Note: from the list of manuals below, we recommend downloading the factory service manual for your model engine first. If you model isn’t listed amongst the factory service manuals, download the workshop manual. Download a manual straight to your computer in just seconds. DOWNLOAD HONDA FACTORY SERVICE MANUALS   BF2D MODELS BF8D BF9.9D BF10D BF8B BF10B BFP8D BFP9.9D BFP10D BFP8B BFP10B MODELS BF9.9 BF15A MODELS BF15D BF20D MODELS BF20A BF25A MODELS BF25D BF30D MODELS BF35A BF45A MODELS BF40A BF50A MODELS BF75 BF100 MOELS AND BF8A SUPPLEMENT BF75A BF90A BF75AV BF90AV MODELS BF115A BF130A MODELS BF135A BF150A MODELS BF175A BF200A BF225A MODELS   DOWNLOAD HONDA WORKSHOP MANUAL BELOW   1978-2001 Honda Outboard 2HP thru 130HP Workshop Manual

DOWNLOAD 1978-2001 Honda 4-Stroke Service Manual 2-130 HP Motors

Workshop Service Manual Repair Application: Honda Outboard 4-Stroke Motors for 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 & 1999 2000 2001 2 hp, 5 hp, 7.5 hp, 8 hp, 9.9 hp, 15 hp, 25 hp, 30 hp, 35 hp, 40 hp, 45 hp, 50 hp, 75 hp, 90 hp, 115 hp & 130 hp engines.

This Honda Outboard Workshop Service Repair Manual describes the service & maintenance procedures for the complete Honda Outboard motor. Follow the Maintenance Schedule recommendations to ensure that the engine is in peak operating condition. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the engine.

All chapters in the service manuals apply to the whole Honda Outboard engine and illustrates procedures for removal & installation of components that are in detailed step-by-step fashion.

Manual Language: ENGLISH
Pages: 369
File Format: PDF
File Delivered In: PDF Format 
Zoom in/out: YES
Works on all computers!

EXACT MODELS COVERED IN THIS WORKSHOP SERVICE REPAIR MANUAL:

HONDA YEARS AND MODELS:

1978 Honda Outboard 4-Stroke Models

9.9 - 1978 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
7.5 - 1978 Honda 7.5HP (7.5 HP) Outboard 4-Stroke
2 -    1978 Honda  2HP (2 HP) Outboard 4-Stroke

1979 Honda Outboard 4-Stroke Models

9.9 - 1979 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
7.5 - 1979 Honda 7.5HP (7.5 HP) Outboard 4-Stroke
2    - 1979 Honda  2HP (2 HP) Outboard 4-Stroke

1980 Honda Outboard 4-Stroke Models

9.9 - 1980 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
7.5 - 1980 Honda 7.5HP (7.5 HP) Outboard 4-Stroke
2    - 1980 Honda  2HP (2 HP) Outboard 4-Stroke

1981 Honda Outboard 4-Stroke Models

9.9 - 1981 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
7.5 - 1981 Honda 7.5HP (7.5 HP) Outboard 4-Stroke
2 -    1981 Honda  2HP (2 HP) Outboard 4-Stroke

1982 Honda Outboard 4-Stroke Motor

9.9 - 1982 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
7.5 - 1982 Honda 7.5HP (7.5 HP) Outboard 4-Stroke
2    - 1982 Honda  2HP (2 HP) Outboard 4-Stroke

1983 Honda Outboard 4-Stroke Motors

9.9 - 1983 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
7.5 - 1983 Honda 7.5HP (7.5 HP) Outboard 4-Stroke
2    - 1983 Honda  2HP (2 HP) Outboard 4-Stroke

1984 Honda Outboard 4-Stroke Motor

9.9 - 1984 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
7.5 - 1984 Honda 7.5HP (7.5 HP) Outboard 4-Stroke
2    - 1984 Honda  2HP (2 HP) Outboard 4-Stroke

