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HONDA marine BF225A User Manual

HONDA marine BF225A
535 pages
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BF175A - BF200A - BF225A
[BF175A USES BF200A/225A AS BASE MANUAL]
HONDA OUTBOARD SERVICE
WORKSHOP AND REPAIR

Table of Contents

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HONDA marine BF225A Specifications

General IconGeneral
Rated Power225 HP @ 5500 RPM
Ignition SystemMicroComputer Programmed
Starting SystemElectric
Lubrication SystemWet Sump
Cooling SystemWater Cooled
Trim Range-4° to +16°
Tilt Range72°
Recommended FuelUnleaded Gasoline (86 Octane)
SteeringRemote
ExhaustThrough Propeller
Bore & Stroke89 mm x 3.5 in
Full Throttle RPM Range5000 - 6000 rpm
Valve TrainSOHC
Fuel DeliveryProgrammed Fuel Injection
Alternator Output90 amp
Shaft LengthL, X
Engine Type4-Stroke SOHC 24-Valve V6
Displacement3, 583 cc (219 cubic inches)

Summary

Specifications

Dimensions and Weights

Detailed dimensions and weights for BF175A and BF200A/BF225A outboard motors.

Frame

Specifications related to the frame, including transom height, tilting angle, and swivel angle.

Types of Honda BF175A Outboard Motors

Chart detailing types, shaft lengths, and features of BF175A outboard motors.

Engine

Detailed specifications for the BF200A and BF225A engines, including displacement, power, and lubrication.

Lower Unit

Specifications for the lower unit, including clutch, gear ratio, and oil capacity.

Service Information

Symbols Used in This Manual

Explanation of symbols used in the manual for procedures and references.

Serial Number Location

Information on where to find the engine and product identification numbers.

Maintenance Standards

Standards for engine parts, including valve clearance, piston O.D., and ring groove width.

Torque Values

Table of specified torque values for various engine and gear case bolts and nuts.

Special Tools

List of special tools required for specific procedures with their part numbers and applications.

Troubleshooting

Diagnostic flowcharts for engine problems like hard starting and rough running.

Cable/Harness Routing

Diagrams showing the routing of various cables and harnesses on the engine.

Tube Routing

Illustrations and labels for routing various tubes, including fuel and water lines.

Lubrication

Instructions and diagrams for applying marine grease to specific parts for lubrication.

Maintenance

Maintenance Schedule

Regular service schedule for the outboard motor, detailing items and intervals.

Engine Oil

Procedures for checking and changing the engine oil, including oil level and capacity.

Oil Filter

Instructions for replacing the engine oil filter, including torque specifications.

Gear Case Oil

Procedures for inspecting, adding, and replacing gear case oil.

Spark Plugs

Inspection, cleaning, and replacement of spark plugs, including gap measurement.

Valve Clearance

Procedure for inspecting and adjusting valve clearance with specified cold engine values.

Thermostat

Instructions for thermostat removal, installation, and inspection, including opening temperatures.

Fuel Strainer (Low Pressure Side)/Water Separater

Procedures for inspecting, removing, and reassembling the low-pressure fuel strainer.

Fuel Strainer (High Pressure Side)

Instructions for replacing the high-pressure fuel strainer, including relief procedures.

Idling

Inspection and adjustment procedures for engine idling speed and idle control system.

Throttle Control Cable/Throttle Link

Adjustment procedures for throttle control cables and links to ensure proper operation.

Shift Control Cable

Inspection and adjustment of the shift control cable, including alignment checks.

Timing Belt

Procedures for inspecting, adjusting, and installing the timing belt.

Alternator Belt

Inspection of the alternator belt for tension and deflection, and adjustment procedures.

Engine Cover/Cover Lock

Engine Cover

Disassembly and adjustment procedures for the engine damper hook.

Front Separate Cover

Procedures for removing and installing the front separate cover.

Electric Parts Cover

Procedures for removing and installing the electric parts cover.

Left/Right Engine Under Cover

Removal procedures for the left and right engine under covers.

Cover Lock Cable/Engine Cover Bracket

Removal and exploded view of the cover lock cable and engine cover bracket.

Front Lock Assembly/Front Cover Bracket

Procedures for removing and installing the front lock assembly and front cover bracket.

Engine Cover Bracket

Removal/installation and exploded view of the engine cover bracket.

Programmed Fuel Injection

Service Precautions

Important precautions for PGM-FI system troubleshooting and ECM handling.

Vacuum Connections

Diagram showing vacuum connections for the PGM-FI system.

Circuit Diagram

Electrical circuit diagram for the PGM-FI system.

Troubleshooting

Guide for troubleshooting PGM-FI system issues using MIL blinking codes.

Fuel Lines

Procedures for relieving fuel pressure, measuring fuel pressure, and inspecting fuel lines.

Fuel Injectors/Fuel Pressure Regulator

Inspection and replacement of fuel injectors and the fuel pressure regulator.

