 Band tube clip (12.5 mm) 1 1 1 1 1 1 1 1 17704-ZV4-01029 Hex bolt (6 x 16 mm) 1 1 1 1 1 1 1 1 90127-ZV4-000


9. BF200A/BF225A

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

REF. NO. DESCRIPTION

BF200A BF225APART NO. REMARKS

LA XA XCA

LA XA XCA

XXA

XXC

A

30 Washer (6 mm) 2 2 2 2 2 2 2 2 90508-ZY3-00031 Cable clamp (7.5 mm) 1 1 1 1 1 1 1 1 90627-ZA8-E5032 Cable tie 5 5 5 5 5 5 5 5 32901-952-77033 Cable end 2 2 2 2 2 2 2 2 24618-ZY3-00034 Connector cover 1 1 1 1 1 1 1 1 30421-ZY3-00035 Gear case cover 1 1 1 41102-ZY3-710ZA

36 Owner’s Manual 1 1 1 1 1 1 1 1 (1) Give tocustomer.


9. BF200A/BF225APARTS LISTING

2425

36


9. BF200A/BF225ATYPICAL 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 BF200A/BF225A. 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.


9. BF200A/BF225A 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.


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



9. BF200A/BF225A 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.


GaugesAnalog or digital gauges.



9. BF200A/BF225A 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-ZW7-100AHIncludes all 8 warning lights, emergency stop switch.


GaugesAnalog or digital gauges.



9. BF200A/BF225AINSTALLATION HEIGHT RECOMMENDATIONS

With the boat loaded, stationary and the motor perpendicular to the water surface, there must be a minimum of 5 inches 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)

XX type 762 mm (30 in) 737 ~ 762 mm(29 ~ 30 in)

IDLE EXHAUSTPORTS

Maximum Boat Transom Board Thickness85 mm (3.35 in)

TRANSOM DRILL FIXTURE 07MPZ-ZV3010D

USE THE UPPER “C” AND LOWER “D” GUIDES.

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



9. BF200A/BF225AStandard Bracket Dimensions STEERING CONNECTIONS

SELECTIONA single cable steering system is not recommended for either the BF200A or BF225A.The steering system selection is determined by the particular application. Consult the boat manufacturer or steering manufacturer for recommendations.A hydraulic steering system is 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 the 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.

53.5

mm

(2

.11

in)

18.5

mm

(0

.73

in) x

5

327 mm (12.87 in)

251 mm (9.88 in)

Ø13.5 mm (0.53 in) -10

254

mm

(10

in)

328

mm

(12.

91 in

)

TRANSOM BOARD TOP

BO

AT T

RA

NSO

M

CEN

TER

CAP


9. BF200A/BF225ASTEERING LINK ARM INSTALLATION Remove the bolts and shipping bracket from the steering arm. Discard the hardware indicated and reinstall the 1/4-28 bolts.

Steering Link Arm P/N 06532-ZY3-U00 (optional part, includes all hardware).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.

1. Install bolt, washer and collar into link arm. Remove access grommet from inside engine cover area and thread bolt into steering arm inside hole. Tighten bolt then tighten lock nut. Do not use 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)The steering link arm to steering system self-locking nut is normally tightened to 8–11 N•m (7–8 lb-ft) then loosened 1/8 turn. The link arm needs to be able to pivot at the steering attaching point. 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.

2. Directly after completing the steering link arm 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 check again.

BOLT (discard)

WASHER (discard)

FIBER WASHER (discard)

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

NUT(discard)

SHIPPING BRACKET (discard)

3/8-24 UNF BOLT

WASHER (3)

(marine grease)

COLLAR

3/8-24 UNF STEERING LINK ARM SELF-LOCKING NUT

STEERING LINK ARM

STEERING ARM

3/8-24 UNF SELFLOCKING NUT


9. BF200A/BF225ABOLTING 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 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.

Ensure 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 PLAIN WASHER (8)

12 x 119 mmBOLT (4)

12 mmFENDER

WASHER (4)

SUPPORT PLATE (2)[optional (refer to boat

manufacturer)]

12 mm SELF-LOCKING NUT (4)

12 mm WASHER (4)

Apply sealant.

(marine grease)

PAINTED SURFACE

Install with rounded edge/side against paint surface.


9. BF200A/BF225ADUAL MOTOR INSTALLATION 1. Install the steering system of choice.2. Install a commercially available tie bar.3. Adjust the toe-in or toe-out.