1985 Honda Outboard 4-Stroke Engine

9.9 - 1985 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
7.5 - 1985 Honda 7.5HP (7.5 HP) Outboard 4-Stroke
2    - 1985 Honda  2HP (2 HP) Outboard 4-Stroke

1986 Honda Outboard 4-Stroke Engines

9.9 - 1986 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
7.5 - 1986 Honda 7.5HP (7.5 HP) Outboard 4-Stroke
5    - 1986 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1986 Honda  2HP (2 HP) Outboard 4-Stroke

1987 Honda Outboard 4-Stroke Engines

9.9 - 1986 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
7.5 - 1986 Honda 7.5HP (7.5 HP) Outboard 4-Stroke
5    - 1986 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1986 Honda  2HP (2 HP) Outboard 4-Stroke

1988 Honda Outboard 4-Stroke Engine

15  - 1987 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1987 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1987 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1987 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1987 Honda  2HP (2 HP) Outboard 4-Stroke

1989 Honda Outboard 4-Stroke Engine

15  - 1989 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1989 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1989 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1989 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1989 Honda  2HP (2 HP) Outboard 4-Stroke

1990 Honda Outboard Four Stroke Engine

15  - 1990 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1990 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1990 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1990 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1990 Honda  2HP (2 HP) Outboard 4-Stroke

1991 Honda Outboard Four Stroke Engines

45  - 1991 Honda 45HP (45 HP) Outboard 4-Stroke
35  - 1991 Honda 35HP (35 HP) Outboard 4-Stroke
15  - 1991 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1991 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1991 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1991 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1991 Honda  2HP (2 HP) Outboard 4-Stroke

1992 Honda Outboard Four Stroke Engines

45  - 1992 Honda 45HP (45 HP) Outboard 4-Stroke
35  - 1992 Honda 35HP (35 HP) Outboard 4-Stroke
15  - 1992 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1992 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1992 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1992 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1992 Honda  2HP (2 HP) Outboard 4-Stroke

1993 Honda Outboard Four Stroke Motors

45  - 1993 Honda 45HP (45 HP) Outboard 4-Stroke
35  - 1993 Honda 35HP (35 HP) Outboard 4-Stroke
15  - 1993 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1993 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1993 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1993 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1993 Honda  2HP (2 HP) Outboard 4-Stroke

1994 Honda Outboard Four Stroke Motor

45  - 1994 Honda 45HP (45 HP) Outboard 4-Stroke
35  - 1994 Honda 35HP (35 HP) Outboard 4-Stroke
25  - 1994 Honda 25HP (25 HP) Outboard 4-Stroke
15  - 1994 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1994 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1994 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1994 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1994 Honda  2HP (2 HP) Outboard 4-Stroke

1995 Honda Outboard 4-Stroke Motor Service Manual Models

50  - 1995 Honda 50HP (50-HP) Outboard 4-Stroke
40  - 1995 Honda 40HP (40 HP) Outboard 4-Stroke
30  - 1995 Honda 30HP (30 HP) Outboard 4-Stroke
25  - 1995 Honda 25HP (25 HP) Outboard 4-Stroke
15  - 1995 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1995 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1995 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1995 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1995 Honda  2HP (2 HP) Outboard 4-Stroke

1996 Honda Outboard 4-Stroke Engine Repair Manual Models

90  - 1996 Honda 90HP (90 HP) Outboard 4-Stroke
75  - 1996 Honda 75HP (75-HP) Outboard 4-Stroke
50  - 1996 Honda 50HP (50-HP) Outboard 4-Stroke
45  - 1996 Honda 45HP (45 HP) Outboard 4-Stroke
40  - 1996 Honda 40HP (40 HP) Outboard 4-Stroke
35  - 1996 Honda 35HP (35 HP) Outboard 4-Stroke
30  - 1996 Honda 30HP (30 HP) Outboard 4-Stroke
25  - 1996 Honda 25HP (25 HP) Outboard 4-Stroke
15  - 1996 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1996 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1996 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1996 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1996 Honda  2HP (2 HP) Outboard 4-Stroke

