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SHOP MANUAL NEWS

SHOP MANUAL NEWS

SHOP MANUAL NEWS

SHOP MANUAL NEWS

SHOP MANUAL NEWS

SHOP MANUAL NEWS

BF4OA.BFSOA Paper Book Part No. 66ZV3OOU

PREFACE

This manual covers the construction, function and servicing procedures of the Honda BF40A-BF50A Outboard motors.

For service information which i s not covered in this supplement, please refer to the base shop manual

(66ZV300, 66ZV3OOZ, 66ZV3O0YI 66ZV300X, 66ZV3OOW,

66ZV300V).

CONTENTS

OUTLINE OF CHANGES

SPECIFICATIONS

SERVICE INFORMATION

MAINTENANCE

~~

All

information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables.

FUEL SYSTEM

FLWHEEIAMING BELT

0 Honda Motor Co., Ltd.

Service Publication Office

OIL PANPRIMARY GEAR CASEBWIVEL CASE

GAS ASSISTED/POWER TILT

THROlTLE BRACKETBHIFT LEVER/

HANDLEBAR (TILLER HANDLE TYPE ONLY)

ELECTRICAL EQUIPMENT

WIRING DIAGRAM

The marked sections contain no changes.

They are not covered in this manual.

Date of Issue: Sept. 2003

0 Honda Motor Co., Ltd.

OUTLINE OF CHANGES

ECT sensor installation position changed.

ECT SENSOR

BF40AmBF50A

[3]

Before change

[6] ECT switch

[611 ECT SWITCH

/

[7] Water hose joint

I811

WATER HOSE

JOINT

PI-1

WATER HOSE

JOINT

i

[9]

CDI unit

[lo] to

digital CDI unit

[l 11

Analogue CDI unit

I

I

I

1.1

2

After change

[4] Oil pressure switch [S] Connecting terminal, connection method changed.

151-1

OIL PRESSURE SWITCH

BF40AeBF50A

[3] Before change

151-2

4 x Q m m

TERMINAL SCREW

15l-3

OIL PRESSURE

SWITCH

I

[6] Power coil

[5]4 MALE CONNECTOR

p]

Change to power coil from exciter coil. ml

POWER COIL

[8] Power trimhilt assembly

[eE1

POWER TRlMmLT ASSEMBLY

M-1

I

POWER TRIMmLT ASSEMBLY

[4]

Gas assisted damper

[2] After change

BF40AeBF50A

[3] Before change

161 Inverted type

[7]

Mount frame

[5]-1 GAS ASSISTED DAMPER m-1 MOUNT FRAME

[6]-1 GAS ASSISTED DAMPER m-1 MOUNT FRAME

[8] Stern bracket

FRICTION PLATE MOUNTING SECTION

STERN

BRACKET

181-1

STERN

BRACKET

3

[4] Swivel case

141-1

STEERING FRlNCTlON STUD

INSTALLATION HOLE

~~

[5] Tiller handle

CASE

[6] Long tiller handle type added

M-1

LONG TILLER HANDLE

BF40AaBF50A

[3]

Before change

CASE

[7] Friction adjusting lever

[8] Tiller handle friction lever being added in connection with addition of the long tiller handle type

/

181-1

FRICTION PLATE

FRICTION

ADJUSTING

LEVER

4

5

[4]

Carburetor

141-2

SE THERMAL VALVE

/

BF40AaBF50A

[3] Before change

[4]-3 CHOKEVALVE

/

151 Remote control box [6] Choke switch is no longer installed.

[4]-5 CHOKE ARM [4]-4

CHOKE SOLENOID

(REMOTE CONTROL

TYPE)

161-1

CHOKE

SWITCH

[4] Fuse holder bracket [5] Newly provided.

[51-1

FUSE HOLDER BRACKET

BF40AaBF50A

[3] Before change

[5]-2

FUSE HOLDER

[5]-3

REGU LATOWRECTIFIER

BRACKET

REG U LATO

WR

BRACKET

1.

SPECIFICATIONS

I

1.

SPECIFICATIONS

2. DIMENSIONAL DRAWING

BF40AoBF50A

1.

SPECIFICATIONS

DIMENSIONS AND WEIGHTS

1

Model

Description code

Type

Overall length

Overall width

Overall height

Dry weight

(With propeller mounted)

Operating weight

Transom height

Transom angle

Tiltina anale

Trimming angle

Swivel angle

I

BF40A

SH

LH

770 mm (30.3 in)

LHT

BAYS

SR

I

SRT

685 mm (27.0 in)

1,260 mm 1,365 mm (53.7 in)

370 mm (14.6 in)

1,260 mm (49.6 in)

[

LR

1

LRT

1,365 mm (53.7 in)

(49.6 in)

96 kg tb7

95.5 kg 97.5 kg

(316 Ib)

(322 Ib)

89 kg

(294 Ib)

91 kg

(301 Ib)

91 kg

(301 Ib)

93 kg

(307 Ib)

98 kg 100 kg 91.5 kg 93.5 kg 93.5 kg 95.5 kg

(31 7 Ib) (324 Ib) (322 Ib) (302 Ib) (309 Ib) (309 Ib) (316 Ib)

416 mm 521 mm (20.5 in) 416 mm (16.4 in) 521 mm (20.5 in)

(1 6.4 in)

—

5 stage adjustment (8″, 12″, 16′, 20″, 24′)

-4′

—

63″

1

— 4 » — 1 2 »

I

—

I

— 4 » — 1 2 » j

—

I

— 4 » — 1 2 ‘

37.5″ right and left

Types of Honda BF40A Outboard Motors

It may be necessary to refer to this chart for reference purposes when reading this manual.

1

Model

Shaft Remote Electric

Power assisted enrichment system

~

Type

I length

I

Long

I control

I starter

1 trimhilt

I

Gas- ti,t

I

Starting

I

I

LRT

I

L

~

S:

Short shaft, L: Long shaft

0 0 0 0

1-1

BF40AeBF50A

Model

Description code

Type

Overall length

Overall width

Overall height

Dry weight

(With propeller mounted)

Operating weight

Transom height

Transom angle

Tiltina anale

I

Trimmina anale

I

Swivel angle

Model

Description code

Type

Overall lenath

I

Overall width

Overall height

Dry weight

(With propeller mounted)

Operating weight

Transom height

Transom angle

Tiltina anale

I

Trimmina anale

I

Swivel angle

I

BF50A

BAZS

LH YH XH

Y

HT

770 mm (30.3 in)

I 1,365 mm (53.7 in)

95.5 kg (211

Ib)

I

370 mm (14.6 in)

I

1,400 mm (55.1 in)

I

1,470 mm (57.9 in)

1

1,400 mm (55.1 in)

96.5 kg (213 Ib)

1

99.5 kg (219

Ib)

I

98.5 kg (217 in)

1

98 kg (21 6 Ib)

521 mm (20.5 in)

99 kg (218 Ib)

556 mm (21.9 in)

102 kg (225 Ib)

622 mm (24.5 in)

5 stage adjustment (8″, 12″, 16″, 20″, 24″)

-4″

—

63″

— j

37.5″ right and left

101 kg (223

Ib)

556 mm (21.9 in)

-4′

~

—1

BF50A

BAZS

SRT

I

1,260 mm (49.6 in)

LR LRT

685 mm (27.0 in)

370 mm (14.6 in)

1,365 mm (53.7 in)

YRT XRT

1,400 mm (55.1 in) 1,470 mm (57.9 in)

91 kg (201 Ib) 91 kg (201

Ib)

93 kg (205 Ib) 94 kg (207 Ib) 97 kg (214 Ib)

I

I

93.5 kg (206

Ib) 93.5 kg (206 Ib)

95.5 kg (21 1 Ib) 96.5 kg (213

Ib)

99.5 kg (219

Ib)

41 6 mm (1 6.4 in) 521 mm (20.5 in) 556 mm (21.9 in) 622 mm (24.5 in)

—

5 stage adjustment (8″, 12″, 16″, 20″, 24″)

-4″

—

63″

I

-4″

—

12″

37.5″ right and left

1

Types of Honda BF50A Outboard Motors

1

It may be necessary to refer to this chart for reference purposes when reading this manual.

Model

I

Type

I

Shaft length

~

I

Remote control

~

Electric starter

I trimhilt

I

Gas- tilt

1

Starting

Power assisted enrichment system

I

XH

Y

HT

SRT

LR

LRT

UL

LL

S

L

I

L

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

S:

Short shaft, L: Long shaft, LL: Semi-long shaft, UL: Extra long shaft

1-2

ENGINE

Model

Description code

Type

Displacement

Bore x stroke

Rated horsepower

Maximum torque

Compression ratio

Fuel consumption

Cooling system

Ignition system

Ignition timing

Spark plug

Carburetor

Lubricating system

Oil capacity

Recommended oil

Starting system

Stopping system

Fuel used

Fuel tank capacity

Fuel pump

Exhaust system

Recommended battery

I

BF40A

BAY E

I

BF50A

BAZE

Water cooled 4-stroke, overhead valve, vertical 3 cylinders

808 cm3 (21.5 cu. in)

70 x 70 mm (2.8 x

2.8 in)

29.4 kW (40 PS) at 5.500 min-‘ h r n )

I

62.3 N-m (6.36 kgf-m, 46.0 Ibfaft) at 3,500 min-l (rpm)

36.8 kW

(50

at 6,000 min-l (rpm)

1

65.2 N-m (6.65 kgf.m, 48.1 Ibf-ft) at 4,500 min-I (rpm)

9.2: 1

335 g (1 1.9 oz.)/kWh

329 g (1 1.6 oz.)/kWh

Forced water circulation by impeller pump with thermostat

CDI

5″

—

26′ B.T.D.C.

DR7EA (NGK), X22ESR-U (DENSO)

Horizontal butterfly valve type, vertical 3 carburetors

Forced lubrication by trochoid pump

2.0

2.4

e

(2.54 US qt, 2.1 1 Imp qt)

e

(2.12 US qt, 1.76 Imp qt) at oil change

SAE 5W-30, API Service classification SG/SH/SJ

Electric starter

Ignition primary circuit ground

Automotive unleaded gasoline (minimum 86 pump octane)

25

e

(6.6 US gal, 5.5 Imp gal)

Mechanical plunger type

Under water type

12V 65Ah (65D23R)

LOWER

UNIT

Model

Clutch

Gear ratio

Reduction type

Gear case oil capacity

Propeller Rotating direction

BF4OA, BF50A

Dog clutch (Forward-neutral-reverse)

0.48 (26/33 x 14/23)

Spiral bevel gear

0.41

e

(0.43 US qt, 0.36 Imp qt)

Clockwise (viewed from rear)

1-3

2. DIMENSIONAL DRAWING

Tiller Handle Type

H

SType

1,260

(49.6)

T S

416

805

(1 (31.7)

LType

1,365

(53.7)

521 900

(20.5) (35.4)

LLType

1,400

556 930

(57.9) (21.9) (36.6)

ULType

I

1,470 622

(57.9)

I

(24.5)

1

( & :

1,284.5 (50.57)

BF40AaBF50A

Unit: mm (in)

370 (1 4.57)

