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    Honda outboard repair manual 1987 to 2001 2 hp to 130 hp

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    Honda outboard repair manual 1987 to 2001 2 hp to 130 hp

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    Download as pdf
    97 views369 pages

    1978-01 Honda Outboards 2-130hp

    Uploaded by

    chuck
    Honda outboard repair manual 1987 to 2001 2 hp to 130 hp

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    GENERAL INFORMATION HOW TO USE THis MANUAL 411 SAFETY IN SERVICE re Un cy gang BOATING SAFETY ‘TOOLS AND EQUIPMENT © 2=12 FASTENERS, MEASUREMENTS AND TOOLS AND EQUIPMENT ee CONVERSIONS 3-2 ENGINE MAINTENANCE © 3-38 WINTER STORAGE MAINTENANCE 3-21. SOAT MAINTENANCE CHECKLIST mR al 3-25 TUNe-UP 3-38 sas coumssonns cHecKUS FUEL SYSTEM BASICS «== 4-19 FUEL INJECTION SN CAURETIN F Led ‘AND 5-35 CHARGING CIRCUIT NU UBLESHOOTING , vn ele) by) Teomcarorstevg 5°43 STARTING CIRCUIT eae) SREMER PoWTs 5-48 COMPONENT LOCATIONS IGNITION (MAGNETO 5-52 IGNITION AND iGNTON) ELECTRICAL WING CAPACITOR DISCHARGE Cd IGNITION (CDI) SYSTEM ELECTRONIC IGNITION LUBRICATION SYSTEM = 6-9 COOLING SYSTEM eee COOLING Contents 7-2 ENGINEMECHANICAL —-7=37_ ENGINE RECONDITIONING relia 0) 8-2 LOWERUNIT 8-68. JET ORNE 8-10 LOWER UNIT OVERHAUL oe a 9-2 MANUAL TILT 9-4 POWER TRIM AND TILT 9-2 CAS ASSISTED THT SEO ea 10-2 REMOTECONTROL BOX —10+11 TILLER HANDLE a | REMOTE CONTROL 11-2 HAND REWIND STARTER DO REL 11-13 Glossary GLOSSARY 11-17 0% DSS HOW TO USE THIS MANUAL 1-2 CAN YOU DO IT? 1-2 WHERE TO BEGIN 1-2 AVOIDING TROUBLE 1-2 MAINTENANCE OR REPAIR? 1-2 DIRECTIONS AND LOCATIONS 1-2 PROFESSIONAL HELP’ 1-2 PURCHASING PARTS 1-3 AVOIDING THE MOST COMMON MISTAKES 1-3 BOATING SAFETY 1-3 REGULATIONS FOR YOUR BOAT 1-3 DOCUMENTING OF VESSELS 1-4 REGISTRATION OF BOATS 1-4 NUMBERING OF VESSELS. 1-4 SALES AND TRANSFERS 1-4 HULL IDENTIFICATION NUMBER 1-4 LENGTH OF BOATS 1-4 CAPACITY INFORMATION 1-4 CERTIFICATE OF COMPLIANCE 1-4 VENTILATION 1-4 VENTILATION SYSTEMS 1-5 REQUIRED SAFETY EQUIPMENT 1-5 TYPES OF FIRES 1-5, FIRE EXTINGUISHERS 1-5, WARNING SYSTEM 1-6 PERSONAL FLOTATION. DEVICES 1-6 SOUND PRODUCING DEVICES 1-8 VISUAL DISTRESS SIGNALS 1-8, EQUIPMENT NOT REQUIRED BUT RECOMMENDED 1-10, SECOND MEANS OF PROPULSION 1-10 BAILING DEVICES 1-10, FIRST AID KIT 1-10 ANCHORS 1-10 VHF-FM RADIO. 1-10 TOOLS AND SPARE PARTS 1-10 COURTESY MARINE EXAMINATIONS 1-11 ‘SAFETY IN SERVICE 1-11 DOS 1-11 DONTS 1-11 Clallam ROVE BEN Niall 1-2 GENERAL INFORMATION AND BOATING SAFETY POEs ‘Tis mana is designe to ea handy ene gue to mating and repaing you Honda 4-stoke outoard, We stongly bel hat regarges of how ayo: how en yeas experience you may have his somehing em wala er for you “This manal covers the topics ata factory service manual designed fo fectry tained mechanics) ara menutacret owners marvalGesigned more by lamers hese days) covers. wl take you rough te basis of maining and epg you Otboad, stp lp, elp you understand wat tory trained mechanics already Know by hear, By using the intrmatin in his manual, ay boat omer shou be abl to make ber farmed dexsions abot wal they nee odo to tan and enjoy ther ouboar vn you never lan on touching a wench ari so, we hope hal you wl change your rin) his anal wil il ep you understand what a metric ee to do node fo marian your engi. Crna Ifyou aero the type who prone to king a wrench fo sareting, NEVER. AR, The procedures inthis manual cover top la eve! vitually anyone wl te able to nde. Ad jut he fact at you purcased this manval shows you inerest in beter understanding you cubed, "Yura in ta iting you outoad yours is preabe n ost cases, Froma malay Sandpoit evi as be bn. The money spent an alg your oa tomer ard paying a sho serie he engine coud buy yu fl fora whl weaken tng you are unio! your oan mechanical biti, he vay es you soul fly urdesand wt mana ‘Tecan does io your boa. You may dace anyhng cer than maiornce ad ajsineris shoul be peared by a machi (ad thas orca, bt ‘now tha vy tine you board your ta, you ae placing