Refer to page 1-67 for details.On a dual motor installation when the minimum distance between motors is used, the engine cover of one motor may interfere with the adjacent motor if only one motor is tilted up when the boat is steered full right or full left.

NOTICEDo not tilt only one motor when the boat is steered full right or full left. The engine covers could be damaged.

REMOTE CABLE INSTALLATIONRoute the electrical harnesses and cables through the boat. Connect the cables to remote control before connecting them to the motor.

Prior to selecting the appropriate harness, check the style of gauge connection on the motor. Early 2004 BF200A/BF225A motors utilized a 3-pin flat connector, while later 2004 motors utilized a rectangular green 6-pin connector.

1. Route the battery cable to the front cover bracket. Position the battery cable white tape mark so it aligns with the edge of the front cover bracket.

2. Spray the grommet with silicone spray.3. Run the fuel hose, indicator wire harness,

battery cable and main harness through the undercase grommet A.

WHITE TAPE

BATTERY CABLE

FRONT COVER BRACKET

VIEWED FROM OUTSIDE.

REMOTE CONTROL CABLE (Throttle control)

INDICATOR PANELWIRE HARNESS

WATER PRESSURE HOSE [(optional part) puncture rubber membrane]

BATTERY CABLE

MAIN WIRE HARNESS

FUEL HOSE

UNDERCASE GROMMET A

REMOTE CONTROL CABLE (Shift control)



9. BF200A/BF225A4. Install the grommet by aligning it with the

groove in the front cover bracket.

5. Install the remote control cable plate with the 6 x 16 mm hex bolt.

6. Connect the indicator panel (6 pin) and main 14 pin connectors to the engine electrical bracket. Secure the connectors to the locking tabs on the bracket. Route the wires through the locking plastic loop and follow the path to the grommet. Route the two individual portions of the harness through the grommet as indicated.

7. Loosen the control cable lock nuts approximately 1/2 inch from the end of the cable. Thread the cable ends onto the cables with a minimum of 1/2 inch thread engagement as a starting point for adjustment. Do not tighten the lock nuts at this time.With the remote control lever in the NEUTRAL position, the shorter cable will always be the throttle cable.

8. Install the control cables with the throttle cable inside and the shift cable outside. Install the clamp (included with engine) on the undercase grommet A or slip a 50 mm (2 in) corrugated flexible hose over the undercase grommet A and secure the corrugated flexible hose (not included) with the clamp.

FRONT COVER BRACKET GROOVE

UNDERCASE GROMMET A

6 x 16 mm HEX BOLT

REMOTE CONTROL CABLE PLATE

ENGINE ELECTRICAL BRACKET

3 PIN (or 6 PIN) CONNECTOR

14 PIN CONNECTOR

INDICATOR PANEL WIRE HARNESS

LOCKING PLASTIC LOOP MAIN WIRE HARNESS

REMOTE CONTROL CABLE PLATE

THROTTLE CABLE

SHIFT CABLE

UNDERCASE GROMMET A

CLAMP


9. BF200A/BF225ASHIFT CABLE CONNECTION1. Centering remote control lever:

a. Move remote control lever to full FORWARD position.

b. Slowly return control lever to NEUTRAL position.

c. Move control lever to full REVERSE position.

d. Slowly return control lever to NEUTRAL position.

2. With the outboard motor in the NEUTRAL position, ensure the detent spring roller is set in the center of the shift arm neutral position groove. If not, move the detent spring LEFT or RIGHT.

3. Apply a light coat of marine grease to the pivot pin and sliding surface.

4. Adjust the cable end until it will just slip over the shift link rod pivot pin. Slide the locking plate into the locked position.

After attaching the shift cable to the shift link, check for smooth operation by moving the remote control lever to the forward and the reverse positions. Ensure that the shift link moves smoothly and returns to the neutral detent position when the remote control lever is returned to neutral.

NOTICEIf the control lever is hard to shift, place a shop towel over the propeller shaft and turn the shaft by hand. Shifting with force will damage the shift mechanism.Once the shift arm moves smoothly and neutral detent aligns, tighten cable lock nut.

THROTTLE CABLE CONNECTION1. Put the remote control lever in the neutral

position.2. Apply a light coat of marine grease to the pivot

pin and sliding surface.

3. Adjust the cable end until it will just slip onto the throttle arm. Slide the locking plate forward into the locked position.