r 1

i

1

1-5

~~~ ~~~

Remote

Control

Type

370 (1 4.57)

-m m i

I

V

—

770 (30.31)

T

cu

$!

v r

5;

Unit: m m (in)

2.

SERVICE INFORMATION

1. MAINTENANCE STANDARDS

2.

TORQUE VALUES

3.

SPECIAL TOOLS

4. APPLYING LIQUID SEALANT

BF40AoBF50A

5. TROUBLESHOOTING

6. CABLE 8t HARNESS ROUTING

7.

TUBE ROUTING

1.

MAINTENANCE STANDARDS

1

Part

Carburetor

Powercoil

Main jet

Pilot screw opening

BF50A

I

Float height BF40A

BF50A

Exhaust emission

Bondensee type only

con

I

NOX co

Item

BF4OA Bondensee type

Except Bondensee type

BF50A

BMOA Bondensee type

Standard

#loo

#lo5

#135

3-318 turns out

Except Bondensee type 3-112 turns out

2-118 turns out

14.0 mm (0.55 in)

13.0 mm (0.51 in)

15.8

—

24.2

Q

10% min.

I

546oom max.

I

7.0% max.

Measurina idle soeed

I

Resistance

950

—

1,150 min-I (rpm)

I

7.02

—

8.58

Q

I

2. TORQUE

VALUES

Item

Engine

Crankcase cover bolt

Thread dia. x pitch

N-m

Service limit

—

—

—

—

—

—

—

—

—

—

—

—

—

—

Torque kgfom

7

Note

Cylinder head bolt

Oil strainer bolt

Water tube joint

Flywheel bolt

Gear case

Propeller castle nut

Gear case end nut

Gear case nut

(UL type)

Gear case stud (UL type)

M8 x 1.25

M6 x 1

.O

M10 x 1.25

M8 x 1.25

M6 x 1

.O

PT1/8

M l O x 1.0

1

69

34

22

1.5

1.3

1

27

12

39

26

13

9

65

2.8

1.2

4.0

2.7

1.3

0.9

6.6

Water screen screw

M16x 1.0

M80 x 1.5

M l O x 1.25

M8 x 1.25

M l O x 1.25

M8 x 1.25

Id5 x 0.8

0.1

7.0

3.5

2.2

0.15

0.13

0.1

0.7

51

25

16

1.1

0.9

0.7

I

(4)

(5)

1

I

I

2-1

BF40AoBF50A

Nsm

9.5

22

39

34

7

1.3

7

1.3

4.5

54

29

34

4.5

7

2.2

6.5

Toraue kgf-m

0.95

2.2

Ibf*ft

6.9

16

4.0

3.5

5.5

3.0

3.5

0.45

0.7

0.22

0.7

0.13

0.7

0.13

0.45

0.65

29

25

5.1

0.9

5.1

0.9

3.3

40

22

25

3.3

5.1

1.6

4.7

Note

Item

Extension/Mount

Steering friction lever nut

(Long tiller handle type)

Lower motor mount housing bolt

Stern bracket

Stern bracket left side nut

Stern bracket right side nut

Tiller handle

Steering bracket pivot lock nut

Steering bracket pivot nut

Steering bracket nut

Throttle arm holder bolt

Throttle grip bolt

Under cover screw

Cable holder bolt

Emergency stop switch nut

Connector bracket bolt

Throttle cable pivot lock nut

Switch bracket bolt

Gas assisted damper

Tilt lever nut

Thread dia.

x

pitch

M8 x 0.75

M8 x 1.25

7/8-14UNF

M10 x 1.25

M12 x 1.25

M12 x 1.25

MlOx 1.25

M5 x 0.8

M6 x 1

.O

M5 x 0.8

M5 x 1

.O

M16x 1.0

M6 x 1

.O

M6 x 1

.O

M5 x 0.8

M6 x 1

.O

NOTE:

Apply oil to the thread and seating surface.

Tighten to the specified torque first, then tighten an additional 90″- 120″.

Clean

off oil or grease from the crankshaft and flywheel mating surfaces (see page 6-1). Apply oil to the

thread and seating surface of the flywheel bolt, then tighten them to the specified torque.

If the split pin cannot be set by tightening the castle nut to the specified torque, tighten the castle nut addi- tionally until the split pin can be set. Do not exceed the maximum torque of 34 N-m (3.5 kgf-m, 25 Ibf-ft).

If the tab of the washer does not align with the groove of the gear case end nut by tightening it to the speci- fied torque, tighten the castle nut additionally until the groove aligns with the tab.

Do not exceed the maxi- mum torque of 98 Nem (10.0 kgf-m, 72 Ibf-ft).

Turn the friction lever to the right side fully, and hold it in this position and tighten the friction lever nut to the specified torque.

Tighten the stern bracket nut to the specified torque, then turn it back to 180

—

210″.

2-2

3. SPECIAL TOOLS

No.

I

Tool name

1

2

Vacuum gauge attachment

5 x 08 x 120L

Vacuum gauge attachment

5 x 08 x 50L

I

Toolnumber

0751 0-30001 00 or

0751 0-3000200

Application

Carburetor synchronization

BF40A-BF50A

4.

APPLYING LIQUID SEALANT

Apply liquid sealant to the primary gear case gasket and oil pan gasket as follows:

Assemble the crankcase side cover and oil pan within the specified time after application of a sealing agent.

Example:

—

Within 90 minutes when using Three Bond #1211.

—

Within 30 minutes when using Three Bond #1216.

Apply about 1

—

5 mm (0.04

—

0.20 in) width.

Wait for 15 minutes after assembly.

Do not add oil dur- ing this period.

PRIMARY GEAR CASE GASKET

1) Clean the engine and primary gear case mating sur- faces with a degreasing cleaning agent or a clean

shop towel (see base shop manual).

2) Apply liquid sealant to the position shown on both side of a new primary gear case gasket.

OIL PAN GASKET

1) Clean the engine and oil pan mating surfaces with a degreasing cleaning agent or a clean shop towel (see base shop manual).

2) Apply liquid sealant to the position shown on both side of a new primary gear case gasket.

Applying area

,

Apply 1

—

5 mm

(0.04

—

0.20 in) width.

PRIMARY GEAR

CASE GASKET

Applying area

7?L

LJ

OIL PAN GASKET

I

Apply 1

—

5 mm (0.04

—

0.20 in) width.

2-3

BF40A-BF50A

5.

TROUBLESHOOTING a. ENGINE

Hard Starting

Sufficient fuel in the tank

4 and check whether fuel reached the carburetor.

I

Reaching the carburetor.

No fuel in the tank

—

Add fuel.

Not reaching thc carburetor

Check for collapsed or pitched fuel line.

Check for clogged fuel tank breather hole: Close the tank and open the vent knob, listen for hiss.

Check for air leaks past primer bulb.

Squeeze the primer bulb and be sure that the fuel is reaching the car- buretor.

Check for clogged fuel filter, fuel tubes and connector.

4

Dry

Wet

—

SE valve (P.

5-18 and 19).

Clean the electrode and restart with

— the throttle 1/4 open or gradually opening wider.

4.

Perform spark test (See base shop manual).

No spark or weak sparks

—

Perform IGNITION SYSTEM trou-

bleshooting (P. 2-7).

5. Check compression of each cylinder

__

(See base shop manual).

I

Normal compression

1

Reinstall the spark plugs securely and restart the engine according to the bustion chamber. correct.

Check for defective cylinder head gasket, valves or valve seats.

Check that the cylinder head bolts are correctly tightened.

Check for worn piston, piston rings or cylinder.

BF40AoBF50A

Engine Does Not

Run Smoothly

Engine starts, but stalls soon.

Idle speed is not stable or stalls.

~

—+

SE (Starting

Enrichment) valve.

Spark plug faulty.

Inspect: P.

5-18 and 19

Clean and adjust or replace

(see base shop manual).

Adjust (see base shop manual).

throttle stop screw misadjusted.

Overflowed carburetor. and intake manifold mounting bolts, and/or damaged carbure- tor insulator and gasket.

Valve clearance misadjusted.

Low cylinder compression.

Drain the carburetor and prime again. If still not good, check the carburetor float valve.

Retighten the carburetor mounting bolts or intake manifold bolts, if they are loose.

Make sure the carburetor and insulator are installed correct- ly. Replace the gaskets if they are damaged.

Adjust (see base shop manual).

Check for defective cylinder head gasket, valves or valve seats.

Check that the cylinder head bolts are correctly tightened.

Check for worn piston, piston rings or cylinder.

2-5

Throttle cable misadjusted.

Readjust (see base shop manu- al)

.

BF40AeBFSOA

b. IGNITION SYSTEM

These outboard motors are equipped with an engine overrev limiter which is provided in the ignition control module.

The overrev limiter is activated when the engine speed exceeds 6,300 rpm. When activated the sparks are emitted to the No. 1,

No.

2 and No. 3 cylinders. The overrev limiter may be activated under such conditions as; light pro- peller load or propeller ventilation.

Hard

Starting

1.

Measure the spark plug gap and perform the spark test (See base shop manual).

I

No spark or weak spark

Standard plug: DR7EA (NGK), X22ESR-U (DENSO)

Plug gap: 0.6

—

0.7 mm (0.24

—

0.28 in)

2. Perform the spark test again using a new spark plugs.

Goodspark

1

No spark

3. Check that the switch clip is installed on the emergency stop switch correctly.

___

Disengaged

—

Install the clip securely.

I

Installed

c

4. Disconnect the blackhed wire of the emergency stop switch and perform spark test.

Good spark

No spark

c

5. Disconnect the power coil wire con- nector, and check for resistance.

Resistance: 7.02

—

8.58 Q

Abnormal

Normal

c

Go to page 2-8.

2-7

BF40AoBF50A

From page 2-7.

1

Abnormal lation. Check the ignition coil resis- tances (see base shop manual).

Resistance:

Primary: 0.19

—

0.23

R

Secondary: 2.8

—

3.4 kR

Normal

Abnormal resistance between the terminals

(P. 16-1).

~

Normal

9.

Bring a screwdriver or equivalent tool close to the magnetic section of the flywheel and cam pulley and check the magnetic force.

Abnormal Replace the flywheel or cam pulley. open circuit. Replace or repair the wire harness.

2-8

o N

BF40AoBF50A c.

ALERT SYSTEM

Long Tiller Handle Type:

ning.

1.

Stop the engine and check the oil level. Is the oil level correct?

I

CORRECT LEVEL

NOTE:

No problem if the oil pressure light comes

OFF when the engine speed is slowed down suddenly, but goes ON after idling for 1 or 2 minutes.

LOW LEVEL

System is OK (oil level was low). pressure light with the engine idling.

Does the oil pressure light comes

I

NO wire. Does the oil pressure light

I

YES

.

4.

Check the oil pressure switch (see base shop manual). Is the oil pres-

sure switch good?

I

YES

.1

5. Check the oil pressure. Is the oil pressure normal?

YES

c

Check the CDI unit (P. 16-1). Replace

or repair the wire harness if the CDI unit is in good condition.

Replace the oil pressure switch.

Check the oil strainer for clogging.

Clean the oil strainer if necessary.

Check the oil pump. Replace or overhaul the oil pump if necessary.

Check the oil passage for clogging.

Clean the oil passage if necessary.

Replace the oil filter.

2-9

the water intake screen clogged?

I

NO c

2. Start the engine and check the cooling system indicator with the engine idling. Does cooling water constantly flow through the cooling system indicator?

ON while the engine is running

1.

Stop the engine and check the water intake screen for clogging. Is

.

NOTE:

No problem if the overheat indicator light comes ON when restarting the engine after hot soak at high temperature, but comes OFF after

—

YES Remove the foreign material and recheck.

NO

Check the discharge port for clog- ging, clean the discharge port i f necessary.

Check the water pump for wear or damage. Replace or repair the water pump.

Check the water tube for clogging or damage. Clean or replace the water tube if necessary.

~

OFF?

YES

w

System is OK (engine temperature

3. Idle in gear for a few minutes to cool down the engine. Check the overheat indicator light. Does the overheat indicator light go OFF?

4.

Check the thermostat. Is the ther- mostat good?

NO

J.

NO was high).

.

YES

5. Disconnect the ECT (Engine coolant temperature) sensor 2P connector.

Check the overheat indicator light.

Does the overheat indicator light go

Check the CDI unit (P.

16-1).

Replace the ECT sensor.

6.

Check the ECT sensor (P. 16-3). Is

the ECT sensor in good condition.

I

YES

i.

1

Replace or repair the wire harness.

2-1 0

NO

Remote

Control Type:

I

Warning buzzer sounds continuously.

I cator lights.

2. Stop the engine and check the oil level. Is the oil level correct?

YES

3. Start the engine and check the oil

NO

—

Fill to the proper level and recheck.

YES

—

System is OK (oil level was low).

Buzzer stops but oil pressure indicator light does not come

—

Check the indicator light

(see base shop manual).

Oil pressure indicator light ON

NO

Check the CDI unit (P. 16-1).

4.

Disconnect the oil pressure switch wire. Does the buzzer stop?

YES

Replace the oil pressure switch.

base shop manual).

Is the oil pres-

YES

16. Check the oil

L

YES

NO

4

Check the oil strainer for clogging.

I

Clean the oil strainer if necessary.

Check the oil pump. Replace or

I overhaul the oil pump if necessary.

Check the oil passage for clogging.

t

Clean the oil passage if necessary.

Check the CDI unit (P. 16-1). Replace

Replace the oil filter. or repair the wire harness if the CDI unit is in good condition.

2-1 1

BF40AoBF50A

I

4

From P. 2-1 1

water intake screen for clogging.

Is

1

I

NO c

3. Start the engine and check the cooling system indicator with the engine idling. Does cooling water constantly flow through the cooling system indicator?

I

YES

-w

NO

YES

~ cool down the engine. Check the overheat indicator light. Does the overheat indicator light come OFF?

Overheat indicator light ON

Remove the foreign material and

1 recheck.

1

J

Check the discharge port for clog- ging, clean the discharge port if necessary.

Check the water pump for wear or damage. Replace or repair the water pump.

Check the water tube for clogging or damage. Clean or replace the water tube if necessary.

System is OK (engine temperature was high).

Buzzer stops but overheat

—

indicator light does not go

Check the indicator light

(see base shop manual).

mostat good?

I

YES

6. Disconnect the ECT (Engine coolant temperature) sensor 2P connector.

Check the buzzer. Does the buzzer stop?

YES

c

7. Check the ECT sensor (P. 16-3). Is

the ECT sensor in good condition.

I

YES

f

Check the thermostat. Replace the thermostat if necessary.

Replace or repair the wire harness.

2-1 2

NO

Check the CDI unit

(P. 16-1).

d.

SHIFT LEVER

Long Tiller Handle Type:

Shift lever does not move smoothly.

—

Gear shift mechanism (motor side; shift arm and/or shift link)

+ al

.

damaged.

Overhaul: Section 15

Overhaul: Section 15

Readjust: Section 15

Replace: Section 15

Shift cable corroded.

2-1 3

BF40AoBF50A

e. THROTTLE GRIP

Long Tiller Handle Type:

Throttle grip does not move smoothly.

—

~

Throttle arm (tiller handle side) stuck or damaged.

—

Throttle arm (motor side) dam- aged.

Throttle cable misadjusted.

Throttle cable cor

Replace: Section 15

Replace: Section 5

Readjust: P. 3-6

Replace: Section 14

2-1 4

f. GAS ASSISTED TILT

Excessive tilt up load

I

Clean and lubricate: (See base shop manual).

I

Replace: (P. 13-1 thru. 13-5).

I

Does not hold t

Tilt lever is in TILT position.

Faulty gas assisted tilt.

g. POWER TRIM/TILT

Power TriMilt Does Not Move

Check the motor sound.

Sounds

Does not sound

Loose

Tight

Faulty power trim/tilt assembly.

Power TriMilt Does Not Hold

Check the manual valve for tightness.

Tight

1

Faulty power trim/tilt assembly.

I

Loose

Turn to RUN position.

Replace:

(P.

13-1 thru. 13-5).

Turn «TROUBLESHOOTING» on page

2 4 5

Power TriMilt Motor

Does Not Turn

Does not turn

Turn

Check the power trimhlt relay (See base

I

Normal

Check the power trim/tilt switch (See base shop manual).

I

Normal

t

Check the power trimhilt line for open or short circuit. Repair or replace the wire harness if necessary.

—

Abnormal

Abnormal Replace the power trim/tilt switch.

2-1 6

6.

CABLE & HARNESS ROUTING

BF40AoBFSOA

2-1

7

[ l l ] BAlTERY CABLES

’

[lo] TILLER HANDLE WIRE HARNESS

(Long tiller handle type)

REMOTE CONTROL BOX WIRE HARNESS

