INTRODUCTION
This manual covers service and repair procedures for
Honda BF40D•BF50D 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
NOTICE
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:
• S S a a f f e e t t y y l l a a b b e e l l s s –– on the engine cover.
• S S a a f f e e t t y y m m e e s s s s a a g g e e s s –– Preceded by a safety alert symbol
and one of three signal words, DANGER, WARNING,
or CAUTION.
These signal words mean:
You
DANGER
SERIOUSLY HURT if you don't
follow instructions.
You
WARNING
SERIOUSLY HURT if you don't
follow instructions.
You CAN be HURT if you don't
CAUTION
follow instructions.
• I I n n s s t t r r u u c c t t i i o o n n s s –– how to service this outboard motor
correctly and safely.
Date of lssue: March, 2008
© Honda Motor Co., Ltd.
WILL
be
KILLED
or
CAN
be
KILLED
or
H H o o n n d d a a M M o o t t o o r r C C o o . . , , L L t t d d . .
S S e e r r v v i i c c e e P P u u b b l l i i c c a a t t i i o o n n s s O O f f f f i i c c e e
1
CONTENTS
SPECIFICATIONS
SERVICE INFORMATION
MAINTENANCE
COVER
PROGRAMMED-FUEL INJECTION
ENGINE REMOVAL/INSTALLATION
ALTERNATOR/PULSER ROTOR/TIMING BELT
WATER JACKET COVER/THERMOSTAT
CYLINDER HEAD/VALVES/OIL PUMP
CRANKCASE/CYLINDER BLOCK/
CRANKSHAFT/PISTONS
PROPELLER/GEAR CASE/EXTENSION CASE/
OIL CASE
SHIFT ROD/ENGINE UNDER CASE
MOUNT CASE/STERN BRACKET/
SWIVEL CASE
POWER TRIM/TILT ASSEMBLY/GAS ASSISTED
DAMPER ASSEMBLY
STEERING ROD/REMOTE CONTROL BOX
[REMOTE CONTROL TYPE]
TILLER HANDLE [TILLER HANDLE TYPE]
CABLES/THROTTLE ARM BRACKET
ELECTRICAL EQUIPMENT
WIRING DIAGRAMS/SYSTEM DIAGRAM
Sections in pale print are included in VOLUME 2.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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