1997 Honda Outboard Four Stroke Motor Service Repair Models

90  - 1997 Honda 90HP (90 HP) Outboard 4-Stroke
75  - 1997 Honda 75HP (75-HP) Outboard 4-Stroke
50  - 1997 Honda 50HP (50-HP) Outboard 4-Stroke
40  - 1997 Honda 40HP (40 HP) Outboard 4-Stroke
30  - 1997 Honda 30HP (30 HP) Outboard 4-Stroke7
25  - 1997 Honda 25HP (25 HP) Outboard 4-Stroke
15  - 1997 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1997 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1997 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1997 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1997 Honda  2HP (2 HP) Outboard 4-Stroke

1998 Honda Outboard Four Stroke Engine Service Manual Models

130- 1998 Honda 130HP (130 HP) Outboard 4-Stroke
115- 1998 Honda 115HP (115 HP) Outboard 4-Stroke
90  - 1998 Honda 90HP (90 HP) Outboard 4-Stroke
75  - 1998 Honda 75HP (75-HP) Outboard 4-Stroke
50  - 1998 Honda 50HP (50-HP) Outboard 4-Stroke
40  - 1998 Honda 40HP (40 HP) Outboard 4-Stroke
30  - 1998 Honda 30HP (30 HP) Outboard 4-Stroke7
25  - 1998 Honda 25HP (25 HP) Outboard 4-Stroke
15  - 1998 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1998 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1998 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1998 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1998 Honda  2HP (2 HP) Outboard 4-Stroke

1999 Honda Outboard Four Stroke Engine Service Repair Manual Models

130- 1999 Honda 130HP (130 HP) Outboard 4-Stroke
115- 1999 Honda 115HP (115 HP) Outboard 4-Stroke
90  - 1999 Honda 90HP (90 HP) Outboard 4-Stroke
75  - 1999 Honda 75HP (75-HP) Outboard 4-Stroke
50  - 1999 Honda 50HP (50-HP) Outboard 4-Stroke
40  - 1999 Honda 40HP (40 HP) Outboard 4-Stroke
30  - 1999 Honda 30HP (30 HP) Outboard 4-Stroke7
25  - 1999 Honda 25HP (25 HP) Outboard 4-Stroke
15  - 1999 Honda 15HP (15 HP) Outboard 4-Stroke
9.9 - 1999 Honda 9.9HP (9.9 HP) Outboard 4-Stroke
8    - 1999 Honda 8HP (8 HP) Outboard 4-Stroke
5    - 1999 Honda 5HP (5 HP) Outboard 4-Stroke
2    - 1999 Honda  2HP (2 HP) Outboard 4-Stroke

 

TAGS: Honda Outboard 4-stroke motor service manual repair BF130A BF130 BF 130 BF115A BF115 115 BF90 BF90A 90 BF75 BF75A 75 BF45A BF45 45 BF40A BF40 40 BF35 BF35A 35 BF30 BF30A 30 BF25 BF25A 25 BF15 BF15A BF 15 BF9.9A BF9.9 9.9 BF75 BF100 BF8A BF8 8 BF80 BF5A BF50 BF2A BF20 Horsepower (horse power) 1 cylinder, 2 cylinder 3 cylinder 4 cylinder, Impeller, how to change impeller, why does engine stall, engine stalls at trolling speed, engine hisitates when throttle applied, engine lacks power, engine bogs during acceleration, excessive blue smoke, spark plug gap, spark plug heat range spark plug brand, how to rebuild power head, how to remove lower unit, engine is overheating

COMMON HONDA 4-STROKE SEARCHES:

The gear case is considered that part of the outboard below the mid section exhaust housing. The gearcase contains the propeller shaft, the driven and pinion gears, the drive shaft from the powerhead and the water pump. On models equipped with shifting capabilities, the forward and reverse gears, together with the clutch, shift assembly, and related linkage, are all housed within the case. The single most important task for proper gearcase maintenance is inspecting it for signs of leakage after each use. If oil can get out, then water can get in. And, water, mixing with or replacing the oil in the gearcase will wreak havoc with the shafts and gears contained within the housing.