(Remote control type)

[lo]-1 CASE GROMMET

CABLE TIES

(Remote control type only)

Align the cable ties with the case grommet as shown.

[ l ] STARTER MAGNETIC

SWITCH GROUND

TERMINAL

the engine as shown.

BF40A-BF50A

PI

BATTERY GROUND TERMINAL

Install the battery ground terminal to the starter motor as shown.

[3] MAIN WIRE HARNESS

GROUND TERMINAL

Install the ground terminal to the engine as shown.

I

[81

REGULATOWRECTIFIER

ND TERMINAL

[4] WIRE HARNESS CLIP

open end facing up as

r71

BATTERY POSITIVE CABLE and STARTER MOTOR CABLE

‘

Install the battery positive cable and power trimhilt relay wire (power trimhilt type only), and starter motor cable as shown.

PI-1

BATTERY r71-2

,STARTER

POSITIVE

CABLE

MOTOR

CABLE

[6] WIRE HARNESS CLIP

mal valve heater wire, power trim/tilt relay wire, regulatorhectifier ground wire, and starter magnetic switch wire) with the open end facing up as shown.

[TI-3

POWER TRIM/TILT

POWER SUPPLY WI

(Power trimhilt

[5] WIRE HARNESS CLIP

Clamp the wires (main wire harness, power trimhilt relay wire, regulatorhectifier wire, neutral switch wire, and starter magnetic switch wire) with the open end facing up as shown.

2 4 8

BF40AoBF50A

Power T r i M i l t Type

Frame serial number:

BF40A: Up to BAYS-3400529

1

1

BF50A: Up to BAZS-3400006

[25] 2P CONNECTOR

[24] REGULATOR/

[23] POWER TRIMRILT

SWITCH WIRE

[22] 4P CONNECTOR

[21] POWER T R I W I L T

RELAY WIRE

MAIN WIRE HARNESS

[4] CDI UNIT

[8]

HIGH TENSION

CORD CLAMP

No.

1

IGNITION COIL

No. 2 IGNITION COIL

[12] MAIN WIRE HARNESS open e n d facing u p shown. as

POWER TRIMRILT

MOTOR WIRE

11 61

TRIM ANGLE

SENSOR WIRE

1151 PURSE LOCK CLIP trimhilt switch wire, power

[28] CDI UNIT

WIRE

— L W

121

1

POWER T R I M I L T RELAY WIRE

-W —

1241

REGULATOWRECTIFIER WIRE

-W

[27]

STARTER MAGNETIC SWITCH WIRE

-BW-BW

e

11 61

-BI —BI

TRIM ANGLE SENSOR WIRE

[email protected]/BI

—YiBu—YlBu-

W

2-1 9

1261

BAlTERY CABLE (MAIN FUSE WIRE)

11

21

MAIN WIRE HARNESS

BF40A-BF50A

Gas-Assisted

Tilt

Type:

[3] SENSOR WIRE HARNESS

IGNITION PULSE

GENERATOR WIRE

[4] CDI UNIT

[5] CHARGE COIL WIRE

[6] CORD CLIP the sensor wire ition pulse genera-

2P CONNECTOR pulse generator wire and No. 1 high tension

[8] HIGH TENSION

CORD CLAMP

4P CONNECTOR

No. 2 IGNITION COIL

No. 3 IGNITION COIL

121 MAIN WIRE HARNESS

131 REGULATOWRECTIFIER WIRE

41 NEUTRAL SWITCH WIRE

-Gr

V

— G ~

[I31 REGULATOWRECTIFIER WIRE

-Gr-~r-

— W B I

—

CHARGE COIL WIRE

[12]

MAIN WIRE HARNESS

[21] CDI UNIT WIRE

1131 REGULATOWRECTIFIER WIRE

[20] STARTER MAGNETIC SWITCH WIRE

D

2-21

[l] CHARGE COILS

n

[2]

/

POWER COIL

BF40AoBF50A

PI

WIRE HOLDER B

171

CAM

I

[6] WIRE HOLDER A

[5] POWER COIL WIRE

2-22

Power T r i M i l t

_ .

[ l ] PURSE LOCK CLIP

Clamp the wires (power trimhilt switch wire, power trimhilt relay wires, and trim angle sensor wire).

I

BF40AoBF50A

[2] POWER TRIM/TILT RELAY

GROUND TERMINAL

Install the ground terminal to the engine as shown.

I

1 2 9 0 »

POWER TRIM/TILT SWITCH

151 POWER TRIMnILT RELAY

open end facing up

I shown.

MOTOR WIRE

L. J

TRIM ANGLE SENSOR WIRE

[6] POWER TRIMnILT

SWITCH WIRE

[14] mm TUBE CLIP

,

[lo] TRIM ANGLE SENSOR

protector after clamping the

[9] WIRE HARNESS CLIP

MOTOR CORD BUSH

SENSOR WIRE

MOTOR WIRE

2-23

BF40AoBF50A

Remote Control Type With Power T r i m l t :

R-R-

Y-Y-

*5=/

[2] WIRE BAND

131

EMERGENCY STOP SWITCH

[71

CONTROL BOX

WIRE HARNESS

W/BI-W/BI-

141

IGNITION SWlT

[ l ] INDICATOR

[14] WIRE TIE

131

EMERGENCY STOP

SWITCH

PI

POWER TRIMRILT

SWITCH

191

[5] WARNING BUZZER

11 31

REMOTE CONTROL

BOX WIRE HARNESS

[ l l ] Starboard

edge of the control box as

rnou

[lo] Port mount type

POWER TRlMRlLT

SWITCH WIRE

2-24

Long Tiller Handle

Type:

[l] SHIFT CABLE

BF40AoBF50A

ROTTLE CABLE

[3]

CABLE BRACKET

cable with the cutout of the

2-25

Long Tiller Handle Type:

*: With power trimhilt type only

See

next

page for wire connection.

P I

* POWER T R I M I L T

1

SWITCH

I —

BF40A-BF50A

121

*

POWER T R I M I L T SWITCH WIRE

wire does not interfere with the

5 x 10 mm hex bolt head.

[3]

WIRE TIE (2)

[lo]

BAND CLIP

(3)

-d

k-

10

—

20

—

0.8

in)

[lo]-1

After securing the wires with wire band clips, cut the end as projected length is 10

—

20 mm (0.4

—

0.8 in), provided that the length is not specified in the corresponding drawings.

2-26

J

Align the wire tie with the

Wire Connection in the Long Tiller Handle:

r’

[l] WIRE BAND CLIP (3)

EMERGENCY

STOP SWITCH

— —

COVER B

[A

IGNITION SWITCH

131

TILLER HANDLE

WIRE HARNESS

2-27

141

30 mm

CONNECTOR

COVER

BF40AoBF50A

7. TUBE ROUTING

[27] VINYL TUBE (160 mm)

[26] FUEL TUBE CLAMP

[25] FUEL TUBE (240 mm)

[24] VACUUM TUBE D

[23] FUEL TUBE CLAMP A

[221

FUEL TUBE CLIP

[21] FUEL TUBE F

[20] FUEL PUMP

[41

[3] AIR VENT TUBE A SE TUBE

[2] AIR VENT TUBE B

FUEL CONNECTOR

DASHPOT CHECK VALVE

141 FUEL FILTER

FUEL TUBE B

2-28

3-WAY JOINT A

(2)

AIR VENT TUBE C

[20] 3-WAY JOINT B

AIR VENT TUBE

D

[18] TUBE CLAMP

[17] AIR VENT TUBE

[16] AIR VENT TUBE

(4.5 x 170 mm)

2-29

BF40AoBF50A

[ l ] VACUUM TUBE (3)

(3.5 x 45 mm)

[3] TUBE CLIP B10

[7] FUEL TUBE F

FUEL TUBE CLIP

3-WAY JOINT PIPE

BE CLIP B10 (5)

2.

CARBURETOR SYNCHRONIZATION

CAUTION

Running the outboard motor without sufficient cooling water will damage the water pump and overheat the engine. Be sure that water flows from the cooling system indicator while the engine is running. If not, stop the engine and determine the cause of the problem.

1) Remove the engine cover.

2) Remove the 5 x 10 mm plugs and sealing washers from the intake manifold of each cylinder.

3) Attach the vacuum gauge adapters to each intake manifold plug hole and connect the vacuum gauge hoses to the adapters.

Connect:

The

No. 1 vacuum gauge hose to the No. 1 vacu- um gauge adapter.

The No. 2 vacuum gauge hose to the No. 2 vacu- um gauge adapter.

The No. 3 vacuum gauge hose to the No. 3 vacu- um gauge adapter.

4) Attach an engine tachometer and restart the engine.

Follow the tachometer manufacturer’s instructions.

5) Run the outboard motor in an outboard test tank with the water at least

4 inches above the antiventilation plate. Allow the engine to warm up to normal operat- ing temperature (Approx. 10 minutes).

SEALING WASHER

(3)

Gzi]

111 VACUUM GAUGE ADAPTER

5

x

0.8 x

120L (3)

0751 0-30001 00

or

Engine exhaust contains poisonous carbon monoxide gas that can cause unconsciousness and death.

If the engine must be running, make sure the area is well ventilated.

6)

Check the idle speed (See base shop manual).

VACUUMGAUGE

(Commercially available)

3-2

3. DASHPOT DIAPHRAGM

Adjust the dashpot diaphragm after adjusting the idle

speed (see base shop manual).

1)

Remove the engine cover.

2) Remove the throttle rod from the throttle cam.

121

THROTTLE

ROD

3) Loosen the 6 x 16 mm torx bolts using a commercial- ly available torx bit (T30H).

11

1

TORX BIT T30H

(Commercially available)

4) Disconnect the vacuum tube from the dashpot check valve.

I

[ I ] VACUUM TUBE

PI

DASHPOT

CHECK VALVE

5) Move the throttle cam in the direction pointed by arrow until the throttle cam roller is set free from the throttle cam and hold the throttle cam.

3-4

CAM ROLLER

6) Move the diaphragm up or down slowly until the clearance between the throttle cam roller and throttle opener cam is 0.2

—

0.8 mm (0.008

—

0.031 in). While holding the clearance, tighten the 6 x 16 mm torx bolts to the specified torque.

TORQUE: 9 N*m (0.9 kgfam, 6.5 Ibf*ft)

7)

Connect the vacuum tube to the dashpot check valve and attach the throttle rod to the throttle cam.

4.

THROTTLE LINKAGE ADJUSTMENT

Throttle Rod Length Adjustment

1)

Remove the lock pin and washer, and disconnect the throttle cable from the throttle arm.

6 mm WASHER (2)

BF40AoBF50A

TORX BOLT (2)

0.2

—

0.8 mm

2)

Move the throttle arm to the fully open position and be sure that the throttle arm contacts the fully open stopper.

3)

Check that the throttle cam is also at the fully open position and that there is clearance of 1 mm (0.04 in) or less between the carburetor throttle lever and stop- per on the

No. 3 carburetor.

THROTTLE ARM

THROTTLE CAM

4)

If either the throttle arm or throttle cam is not at the fully open position, adjust as follows.

5) Loosen the throttle rod pivot lock nut, detach the throttle rod pivot from the throttle cam, and adjust by turning the throttle rod pivot.

6) Attach the throttle rod pivot to the throttle cam and tighten the throttle rod pivot lock nut securely.

THROTTLE CAM

131

[2] LOCK NUT

3-5

7)

After adjustment, move the throttle cam to the fully open position and be sure that there is clearance of 1

mm

(0.04

in) or less between the carburetor throttle lever and stopper on the No. 3 carburetor.

If the clearance is more than 1 mm (0.04 in), readjust by turning the throttle rod pivot.

9) Adjust the throttle cable, then connect the throttle cable to the throttle arm.

THROTTLE

CAM ROLLER

[2] 1 mm (0.04 in) or less

Throttle Cable Length Adjustment

Adjust the throttle cable length after adjusting the throttle rod length.

1)

Turn the throttle grip to the fully open position and check that the throttle arm contacts the fully open stopper.

PI

THROTTLE ARM

121

THROTTLE CABLE

/

131

FULLY OPEN

STOPPER

2)

Return the throttle grip to the fully close position.

3) Pushing the throttle arm lightly (i.e. by the amount of throttle link play) in the direction of arrow, check whether the center of throttle cam roller is at the right side (i.e. advancing direction) to the reference marks.

151

/

THROTTLE ARM

[4] REFERENCE

[2] THROTTLE CAM

ROLLER

/

3-6

BF40AoBFSOA

4)

Adjust as follows, if necessary.

5) Loosen the shift pivot lock nut, remove the 6 mm lock pin and 6 mm washer, and disconnect the throttle cable.

6) Turn the throttle grip to the fully open position and hold it in the position using the friction grip.

7) Remove the throttle rod pivot from the throttle cam.

[4] mm LOCK PIN

Pulling the throttle cable’s shift pivot lightly, turn the shift pivot so that the throttle cable can be connected smoothly to the throttle arm that is set in the fully open position (i.e. throttle arm is lightly in contact with the fully open stopper).

9) Connect the throttle cable to the throttle arm and tighten the shift pivot lock nut securely.

11

1

SHIFT PIVOT

1

‘ ‘

1

THROTTLE ARM

10) Install the throttle rod pivot on the throttle cam.

11)

Turn the throttle grip to the fully closed position.

Pushing the throttle arm lightly in the direction of arrow, check whether the center of throttle cam roller is at the right side (advancing side) to the reference marks.

I

STOPPER

MARKS

3-7

5.

SHIFT CABLE ADJUSTMENT

(Long Tiller Handle Type)

Shift Cable Length Adjustment

Adjust the shift cable length after adjusting the shift rod

adjustment (see base shop manual).

Loosen the shift link pivot lock nut, and remove the 6 mm lock pin and 6 mm washer.

Disconnect the shift cable from the shift link B and remove the 6 mm washer.

Set the shift link B in the «N» (neutral) position.

Set the shift lever in the neutral position.

Rotate the shift pivot by the necessary amount until it will easily insert into the shift link B.

Install the 6 mm washer over the pin of the shift pivot and connect to the shift link B using the

6 mm washer and 6 mm lock pin.

Tighten the shift pivot lock nut securely.

After adjustment, be sure that the shift lever moves smoothly into all positions.

141

6 mm WASHER (2)

[ l ] SHIFT LINK B

[2] SHIFT CABLE

3]6mm

A

LOCK PIN

STEERING FRICTION ADJUSTMENT

(Long Tiller Handle Type)

Move the friction adjusting lever to the left side fully until the friction lever contacts to the stopper as shown.

Check the starting torque by measuring the starting force using a spring scale at the center of the throttle grip as shown.

The motor should start to move with 100 N (10.0 kgf,

22.0 Ibf).

If it does not, loosen the lock nut once. Then, retight- en the self-locking nut to the specified torque by turn- ing the adjusting lever to the left side fully.

Tighten the friction adjusting lever and tighten the lock nut to the specified torque.

TORQUE: 9.5 N*m (0.95 kgfm, 6.9 Ibf*ft)

Recheck the starting force. If the starting forces is less than 100 N

(10.0 kgf, 22.0 Ibf), check the friction

discs for contaminated with grease (P. 12-1).

11

1

STOPPER

I I

[2] LOCK NUT

/

ADJUSTING

[4] THROTTLE GRIP

3-8

5.

FUEL SYSTEM

BF40A-BF50A

1.

SILENCER COVER

2.

CARBURETOWMANIFOLD REMOVAL

1. SILENCER COVER a. REMOVAUINSTALLATION

1)

Remove the engine cover.

2) Pull off the breather tube from the silencer cover.

3) Unfasten the SE thermal valve heater wire from the clamp on the silencer cover.

4)

Pull off the vinyl tubes from the engine under case.

5) Remove the 6 mm flange bolts, washers and cover nut, then remove the silencer cover from the silencer plate.

6) Install the removed parts in the reverse order of removal.

3.

CARBURETOR

4.

CARBURETOWMANIFOLD INSTALLATION

[2] BREATHER TUBE

ASSEMBLY:

Insert until the white line aligns with the hole edge as shown.

121-1

BREATHER

TUBE

121-2

WHITE LINE

11

1

COVER NUT

[ 3 ] 6 mm WASHER(2)

SE THERMAL VALVE

HEATER WIRE

[GI

VINYL TUBE (2)

ASSEMBLY:

Insert the vinyl tubes into the holes in the engine under case as shown.

[6]-1 VINYL

SILENCER COVER

5-1

2.

CARBURETOWMANIFOLD REMOVAL

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when han- dling fuel.

Keep heat, sparks, and flame away.

Handle fuel only outdoors.

Wipe up spills immediately.

1) Remove the engine cover.

2)

Remove the flywheel cover (P.

6-1).

3) Drain the carburetor by loosening the drain screws.

4) Pull off the breather tube from the silencer cover.

I

[ l ] BREATHER TUBE

BF40AoBF50A

5) Remove the 14P connector (remote control box wire harness or tiller handle main wire harness) and 2P connector (SE thermal valve heater wire) from the connector holders, and disconnect the 2P connector.

— —

14P CONNECT0

121 2~ CONNECTOR

6) Disconnect the throttle rod from the throttle cam. I

121

THROTTLE

11

1

THROTTLE

CAM

7)

Pinch the fuel tube with a commercially available tube clip and disconnect the fuel tube (No. 1 carburetor supply line) from the fuel pump.

[1

I

TUBE CLIP

BF40AoBF50A

[2] FUEL TUBE

8 )

Pinch the fuel tube with a commercially available tube clip and disconnect the fuel tube E (No. 2 and 3 car- buretor supply line) from the fuel pump.

r i i

L — A

FUEL TUBE E

9) Pull off the vinyl tubes from the engine under case.

FUEL PUMP

[ l ] VINYL TUBES

PI

TUBE CLIP

(Commercially available)

10) Pull off the air vent tubes from the engine under case.

I

ENGINE UNDER CASE

AIR VENT TUBES

5-3

11) Remove the two 6 mm cap nuts and five 6 x 32 mm flange bolts, then remove the carburetor and manifold assembly from the crankcase.

BF40AoBF50A

BF40AoBF50A

THROlTLE CAM/DASHPOT

DIAPHRAGM

The throttle cam and dashpot diaphragm servicing can be made with the engine installed.

