BF15D.BFZOD Paper Book Part No. 66ZYOOO
PREFACE CONTENTS
This manual covers the construction, function and ser-
vicing procedures of the Honda BF15D, BF20D SPECIFICATIONS
Outboard Motors.
All information contained in this manual is based on the SERVICE INFORMATION
latest product information available at the time of print-
ing. We reserve the right to make changes at anytime
without notice. MAINTENANCE
No part of this publication may be reproduced, stored in
a retrieval system, or transmitted, in any form, by any PROPELLEWGEAR CASElEXTENSION CASE
means, electronic, mechanical, photocopying, record-
ing, or otherwise, without prior written permission of the
publisher. This includes text, figures, and tables. ENGINE COVERS
As you read this manual, you will find information that is
preceded by alNOTlcE symbol. The purpose of this mes- FUEL SYSTEM
sage is to help prevent damage to the outboard motor,
other property, or the environment.
RECOIL STARTER
SAFETY MESSAGES
Your safety, and the safety of others, are very impor-
tant. To help you make informed decisions, we have ENGINE REMOVALANSTALLATION
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
FLYWHEEMIMING BELT
with servicing these outboard motors. You must use
your own good judgment. CYLINDER HEADNALVESIOIL PUMP
You will find important safety information in a variety of
forms, including:
CRANKCASWCRANKSHAFT/PISTON
Safety Messages -- preceded by a safety alert A
symbol and one of three signal words, DANGER,
WARNING, or CAUTION. OIL CASElSTERN BRACKETBWIVEL CASE
These signal words mean:
You WILL be KILLED or SERIOUSLY SHIFT MECHANISM
HURT if you don't follow instructions.
! 1 . You CAN be KILLED or SERIOUSLY STEERING ROD/REMOTE CONTROL BOX
HURT if you don't follow instructions.
You CAN be HURT if you don't follow TILLER HANDLE
instructions.
Instructions -- how to service this outboard motor
ELECTRICALEQUIPMENT
correctly and safely.
WIRING DIAGRAMS
Honda Motor Co., Ltd
Service Publication Office
Date of Issue: July 2002
0 Honda Motor Co., Ltd.
,INDEX
BF15DmBF20D
1. SPECIFICATIONS ...................................................... 1-1 .
10 CYLINDER HEADNALVESIOIL PUMP ..................... 10-1
1. SPECIFICATIONS................................................... 1-1 1. CYLINDER HEAD REMOVAL................................. 10-2
2. DIMENSIONAL DRAWINGS ................................... 1-4 2 . OIL PUMP ............................................................... 10-5
3 . CYLINDER HEAD DISASSEMBLY ......................... 10-8
2. SERVICE INFORMATION .......................................... 2-1 4. VALVE SEAT REFACING ....................... 10-14
1. THE IMPORTANCE OF PROPER SERVICING ..... 2-1 5. CYLINDER HEAD ASSEMBLY ........... 1016
2 . IMPORTANT SAFETY PRECAUTIONS ................. 2-1 6. CYLINDER HEAD INSTALLATION............................ 1@18
3 . SYMBOLS USED IN THIS MANUAL ...................... 2-2
4 . SERIAL NUMBER LOCATIONS ............................. 2-2 11.CRANKCASE/CRANKSHAFT/PISTON..................... 11-1
5 . MAINTENANCE STANDARDS ............................... 2-3 1. THERMOSTATNVATER JACKET .......................... 11-2
6 . TORQUE VALUES ................................................ 2-6 2 . OIL STRAINER ... ...................... 11-8
7. SPECIAL TOOLS .................................................. 2-9 3 . PISTON............... ...................... 11-9
8. TROUBLESHOOTING........................................... 2-1 1 4. CRANKSHAFT/CYLINDERBLOCK ......................... 11-15
9. CABLE & HARNESS ROUTING............................ 2-29
10. LUBRICATION POINTS ........................................ 2-41 12.OIL CAWSTERN BRACKETKWIVEL CASE ......... 12-1
1 . OIL CASE ............................. ...................... 12-2
3. MAINTENANCE.......................................................... 3-1 2 . FRICTION ADJUST ...................... 12-4
1. MAINTENANCE SCHEDULE.................................. 3-1 3 . MOUNT FRAME ..... ...................... 12-6
2 . ENGINE OIL .............................................. 4 . STERN BRACKET .................................. 12-7
3. OIL FILTER CARTRIDGE ......................... 5 . SWIVEL CASE........................................................ 12-11
4 . GEAR CASE OIL .........................................
