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Honda BF135A User Manual

Honda BF135A
692 pages
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This manual covers the construction, function and
serving procedures for the Honda BF135A•BF150A
outboard motors.
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 anytime
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 prior written permission of the
publisher. This includes text, figures, and tables.
As you read this manual, you will find information that is
preceded by a symbol. The purpose of this
message is to help prevent damage to the outboard
motor, other property, or the environment.
SAFETY MESSAGES
Your safety, and the safety of others, are very important.
To help you make informed decisions, we have provided
safety messages and other safety information throughout
this manual. Of course, it is not practical or possible to
warn you about all the hazards associated with servicing
these outboard motors. You must use your own good
judgment.
You will find important safety information in a variety of
forms, including:
Safety Labels –– on the engine cover.
Safety messages –– Preceded by a safety alert symbol
and one of three signal words, DANGER, WARNING,
or CAUTION.
These signal words mean:
You WILL be KILLED or
SERIOUSLY HURT if you don't
follow instructions.
You CAN be KILLED or
SERIOUSLY HURT if you don't
follow instructions.
You CAN be HURT if you don't
follow instructions.
Instructions –– how to service this outboard motor
correctly and safely.
Honda Motor Co., Ltd.
Service Publications Office
NOTICE
PREFACE CONTENTS
SPECIFICATIONS
1
SERVICE INFORMATION
2
MAINTENANCE
3
ENGINE COVER/COVER LOCK
4
PROGRAMMED-FUEL INJECTION
5
ALTERNATOR
6
ENGINE REMOVAL/INSTALLATION
7
THERMOSTAT/RELIEF VALVE/FLUSH VALVE
8
CRANKSHAFT PULLEY/CAM CHAIN
9
CYLINDER HEAD/VALVES
10
OIL PUMP/FLYWHEEL
11
CRANKCASE/BALANCER
12
CYLINDER BLOCK/CRANKSHAFT/PISTONS
13
PROPELLER/GEAR CASE/EXTENSION CASE/
OIL CASE
14
MOUNTING CASE/STERN BRACKET/SWIVEL
CASE/POWER TRIM/TILT ASSEMBLY
15
STEERING ROD/REMOTE CONTROL BOX
16
CABLES/SHIFT LINK BRACKET/SHIFT ARM/
NEUTRAL SWITCH
17
ELECTRICAL EQUIPMENT
18
OPERATION
19
SYSTEM DIAGRAM/WIRING DIAGRAM
20
21
21
Date of lssue: November, 2003
© Honda Motor Co., Ltd.
DANGER
WARNING
CAUTION

Table of Contents

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Honda BF135A Specifications

General IconGeneral
Horsepower135 hp
Bore & Stroke87 mm x 99 mm (3.4 x 3.9 inches)
Full Throttle RPM Range5000-6000 RPM
Cooling SystemWater cooled
Fuel DeliveryProgrammed Fuel Injection (PGM-FI)
Ignition SystemMicroComputer Programmed
Starting SystemElectric
LubricationWet Sump
Gear Ratio2.14:1
Alternator Output40 Amp
Trim Range-4° to +16°
Gear ShiftF-N-R
Trim MethodPower Trim & Tilt
Displacement2354 cc
ExhaustThrough Prop
Recommended FuelUnleaded Gasoline (86 Octane)
Shaft LengthL: 20 inches / X: 25 inches
WeightL: 217 kg (478 lbs) / X: 220 kg (485 lbs)
Recommended Engine OilSAE 10W-30
Engine Type4-Stroke SOHC 4 Cylinder

Summary

PREFACE

SAFETY MESSAGES

General safety information and precautions for servicing outboard motors.

SERVICE INFORMATION

1. THE IMPORTANCE OF PROPER SERVICING

Explains why proper servicing is essential for safety and reliability.

2. IMPORTANT SAFETY PRECAUTIONS

Details essential safety practices and equipment for servicing.

3. SERVICE RULES

Rules to follow for safe and correct servicing procedures.

4. SYMBOLS USED IN THIS MANUAL

Explains symbols used throughout the manual for instructions.

5. SERIAL NUMBER LOCATIONS

Shows where to find engine and product identification numbers.

6. MAINTENANCE STANDARDS

Provides standard specifications and service limits for engine parts.

7. TORQUE VALUES

Lists torque specifications for various engine bolts and nuts.

8. SPECIAL TOOLS

Lists special tools required for specific tasks.

9. TROUBLESHOOTING

Troubleshooting guide for engine, ignition, starter, fuel, charging, and alert systems.

MAINTENANCE

1. MAINTENANCE SCHEDULE

Outlines regular service intervals for various maintenance items based on time or hours.

2. ENGINE OIL

Procedures for checking and changing engine oil, including capacity and recommended oil.

3. OIL FILTER

Instructions for replacing the oil filter, including required tools and torque.

4. GEAR CASE OIL

Details on checking and adding gear case oil, including capacity and recommended oil.

ENGINE COVER/COVER LOCK

1. ENGINE COVER

Procedures for removing, installing, disassembling, and assembling the engine cover.

2. FRONT SEPARATE COVER

Steps for removing and installing the front separate cover.

3. L./R. ENGINE UNDER COVERS

Procedures for removing and installing the left and right engine under covers.

PROGRAMMED-FUEL INJECTION

1. SERVICE PRECAUTIONS

Crucial precautions for PGM-FI system troubleshooting and fuel line service.