1)

Disconnect the throttle rod pivot (P. 5-2).

2) Remove the 6 x 40 mm flange bolt and

6

mm washer.

3) Remove the following:

— throttle cam.

— assist spring.

— assist plate.

— throttle opener cam.

— opener cam return spring.

—

6.7 x 12.5

x 24 mm collar.

PI

THROTTLE CAM

161

ASSIST SPRING

151

THROlTLE OPENER CAM

[41

6.7 x 12.5 x

24 mm x 40

.

[2]

131

OPENER CAM RETURN

SPRING

4) Remove the

6

x

16

rnm torx bolts using a commer- cially available torx bit (T30H) and remove the dash- pot diaphragm.

[31

DASHPOT

DIAPHRAGM

5-7

INTAKE MANIFOLD

1)

Remove the throttle link rod taking care not to bend it.

2) Remove the six 6 x 97 mm flange bolts.

3) Separate the intake manifold and carburetor as shown.

[51

6 x 16 mm TORX BOLT (2)

[6] DASHPOT DIAPHRAGM

5 10 mm PLUG

(3)

[lo]

18 mm SCREW

SILENCER PLATE

6 x

97 (6)

b. DISASSEMBLY

Before disassembly, completely drain the carburetor by loosening the drain screw. Clean the outside of the car- buretor before disassembly.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when han- dling fuel.

Keep heat, sparks, and flame away.

Handle fuel only outdoors.

Wipe up spills immediately.

1)

No.

1

carburetor only:

Remove the screw and set plate, then remove the SE thermal valve and O-ring with care not to damage the needle.

[l] SE THERMAL

BF40AoBF50A

EW

2)

Remove the four washer screws, and remove the float chamber and bowl gasket.

3)

Remove the drain screw and O-ring from the float chamber if necessary.

[31

WASHER SCREW (4)

PI

FLOAT CHAMBER

J

0

/

I

I

5-9

4)

Remove the float pin by using a commercially avail- able 2.0 mm pin driver.

Drive out the float pin by lightly tapping the pin dri- ver from the opposite side of the knurled section of the float pin.

5) Remove the float and float valve.

[51

KNURLED SECTION

141

FLOAT

BF40AoBF50A

[ I ] 2.0 mm PIN DRIVER

(Commercially available)

PIN

6) Remove the main jet taking care not to damage the main jet.

7)

Remove the plug screw, main nozzle and jet nozzle taking care not to damage them.

11

1

PLUG SCREW

151

MAIN NOZZLE

141

JET NOZZLE

[3] O-RING

Do not reuse.

MAIN JET

5-1 0

c.

CLEANING

CAUTION

Some commercially available chemical cleaners are caustic. These cleaners may damage plastic parts such as O-rings, float and float valve.

Check the container for instructions. If you are in doubt, do not use these products to clean carbu- retor.

High air pressure may damage the carburetor.

Use low pressure setting when cleaning the pas- sages and parts.

1) Clean the carburetor body, removed parts and float chamber with cleaning solvent.

2) Use low air pressure and blow off the removed jets, nozzles and passages of the carburetor body and float chamber.

d.

INSPECTION

Float Level Height

Place the carburetor as shown and measure the distance between the float top and carburetor body when the float just contacts the seat without compressing the valve spring.

Standard float height BF40A: 14 mm (0.55in)

BF50A: 13 mm (0.51 in)

If the height is out of specification, adjust the float height by bending the float mounting tab carefully.

/

,p====

[l]

FLOAT GAUGE

FloatlFloat Valve/Float Valve Seat

1)

Check the float for crack or damage. Replace if nec- essary.

2) Check the float valve for wear or damage. Replace if necessary.

5-1 1

BF40AoBF50A

NouledJets

Check the main jet, main nozzle and jet nozzle for debris or damage. Replace if necessary.

SE (Starter Enrichment) THERMAL VALVE

1) Check the valve piston and needle for wear or scratches. Replace as assembly, if necessary.

[11

VALVE PISTON

[2] NEEDLE

Resistance

15.8

—

24.2 n

3) Install a vinyl tube as shown.

4) At room temperature, gently blow into the tube and verify air passes through the passage.

5-1 2

11

1

VINYL TUBE

[2]

Blow

5) Connect the 12V battery positive terminal to the

Brown/white terminal and negative to the BlacWgreen terminal for about five minutes. A gentle puff of air should not pass through.

Note that inspection with the battery connected must be made quickly.

The SE thermal valve heater becomes very hot when the battery is connected. Take care not to touch it.

BF40AoBF50A

11

1

BLACKI

121

BROWN/

GREEN WHITE

(NEGATIVE) (POSITIVE)

/

/

[4] VINYL TUBE

5-1 3

e. ASSEMBLY

No.

1

CARBURETOR

DRAIN SCREW

[8] O-RING

~ 9 1

BOWL GASKET

Assembly is the reverse order of disassembly.

—

1

P I

FLOAT CHAMBER

[17] PLUG SCREW

[16] MAIN NOZZLE

[14] O-RING

4

[4] JET NOZZLE

P

I—-

[5] MAIN JET

[6] FLOAT PIN

ASSEMBLY:

P.

5-23

[15] THROTTLE STOP

$

’/

[7] CARBURETOR

BODY

BF40AoBFSOA

5-1

4

11 31

PILOT SCREW tb

[I21

SPRING

[ l l ] SCREW

[9] SE THERMAL VALVE

ASSEMBLY:

P.

5-12

.

No.

2

CARBURETOR

[17] O-RING

BF40AoBFSOA

I

A

[11

WASHER SCREW (4)

/

[2] FLOAT CHAMBER

11

51

BOWL GASKET

[14] FLOAT

[13] PLUG SCREW

/

[12] MAIN NOZZLE

dl

[lo] O-RING

I

Do not reuse. k I I I

[31

FLOAT VALVE

11 THROTTLE

STOP SCREW

[*I r i o i

O-RING

r

[6] FLOAT PIN

ASSEMBLY: P.

5-23

I?]

CARBURETOR

BODY

[9] PILOT SCREW

5-1 5

No. 3 CARBURETOR

r11

WASHER SCREW

(4)

/

PI

BF40AoBF50A

11 51

BOWL GASKET

1111

O-RING

1

DO

not

reuse.

I I w — w

C e — Y

h m

1

Do not reuse.

I

THROTTLE STOP

SCREW

1

ASSEMBLY: P.

5-23

r71

CARBURETOR

BODY

5-1 6

FLOAT PIN INSTALLATION

1)

Set the float onto the float tab, then set them on the carburetor body.

2)

Install the float pin using the 2.0 mm commercially available pin driver.

Install the float pin by lightly tapping the pin at the knurled section side of the float pin.

SE THERMAL VALVE INSTALLATION

1) Install a new O-ring to the

SE thermal valve.

2) Install the SE thermal valve with the set plate and loosely install the screw.

3)

Set the SE thermal valve as shown noting the direc- tion and tighten the screw securely.

2.0 mm PIN DRIVER

’

(Commercially available)

[l] SE THERMAL VALVE

BF40AoBF50A

11

1

KNURLED SECTION

EW

[4]

INTAKE

MANIFOLD SIDE kE THERMAL

VALVE

5-1 7

CARBURETOWlNTAKE MANIFOLD

Assembly is the reverse oder of disassembly.

[ l ] CARBURETOR INSULATOR (3)

1

Note the installation direction.

I

[13] THROTTLE LINK ROD

~

1

Install the throttle link rod with the

«UP»

1 ma

Irk facing toward the No. 1 carbure- tor

.

Take care not to bend the throttle

I link rod.

[13]-1

121

CARBURETOR GASKET

(6)

1

DO not reuse.

I

15 mm DOWEL PIN (6)

[4] INTAKE MANIFOLD

J.

I

n-%sc

CARBURETOR

[7’j

No.

1

CARBURETOR

[8] No. 2 CARBURETOR

[9] SILENCER PLATE

(6)

6 97 (6)

I

10

N*m (1.0 kgf*m, 7 Ibf*ft)

I

5-1 8

THROTTLE CAM/DASHPOT DIAPHRAGM

1) Place the dashpot diaphragm on the intake manifold, and loosely install the 6 x 16 mm torx bolts.

2) Apply grease to the sliding surface of the 6.7 x 12.5 x

24 mm collar and install it.

r11

TORX BIT T30H

(Commercially available

3) Install the opener cam return spring by aligning the hook with the boss of the intake manifold.

4)

Install the throttle opener cam by aligning the hole with the dashpot diaphragm rod end and the groove with the opener cam return spring end.

5)

Align the point «A» of the assist spring with the groove in the throttle cam.

I

r31

DASHPOT

DIAPHRAGM

6) Set the projection of the assist plate in the hook of the assist spring and align the flat surface of the throttle cam with the tab of the assist plate.

7) Install the throttle cam, assist spring and assist plate on to the collar as an assembly.

Install the 6 mm washer and tighten the 6 x 40 mm flange bolt to the specified torque.

9)

After assembly, adjust the dashpot diaphragm (P.

3-

4).

6 x 40

[16] 6 mm WASHER

[15] THROTTLE CAM

[14] ASSIST SPRING

[13] ASSIST PLATE

[I21

THROTTLE OPENER CAM

[ l l ] OPENER CAM

RETURN SPRING

ASSIST SPRING r11

THROTTLE CAM

[2]HOOK

[31

PROJECTION

ASSIST PLATE

191

6.7 x 12.5 x 24 mm COLLAR

5-1 9

BF40AoBF50A

.TUBES

1) Install the following:

— fuel tubes.

— air vent tubes, joint pipe and tube joints.

— vacuum tube.

-tube clips.

— vinyl tube.

(4.5 x 9 3 mm)

[2] VACUUMTUBE(3)

(3.5 x 45 mm)

I

[3] AIR VENT TUBE A

[4] TUBE CLIP B10

1231

AIR VENT TUBE C

VACUUM TUBE

[8] FUEL TUBE F

FUEL TUBE CLIP

[21] 3-WAY JOINT B

AIR VENT TUBE D

[19] TUBE CLAMP

[18] AIR VENT TUBE

[17] AIR VENT TUBE

(4.5 x 170 mm)

-WAY JOINT A

5-20

[12] TUBE CLIP B10 (5)

BF40AoBF50A

2)

Install the following:

— vacuum tube D and dashpot check valve.

— fuel tube clamp A.

— air vent tubes.

—

SE

B and tube clips.

—

SE tube A and tube clip B10.

PI

SE TUBE B (2)

[31

TUBE CLIP (4)

VENT TUBE D

5-2 1

CLAMP A

AIR VENT TUBE B VACUUM TUBE D

[6] DASHPOT CHECK VALVE

[7] ARROW MARK

CARBURETOWINTAKE MANIFOLD

INSTALLATION

Install a new intake manifold gasket onto the cylinder head.

Install the carburetor and manifold assembly and loosely install the 6 mm cap nuts, fuel tube clamp and

6 x 32 mm flange bolts.

1

CARBURETORlMANlFOLD

INTAKE MANIFOLD GASKET

[4] FUEL TUBE CLAMP

12

N*m

(1.2

kgf*m,

Tighten the 6 x 32 mm flange bolts and 6 mm cap nuts to the specified torque in the numbered sequence shown in 2

—

3 steps.

TORQUE: 26 N *m (2.7 kgf em, 20 Ibf

O f t )

6

x

32

(5)

5-22

4) Insert the air vent tubes into the holes of the engine under case as shown.

[ l ] AIR VENT TUBES

BF40AoBF50A

5)

Connect the fuel tubes to the fuel pump and secure them with the tube clip B10.

Connect the fuel tube E (No. 2 and 3 carburetor supply line) to the

I’

Q

» marked fitting.

Connect the 240 mm fuel tube (No. 1 carburetor supply line) to the

»

0

» marked fitting.

I

CASE

[ l ] FUEL TUBE (240 mm)

TUBE E

6) Connect the SE thermal valve heater wire 2P connec- tor and set the 2P connector to the lower connector holder, then set the 14P connector to the upper con- nector holder.

14PCONNECTOR

[2] 2P CONNECTOR

7)

Insert the breather tube in the silencer cover until the white mark aligns with the hole edge as shown.

I

r l —

1′

1

BREATHER

TUBE

[31

.

[2] WHITE MARK

5-23

Insert the vinyl tube ends into the holes of the engine under case.

I

[ l ] VINYL TUBES

9) Connect the throttle rod to the throttle cam.

10)

After installation, adjust the throttle linkage (P. 3-5).

11) Install the removed parts in the reverse order of removal.

121

I

ENGINE

UNDER

CASE

121

THROTTLE

ROD

PI

,

6.

FLYWHEEWIMING BELT

1

1. FLYWHEEL

1.

FLYWHEEL a. DlSASSEMBLY/ASSEMBLY

11

10 x

25 (4)

ASSEMBLY:

Apply thin coat of engine oil to the flanged part and threaded part.

Do not apply too much engine oil so that it drips from the thread of the bolt.

Tighten the bolts to the specified torque in crisscross pattern in 2

—

3 steps.

Torque: 65 N-m (6.6 kgf-m, 48 Ibf-ft)

6 x

32 (4)

[2] FLYWHEEL

ASSEMBLY:

Wipe the flywheel and crankshaft mounting surfaces with a clean shop towel sprayed with degreasing agent.

10 x 25 (4)

!r v

IA A A A A

A 1

121-1

FLYWHEEL

T T T ? ? T

PI-2

CRANKSHAFT

~

6-1

12. OIL PAN/PRIMARY GEAR CASUSWIVEL CASE

BF40AoBF50A

1.

STEERING FRICTION LEVER (Long Tiller Handle Type)

1.

STEERING FRICTION LEVER

(Long Tiller Handle Type) a. DISASSEMBLY

1) Remove the engine cover and tiller handle (P. 15-1).

2) Remove the 8 mm self locking nut.

3) Remove the 8 mm washer, friction adjusting lever, 8 mm nylon washer and friction disc.

4) Remove the two 6 x 12 mm flange bolts and friction plate.

5) Remove the friction disc.

LEVER

[71

FRICTION ADJUSTING

x

6 x 1 2

[GI

FRICTION PLATE

w i n — #

i L n

NYLON WASHER

141

FRICTION DISC

12-1

b. ASSEMBLY

1) Install a new friction lever shaft. Turn the friction lever shaft until it stops.

2) Adjust the friction lever shaft direction as shown by turning back the friction lever shaft /4

—

314 turn. p%EyG

3) Before installation, check the disc surface of the fric- tion discs for wear. Replace if necessary.

4) Clean off grease or oil from the disc surfaces of the friction discs and friction plate. Install one of the fric- tion disc onto the friction lever shaft by aligning the cutout with the boss on the swivel case and facing the disc surface toward the friction plate as shown.

131

CUTOUT

5)

Install the friction plate to the mount frame by aligning the groove with the friction lever shaft and loosely install the two 6 x 12 mm flange bolts.

6)

Push the friction plate toward the mount frame in the direction shown by arrow and tighten the 6 x 12 mm flange bolts securely.

12 (2)

11

1

FRICTION PLATE

121 MOUNT FRAME

[ l ] FRICTION PLATE

I

I i

I

12-2

1213

shaft by aligning the cutout with the boss on the swiv- el case and facing the disc surface toward the friction plate.

I

Install the 8 mm nylon washer, friction adjusting lever and 8 mm washer.

9) Turn the adjusting lever to the left side fully, and hold it in this position and tighten the 8 mm self-locking nut to the specified torque.

TORQUE:

9.5 N * m (0.95 kgf*m, 6.9 Ibfoft)

10)

Check the starting torque by measuring the starting force using a spring scale at the center of the throttle

grip (P. 3-8).

[I1

FRICTION

[2]

8 mm

SELF-LOCKING

NUT

/

131

8 mm WASHER

ADJUSTING LEVER

I

I

—

I//-

141

8 mm NYLON

WASHER

/ /

[5] FRICTION

ADJUSTING

LEVER

13.

GAS ASSISTED/POWER TILT

1. GAS ASSISTED DAMPER

1. GAS ASSISTED DAMPER a. REMOVAL

Drain the carburetor by loosening the drain screws.

2.

POWER TRIMnILT ASSEMBLY

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

Keep heat, sparks, and flame away.

Handle fuel only outdoors.

Wipe up spills immediately.

Lay the outboard motor on its right side (carburetor side).

Raise the outboard motor to the uppermost position and set the tilt stopper to the RUN position.

Remove the 10 mm E-ring from the upper cylinder pin, and then remove the upper cylinder pin.

Remove the upper mount of the gas-assisted damper from the swivel case.

Remove the upper cylinder bushings if necessary.

Replace with new ones when the upper cylinder busings are removed.

Remove the transom angle adjusting rod.

Remove the 6 x 25 mm hex. bolts, 6 mm plain wash- ers and anode metal.

Remove the 10 mm self-locking nut and remove the

10 mm plain washer and

10 x 158 mm hex. bolt.

HEX.

[5]

ANODE

BOLT (2) METAL

—

[3]

121

TRANSOM

ANGLE

ADJUSTING

ROD

WASHER

SELF-LOCKING

NUT

I

10)

Loosen the 7/8-14 UNF self locking nut.

11

1

SELF-LOCKING

NUT

13-1

BF40AoBF50A

11)

Lift the left stern bracket and remove the gas assisted damper.

Make sure that the tilt lever is in «RUN» position before removal.

Store the gas assisted damper with fully extended position

12) Remove the 26 mm wave washer and 10 mm dis- tance collar.

13) Remove the lower cylinder bushings if necessary.

Replace with new ones when the lower cylinder busing is removed.

11

1

10 mm DISTANCE

COLLAR

*TILT LEVER REPLACEMENT

Before removing the tilt lever, set the tilt lever in the

«RUN» position

Install the tilt lever by aligning the mounting hole of the lever with the tilt lever shaft and noting the installation direction as shown.

141

‘

LOWER CYLINDER

BUSHING (2)

DAMPER

[3] 26 mm WAVE

p x E i q

WASHER

1

[41

/

TILT LEVER

[31

6

mm SELF-LOCKING NUT

1