fh ne mechan wrk and tstng hin ote ih your wal-bing ard maybe your le. should ls be noted ta in most rs a ator tained mecha wl amanda hey uty a fro seservie, Ths hours charged from tte they leave tar top fo te tine tey rtm None The xs sa ing in dong fe ob yousel shouldbe easly appeerta s po Wee Bore spending any money on pats, and bel emoving any nu ool, read hough teenie procure or oi. This wl ie you the evra view of ‘at tools an suis wil be equied to part he poco wal ques- ‘ins ne o be answered efore purchasing pars. So read aed and plan ated. Each operation shoul be egprache lagcaly anal procures to ‘ugly understao elore ating any work. ra Some procedures in hs manual may requite you to late and disconnect * a group of ines, hoses or wes. Dan elle into inking you tan ‘enemter were eventing goes — you wont. you recoanect or ins a pat inca, ings may ope pot, iat al. you took un eectical wing incre you may iti a ery, vy expense sso, ‘pics of masking ape, fr example, pea on 2 Nose and anata an its fing wil allow yout assign your con be suchas he eter“ or 2 sho tame. As lang 2s you red your cw cove, thelr be cane by matching iter or rares. Do rrr lp wil issove whan sa ‘ale infu a component iso be washed oceans, use anohe aod of ideation. A permanent eiped mar canbe very Nandy fr marking etal part; bt reer Wat tds wil eave permane make ‘SAFETY she ost impo hing to enenber when petorming maine rane oF reais, Be sue ore he norton on salty ins anual Maintenance or Repair? Prope inna is he kayo long and trot engie ie, a th work an yes onnrenads A propery anand engine perms bet tan one tats neglected sa consieous bat one, sl asite 2 Study moing at leas onc amt to perom aorugh check of ens which cau cause e- lens Keep yout own prsra logo jo down which sees you pred ow ‘ru th pats cost yo, he dean the amount of hours on the engine a he tine, Kep a eps or pats purchased soit hey maybe reared i incase fred problems oro deterring operating expenses, AS do--yousaer, ese recite ony prot you have hat he equied mariennce was pore Ire eet of a nary problem hase recip wil be malate aessaryo meton the aiteence between aiienance and epi, Mrtesance inde routine inspections, adjustments, and replacement ot pars at show sigs of normal wat Maienaoe corgensls for wer or orion. Repar ingles tha somelhiag fas bot orf no working. A orp of caused by lack of aoe For etal raring a efling the engine os maintrane recomended by all mance a peices Faure odo ths can allow intra cor- "esion a daage ana impale operation ofthe eng, equing pensive rept. While no maintrance program can prevent es rom bresing wear ingot a genera can be sae: MAINTENANCE IS CHEAPER THAN REPAIR Poser 1 See Figure Two basic us shouldbe mentond hr. Fist, where the Prt sie of ‘he engine (bal is eee fo, maar to spel the le sie of he egite whan you sing a the heim. Conese. he Soar means your sa sie Te Bow sth oko the boa ad the Stam the re. ‘Most sre and bol are eoved by uring coutleokw'se, an tenes by ing clack, An easy way fo remarry, ase. Chomy, tuft, And it you array dose ard we eal been so at one time orate by ache ats mated ON and OFF, mark your own enon) (uerT 50) ceo) Cczsioaly tee ae some things when working onan cuboad tat re yond ne capable o tools ofthe average Do-t-Yousele (DN), Tis shoul include most ofthe topic fis aru, at you wl ave ob he doe. Some engines equite special fools or a selectn of special pas, even foc asic maintenance, Taktooher bats who use the same mado rigieand speak witha trusted marina I ers paral syste or agora on your tng the is felt o malta, For exer, though he xhnque of valve adjuster on some egies ay be easly undatstond and even plored by 4 DWVe, i might equie a handy assariman of stirs varius ss and a ew ous of sassy to a to that point Not having te assortment shins | ay might mean tile tps back and forth ote pars store, and this ight at be wet you time. GENERAL INFORMATION AND BOATING SAFETY 1-3 ‘You wil tat dace or ourself whee asic mlnenanoe ends and where olessional save should bei. Take your ine and do your research