NEUTRAL POSITION GROOVE

SHIFT ARM

DETENT SPRING

DETENTSPRINGROLLER

(marine grease)

CABLE END

SHIFT LINK RODCABLE LOCK NUT

THROTTLE ARM

CABLE END

(marine grease)


9. BF200A/BF225A4. Move the remote control lever to the full

throttle position. Make sure the throttle arm contacts the throttle arm stop. If the throttle arm does not contact the throttle arm stop, check for full stroke at the remote control lever.

The engine must also return to an ECM controlled idle position when the control lever is returned to the idle position.Tighten the lock nut securely.

5. Operate the control lever to check for smooth, proper shift cable and throttle cable operation.

THROTTLE ARM STOPPER

LOCK NUT

THROTTLE ARM


9. BF200A/BF225ATHROTTLE CABLE ADJUSTMENTTo ensure the throttle valve obtains full throttle position, inspect and adjust the throttle cable assembly using the shop manual (BF200A/BF225A Shop Manual, page 3-18 through 3-21) and the information provided here.1. Remove the engine cover.2. Move the remote control lever to the full

throttle position.

3. Inspect the throttle arm to see if it is in contact with the full throttle stop.

4. If throttle arm does not contact the full throttle stop, loosen the shift cable pivot lock nut.

5. Remove the shift cable pivot from the throttle arm pin. Turn the shift cable pivot as necessary until the throttle arm contacts the full throttle stop when the remote control lever is in the full throttle position.

6. Grease the throttle arm pin then reconnect the shift cable pivot to the throttle arm pin.

7. Tighten the shift cable pivot lock nut.

8. With the remote control lever in the full throttle position, check to see if there is a 1 mm (0.04 in) gap or less between the throttle lever and the full throttle stop.

NEUTRAL

FULL THROTTLE

THROTTLE ARM

FULL THROTTLE STOP

LOCK NUT

SHIFT CABLE PIVOT

SHIFT CABLE PIVOT

THROTTLE ARM PIN

1 mm (0.04 in)OR LESS

THROTTLE LEVER

FULL THROTTLE STOP

http://www.in.honda.com/rramdctm/content/paw/pw95/ml.repaw95a.BF200A_(BAEJ-1000001-1100438).pdf#page=77


9. BF200A/BF225A9. If the gap exceeds 1 mm (0.04 in), check the

OPEN and CLOSE side throttle cable measurements.OPEN SIDE: 14 mm (0.55 in)CLOSE SIDE: 19 mm (0.75 in)

10. If adjustment is required, move the remote control lever to the full throttle position and loosen the OPEN and CLOSE side lower adjusting nuts.

11. Move the OPEN side adjuster nuts up or down until a 1.0 mm (0.04 in) gap or less is obtained between the throttle lever and the full throttle stop with the remote control lever in the full throttle position.

12. Tighten the OPEN side lower adjuster nut.

13. Move the remote control lever to the NEUTRAL position.

14. Check whether the “ “ mark on the throttle cam aligns with the center of the throttle lever roller.

15. If the “ “ mark on the throttle cam does not align with the center of the throttle lever roller, move the CLOSE side adjusting nuts up or down as necessary.

16. Tighten the CLOSE side lower adjusting nut.

17. After all adjustments have been made, move the remote control lever to the full throttle position and check that the throttle lever has a 1 mm (0.04 in) gap or less at the full throttle stop. Readjust if necessary.

18. Start the engine and check the throttle operation and for proper engine idle.

19. Install the engine cover.

OPEN SIDE CLOSE SIDE

14 mm (0.55 in) 19 mm (0.75 in)

ADJUSTING NUTS

LOWER ADJUSTING NUTS

“ “ MARK THROTTLE CAM

THROTTLE LEVER ROLLER

1 mm (0.04 in)OR LESS

THROTTLE LEVER

FULL THROTTLE STOP


9. BF200A/BF225AAVAILABLE 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 connections 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 SIDE

If you are unable to properly crimp the band type clamp provided, use a quality stainless steel lined 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). Make sure the fuel hose is not pinched or crushed as it routes to the boat fuel supply. 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 this hose by using a fuel hose clamp type as listed above. Secure the hose joint so that it does not bounce and become damaged on a hard surface.

Water SeparatorA water separator is highly recommended between the boat fuel tank and the motor. Remove the hose barb from the fuel hose end and connect the fuel hose directly to the water separator outlet 7.5 mm (5/16 in) brass hose barb (not included) and clamp securely.PRIMER

BULBARROW

Marine Rigging Guide K3.book(09BF200 Set-Up.fm) - sub.honda.se · Let the engine and exhaust system cool before working in those areas. Injury from moving parts. If the instruction

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