12 N*m (1.2 kgf*m, 9 Ibf*ft)

1

13-2

b. DISPOSAL

1) Set the tilt lever in the «TILT» position with the piston rod fully extended, then remove the tilt lever.

2) Wrap the damper inside a plastic bag and support the damper in a vice as shown.

3)

Through the open end of the plastic bag, insert a drill motor with a sharp 2

—

3 mm

—

1/8

in) drill bit.

CAUTION

The gas assisted damper contains nitrogen gas and oil under high pressure. Do not drill past the reservoir top, or you may drill into the oil chamber; oil escaping under high pressure may cause serious personal injury.

Do not use a dull drill bit which could cause a build-up of excessive heat and pressure inside the damper, leading to explosion and severe personal injury.

Always wear eye protection to avoid getting metal shaving in your eyes when the gas pres- sure is released. The plastic bag is only intend- ed to shield you from the escaping gas.

4)

Hold the bag around the drill motor and briefly run the drill motor inside the bag; this will inflate the bag with air from the drill motor and keep the bag from getting caught in the bit when you start.

5) Drill the plug bolt on the reservoir top.

11

1

PLUG

BF40AoBF50A

13-3

c. INSTALLATION

Install the gas-assisted damper in the reverse order removal.

BF40A-B F50A

[2] TRANSOM ANGLE

ADJUSTING ROD

SELF-LOCKING NUT

[4] 10 mm E-RING

CYLINDER PIN

I I /

ANODE METAL

11 01

LOWER CYLINDER

BUSHING (2)

I

Do not reuse.

I

After installing the gas assisted damper, tighten the

7/8-14

UNF self-locking nut to the specified torque.

Then turn it back

1/2

—

3/4 turns.

TORQUE: 39 Nom (4.0 kgfom, 29 Ibfoft)

DAMPER

171

UPPER

CY LlNDER

BUSHING (2)

I

Do not reuse.

I

11

1

7/8-14 UNF

SELF-LOCKING

NUT

13-4

BF40AoBF50A

2. POWER TRlMITlLT ASSEMBLY a.

REMOVAL

Drain the carburetor by loosening the drain screws and remove the motor from the engine.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when handling fuel.

Keep heat, sparks, and flame away.

Handle fuel only outdoors.

Wipe up spills immediately.

Lay the outboard motor on its right side (carburetor side).

Raise the outboard motor to the uppermost position and set the tilt stopper in the TILT position.

Remove the engine cover and CDI unit cover (see base shop manual).

Pull the fuse holder from the fuse holder bracket.

Remove the

6 x 12 mm flange bolt and main wire har- ness ground terminal.

I

131

FUSE

6×12

/

GROUND TERMINAL

Remove the 6 x 25 mm flange bolt, 6 mm plain wash- er and fuse holder bracket.

Remove the CDI unit case mounting three 6 x 25 mm flange bolts and 6 mm plain washers, then pull out the CDI unit case slightly from the engine.

6i28

6 mm PLAIN WASHER (3)

13-5

9)

Disconnect the power trimhilt motor wire 2P connec- tor.

‘CONNECTOR

BF40AoBF50A

r n

10) Pull off the trim angle sensor’s three connectors from the connector holder and disconnect them.

I

[ l ] CONNECTOR HOLDER

[2]

CONNECTORS

11) Unfasten the purse lock clip und pull out the trim angle sensor wire through the hole of the CDI unit case.

I

SENSOR

WIREY

SENSOR WIRE

12) Loosen the rivet screw and remove the 14 mm clip.

13) Remove the upper case grommet C from the engine under case and pull the power trimhilt motor and trim angle sensor wires from the engine under case.

TRIM ANGLE

SENSOR WIRE

GROMMET

13-6

14)

Remove the spiral protector, and open the wire har- ness clip and unfasten the power trimhilt motor wire and trim angle sensor wire.

15) Remove the motor cord bushing from left stern brack- et.

[I

1

BF40AoBF50A

[2] WIRE HARNESS CLIP

16) Remove the transom angle adjusting rod.

17) Remove the 6 X 25 mm hex. bolts, 6 mm plain wash- ers and anode metal.

TRl W I L T

MOTORAND

TRIMANGLE

SENSOR

WIRES

0

PI

TRANSOM

ADJUSTING ROD

CORD

BUSH IN G

[4]

6 x 25 mm HEX. BOLT

(2) mm PLAIN WASHER (2)

18)

Remove the 10 mm E-ring from the upper cylinder pin, and then remove the upper cylinder pin.

19) Remove the upper mount of the power trimhilt from the swivel case.

20) Remove the upper cylinder bushings if necessary.

Replace with new ones when the upper cylinder busing is removed.

I

113 10 mm E-RING (2)

CYLINDER PIN

I

BUSHING

13-7

BF40AoBF50A

21) Remove the two 6 x 20 mm hex bolts and 6 mm plain washers and remove the trim angle sensor if neces- sary.

22)

Remove the 10 mm self-locking nut and remove the

10 mm plain washer and 10 x 158 mm hex. bolt.

23) Loosen the 7/8-14 UNF self locking nut.

24) Lift the left stern bracket and remove the power trim/tilt assembly.

25) Remove the 28 mm wave washer, 19.4 x 6 mm thrust washer and distance collar.

26) Remove the lower cylinder bushings if necessary.

Replace with new ones when the lower cylinder busings are removed.

11 21

..

I V

n

I V V 1 1 1 1 1 1

hi&

~

11

1

718

—

14 UNF SELF-LOCKING NUT

[11-1

SELF-LOCKING NUT

(Loosen.)

I

‘

INSPECTION:

See base

20 mm HEX.

[ll] mm PLAIN

WASHER

[lo1

10 mm SELF-LOCKING

NUT

28 mm WAVE

WASHER

THRUST WASHER

POWER TRIM/TILT

13-8

b. INSTALLATION

1)

Install the power trimhilt motor in the reverse order of removal.

Apply grease to the following:

— upper cylinder bushings and upper cylinder pin.

— lower cylinder bushings, 28 mm wave washer, distance collar and 19.4 x 6 mm thrust washer.

If the upper cylinder bushing and lower cylinder bushing have been removed, replace with new ones.

131

BF40AoBF50A

13-9

11 41

LOWER CYLINDER

BUSHING (2)

I

DO

not reuse.

1

[13] 19.4 x

6

THRUST WASHER

2) After installing the power trim/tilt assembly, tighten the 7/8-14 UNF self-locking nut to the specified torque. Then turn it back 1/2

—

3/4 turns.

TORQUE: 39 N*m (4.0 kgfom, 29 Ibfoft)

11

1

7/8-14

UNF

SELF-

LOCKING NUT,

3) Route the power trim/tilt motor and trim angle sensor wires and secure them with the clips.

I

[ l ] WIRE HARNESS CLIP

Clamp the trim angle sensor wire together with the power trimhilt switch wire and power trimhilt relay wires as shown.

[2] PURSE LOCK CLIP

trim/tilt switch wire, power trimhlt relay wires, and trim

151

TRIM ANGLE SENSOR

WIRE

[3] POWER TRIMITILT’

MOTOR WIRE

[9] 14 mm TUBE CLIP

I

Clamp the center of the gray tape position of the power trimhilt motor wire with the wire harness cliD.

SPIRAL PROTECTOR

angle sensor wires, wrap the wires between the 1 4 mm

[3] POWER TRIMITILT

MOTOR WIRE

141

((

TRIM ANGLE SENSOR

,

TRIM ANGLE SENSOR WIRE

POWER TRIMITILT

MOTOR WIRE

[6] MOTOR CORD BUSHING

13-1 0

4)

Set the trim angle sensor wire connectors on the con- nector holder.

5)

Set the CDI unit case in the place and install the 6 mm plain washers and

6

x 25 mm flange bolts, and tighten the bolts securely.

6 )

Install the fuse holder bracket with the

6

x

28 mm flange bolt, then install the fuse holder.

[11

6 mm

PLAIN

WASHER

BF40A-BF50A

PI

CDI UNIT CASE

/

[71

FUSE HOLDER BRACKET

[3]BLACK

LIGHT GREEN/

YELLOWlBLUE

TRIM ANGLE

SENSOR WIRE

7) Set the ground terminal as shown and tighten the 6

x

12 mm flange bolt securely noting the terminal direc- tion.

PI

GROUND

TERMINAL

‘ 6 x 1 2

13-1 1

THROTTLE BRACKETISHIFT LEVER/

15.

HANDLEBAR (TILLER HANDLE TYPE ONLY)

~

1. LONG TILLER HANDLE

1. LONG TILLER HANDLE a. REMOVAL

1) Remove the engine cover and set the shift lever in the neutral position.

2) Remove the two 6 x 28 mm flange bolts, two 6 x 40 mm flange bolts and four 6 mm plain washers, and remove the separator cover.

111

6 mm PLAIN

SEPARATOR

I

3) Remove the 14P connector from the connector holder and disconnect the 14P connector.

PI

14P

121

CONNECTOR

HOLDER

4)

Remove the

6

mm lock pins and 6 mm washers, the disconnect the throttle and shift cables.

I

[ l ] THROTTLE CABLE [2] SHIFT CABLE

[31

6 mm

WASHER (4)

15-1

5) Pull up the control cable from the control cable set plate.

6 )

Remove the under case grommet.

BF40AoBF50A

11

1

THROTTLE CABLE

7) Remove the two 10 mm self-locking nuts and two 10 mm washers, then remove the long tiller handle assembly.

[41

I

TILLER HANDLE

WIRE HARNESS

GROMMET A

15-2

b.

DISASSEMBLY

1) Remove the six screws and under cover.

BF40AoBF50A

I

[2] UNDER COVER

SCREW(6)

T Q

2) Remove the 4 mm E-clips and disconnec the control cables from the throttle arm and shift arm.

Remove the control cables and grommet.

Remove the

6

x 12 mm bolt washer and cable holder.

~

[4] 6 12 mrn

BOLTWASHER

[3] CABLE HOLDER

—

[2] THROTTLE ARM

151

GROMMET

/

[81

4 mm E-CLIP (2)

Release the wire band clip and disconnect the emer- gency stop switch wire connectors.

PI

WIRE BAND CLIP

[7] SHIFT CABLE

PI

. EMERGENCY

STOP SWITCH

15-3

BF40AoBF50A

6)

Remove the connector cover B and disconnect the power trim/tilt switch wire connectors (power trim/tilt type only).

7)

Release the wire band clips and disconnect the con- nectors.

Remove the

30 mm connector cover.

9)

Slide the connector cover A and disconnect the con- nectors, and then remove the tiller handle wire har- ness.

10) Remove the 6 x 12 mm bolt washer and connector bracket

.

[I1

WIRE BAND CLIP

(3)

11 01

POWER TRIM/TILT

SWITCH WIRE

[91

CONNECTOR COVER A

[2] CONNECTOR COVER B

[31

TILLER HANDLE

WIRE HARNESS

[8] IGNITION

SWITCH WIRE

’

[71

INDICATOR WIRE

161

141

30 mm CONNECTOR

COVER

*THROTTLE GRIP, THROlTLE ROD

1)

Remove the grip rubber, then remove the 6 x 12 mm flange bolt.

2) Remove the throttle friction grip and throttle friction pad.

3) Remove the throttle grip pipe by turning clockwise viewed from the grip end, and remove the throttle fric- tion disc.

/

FRICTION GRIP

[4] GRIP PIPE

FRICTION DISC

15-5

BF40AeBF50A

4)

Remove the 9 mm E-clip and 10 mm washer.

5) Disconnect the throttle rod from the throttle arm and remove the 10 mm washer.

6) Remove the throttle cable pin from the cable pivot.

7) Loosen the lock nut and remove the throttle cable pivot.

[ l ] 10 mm WASHER (2)

THROTTLE ROD

9 mm E-CLIP

POWER TRlM/TlLT SWITCH

Power TrimRiIt Type:

1)

Release the wire bands, remove the 5 x 10 mm screws and remove the wire cover.

2) Remove the 5 x 8 mm hex. bolt and 5 mm washer and remove the power trim/tilt switch and switch grommet.

Gas Assisted Tilt Type:

1)

Remove the 5 x

8 mm hex. bolt and

5 mm washer and remove the switch bracket and switch hole grom- met.

131 *1

5 x 10 mm SCREW (2)

—

_-.

—

r21

H t X . EULI

&pa

5 mm

WIRE COVER

SWITCH

181

*1: Power trimhilt type only

*2: Gas assisted tilt type only

1’1

— 1

SWITCH

GROMMET

15-6

BF40AoBFSOA

SHIFT LEVER, SHIFT UNIT, THROTTLE ARM

1) Remove the hole cap and remove the 8 x 50 mm socket bolt.

2) Remove the shift lever stopper and shift lever.

1

111

HOLE CAP

I

121

8 x

50 mm SOCKET BOLT

FT LEVER STOPPER

[51

SHIFT LEVER BUSHING

‘P

[41

SHIFT LEVER

3) Remove the three 5 x 12 mm hex bolts and three 5 mm washers.

4)

Remove the guide plate and throttle arm.

5) Remove the two 6 x 12 mm bolt washers and remove the shift unit.

[ l ] 5 x 12 mm HEX BOLT (3)

1215 mmWASHER(3)

/

PI

[4]

THROTTLE ARM

/

/ /

[5]

6 x 12 mm BOLT

WASHER(2)

15-7

BF40AoBF50A

SHIFT UNIT DISASSEMBLY

1) Remove the two screws and remove the lock plate.

2 Remove the two screws and remove the spring guide, spring, shift arm pin and roller.

3)

Remove the shift gear and plate. bushing from the shift

[3]

( ,

PI

[11

SPRING.

SHIFT ARM PIN

/

151

SHIFT GEAR

[91

BUSHING

[81

ROLLER

STEERING BRACKET

1) Remove the 12 mm lock nut, 12 mm hex. nut, 14 mm wave washer and distance collar.

Remove the 12 x 80 mm hex bolt and 12 mm washer.

Remove the steering bracket.

Remove the 12 mm thrust washer.

Remove the steering handle bushings if necessary.

Replace with new ones when the steering handle busings are removed.

12 mm

191

12 mm LOCK NUT

[81

14 mm WAVE WA

171

12 mm THRUST

SCRE1.1

131

STEERING BRACKET

12 mm WASHER

[51

12 x

80 mm

HEX. BOLT

STEERING HANDLE

BUSHING

(2)

1

Do not reuse.

1

15-8

IGNITION SWITCH, EMERGENCY STOP

SWITCH, INDICATOR

1) Remove the emergency stop switch clip and 16 mm lock nut, and remove the emergency stop switch.

2) Remove the lock nut and remove the ignition switch.

3) Remove the indicator.

[3] EMERGENCY STOP SWITCH

INSPECTION:

See base shop manual.

BF40AoBF50A

11

1

SWITCH

I

INSPECTION: P.

16-4

I

1519

c. ASSEMBLY

Assembly is the reverse order of disassembly.

INDICATOR

Install the indicator noting the direction.

IGNITION SWITCH, EMERGENCY STOP SWITCH

Install the switch by aligning the cutout of the switch with the flat section of the installation hole as shown.

Tighten the lock nut to the specified torque.

Torque:

Ignition switch lock nut: 7 N*m (0.7 kgfom, 5.1 Ibf*ft)

16 mm lock nut: 1.5 N*m (0.15 kgf*m, 1.1 Ibfuft)

[ l ] CUTOUT 121

IGNITION SWITCH

FLAT SECTION t41

IGNITION SWITCH LOCK NUT

I

7

N*m (0.7 kgf*rn, 5.1 Ibfoft)

I

/

[6] 16 mm LOCK NUT

1.3 N*m

PI

EMERGENCY

STOP SWITCH

Y

CUTOUT

[31

FLAT

SECTION

15-1 0

BF40AoBFSOA

SHIFT LEVER, SHIFT UNIT, THROlTLE ARM

r7i

SPRING

[6] SHIFT ARM PIN

[8]SCREW(2)

.

E I

i i n c

[2] 5 x 12 mm HEX BOLT (3)

1

4.5

N*m

(0.45

Ibfoft)

[11

5 mm WASHER (3)

GUIDE PLATE

/

1141

BUSHING

SHIFT FRAME

11 71

SHIFT LEVER STOPPER

154 1

Apply grease to the:

— roller, shift arm pin and spring.

— gear and roller sliding section of the shift gear.

— bushing.

— gear of the shift arm.

Note the installation direction of the shift arm pin.

Set the roller and shift gear in the neutral position as shown.

Install the shift gear and spring guide assembly with the shift arm set in vertical position as shown.

BF40AoBFSOA

[3] SHIFT FRAME SIDE

SHIFT ARM PIN

&

[9] SHIFT GEAWSPRING

GUIDE ASSEMBLY

[6] SPRING GUIDE

171

,

—

‘

FRAME

Apply grease to the pivot point of the throttle arm.

Tighten the

5 x 12 mm hex bolt to the specified torque.

TORQUE: 4.5

N*m (0.45 kgFm, 3.3 I b M )

[ l ]

5

12 mm HEX BOLT (3)

4.5 N*m (0.45 kgf*m, 3.3 Ibf*ft)

[41

5 mm WASHER (3)’

[31

GUIDE PLATE

I ‘

a

//

121

THROTTLE

ARM

15-1 2

BF40AoBF50A

Apply grease to the:

— sliding surface of the lever stopper.

— sliding surface of the shift lever.

— busing.

Position the shift arm in a vertical position to align the shift unit square and shift gear. Install the shift lever.

Install the shift lever by aligning the square of the lever stopper and that of the shift gear.

PI

SHIFT LEVER STOPPER

[3]

SHIFT UNIT

I

141

,6~12rnrnBOLT

SOCKET BOLT

[7]

8

rnrn WASHER

[6] BUSHING

’

[5] SHIFT LEVER

I

AJ

15-1 3

POWER TRIWILT SWITCH

Power trim/tilt type only: Install the power tilt switch so that the

«UP» mark is at the bracket bolt installation hole side (lower side) as shown, and install the switch grommet noting the direction.

Power trimhilt type only: Replace the wire band with a new one, if it has been cut. After securing the wires with a new wire band, cut the end of the wire band so the projected end length is 10

—

20 mm (0.4

—

0.8 in).

Tighten the 5 x 10 mm hex. bolt to the specified torque.

Torque: 4.5 N*m (0.45 kgf*m,

3.3

Ibfuft)

Power trim/tilt type only: Check whether the power tilt switch wire does not interfere with the 5 x

8

mm hex