2. CIRCUIT DIAGRAM

Electrical circuit diagram for the PGM-FI system, showing component connections.

5. TROUBLESHOOTING

General troubleshooting guide for the PGM-FI system when the MIL is ON or OFF.

ALTERNATOR

1. SILENCER DUCT

Procedures for removing and installing the silencer duct.

2. ALTERNATOR

Inspection and disassembly/assembly of the alternator.

ENGINE REMOVAL/INSTALLATION

1. REMOVAL

Step-by-step procedure for removing the engine from the outboard motor.

2. INSTALLATION

Step-by-step procedure for installing the engine onto the outboard motor.

THERMOSTAT/RELIEF VALVE/FLUSH VALVE

1. THERMOSTAT

Procedures for inspecting, identifying, and assembling the thermostat.

2. WATER RELIEF TUBE/RELIEF VALVE

Steps for removing, disassembling, and inspecting the water relief tube and relief valve.

3. FLUSH VALVE

Procedures for disassembling, inspecting, and assembling the flush valve.

CRANKSHAFT PULLEY/CAM CHAIN

1. DISASSEMBLY

Detailed steps for disassembling the crankshaft pulley and cam chain components.

2. ASSEMBLY

Detailed steps for assembling the crankshaft pulley and cam chain components.

CYLINDER HEAD/VALVES

1. CYLINDER HEAD COVER REMOVAL

Steps for removing the cylinder head cover.

2. CYLINDER HEAD COVER DISASSEMBLY

Steps for disassembling the cylinder head cover.

3. CAMSHAFT/ROCKER ARM DISASSEMBLY

Procedures for disassembling camshafts and rocker arms.

4. CAMSHAFT/ROCKER ARM INSPECTION

Inspection procedures for camshafts and rocker arms, including clearances and O.D.

OIL PUMP/FLYWHEEL

1. EOP SWITCH/OIL FILTER FLANGE

Removal and installation of the EOP switch and oil filter flange.

2. OIL PUMP

Procedures for removing, disassembling, inspecting, and assembling the oil pump.

3. FLYWHEEL

Procedures for removing and installing the flywheel.

CRANKCASE/BALANCER

1. CRANKCASE/BALANCER CASE ASSEMBLY REMOVAL

Steps to remove the crankcase and balancer case assembly.

2. BALANCER CASE ASSEMBLY DISASSEMBLY

Procedures for disassembling the balancer case assembly.

3. INSPECTION

Inspection of balancer shaft journal O.D., axial free play, and oil clearance.

CYLINDER BLOCK/CRANKSHAFT/PISTONS

1. DISASSEMBLY

Steps to disassemble the cylinder block, crankshaft, and pistons.

2. INSPECTION

Inspection of piston skirt O.D., cylinder sleeve I.D., and clearances.

3. BEARING SELECTION

Guide to selecting connecting rod and main bearings based on code letters and tolerance.

PROPELLER/GEAR CASE/EXTENSION CASE/OIL CASE

1. PROPELLER

Procedures for removing and installing the propeller.

2. GEAR CASE ASSEMBLY [*1]

Steps for removing and installing the gear case assembly for specific types.

3. WATER PUMP/SHIFT ROD [*1]

Procedures for removing and installing the water pump and shift rod.

MOUNTING CASE/STERN BRACKET/SWIVEL CASE/POWER TRIM/TILT ASSEMBLY

1. MOUNTING CASE

Removal and installation procedures for the mounting case.

2. STERN BRACKET/SWIVEL CASE REMOVAL/INSTALLATION

Steps for removing and installing the stern bracket and swivel case.

3. STERN BRACKET/SWIVEL CASE/POWER TRIM/TILT ASSEMBLY

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

STEERING ROD/REMOTE CONTROL BOX

1. STEERING ROD

Procedures for removing and installing the steering rod.

2. REMOTE CONTROL BOX (OPTIONAL PART)

Disassembly and assembly of the remote control box.

3. CONTROL PANEL (OPTIONAL PART)

Disassembly and assembly of the control panel.

CABLES/SHIFT LINK BRACKET/SHIFT ARM/NEUTRAL SWITCH

1. REMOTE CONTROL CABLE/GROMMET

Procedures for removing and installing the remote control cable and grommet.

2. SHIFT LINK BRACKET/NEUTRAL SWITCH

Steps for removing and installing the shift link bracket and neutral switch.

3. SEAL HOLDER

Procedures for removing and installing the seal holder.

ELECTRICAL EQUIPMENT

1. STARTER MOTOR

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

2. STARTER CABLE

Procedures for removing and installing the starter cable.

3. ECM/PGM-FI MAIN RELAY/FUSE BOX

Procedures for removing and installing the ECM, PGM-FI main relay, and fuse box.

OPERATION

1. DOHC (SWING ARM TYPE) + VTEC

Explains the structure and features of the DOHC engine with VTEC system.

2. CHAIN DRIVE CAM DRIVE SYSTEM

Describes the chain drive cam drive system structure and features.

3. INDEPENDENT CYLINDER HEAD/CYLINDER BLOCK COOLING SYSTEM

Details the independent cooling system for cylinder head and block.

SYSTEM DIAGRAM/WIRING DIAGRAM

WIRING DIAGRAM

Electrical wiring diagram showing connections for various components.

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