ist (Gang whe intron in this marl an then mate your own decison "you realy dot al confortable wih atoning a procedure, CONT DO. youve got ino sorehing Pat ray be ove your Pad, do pan Tuck you {al baleen your las ad cal a marine mechanic. Marinas and indeende haps wil ate fishaob for you. You ego may be daaged, but your boa wil be propery restored os ul runing oder So, as ang as you gproach obs slowly ad cart, you relly have nothing i ose an re thing to gain by doing t yours Ginnie 1 See Figures 2, 3 and 4 ‘Wien purchasing pats the ae wo things to consider. The ists vay andthe second Is be suet ete cae pat or your engin To gt quale iy parts, eas deal creay wi a eabe rele To gt th proper pars ‘ays rile tte ionmation fag on our engine prior to caling tapas Courier, An incarect par can advosey af your engine petormance and ie canary, and wil cast you ore mney and ogra in he ee ‘st emerber, fw tact shore wil cos panty. Tal charg i per hue rm the timo to toboat leas thet home po, the time thay re heir ae po Gl he picture $88? 'o wo shoul you calf pars? Wel, ther mary Sources fore pars you willed, Wha ou sh fr pat wil be etermind by wha kn fps you eg, how meh you want op, andthe types of tar in your eghtarond, "Your marin an supply you wit mary othe common pats you require Using a marin foc a ou pats sup maybe Rand because of locaton (st wal it Conn the doco base th mana specs in you pacar brand of engine. In adion ts ays a good fea og to know te marina Stal (ospevaly he mazine mecha), ‘The rarine pats tbe who [s usual sted inthe yellow pages r whose rare cn e blaine fro the maa noe excelent source for pats. In tion fo supplying local marinas, thy as do a sirable business in ovet- ‘he count pats sas forte do-it yours Almost every community has on of mare convenient mane chan toes, ‘hase lors often of th est real pies andthe coneriene of one-stop happing fal you neds, Sine they cart the d-t-yursaiy, tes tres ‘ae amest always open weknighs, Saturdays, and Sunday, when te bess ae usualy closed Te lone ries or part are most tl fundindscountsos or be ao charmer of Ts machi, Pars ohare nae ard ate band ars bau in ge cui, so thy car ofa compete rie Pivae band ars rea ty Mor Tarutaduers and soto lage cha ude soe abe (MMe ee “Thee ae 3 common mists In mechanical wor 1. fpeonet order of assembly, sassy or dust, When king saething apart puting I ogee, gaming ses i the wrong ode usu- aly ust ests yo ea ne, weve CAN break somthing. eat te ene oad oer bogining disassembly, Paro everyting inthe order in ‘ih te isutins say you should, een you cant inediaely se ae ‘afr. Wen you king apa someting tas very nical, you might wet fo awa peur ol ow lt loks when assembled a one pont in oer ta rake sur you ge eying bakin proper postion When mating ads rari, prior tam ithe ropes cde: ofn, one ausimet ates anaes ‘ad you cannot exp satay resus nls each arusents mad only ‘wen icant be cangot ty ater vetoing (oF undertoraung). While ts mre common for oe ‘orquing cause darian, underioqing may alow ster to bate ose using srous damage Espaialy when dealing wth aluminum pars, py terion to oruespesiatnsand ula a oxque wrench in assembiy. a Torque igus ot aval, rreber hati you are sing he ig too to parr hc, you wl prob not have to stan yoursel og aster Tg enough Te pth of most treads 30s a he esion you pt on the wrench wil emul many tines natal force on wha yo ae ight ‘ning 3 Crosstveading. Tis dou when apart such a bot is soewed ino @ ror easing a he wrong ange ad ace, Crosstatng fs marley to ‘nur aes scl ps olen an ica aslenes, thn fo tat threading wih he pat tobe installed postion straight in Aways sat a as teres, a. wih your tings. you ancount esistnce, unscrew he pat and ‘tr ova al 2 rental nl can be inset and tured severl times without mh eo Keepin mind tat some pars ray have pred threats, so thal go ening wil atomically bing th part youre treating tothe proer ang, but oly you dor’ ace or ress a change in angle Dor puta were one part Unt i has been ighened 2 couple of us by and you sudoeny encour eistnce, and ih pat has al seated