bolt head.

BF40AoBF50A

[2] POWER T R I W I L T

131

SWITCH GROMMET

/

[4] «UP» MARK

131

*1

5 x 10 mm SCREW (2)

11 01

5 mm WASHER

—

SWITCH BRACKET

POWER TRlM/TlLT

SWITCH

161

*1

SWITCH GROMMET

SWITCH HOLE GROMMET

171

*1:

Power Trim/Tilt Type

*2: Gas assisted Tilt Type

15-1

4

BF40A-BF50A

THROTTLE ROD, THROTTLE GRIP

‘

[3]

LOCK NUT

1.3 N*m (0.13 kgfom, 0.9 Ibf*ft)

1

I

141

I

11

1

THROTTLE

CABLE PIN

[51

10 (2)

4

181

THROTTLE

6×12

/

1

7 N*m (0.7 kgf*m, 5.1 Ibf*ft)

I

15-1 5

Loosen the lock nut fully and screw the cable pivot as shown. Tighten the lock nut to the specified torque.

TORQUE: 1.3 N*m (0.13 kgfem, 0.9 Ibfoft)

Apply grease to the sliding surfaces of the cable pivot.

Apply grease to the pivot point of the throttle arm, then install the throttle rod with the two 10 mm washers and

9 mm w-clip.

Power trim/tilt type only: Check whether the power tilt switch wire does not interfere with throttle rod.

BF40A-BF50A

9

—

10 mm (0.35

—

0.39 in)

9 mm E-CLIP

Apply grease to the throttle grip installation surface of the tiller handle and friction disc. Install the friction disc by aligning the grooves of the throttle friction disc with the bosses of the tiller handle as shown.

[5] THROTTLE

CABLE PIVOT

’

[2] BOSS

Install the throttle cable pin on the cable pivot with the projected length at both ends of the pin equal as shown.

I

11

1

15-1 6

BF40AoBFSOA

Apply grease to the inside of the throttle grip pipe, inside of the friction grip, both ends of the throttle cable pin, handle pipe and both sides of the friction pad. Set the throttle friction pad on the grip pipe.

Install the grip pipe on the tiller handle by slowly turning it clockwise.

161

CUTOU

FRICTION DISC

4——.

PIPE

7

\

151

THROTTLE

FRICTION GRIP

Tighten the throttle friction grip against the thrqttle fric- tion disc by aligning the cutout of the friction pad with the boss of the friction disc. Tighten the 6

x 12 mm flange bolt securely.

Turn the grip pipe to the fully close position and install the grip rubber by aligning the mark.

~~

FRICTION GRIP

/

11

1

GRIP PIPE

[41

GRIP RUBBER

6×12

[31

15-1 7

BF40AeBF50A

STEERING BRACKET

Install a new steering handle busing when it has been removed.

Apply grease to the inside of the steering handle bush- ings, both ends of the 12 mm thrust washer, inside of the distance collar and both ends of the wave washer.

Clean off grease on the threads of the 12 x 80 mm hex. bolt, then tighten the 12 mm hex. nut to the specified torque.

TORQUE: 29 N*m (3.0 kgfam, 22 Ibfdt)

Hold the 12 mm hex. nut and tighten the 12 mm lock nut to the specified torque.

TORQUE: 54 N*m (5.5 kgf*m, 40 Ibfdt)

[l] mm LOCK NUT

1

54

N*m

(5.5 kgf*m, 40

Ibf*ft)

[2] mm WAVE WASHER

i

141

/STEERING BRACKET

. /

1

1

29 N*m (3.0 kgfmrn, 22 Ibfsft)

L

A h

1

[5] 12 mm WASHER

/

[81

12 mm THRUST WP

171

STEERING HANDLE BUSHING (2)

I

Do not reuse.

I

161

12 x 80 mm

HEX. BOLT

15-1 8

*TILLER HANDLE

WIRE

HARNESS

Connect connectors to the wire connectors of the same color, cover the connectors with the connector covers and secure them with the harness band clip.

Replace the wire band with a new one, if it has been cut. After securing the connectors and wires with a new wire band, cut the end of the wire band so the project- ed end length is 10

—

20 mm (0.4

—

0.8 in).

Install the tiller handle wire harness by aligning the wire tie with the grommet as shown

Power Tri m n i It Type:

BF40A-B F50A r11

WIRE BAND CLIP

%

10

—

20 mm

(0.4

—

0.8 in)

[4] GROMMET

%

[6] WIRE BAND CLIP (3)

r51

POWER TRIM/TILT

11 41

CONNECTOR

COVERA

TILLER HANDLE

WIRE HARNESS r71

$ — F +

r81

COVER B

15-1 9

Gas Assisted Tilt Type:

[l] (3)

[lo1

CONNECTOR

COVER A r91

IGNITION

SWITCH WIRE

181

INDICATOR WIRE

BOLT WASHER

BF40AoBFSOA

EMERGENCY STOP

SWITCH WIRE

] CONNECTOR COVER B

141

TILLER HANDLE

WIRE HARNESS

30 mm CONNECTOR

CONNECTOR BRACKET

15-20

B F40AoBF50A

CONTROL CABLES, UNDER COVER

Install the cable holder as shown noting the installation direction and tighten the 6 x 12 mm bolt washer to the specified torque.

TORQUE: 0.7 Nom (0.7 kgfom, 5.1 Ibfa)

Apply grease to the link pins of the throttle arm and shift arm, then connect the throttle cable and shift cable.

Set the shift cable by aligning the groove of the cable with the cutout of the mounting point.

Set the throttle cable by aligning the groove with the cutout of the cable holder.

Route the throttle and shift cable through the grommet

(upper hole: shift cable, lower hole: throttle cable) holes and set the grommet in the case correctly.

Power trimhilt type only:Check whether the power tilt switch wire does not interfere with the throttle cable.

Tighten the cover screw to the specified torque.

TORQUE: 2.2 N*m (0.22 kgfom, 1.6 Ibf*ft)

[ l ] SCREW (6)

I

2.2 N*m

I

[9] 4 mm E-CLIP (2)-

181

THROTTLE ARM

—

[7] SHIFT ARM

A

/

15-21

161

GROMMET

BF40AoBF50A d. INSTALLATION

Install the long tiller handle assembly to the motor.

Install the 10 mm washers and tighten the 10 mm self-locking nuts to the specified torque.

TORQUE: 34 Nom (3.5 kgfom, 25 Ibfoft)

Pass the long tiller handle wire harness through the under case grommet, and secure it with the wire har- ness clamp.

Set the control cable setting plate into the groove of the under case.

Pass the control cables through the under case grom- met and set the control cables by aligning the groove of the control cable with the cutout of the control cable setting plate.

Adjust the control cables (throttle control cable length:

P. 3-6, shift control cable length: P. 3-8).

Connect the control cables to the shift arm and throt- tle arm with the 6 mm plain washers and 6 mm lock pins

[2] SHIFT CABLE

/

P I

WIRE HARNESS r91

THROTTLE CABLE

[5] WIRE HARNESS

CLAMP

[61

SHIFT CABLE

6 mm LOCK PIN (2)

[7] 6 mm

WASHER

(4)

15-22

Install the separator cover with the two 6 x 28 mm

I flange bolts and two 6 mm washers and 6 x 40 mm hex. bolts.

[l]

6 mm PLAIN

WASHER (2)

9) Tighten the two

6

x

28 mm flange bolts and two 6 x

40 mm hex. bolts securely.

BF40AaBF50A

10) Connect the 14P connector of the long tiller handle wire harness to the main wire harness and set the

14P connector to the connector holder.

11)

After installation check the throttle operation and gear shift operation.

131

6 mm PLAIN

WASHER (2)

‘6 x

40 (2)

15-23

16.

ELECTRICAL EQUIPMENT

BF40A-BF50A

~~

1.

CDI UNIT

2.

POWER COIL

1. CDI UNIT

a. INSPECTION

Measure the resistance between the terminals and be sure that the measurements conform to the ranges shown in the table below.

Use a tester that is equivalent to or higher than the performance specified;

Internal resistance: 20 kQNDC, 9 W V A C

Be careful not to touch the metallic part of the tester probe with your body, otherwise correct resistance value cannot be obtained.

Read the tester manufacturer’s operation instructions carefully before operation with a tester. Be sure the tester’s battery is fully charged and check the meter before using the tester.

Use a R x 1 scale of an commercially available multi- meter, and meter shows current flowing from negative

(-) to positive (+).

3. ECT (Engine Coolant Temperature) SENSOR

4.

INDICATOR

—

-J (t4

LLt used)

*14 (Not used)

[2] unit: kQ

2

a z

c

v)

—

d

Y

13

*14

15

16

17

8

9

10

11

12

18

19

20

21

22

1

2

3

*4

*5

6

*7

36-150170-3001 1 4 — 6 0 150-2001

—

1 2 0 — 9 0

1

00

1 1 6 — 7 0 18.5-34/1 8.5

—

34

I

10

—

40

1 7 — 7 0 1 1 5 — 6 0

I

1 . 4 — 6 1 1 1 — 5 0

I m

14.6-191 m

1

2 — 8 . 5 10.4-1.8/

03

I

1 8 — 8 0 1 3 0 — 1 5 0 1 5 . 5 — 2 4 1 2 4 — 1 0 0 1

00

1 4 — 1 6

[

00

1 7 — 2 8 1 3 — 1 3

I .

1 m

12.4-101

1

1 6 — 7 0 30-150 5 . 5 — 2 4 24-100 3.6-15 7 — 2 8 3 — 1 3 2.4-10 7 — 2 8 m

00 00 m m m m m m m m

00 00 00 00

60-300

60-300

20-150

90-400 1 5 — 6 0 60-300

90-400 1 5 — 6 0 60-300

30-150 7 — 2 8 2 2 — 9 0 m m m

22-100

22-100

11 — 4 5 m m m

1 7 — 7 0 9.5-38

1 7 — 7 0 9.5-38

8 — 3 2 4.8-20 m m m

9 — 3 6 1 4 — 6 0

9 — 3 6 1 4 — 6 0

4.4-17

5 — 2 0

24-150 26-150 7 — 2 8 2 2 — 9 0

2 0 — 9 0 1 1 9 — 8 0 13.8-161 1 6 — 7 0 m

11 — 4 5 m

8 — 3 2 4.8-20 m

4.4-17 5 — 2 0

I m

I

7 — 2 8

1 m

14.6-1812.2-9.5j m

I

1 . 8 — 8 12.4-101 m m m m m m m m m

00 00 00

24-150

1 6 — 7 0

26-150 7 — 2 8 22-100

1 5 — 6 0 1 . 4 — 6 11 — 5 0 m

11 — 4 5

03

8 — 3 2 4.8-20 m

4.4-18 5 — 2 0

—

4.2-17

~0

2 — 8 . 5 0.4-1.8 m

0 0.4

—

1.6

I

1 . 4 — 6 1 1 1 — 5 0

I m

14.2-171

00

1 2 — 8 . 5 10.4-1.8/ m

I

0 10.4-1.6

1 6 — 7 0 1 1 5 — 6 0

2 2 — 9 0 1 2 2 — 9 0 1 5 — 2 0 1 1 8 — 6 0 1 m

18.5-341 m

1 6 — 2 4 12.8-121 m

1 2 . 6 — 1 1 1 3 . 2 — 1 3

16-1

BF40AoBF50A

[2]

(+)

[ l ] unit: kQ

16-2

23

24

0.4- 1.6

3.2- 13

m m

2 — 8 2 — 8

3.6-15 3.8-18 1 . 6 — 7 4 — 1 6 3.8-16 0

5.5-24 6 — 2 4 6.5-23 7 — 2 8 4.6- 19

8 — 3 4 7 — 3 0 2.6-11 2.6-11

2.4

—

10

2. POWER COIL

Disconnect the 2P power coil connector, and measure the resistance between the terminals.

I

Standard resistance

I

7.02

—

8.58

R

:

See page 6-1 for the power coil replacement.

BF40AoBF50A

P I

POWER COIL

WIRE

3. ECT (Engine Coolant Temperature) SENSOR

The sensor resistance decreases as the coolant tem- perature increases as shown on the right table.

1)

Disconnect the 2P connector from the thermo sensor and measure the resistance between the sensor ter- minals at the room temperature.

Standard resistance: 1

—

5 k!2

2) Connect the 2P connector and start the engine and warm up the engine to normal operating temperature.

3) Stop the engine, and disconnect the 2P connector and measure the resistance.

Standard resistance: 200

—

400 R

ECT sensor installation/removal is almost the same as installation/removal of the sermo switch.

(See page 8-2 of the Base Manual.)

kR

100

10

W

0 z

3 1

;

W

U

—

E

0.1

111

ECT SENSOR

1

-60

I

0

0 50

I

100

1

I

200

[2] TEMPERATURE

I

300°F

1613

BF40AmBF50A

Paper

Book Part NO. 66ZV300T

PREFACE

This manual covers the construction, function and servicing procedures of the Power Trim/Tilt Assembly for Honda

BF40AoBF50A Outboard motors.

CONTENTS

For service information which is not covered in this supple- ment, please refer to the base shop manual (Parts number

66ZV300U).

.

. . .

. .

Careful observance of these instructions will result in better, safe service work.

Pay attention to these symbols and their meaning:

Indicates a strong possibility of severe per- sonal injury or loss of life if instructions are not followed.

CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed.

All information, illustrations, directions and specifications include in this publication are based on the latest prod- uct information available at the time of approval for print- ing. Honda Motor Co., Ltd. reserves the right to make changes without incurring any obligation whatever. No part of this publication may reproduced without written permission. c c

.

.

……..

… . . . . .

. .

. . . . . . . . . .

. .

..

Honda Motor Co., Ltd

Service Publication Office

GAS ASSISTEDPOWER TILT

.-

The marked sections contain no changes.

They are not covered in this manual.

Date of Issue: October, 2003

INDEX

2

.

SERVICE

INFORMATION ……………………..

2-1

1 . MAINTENANCE STANDARDS

…………………

2-1

2 . TORQUE VALUES

………………………………….

2-1

3

.

SPECIAL TOOLS

……………………………………

2-2

4

.

TROUBLESHOOTING

……………………………..

2-3

13

.

GAS ASSISTED/POWER

TILT

……………..

13-1

1

.

POWER TRlM/TlLT ASSEMBLY

……………….

13-1

BF40A.B F50A

BF40AoBF50A

1.

MAINTENANCE STANDARDS

2.

TORQUE VALUES

1.

MAINTENANCE STANDARDS

POWER TRlM/TlLT

Part

Power trimhilt

I

Item

Lower chamber blow pressure

I

Upper chamber blow pressure

Power t rim/t ilt motor

Brush length

Mica depth

2. TORQUE VALUES

Item

Power trimhilt

Upper joint metal

Oil hole cap bolt

Oil tank socket bolt

Outer tube

Outer tube guide

Gear pump socket bolt

Spool valve cap

Manual valve

2- Way valve

Motor screw

Yoke screw

Thread dia.

x

pitch

M14 x 1.5

3/8- 1 6U N C

M5 x 0.8

M41 x 1.5

M52

x 1.5

M5 x 0.8

M22

x 1

.O

M12 x 1.75

M12

x 1.0

1/4-20 UNC

M5 x 0.8

NOTE:

(1): Apply LOCTITEO #271 to

the thread (See page 13-28).

(2): Apply LOCTITEO #241 to

the thread (See page 13-21).

2.

SERVICE INFORMATION

3.

SPECIAL TOOLS

4.

TROUBLESHOOTING

I

I

Standard

19.3

—

23.0

MPa

(1 97

—

235 kgf/cmz,

2,802

—

3,342 psi)

27.9

(285

—

34.8 MPa

—

355 kgWcm’,

4,054

—

5,049 psi)

9.75 mm (0.384 in)

1.8 mm

(0.07 in)

Service limit

—

5.5 mm (0.22 in)

1.3 mm (0.05 in)

N-m

44

1.1

4.7

64

88

5.1

22

1.7

7

6.4

2.2

Torque kgfom

4.5

0.1 1

0.48

6.5

9.0

0.52

2.2

0.17

0.7

0.65

0.22

Ibf-ft

3.8

16

1.2

6.1

4.7

1.6

33

0.80

3.5

47

65

Note

2-1

BF40AoBF50A

3. SPECIAL TOOLS

No.

Tool name

0

Gauge joint A

0

Gauge joint B

0

Lock nut wrench

@ Lock nut wrench 30 x 40

Tool number

07OPJ-V150100

07OPJ-V150200

Application

Blow pressure inspection

0709A-ZW40100 Outer tube guide removal/installation

0791 6-9690000 Outer tube rernovaVinstallation

0

0

0

2-2

BF40AoBF50A

4. TROUBLESHOOTING

a. POWER TRIM/TILT

Power T r i M i l t

Does

Not Move

1

Check for motor sound.

Sound.

1-

Does not sound

Operate» TROUBLESHOOTING on

page 2-5.

Check the manual valve.

+I

Tighten the manual valve securely.

Tight

~-

A_-

—

Check for oil leakage from each mating

Leaking part. the leaking point.

~

~-

Not leaking

Low

—

j-

Fill with ATF

(P. 13-28).

Check the oil level with the piston rod

fully extended (P. 13-28).

Normal

.1

I

Check ‘or air in the system.

~~

No air

4

Faulty power trim/tilt assembly.

Check and repair the power trim/tilt assembly according to the table on

Air

—

Bleed air

(P. 13-27) and recheck.

I

2-3

Power

T r i d i l t

Does

Not Hold

BF40AoBF50A

Loose

—

Tighten the manual valve securely.

Tight

~

Check for oil leakage from each mating

~ part.

Not leaking

Leaking

Low

~

Check the oil level with the piston rod

fully extended (P. 13-28).

Normal

c

b e

for-air in the system.

No air

_ _

.

~ ~

Air

—+I

_ _ _

Replace the O-ring and/or oil seal at the leaking point.

-1

Fill with ATF (P. 13-28).

Bleed air

(P. 13-27) and recheck:

1

2-4

BF40AmBF50A

Power T r i M i l t Motor

Does

Not Operate

Connect a fully charged battery to the power trirn/tilt motor and check the motor.

’ h

!

Does not turn

Turn

1

Check for open circuit in the motor wire.

Normal

—

Check the motor f-overheat

Normal

-.

Jl

I

Check the breaker.

Open

Overheats

4

Cool down the motor.

3

+ an assembly.

J.

Check for water or oil (ATF) in motor.

Replace the motor.

____

Normal

I-

Disassemble and replace the faulty parts in the motor.

V

Check the power trimhilt relay (See base shop manual).

Abnormal

—

Replace the power trim/tilt relay.

Abnormal

-~

Replace the power trimhlt switch.

T

Check the power trimhilt switch (See base shop manual).

Normal

Check the power trim/tilt line for open or short circuit. Repair or replace the wire harness if necessary.