The second most important task for proper gearcase maintenance is checking and maintaining the oil inside the case. Not only is it important make sire the oil is at t k proper level (not above or below), but it is important to check the oil for signs of contamination from moisture. Water entering the gear case will usually cause the oil to turn a slightly milky-white color. Also, significant amounts of water mixed with the oil will give the appearance of an overfilled condition. If you suspect water in the gearcase, start by draining and closely inspecting the fluid (refer to the procedures found in the Maintenance and Tune-Up section). Then, refill the unit with fresh oil and test the outboard (by using it!). Watch the fluid level closely after the test, and for the first few
outings. If any oil leaks out or water enters, either the propeller shaft seal must be replaced or the gear case must be disassembled, inspected and completely overhauled.

To be honest, a complete overhaul is recommended, because corrosion and damage may have occurred if moisture was in the gearcase long enough. But, in some cases, if the leak was caught in time, and there is no significant wear, damage or corrosion in the gearcase, the propeller shaft seal can usually be replaced with the gearcase still installed
to the outboard. The last, most important task you can perform to help keep your gearcase in top shape, is to flush the inside and outside of the gearcase after each use.'~ e outside of the unit with a hose to remove any sea life, salt, chemicals or other corrosion inducing substances that you may have picked up in the water. Cleaning the gearcase will also help you spot potential.

A neglected lower unit cannot be expected to perform to maximum efficiency, compared with a unit receiving TLC (tender loving care) trouble, such as gearcase oil leaks, cracks or damage that may have occurred during use. Remove any sand, silt or dirt that could potentially damage seals or clog passages. Once you've rinsed the outside, hook up a flushing device and do the same for the inside. Again, details are found in the Maintenance and Tune-up section, look under Flushing the Cooling System.

REMOVAL & INSTALLATION

The most common reason for removrng and installing the gearcase IS to perform service (inspect or replace) the water pump impeller. On all motors except the 2.0-3.5 hp (78cc) motors, the water pump is found on the gearcase-to-midsection (sometimes known as the intermediate or exhaust housing) split line. On 2.0-3.5 hp (78cc) motors the pump is mounted just in front of the propeller, so the gearcase does not have to be removed on these small motors in order to service the pump. Removal and installation ~procedures re ~riveted ere for each of the gearcases used on these ~&nson/~. exploded views are also provided, in case disassembly and overhaul are required.

1. For safety, disconnect the spark plug lead, then ground it to the cylinder head.

2. If necessary for service or access, remove the propeller, for details refer to the procedure in the Maintenance and Tune-Up section.

3. Remove the two screws securing the lower unit to the exhaust housing.

4. Taking Care not to damage the driveshaft and the water tube, separate the lower unit from the exhaust housing by pulling straight downward.

5. If necessary for service or overhaul, drain the gear oil from the gearcase.

6. Thoroughly inspect the gearcase and exhaust housing for signs of damage. Make sure all mating surfaces are clean and free of debris, corrosion or damage.

To install:

7. Apply a light coating of OMC Moly Lube, or equivalent assembly lubricant to the driveshaft splines. Be sure to coat only the SIDES of the splines and not the top of the shaft, as that could hydraulically prevent the driveshaft from fully seating in the crankshaft spline.

8. Apply a light coat of clean liquid soap to the water tube grommet.

9. Apply a light coating of OMC Nut Lock, or equivalent thread lock to the threads of the 2 gearcase mounting screws.

10. Install the gearcase, while carefully aligning the water tube in the grommet and the driveshaft s~linesto the crankshaft shaft. If necessary, turn the propeller shaft slowly clockwise (when viewed from the shaft end) in align the splines.