uly, on fore Puli Bek oul oko sure ts Can and heating propa Fig. 2 By far the mast important asset in purchasing pat isa knowledge enthusiastic parts person pans leand rumbers on your engine when ordering Fig 4 Parts catalogs, ving application and ar number informatio, are provided by manufactures for most replacement pats BOATING SAFETY In 4971 Congas ordered the US. Coast Gia tn prov eration boing sey In response, he Goat Guard drew wo sit of regions Bese thse feral regulations, er af ie and oval laws you must low. These sometimes ex2ed he Coast Guard requiem. This secon dis cases ony the Iederal ans, Sse ad local ans a avai tom you lca Coast Guar, As wih ter ans, “ignoranoe of te oaing lio excuse” “The ules all into two groups regulon ox your balan required salty augment on your oat Regulations For Your B ‘Most boas on waters within Fader jit must be registred cr doo mei. hese wales re seta roid a meas fansportaton baleen ~ ‘wo or more sites or othe se, They also icc teil waters ofthe Unto Ses. 1-4 GENERAL INFORMATION AND BOATING SAFETY DOCUMENTING OF VESSELS LENGTH OF BOATS ese ctv of more rel ons may be documented as aye, his proces, panes ae issued byte U.S. Coast Gund as hoy afr age ships. Documentation is fom of air reysration Tha Bot rust be usd oly to plesise ts omer must be a US. ze, a paar of US. class, of ‘portion contol ay US. ctzers, Te capa an oer ofeers mist also ‘be US. cans. The ce need na Be. you coeur your yc, you have the ga authority tthe yacht ensign. You also ay reo bil of sale, marigages, and oer papers ite with eral autores. ing so gs legal nati that such insrumens exist Doourertaon also emis prefered sas fr marigages. Tis gives you ‘ional seu and ais francing and tater of, You rus cary te ‘ginal documentation papers aboard your vessel. Copies wil at sui. REGISTRATION OF BOATS your boss no documented registration inthe tao is pina uses obey required you use tainly onan ocean gular silat alr, iste inh le where you mooi. you use your bot soll for acing, it may be exept rom the requieent in your st. Ses may also ect cnghies. Some requte region of ocurred vessels and na power ven boats. ‘A hes, exept Alsi, ister bol. n last, he US. Cost Guar issues the repstaton numbers you move your esl oa new sat principal use, a ‘ald eisai clic is good fr 60 days. You must have the egisaton ‘ectfica (ceica of ruber) aboard your vessel wen Xi in se Acopy wl not sufce You may be cai you do nt have he ginal on boar. NUMBERING OF VESSELS ‘registration number ison you region caitet. You mst paint or permanent atch this rumba to ot ides of the forward half of you bat Do nt cisplay ary ote number ee ‘The ein nuaer must be clay vie, Rust nt be plaat en he obscured underside ofa fete bow. you cant pee the ruber one ow, place iton fe foward Pal fer. al does ore. put ion te supers. Pe number an nfl bot on a race oft. Then, my aah to ‘he fora half he boa, The ets and nanbes mst be pan lock chads and mst ea rom eo gh Uso a space oa hyphen to separ tins suf its om he uma. To colr fhe tasers must cons wih at he backround, an they mus be taste inches high ‘in some states your agitation s good fr only one ya In tes itis good for as lng as hee yeas. Renew your region boot expres. At {hat time you wl ecole anew dezal or ec. lee thm as required by lle law. You sould remove od deals bor puting on he new ones, Same ses ‘equi that you show ony he cent decal or decals your ws s moored, ‘ust ave 2 cure deca even fits nt nus. your vessels. destroyed, aanfone, soe, or transeed, you must [nfm be issuing auhariy. you nse your ceria of number o your aces change, nll th suing author as soon 2 pss. SALES AND TRANSFERS ‘Your raison numbers not rafal to ance oat. The number ‘lays ith he brat urless is te of pial uses change, HULL IDENTIFICATION NUMBER A Hu ettcaton Number (HN) i ike he Vil Kenton Number (non you cat Bats built eween Nove, 1972 and ly 3, 1968 Rae ‘ol toma HN. Since August, 1964 anew oma has been used. Yow boos HN must oper in two places. it has anor the primary ruber son is ‘Sarbar side wn vo ches ois op it