2-5

BF40AoBFSOA

Faulty Power T r i M i l t Assemblv Quick Reference Chart

Ioes no tilt up

0

0

~.

SYr

Does no tilt down

~

0

0

tom

Does not hold

2ontractec side

Extended side

—

—

__

0

~

0

0

0

0

0

0

~

~

0

0

0

0

~

0

0 0

0

0

0

0 0

0

~

0

0

0

0

0

~

0

0

Pre

Lower chamber blow pressure low or drops u r e

Upper chamber blow pressure low or drops

~

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Check point

See page 2-7

Checkhepair method

Check the motor.

@

Manual valvc Check the manual valve for tight- ening, damage or foreign material.

Check the O-ring for damage, replace if necessary.Replace the manual valve if necessary.

@

Free piton,

O-ring

@

Piston rod,

O-ring, oil seal

Check the O-ring for damage, replace if necessary.

Check the O-ring, oil seal for dam- age, replace if necessary. Replace the piston rod assembly if neces- saw.

@

Oil (ATF)

Check the oil level and add if nec- essarv.

8

ber check valve

Check the check valve for dam- age, wear or foreign material.

Clean and reassemble the upper chamber check valve DroDerlv.

0

(with built-in upper relief valve)

Check the valve for damage, wear or foreign material.Clean and reassemble the spool valve prop- erly.Do not disassemble the spool valve, either as the upper relief valve is built in the

SDOO~

@

Lower cham- ber check valve

Check the check valve for dam- age, wear or foreign material.

Clean and reassemble the lower chamber check valve properly.

8

ReDlace the aear DumD assemblv.

0

0

@I valve

Check the valve for damage, wear or foreign material.Clean and reassemble the down relief valve

DroDerlv. valve (in the manual valve’

Check the check valve for dam- age, wear or foreign material.

Clean and reassemble the manual valve properly.

0

@

Shock relief valve (in the piston)

Check the relief valve for damage, wear or foreign material. Replace the piston assembly if necessary.

Clean and reassemble the piston

DroDerlv.

0

ber safety valve (with built-in the valve body)

Check the lower chamber safety valve for damage, wear or foreign material. Replace the valve body assembly, if necessary. Clean the valve body and reassemble prop- erly.

@

Upper cham- ber safety valve

Check the upper chamber safety valve for damage, wear or foreign material. Replace the upper cham- ber safety valve if necessary.

Clean and reassemble the upper chamber safety valve properly.

0

Check the 2-way valve for dam- age, wear or foreign material.

Replace the 2-way valve if neces- sary. Clean and reassemble the

2-

wav valve properly.

2-6

13.

GAS ASSlSTEDlPOWER TILT

~ W P O W E R T R l M r r l

ASSEMBLY

~-

I

1.

POWER TRlMRlLT ASSEMBLY b.

DISASSEMBLY

ZAUTION:

Do not disassemble the gear pump assembly. If it is faulty, replace it as an assembly.

Do not use a shop towel, cloth, gloves, etc.

Do not reuse the drained automatic transmis- sion fluid

(ATF).

Do not hold at the outer tube when holding the power trimhilt assembly in a vise during opera- tion.

Clean the removed parts i n fresh automatic transmission fluid (ATF), and blow each port of the parts with compressed air. Set the parts neatly in a suitable container with care not to contaminate them with dust and dirt.

Do not reuse the O-rings oil seals.

Remove each valve and sleeve with care not to damage the sliding surface of the parts.

[ l ] O-RING

( D o n o t i

L

I

[Z]

OIL HOLE CAP

POWER TRIM/TILT MOTOR

1) Connect the power trimhilt motor 2P connector and operate the power trimhilt motor assembly until the piston rod extends fully.

I

2) Loosen the manual valve fully.

3) Remove the oil hole cap and drain container through the bolt hole.

ATF

in a suitable

4) Remove the O-ring from the oil hole cap bolt and dis- card it. Replace the O-ring with a new one during reassembly.

Do not drain ATF by pushing in the piston rod.

[ l ] SCREW WASHER

(4)

[2]

MOTOR

ASSY.

131

MOTOR CORD BRACKET

5) Open the two wire band clips and one wire band, and free the motor wire.

6) Remove the four screw washers, and remove wire protector and power trimhilt motor assembly.

7) Drain ATF from the valve body.

Remove the O-ring from the power trimhilt motor assembly and discard it.

Replace the O-ring with a new one during reassem- bly.

9) Remove the drive joint from the gear pump assembly.

[7]

VALVE BODY

I

CLIP (2)

13-1

CYLINDER, PISTON ROD

1) Hold the valve body in a vise with shop towel or soft jaws as shown.

CAUTION:

Take care not to tighten the vise too tight as it damages the valve body.

BF40A-BF50A

2) Hold the piston rod and remove the upper joint metal.

Clean of locking agent from the threaded points of the piston rod.

[l] UPPER JOINT

METAL

[2] PISTON ROD

13-3

BF40A-BF50A

3) Remove the four 5 mm socket bolts and remove the oil tank and motor cord bracket

B.

4)

Remove the O-ring from the cylinder Comp.

Discard the O-ring. Replace it with new one during reassem bl y.

[ l ] 5 mm SOCKET BOLT (4)

[5] MOTOR CORD

BRACKET B

[2] OIL TANK

5) Remove the oil seal using small screw driver as shown.

Discard the oil seal. Replace it with new one during reassem bl

y

.

CAUTION:

Take care not to damage the oil seal installation section when removing the oil seal.

[41

WIRE BAND

CLIP (2)

[3] O-RING

I

1

Do not reuse.

1

[ l ] OIL SEAL

-1

/ p z z r

PI

OIL SEAL

INSTALLATION

SECTION

13-4

6) Remove the outer tube guide using the lock nut wrench.

Remove the O-rings from the outer tube guide and discard them. Replace the O-rings with new ones dur- ing reassembly.

I

r11

LOCK NUT WRENCH

070PA-ZW40100

BF40AoBF50A

GUIDE

[3] O-RINGS

pzizr

7) Remove the valve body and cylinder assembly from the vise.

Remove the cylinder/piston assembly from the valve body, and drain ATF from the cylinder assembly and valve body.

9) Remove the O-ring from the bottom piece and discard it. Replace the O-ring with new one during reassem- bly.

r11

CY LINDEWPISTON

[2] BOTTOM PIECE

I

Do not reuse.

1

I

/ I

131

VALVE BODY

1315

10) Hold the bottom piece in a vise with shop towel or soft jaws as shown and loosen the outer tube using the lock nut wrench, then remove the cylinder/piston assembly from the vise.

CAUTION:

Take care not to tighten the vise too tight as it damages the bottom piece.

(s.TooII)

[l] LOCKNUT

WRENCH 30 x

40

0791 6-9690000

BF40AoBF50A

11)

Remove the outer tube by loosening the outer tube slowly, and drain the residual ATF from the outer tube and cylinder.

Remove the O-ring from the outer tube using a small screw driver taking care not damage the O-ring instal- lation section, and discard the O-ring. Replace the

0-

ring with new one during reassembly.

Clean the threads of the outer tube.

BOTTOM

PIECE

1

~ o n o t

1

13-6

12) Remove the bottom piece from the cylinder.

Remove and discard the O-ring. Replace the O-ring with a new one during reassembly.

Clean the threads of the bottom piece.

14)

Remove the piston and free piston from the cylinder.

Remove and discard the O-rings and discard them.

Replace the O-rings with new ones during reassem- bly.

BF40AoBF50A

[ l ] BOTTOM PIECE

/

I

141 151

FREE PISTON PISTON ROD

161

CY LlNDER

VALVE BODY

1)

Remove the socket bolts and gear pump assembly.

Do not disassemble the gear pump assembly. If it is faulty, replace it as an assembly.

2) Remove the two O-rings from the valve body and dis- card them. Replace the O-rings with new ones during reassembly.

I ‘

[ l ] SOCKET BOLT B

(3)

131

GEAR PUMP

ASSEMBLY

13-7

BF40AoBF50A

6) Remove the spool valve cap using a commercially available 2.8 mm driver bit.

7) Apply small squirt of air pressure to the oil hole in the spool valve cap to remove the valve

B. Remove the valve B from the spool valve cap.

Remove the O-rings from the spool valve cap and valve B and discard them. Replace the O-rings with the new ones during reassembly.

I

PI

DRIVER BIT, 2.8 mm

(Commercially available)

[l] VALVE B

/

/

121 SPOOL

Remove the spool valve from the valve body.

Check the backup ring on the spool valve for damage and scratches. Replace the backup ring if it is dam- aged or scratched.

1

~ o n o t

1

[l] SPOOL VALVE

1

k K U / p R l N G

[ l ] SPOOL VALVE

13-9

9)

Prepare a piece of piano wire of 1.5 mm in diameter as shown.

7) Set the prepared wire in the holes in both sides of the sleeve as shown, and secure the wire by inserting the

10 mm bolt into the sleeve. Remove the sleeve from the valve body by pulling the wire with care not to damage the valve body.

Remove the O-ring from the sleeve and discard it.

Replace the O-ring with a new one during reassembly.

50 m m

i.—————i

in)

3

—

4

—

0.15 in)

I

[2] PIANO WIRE

Set the valve body as shown. Apply small squirt of air pressure to the manual valve installation hole to remove the valve B. Remove the valve B from the valve body.

Remove the O-ring from the valve B. Replace the

0-

ring with a new one during reassembly.

[5] O-RING

Do not reuse.

13-1 0

BF40AoBFSOA

10)

Remove the 2-way valve.

Remove the O-ring from the 2-way valve and discard it. Replace the O-ring with a new one during reassem- bly.

[2] 2-WAY VALVE b.

INSPECTION

DOWN RELIEF VALVE

Check the down relief valve seat, spring guide, steel ball and spring for wear and damage. Replace the down relief valve seat, spring guide or spring if damaged or worn.

[2] SPRING

[l] SPRING GUIDE

UPPER CHAMBER SAFETY VALVE

Check the upper chamber safety valve for wear and dam- age. Replace the upper chamber safety valve if damaged or worn.

[5] STEEL BALL

CYLINDER

Make sure the piston rod is straight and has no damage.

Replace the piston rod assembly with a new one if neces- sary.

PISTON, FREE PISTON

Check the inner and outer surfaces of the cylinder for damage and scratches. Replace the cylinder with a new one if it is damaged or scratched.

[ l ] FREE PISTON

[3] PISTON ROD

MANUAL VALVE

Check the manual valve for damage and scratches.

Replace if it is damaged or scratched.

[3] UPPER CHAMBER

[4] DOWN RELIEF

VALVE SEAT

[2] CYLINDER

,[l] SEAL WASHER

13-1 1

SPOOL VALVE, SLEEVE, VALVE B

Check the sliding surface of the valve

6 ,

spool valve, sleeve for damage, scratches and wear. Replace if nec- essary.

I

2-WAY VALVE

Check the 2-way valve for damage, scratches and wear.

Replace if necessary.

I

[l] SLEEVE

SPOOL VALVE

OIL TANK

Visually inspect the oil seal installation section of the oil tank. Replace the oil tank if scratched or damaged.

[l] OIL SEAL INSTALLATION

SECTION

POWER TRlMfllLT MOTOR

Brush

Measure the brush length.

Standard

10 mm (0.4 in)

Service limit

6 mm (0.2 in)

13-1 2

Armature

1) Check the armature for wear and damage. Replace if necessary.

2) Visually inspect the commutator surface for dust, rust and other damage. If necessary, wipe it with a clean lint-free cloth or dress with a fine emery cloth.

3) Measure the mica depth. If the grooves are clogged, clean the grooves and measure the depth again. If the measurement is less than the service limit, replace the armature.

Service limit 1.3 mm (0.05 in)

4)

Check for continuity between each segment. If an open circuit exists between any two segments, replace the armature.

5)

Check for continuity between the commutator and armature coil core. If continuity exists, replace the armature.

6)

Check for continuity between the commutator and armature shaft. If there is continuity, replace the arma- ture.

I

,

, I

, /

,

I

N ? f

W

P I

MICA

13-1 3

c.

ASSEMBLY

VALVE BODY ASSEMBLY

CAUTION:

Do not reuse the O-ring.

Do not use a shop towel, cloth, gloves, etc. when reassembly.

Assemble the parts with care not to let the for- eign particles and dirt enter the valve body and gear pump assembly.

1)

Clean the parts in the fresh ATF, and blow each port of the parts with compressed air. Check that the parts are free from contamination with dust and dirt before reassembly.

[ l ] SOCKET BOLT A (3)

5 N * m , (0.5 kgf*m, 3.6 Ibf*ft)

VALVE SPRING

SPRING GUIDE

STEEL BALL

DOWN RELIEF

VALVE SEAT

O-RING 1.5 x 3.5 mm

[5] 2-WAY VALVE

[17] BACKUP RING

[16] SPOOL VALVE

[13] O-RING 1.5 x 15.5 mm

’

[I21

O-RING 1.5 x 19.5 mm

I p Z E G 7

I

[

l]SPOOL VALVE C A i

22 N*m,

(2.2 kgf*m, 16 Ibf*ft)

13-1 4

2)

Apply ATF to a new O-ring, and install it on the valve

€3.

3) Apply ATF to the valve B and install the valve B in the valve body noting the installation direction.

4) Apply ATF to a new O-ring, and install it on the sleeve.

5) Set the new backup ring on the spool valve and apply

ATF to the outer surface of the spool valve.

6 )

Install the spool valve in the sleeve noting the installa- tion direction.

7) Apply ATF to the sleeve, and install the sleeve in the valve body noting the installation direction.

[l] B

/

[2]SLEEVE

/ 1

VALVE

[6] O-RING

1.5 x 10.7

’ /

/

1.5 x

13.5 mm

//

141

/

EfNcKUP

-/

~~ Apply ATF to a new O-ring, and install it on the valve

6.

9)

Apply ATF to the valve B and install it in the spool valve cap noting the installation direction.

10)Apply ATF to the new O-rings, and install the O-rings on the spool valve cap.

11)Tighten the spool valve cap to the specified torque using a commercially available 2.8 mm driver bit.

TORQUE: 22 N * m (2.2 kgf*m, 16 Ibf*ft)

.

-r

VALVE CAP

7

B

1.5 x 15.5 mm

1.5 x 10.7

13-1 5

BF40AoBF50A

12)Apply ATF to the sealing washer, and set it in the valve body at right angles. Be careful not to set it at an inclined angle, which can lead to the collapsed sealing washer.

13)Apply ATF to a new D-ring and a new O-ring, and install them on the manual valve.

14)Tighten the manual valve to the specified torque, and set the internal circlip in the groove in the valve body securely.

TORQUE: 1.7 Nom (0.17 kgfom, 1.2 Ibfoft)

[ l ] MANUAL VALVE

1.2 x 5.8 mm

[3] O-RING

2.4×9.8 mm

[4] SEAL WASHER

[5] D-RING

1.2 x 5.8 mm

2.4×9.8 mm

[6] INTERNAL ClRCLlP

15)Apply ATF to new O-ring, and install it on the 2-way valve.

16) Install the 2-way valve to the valve body and tighten the 2-way valve to the specified torque.

TORQUE:

7

Nom (0.7 kgfom, 5.1 Ibfoft)

I

J

2-WAY VALVE

I

[2] O-RING

1.5 x 9.5 mm

[3] O-RING

1.5 x 9.5 mm

/

-1

[ l ] 2-WAY VALVE

13-1 6

17)Apply ATF to a new O-ring, and install it on the down relief valve seat.

18) Apply ATF to the down relief valve seat and install it in the valve body as shown noting the direction.

19) Install the steel ball, spring guide and the valve spring in the down relief valve seat.

20)Apply ATF to a new O-ring, and install it on the upper chamber safety valve.

21)Apply ATF to the upper chamber safety valve and install it in the valve body noting the direction shown.

22)Apply ATF to the two new O-rings and install the

0-

rings in the valve body in the positions shown.

23)lnstall the gear pump assembly in the valve body by aligning the projection at the bottom of the gear pump assembly with the positioning hole in the valve body.

Take care not to let the O-rings come out of posi- tion in the valve body.

24)Tighten the socket bolts to the specified torque.

TORQUE: 5 N * m (0.5 kgfem, 1.3 Ibfoft)

1.5 x 3.5 mm 161