Fuel Pump (High Pressure Side)/Vapor Separator

Disassembly and installation of the high-pressure fuel pump and vapor separator.

Fuel Pump (Low Pressure Side)

Removal, inspection, and exploded view of the low-pressure fuel pump.

Oil Pressure Switch (High Pressure Side)

Testing and replacement procedures for the high-pressure oil switch.

Oil Pressure Switch (Low Pressure Side)

Testing and replacement procedures for the low-pressure oil switch.

Knock Sensor

Replacement procedure for the knock sensor.

ECT Sensor

Replacement procedure for the Engine Coolant Temperature (ECT) sensor.

Overheat Sensor 1,2

Replacement procedure for overheat sensors 1 and 2.

IAC Valve

Replacement procedure for the Idle Air Control (IAC) valve.

IAT Sensor

Replacement procedure for the Intake Air Temperature (IAT) sensor.

MAP Sensor

Replacement procedure for the Manifold Absolute Pressure (MAP) sensor.

H02S

Replacement procedure for the Heated Oxygen Sensor (H02S).

Baro Sensor

Replacement procedure for the Barometric (BARO) sensor.

CKP Sensor

Replacement procedure for the Crankshaft Position (CKP) sensor.

TDC Sensor 1, 2

Replacement procedure for the Top Dead Center (TDC) sensors 1 and 2.

VTEC System (BF225A)

Operation check and replacement of the VTEC solenoid valve for BF225A models.

Silencer Case

Exploded view and removal/installation procedures for the silencer case.

Throttle Body

Procedures for removing, inspecting, cleaning, and installing the throttle body.

Intake Manifold

Procedures for removing, testing, and installing the intake manifold.

Exhaust Manifold

Procedures for removing, exploded view, and installing the exhaust manifold.

Alternator/Timing Belt/Pulleys

Alternator

Inspection, removal, disassembly, and assembly procedures for the alternator.

Timing Belt/Timing Belt Drive Pulley/Driven Pulleys

Procedures for removing, exploded view, degreasing/cleaning/lubrication, and installation of timing belt components.

Engine Removal/Installation

Removal

Step-by-step instructions for removing the engine, including disconnecting components.

Exploded View

Exploded view diagram showing parts of the engine mount case and related hardware.

Installation

Procedures for installing the engine assembly, including torque specifications and alignment.

Water Jacket/Relief Valve/Flush Valve

Water Line Description

Diagram illustrating the water circulation path within the engine, including thermostat and manifolds.

Water Jacket

Procedures for removing and installing the water jacket, emphasizing gasket replacement.

Relief Valve

Disassembly and reassembly instructions for the relief valve.

Flush Valve

Disassembly and reassembly procedures for the flush valve.

Cylinder Head/Valves

Cylinder Head Assembly Removal

Steps for removing the cylinder head assembly, including component removal and timing belt adjustments.

Cylinder Head Disassembly

Procedures for disassembling the cylinder head, including rocker arm and camshaft removal.

Inspection

Inspection procedures for valve springs, valve face/stem O.D., valve guide I.D., and clearances.

Valve Guide Replacement

Procedures for replacing valve guides, including chilling and reaming steps.

Valve Seat Reconditioning

Instructions for reconditioning valve seats using specialized cutters for smooth and concentric seats.

Cylinder Head Reassembly

Exploded view and steps for reassembling the cylinder head, including lubrication points.

Cylinder Head Assembly Installation

Procedures for installing the cylinder head assembly, including torque specifications and gasket replacement.

Flywheel/Oil Pump

Removal

Steps for removing the oil pump assembly and flywheel, including relevant parts.

Oil Pump Disassembly

Exploded view and steps for disassembling the oil pump assembly.

Inspection

Inspection procedures for oil pump body, rotors, and clearances with standard and service limit values.

Exploded View

Exploded view diagram of the flywheel and related components for removal and installation.

Installation

Procedures for installing the flywheel, flywheel boss, and reassembling the oil pump.

Cylinder Block/Crankshaft/Piston

Oil Filler Extension

Exploded view and installation procedures for the oil filler extension.

Crankcase Cover/Crankshaft/Piston Disassembly

Steps for disassembling the crankcase cover, crankshaft, and pistons.

Inspection

Inspection of piston skirt O.D., cylinder I.D., and piston-to-cylinder clearance.

Bearing Selection

Procedure for selecting crankshaft main and connecting rod bearings based on code numbers.

Exploded View

Exploded view of the cylinder block, crankshaft, and related components.

Crankcase Cover/Crankshaft/Piston Reassembly

Procedures for reassembling pistons, rings, and crankshaft components.

Propeller/Gear Case/Extension Case

Propeller

Procedures for removing and installing the propeller, including torque and split pin details.

Gear Case Assembly

Steps for removing the gear case assembly, including tilt and shift rod procedures.

Water Pump/Shift Rod

Disassembly procedures for the water pump and shift rod.