does at have a ans ort es rot praca fo use he aso, te ruer son the sana, is ase tsb win one to! he tae wii eo inches oe op lhe hull se. On pone tots, tone a rossbeam win on ot fe t= bri atch. Your bol ap has apical number in an unexposed locaton, This on he bet nar or und iting oto a aca, For some purposes, bral ar classed by length, Requied equipment, example, flrs wih boa siz. Mantes may measure 2 beats engi in several ways, Ocal, though, your bats measured along sagt ine rom isbow ts tam. This line paral os ke. ‘The lng doesnot ict bowspris, Deakins, or pups Nor does it Inctute rues, braces, outboard moos, outs, avrg platorns, oe ole ataceens CAPACITY INFORMATION 9 See Figure § etacturers mst put capacty pate on rst etetonal oases than 20 et ong. Sailboats, canoes, ays, an nflalale boats ae usualy ex ‘Outboard beats must isoly fe inci periteshasegewet fhe eng. The ples mst also show te allowable maximum weighs ofthe peo leon board. Ad they must show he allowable maximum combined weights of role, engines, and gea Invoatsan sie dives ad at show he weigh of thar engines onthe capcy pes. The cape late must appear ei is clear wsibe tote operator when underway. This intron saves lo tein yuo te capacity of our boat under normal ccursanoes. You should ask youse, “sm bat loaded above is recomended capaci" and, "ism bol overoaed lr the preset sea nd wind conan?” you ae ‘topped ty aoa author, you may bec you are ote Peer TS nas naa See cons] See TTWS BOAT COMPLIES WIDH U.S. COAST GUARD. SAFETY STANDARDS IM EFFECT ON THE DATE OE GERTIFICATION i BAHAMA INDUSTRIES, INC, #612 LA PALMA.ST, ANAHEIM, CALIF. 92007 _@ Fig. 5 AU.S. Coast Guard certification plate indicates the amount of ‘ccupants and gear appropriate for safe operation ofthe vessel CERTIFICATE OF COMPLIANCE anuacturers are required o pul complianca les on motorboat greater than 20 een inh. The pales must ay, “his boa” or "This equipment ‘amples wih the U.S. Coe! Guard Salty landed in eect onthe de of ‘ection Laters and numbers can ben ethan oe-ghh fa inch high. Al the mandacture’s opto, fe capacty and compance ples may de combine, VENTILATION ‘Acup of gasoline spi nthe bg este potential explosive power 15 sic of damit This stenon, commonly quoted of 20 yeas ape, may Be an exaggeatin, howe, tilts a fact Gasoline ues ne Dig of boat are high exlsive and a sevous danger Tey aera than 2 and wil stayin the bige url hey ae verted au Because ofthis danga, Coast Guard regulon require venlaton on many owe boats. There are several ways lo supply esha lo engine and gasoline lank ompariments ag to remove dangerous vapors. Whaler techie, it rust eet Coast Guar standards, ‘The following i not Intended tobe a complete discussion of he regu- lations. ts lime to the majority of recreational vessels, Contact your local Coast Guard office for tutor intarmation. GENERAL INFORMATION AND BOATING SAFETY 1-5 General Precautions Veriaon syste wil not remove am gasoline hat aks rom aks ok ines. you sel gasoline ues, you need ime epi, The best device foc sersng gasoline fumes fs you nose Use I you smal galing nan engine compartment reset, don tat your engine. The sali the cor aa teks gasoline takes to make an explosive mire Ventilation for Open Boats In open bats, gasoline vapor re speedy he a hat mows trough the, So ey ae exempt For vertlation equerens “ote open abo mus met cet coetions, Engine and fuel tank com parents ad ion naow corprinenis ih jin her ust be open to te stmasere* Ths mons hay mst a tas 15 star inches of pen area for eth eubi fot fet coger volume. Te open area rust be in det carat wh he aesphee Tere rst ao be no lng, une spaces ‘pan lo eine and fu tank compares into which Names could een. entiation for Al Other Boats Ponerd and natural vertlation are requ nan encased compartent witha permanently isle gasoline engine thas a cranking moi. A com atari oxomp ts engine i open ote abmasphere. Diesel powered nats ar also exempt VENTILATION SYSTEMS Tere arto types of vention systems. Ones “aa entation." Ini,

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