DOWN RELIEF

VALVE SEAT w 1

SAFETYVALVE

POSITIONING

13-1

7

BF40AoBFSOA

CYLINDER, PISTON, OIL TANK

CAUTION:

Do not reuse the O-ring.

Do not use a shop towel, cloth, gloves, etc. when reassembly.

Assemble the parts with care not to let the foreign particles and dirt enter the valve body and gear pump assembly.

1)

Clean the parts in the fresh ATF. Check that the parts are free from contamination with dust and dirt before reassembly.

[ l ] UPPER JOINT METAL

44

N-m, (4.5 kgf-m, 33 Ibf-ft)

[30] 5 mm SOCKET BOLT (4)

-,

[2] OIL SEAL

j

~ o n o t

1

/[3] OIL TANK

[4] CYLINDER

T W I R E ; D [71

[6] MOTOR CORD BRACKET A

WIRE BAND CLIP (2)

BRACKET B

10.82 x 1.78 mm

O-RING 2.0 x 52.5 mm

[23] OUTER TUBE GUIDE

Lp—

[22] O-RING 2.0 x 49.5 mm

[21] O-RING 2.0 x 45.54 mm

I i

[20] O-RING 2.4 x 15.8 mm

DO not reuse. j j

/

II

LOWEREND

,/

[16] O-RING 3.5 x41.7 mm

V

127 N-m, (12.9 kgf-m,

93 Ibf o f t )

~

13-1 8

111 VALVE BODY

[12] PISTON ROD

Do not disassemble.

[;4]FREE PISTON

‘

[15] O-RING 2.0 x

28.5 mm

BF40A-BF50A

11

1

2)

Apply ATF to a new O-ring, and install it on the free piston.

3) Apply ATF to a new O-ring and install it on the piston rod.

4) Apply ATF to the inner wall of the cylinder.

5)

Install the free piston in the cylinder taking care not to damage the O-ring, and pour the fresh ATF on the free piston.

6)

Install the piston rod in the cylinder taking care not to damage the O-ring.

11

1

PISTON ROD

121

O-RING

2.0 x28.5 mm

/ a —

7)

Push in the piston rod until the free piston end aligns with the bottom end as shown.

PI

O-RING

2.0 x 28.5 mm

Apply ATF to a new O-ring, and install it in the bottom piece.

141

CYLINDER

/

~

11

1

O-RING

2.0 x 34.5 mm

[2]

BOTTOM

PIECE

13-1 9

9) Apply ATF to the lower end of the cylinder and install the cylinder to the bottom piece.

10)

Set the cylinder/piston assembly vertically on the vise by holding the bottom piece.

CAUTlO N :

Take care not to tighten the vise too tight as it damages the bottom piece.

11)Pour the fresh ATF into the cylinder up to the top edge of the cylinder.

121

OUTER TUBE

,

LOWER END

12)Apply ATF to a new O-ring, and install it in the groove in the outer tube taking care not to damage the

0-

ring.

13-20

13)Attach a thin sealing tape around the threads at the end of the piston rod.

14)Apply ATF to the top of the piston rod and O-ring of the outer tube install the outer tub to the piston rod.

To install turn the outer tube by hand taking care not to damage the O-ring in the outer tube.

P

1 ‘

L

1

[21

Apply sealing tape.

15)Tighten the outer tube 2 or 3 turns, then apply LOC-

TITEB 241 or equivalent to the thread of the outer tube as shown.

16)Tighten the outer tube to the specified torque using the 30 mm lock nut wrench.

TORQUE: 64 Nom (6.5 kgfom, 47 Ibfoft)

17) Remove the pistonkylinder assembly from the vise and clean off the residual LOCTITEB from the outer tube.

,

121

Apply LOCTITEa 241 or equivalent.

[s.]

[41

LOCK NUT

WRENCH

30 40

0791 6-9690000

I I

13-21

18)Apply ATF to a new O-ring, and install it on the bot- tom piece.

19)Hold the valve body in a vise with shop towel or soft jaws as shown

CAUTION:

Take care not to tighten the vise too tight as it damages the valve body.

20)Loosen the manual valve 3 turns or more and pour the fresh ATF into the cylinder chamber up to the top edge of the valve body.

[1

I

CYLINDEWPISTON ASSY.

;7″

I

PI

O-RING

3.5 x 41.7 mm

21 Install the cylinder piston assembly to the valve body.

22)Apply ATF to new O-rings and install them on the outer tube guide.

23)Pour the fresh ATF into the cylinder chamber of the valve body up to the top edge of the valve body.

24)

Install the outer tube guide loosely.

11

1

O-RING

2.4×41.2 mm

[21

OUTER TUBE

GUIDE

/

[31

O-RING

2.0 x 45.5 mm

141

O-RING

I

2.0 x 49.5 mm

13-22

25)Tighten the outer tube guide to the specified torque using the lock nut wrench.

TORQUE: 88 N * m (9.0 kgf*m, 65 Ibf*ft)

26)Tighten the manual valve securely.

(S.]

LOCK NUT WRENCH

070PA-ZW40100

121

OUTER TUBE

GUIDE

27)Apply rubber grease or ATF to a new oil seal.Holding the oil seal with your fingers so that it shapes “U” and install it in the groove in the outer tube taking care not to damage the oil seal.

[2] Push in by deform- ing it lightly.

[ l ] OIL SEAL

0

28)Apply ATF to new O-ring and install it on the outer tube guide.

29)Apply ATF to the piston rod and install the oil tank by turning it taking care not to damage the oil seal in the oil tank.

30)Set the oil tank as shown and tighten the four 5 mm socket bolts to the specified torque.

TORQUE: 4.7 N * m (0.48 kgfem, 3.5 Ibf*ft)

PI

Push in aslant.

0

141

Hold in the shape “U”.

[5] 5 mm SOCKET BOLT (4)

14.7

N * m , (0.48 kgf*m,

3.5

1

—

161

31)Remove the sealing tape from the top end of the pis- ton rod.

~

DO not reuse.

I

13-23

POWER TRIM/TILT MOTOR

9

Make sure there is no metallic part (e.g. washer, etc.) on the magnets before installation.

After installing the yoke, lightly tap on the outer sur- face of the yoke with a plas- tic hammer (for snug fitting of the armature bearing).

,

[S] ARMATURE

Remove the burrs at the armature shaft with a fine emery paper before assem- bly.

Take care not to damage the oil seal during assem- bly.

[5] FRONT BRACKET ASSEMBLY

[2]5 mm SCREW(3)

2.2 N m, (0.22 kgf m,

1.6 Ibf *ft)

/

13-24

1)

Apply grease to the oil seal lip.

Check the oil seal lip.lf the oil seal lip is damaged, replace the front bracket as assembly.

2)

Expand the brushes and install the armature taking care not to damage the oil seal.

Remove the burrs at the armature shaft with a fine emery paper before assembly.

Make sure that the brush springs are in place

[ l ] ARMATURE

151

FRONT

BRACKET

A

I I

PI

BRUSH

SPRING

USHES

[4] OIL SEAL LIP

3)

Apply grease to a new motor O-ring and install it on the front bracket.

[ l ] 5 x 20 mm SCREW (3)

4)

Make sure there is no metallic part (e.g. washer, etc.) on the magnets before installation.

5) Apply grease to the yoke side end of the armature shaft. Hold the armature shaft and install the yoke.

6) Tighten the three 5 x 20 mm screws to the specified torque.

TORQUE: 2.2 N*m (0.22 kgfom, 1.6 Ibfoft)

7) After assembly, lightly tap on the outer surface of the yoke with a plastic hammer (for snug fitting of the armature bearing).

[3] MOTOR O-RING

pGGGJ

—

,[2]YOKE

13-25

MOTOR INSTALLATION

1)

Install the drive joint in the position of the gear pump assembly as shown.

BF40A-BFSOA

[l ] DRIVE JOINT

/

I

2)

Apply ATF to a new O-ring, and install it on the power trimhilt motor assembly.

[l ] OIL FILLER HOLE

[2] GEAR PUMP ASSEMBLY

, I

PI

3) Fill the gear pump chamber with the fresh ATF up to the upper edge of the chamber. If ATF in the valve body contains air bubbles, remove the air bubbles using an oil bottle or equivalent tool.

Do not pour ATF into the valve body gear pump chamber quickly. Pour the fluid slowly.

Trapped air in the system causes faulty operation.

Remove the air bubbles in the fluid completely.

4)

Install the power trimhlt motor assembly on the valve body so that the motor wires is at the oil filler port on the oil tank and align the motor shaft with the groove of the drive joint as shown.

MOTOR O-RING

2.4×66.6 mm

5) Set the motor cord bracket A as shown and tighten the four screw washers to the specified torque.

TORQUE: 6.4 N o r n (0.65 kgfom,

4.7 Ibfoft)

[l] SCREW WASHER (4)

MOTOR CORD

BRACKET A

13-26

6)

Clamp the motor wire to the motor cord bracket A with the wire band.

After securing the wires with a new wire band , cut the end so projected end length is 3

—

5 mm (0.1

—

0.2 in).

[ l ] WIRE BAND CLIP (2)

7)

Set the wire band clips on the clip bracket B, and secure the motor wire with them.

After securing the wires with new wire band clip, cut the end so projected end length is 3

—

5 mm (0.1

—

0.2 in).

[4] WIRE BAN

131

MOTOR CORE

BRACKET A d. AIR

BLEEDING

1) Lay the power trimhilt assembly on its side with the oil filler port facing up.

2)

Connect the battery, power trimhilt relay and the power trimhilt switch so that the power trim/tilt assem- bly functions while it is dismounted from the outboard motor.

3)

Check that the manual valve is loose. Using a syringe or equivalent tool, pour ATF in the oil tank slowly to fill it up.

4) After filling the oil tank, tighten the manual valve securely.

Check that the oil hole cap bolt is not installed.

5) Push the “UP” side of the power trimhilt switch to extend the piston rod fully.

While extending the piston rod, pour ATF into the oil tank to keep the oil level in the oil tank at full level.

6) Push the “DW” side of the power trimhilt switch to compress the piston rod fully.

Do not tighten the oil hole cap bolt this time. Let

ATF flow out of the oil filler port.

7)

Repeat the above steps 5 and 6 three to five times.

Repeat this procedure until the piston rod moves smoothly.

After the piston rod moves smoothly, push the “UP” side of the power trimhilt switch again to extend the piston rod fully.

While extending the piston rod, pour ATF into the oil tank to keep the oil level in the oil tank at full level.

[ l ]

OIL

FILLER HOLE

[2] OIL TANK

/

BF40AoBFSOA

[2] MOTOR CORE

13-27

BF40AoBFSOA

9) Hold the power trimhilt assembly upright and bring the oil level to the lower edge of the oil filler port. Loosely tighten the oil hole cap.

10)Move the piston rod from the fully compressed posi- tion to the fully extended position two or three times by operating the power trimhilt switch.

11)Push the “UP” side of the power trim/tilt switch again to extend the piston rod fully.

12) Remove the oil cap bolt and check the oil level. If the level is low, add ATF with a syringe or equivalent tool until ATF flows out of the oil filler port.

13) Install the new O-ring on the oil cap and tighten the oil cap to the specified torque.

TORQUE: 0.8 N*m (0.08 kgfom, 0.58 Ibf*ft)

14) Wipe up ATF spilled from the cylinder comp. thor- oughly. Operate the power trimhilt switch and check that the piston rod moves smoothly.

15) Check the blow pressure (P. 13-29).

’OLE

11

3IL FILLER

it

Ib

121

OIL LEVEL

(LOWER EDGE

OF

OIL FILLER HOLE)

[31

O-RING e. UPPER JOINT METAL INSTALLATION

1) Apply LOCTITEa 271 or equivalent to the thread of the piston rod.

2)

Install the upper joint metal against the piston rod.

3) Holding the piston rod and tighten the upper joint metal to the specified torque.

TORQUE: 44 N*m (4.5 kgf*m, 33 Ibfaft)

13-28

[4]

OIL HOLE CAP

0.8

N-m (0.08 kgfom,

0.58

[l] UPPER JOINT METAL

f. BLOW PRESSURE INSPECTION

After reassembling the power trim/tilt assembly, per- form the blow pressure inspection. Install the power trimhilt assembly after the blow pressure inspection.

Remove the power trim/tilt assembly if it is mounted.

Before blow pressure inspection, perform the following:

—

Connect each engine side wire and motor 2P con- nector so that the power trimhilt assembly can oper- ate while it is isolated from the outboard motor.

—

Extend the piston rod of the power trim/tilt assembly fully after operating (moving up and down) the pis- ton rod several times.

—

Check ATF level in the power trimhilt assembly oil

tank. It must be at the specified level (P. 13-28).

—

Perform the cylinder upper chamber side and lower chamber side blow pressure inspection using the special tools and commercially available pressure gauge.

—

Use the pressure gauge which measures 40 MPa

(400 kgf/cm2,

5,600 psi) or above with P/F 1/4 thread.

[ l ] For lower chamber side

[s.TooJ

GAUGE JOINT A

07OPJ-V150100

[2} For upper chamber side

[S.]

GAUGE JOINT B

07OPJ-V150200

LOWER CHAMBER SIDE BLOW PRESSURE

1) Remove the internal circlip, manual valve and sealing washer from the valve body. Install the special tool

(gauge joint body B) and the sealing washer, and tighten the special tool to the specified torque.

TORQUE: 1.7 N * m (0.17 kgf*m, 1.2 Ibf*ft)

Be sure to remove the manual valve with the piston rod fully extended, or ATF spurts out.

A small amount of ATF flows out after removing the valve. Install the special tool quickly.

Install the sealing washer securely not to let it col- lapse in the valve body.

2) Attach a commercially available pressure gauge to the special tool that is set in the valve body.

3) Be sure that ATF level in the oil tank

fied level (P. 13-28).

is

at the speci-

INTERNAL ClRCLlP

07OPJ-V150200

(Commercially available)

/

13-29

3) Push the «DN» side of the power trimhilt switch and compress the piston rod fully. With the piston rod compressed fully, measure the upper chamber blow pressure by reading the pressure gauge.

BLOW PRESSURE

(Upper chamber side)

27.9

—

34.8 MPa

(285

—

355 kgf/crn2,

4,504

—

5,049 psi)

If the blow pressure is out of the specified range, check each part of the power trimhilt assembly for oil leakage.

If there is no oil leakage but the blow pressure drops below the specified pressure quickly, the power trimkilt motor assembly can be faulty.

Replace the motor assembly with a new one and measure the blow pressure again.

[ l ] Compress fully.

BF40AoBFSOA

4) Push the «UP» side of the power trimhilt switch and extend the piston rod fully.

5)

Remove the special tool and pressure gauge from the valve body. Install the sealing washer, manual valve and the internal circlip in the valve body.

Be sure to remove the special tool with the piston rod fully extended, or ATF spurts out.

A small amount of ATF flows out after removing the tool. Install the manual valve quickly.

Install the sealing washer securely not to let it col- lapse in the valve body.

[ l ] SEALING WASHER

(S.]

[2] GAUGE JOINT A

07OPJ-V150100

u

6) Tighten the manual valve to the specified torque.

TORQUE: 1.7 N * m (0.17 kgf*m, 1.2 Ibfeft)

7) With the piston rod fully extended, check whether ATF

level is at the edge of the filler port of the oil tank (P.

13-28). If the oil level is low, add ATF up to the edge

of the filler port.

[6] MANUAL VALVE

[5] INTERNAL ClRCLlP

/

/

[4] PRESSURE GAUGE

(Commercially available)

13-31

1. Specifications

2. Service Information

3. Maintenance

4. Engine cover/Throttle/Choke

2 — 9

10 — 45

46 — 64

65 — 69

5. Fuel system

6. Flywheel/Timing belt

7. Engine removal/Installation

70 — 82

83 — 87

88 — 96

8. Water jacket cover/Thermostat/

Thermo switch 97 — 99

9. Cylinder head/Valves/Oil pump 100 — 115

10. Crankcase/Cylinder block/

Crankshaft/Piston 116 — 130

11. Propeller/Gear case/

Extension case

12. Oil pan/Primary gear case/Swivel case

13. Gas assist/Power tilt

14. Steering rod/Remote Control box (Remote Control type only)

15. Throttle bracket/ Shift lever/

Handlebar

(Tiller handle type only)

16. Electrical equipment

131 — 155

156 — 166

167 — 170

171 — 182

183 — 188

189 — 211

17. Operation

BF35a – 45a Y Supplement

212 — 234

235 — 246

BF40a – 50a X Supplement ‘95 247 — 255

BF40a – 50a V Supplement ‘02

BF40a – 50a U Supplement ‘03

BF40a – 50a T Supplement ‘03

262 — 268

269 — 390

391 — 430