Propeller Shaft Holder Assembly

Removal and installation of the propeller shaft holder assembly.

Propeller Shaft/Propeller Shaft Holder

Removal of clutch shifter, shift slider, and related components.

Vertical Shaft/Bevel Gear

Disassembly procedures for the vertical shaft and bevel gear assembly.

Shim Selection

Procedures for selecting and calculating shim thickness for forward bevel gear and thrust shim.

Shim Position

Diagrams showing the correct position of shims for LD, XD, XXD and XCD, XXCD types.

Backlash Adjustment

Procedures for adjusting forward bevel gear backlash and checking thrust clearance.

Lower Rubber Motor Mount

Removal procedures for the lower rubber motor mount and extension case.

Extension Case/Undercover

Removal and installation procedures for the extension case and related components.

Oil Pan/Mounting Case

Oil Pan/Exhaust Pipe/Water Tube

Procedures for removing the oil pan, exhaust pipes, and water tubes.

Mount Case/Upper Mount Rubber/Shift Shaft A

Disassembly procedures for the mount case, upper mount rubber, and shift shaft A.

Swivel Case/Power Trim/Tilt Assembly

Swivel Case/Stern Bracket Assembly Removal/Installation

Procedures for removing and installing the swivel case and stern bracket assembly.

Power Trim/Tilt Assembly/Stern Bracket/Swivel Case Assembly

Disassembly procedures for the power trim/tilt assembly, stern bracket, and swivel case.

Swivel Case/Mount Frame

Disassembly procedures for the swivel case and mount frame.

Power Trim/Tilt Assembly

Disassembly procedures for the power trim/tilt assembly components.

Steering Rod/Remote Control Box

Steering Rod (Optional Part)

Removal and installation procedures for the optional steering rod.

Remote Control Box (Optional Part)

Disassembly and assembly of the optional remote control box.

Control Panel (Optional Part)

Disassembly and assembly procedures for the optional control panel.

Cables/Shift Link Bracket/Shift Arm

Remote Control Cable (Shift Side/Throttle Side)

Procedures for removing and installing the remote control cables.

Throttle Arm/Shift Link Bracket

Removal and installation procedures for the throttle arm and shift link bracket.

Shift Arm/Link Rod/Neutral Switch

Procedures for removing and installing the shift arm, link rod, and neutral switch.

Electrical Equipment

Component Location

Diagrams showing the location of key electrical components on the engine.

PGM-FI Main Relay/Power Tilt Relay

Removal and inspection procedures for the PGM-FI main relay and power tilt relay.

ECM

Procedures for removing and installing the Engine Control Module (ECM).

Starter Motor

Procedures for removing, inspecting, and installing the starter motor.

ACG Fuse Box/Fuse Box

Inspection procedures for the ACG fuse box and individual fuses.

Switch Panel and Indicator Wire Harnesses

Procedures for removing and installing switch panels and indicator wire harnesses.

Inspection

Inspection procedures for ignition switch, emergency stop switch, and warning buzzer.

Operation

Programmed Fuel Injection System (PGM-FI)

General overview of the PGM-FI system, its controls, and self-diagnosis function.

System Configuration

Diagram showing the interconnected components of the PGM-FI system.

Basic Controls

Explanation of basic ECM controls for fuel injection, ignition timing, and idle air control.

Correction Controls

How the ECM makes corrections to fuel injection using various sensor signals.

Device Control

Overview of ECM controls for systems like VTEC, fuel cut solenoid valve, and high-pressure fuel pump.

Ignition Timing Control

How the ECM determines and controls ignition timing based on engine conditions.

Idle Control System

How the IAC valve maintains optimum idle speed by adjusting bypass air.

Alert and Warning System

Function of the alert/warning system using lights and buzzers for system abnormalities.

Indicator Light/Buzzer Operation Mode List

Table detailing indicator light and buzzer operations based on engine conditions.

Alternator Warning System

How the alternator warning system detects and indicates faults like power generation failure.

Water Separator Water Level Sensor Full Level Warning System

System operation when water level sensor detects excess water in the separator.

PGM-FI Buzzer Warning System

How the PGM-FI system sounds the buzzer for anomalies detected by self-diagnosis.

Oil Pressure Alert System

How the ECM detects abnormal oil pressure and reduces engine speed.

Overheat Alert System

How the overheat sensor signals ECM, causing warnings and engine speed reduction.

Fuel Line Cut Solenoid Valve

Function of the fuel line cut solenoid valve in preventing vapor lock.

Intake Air Bypass (IAB) Control System

Function of the IAB system in controlling intake air for optimized engine performance.

VTEC System (BF225A)

How the VTEC system switches valve timing and lift for optimal engine performance.

Wiring Diagrams

Top Mount/Panel Mount Control Box

Wiring diagram for the top mount and panel mount control box.

Side Mount Control Box

Wiring diagram for the side mount control box.

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