5 . SPARK PLUG.......................................................... 3-6 13.SHIFT LINKAGE ........................................................ 13-1
1. SHIFT ARMnHROTTLE ARM ................................ 13-2
2 . SHIFT LEVER ......................................................... 13-3
8. FUEL FILTER ........ ......................................... 3-1 1 3. SHIFT SHAFT ......................................................... 13-4
14.STEERING ROD/REMOTE CONTROL BOX............. 14-1
1. STEERING ROD..................................................... 14-1
12. TIMING BELT ........................................................ 3-15 2. REMOTE CONTROL CABLE ..........................
13. CRANKCASE BREATHER.................................... 3-19 3. CONTROL BOX WIRE HARNESS ......................... 14-4
14. EXHAUST EMISSION (Bodensee model)............. 3-19 4 . REMOTE CONTROL BOX ..............................
4 . PROPELLEWGEAR CASElEXTENSlON CASE ....... 4-1 15.TILLER HANDLE ....................................................... 15-1
1. PROPELLER ........................................................... 4-2 1. TILLER HANDLE .................................................... 15-2
2 . PROPELLER SHAFT HOLDER .............................. 4-3 2 . TILLER HANDLE BRACKET ...................... 15-6
3 . GEAR CASE ASSEMBLY ...................... 3 . THROTTLE GRIP .............................
4 . WATER PUMP ........ .......................................... 4-1 1 4 . STARTER SWITCH ..............
5. VERTICAL SHAFT/BEVEL GEAR ......... 5. EMARGENCY STOP SWlTC
6. WATER PUMP HOUSING ...................................... 4-21
7. GEAR CASEIANODENVATER SCREEN ................ 4-27 16. ELECTRICAL EQUIPMENT....................................... 16-1
8. EXTENSION CASE ................................................. 4-28 1. STARTER MOTOR .......................... ...... 16-1
9. EXHAUST CHAMBER COVER . 2. STARTER CABLE (Type with 12A c ......16-13
3. CHARGE WIRE (Type with6A charge coil) ............. 16-17
5. ENGINE COVERS....................................................... 5-1 4. NEUTRAL SWITCH/INDICATOR ........................... 16-20
1. ENGINE COVER ..................................................... 5-1 5. IGNITION CONTRO
2 . LEFT ENGINE UNDER COVER ............................. 5-2 6. CONNECTOR BRACKET A .................................. 16-24
3 . RIGHT ENGINE UNDER COVER ........................... 5-3 7. IGNITION COIL ......... ...................... 16-27
8 . REGULATOR/RECTI
6. FUEL SYSTEM ........................................................... 6-1
1. SILENCER/CARBURETOR ................................... 6-2 17.WIRING DIAGRAMS .................................................. 17-1
2 . CHOKE CABLE ....................................................... 6-17
3. FUEL PUMP/FUEL FILTER .................................... 6-18
4 . FUEL TANK ............................................................. 6-21
7. RECOIL STARTER ..................................................... 7-1
1. NEUTRAL START CABLE ...................................... 7-1
2. RECOIL STARTER ................................................. 7-2
3 . STARTER CASE B.................................................. 7-10
8. ENGINE REMOVAUINSTALLATION........................ 8-1
1. ENGINE REMOVAL ................................................ 8-1
2 . ENGINE INSTALLATION........................................ 8-6
9. FLYWHEEVTIMING BELT ......................................... 9-1
1. FLYWHEEUCOILS ................................................. 9-2
2 . TIMING BELT/PULLEYS ......................................... 9-8
, 1 SPECIFICATIONS
1. SPECIFICATIONS 2. DIMENSIONAL DRAWINGS
1. SPECIFICATIONS
DIMENSIONS AND WEIGHTS
BF15D
Model BF15D
Description Code I BALJ
TY Pe SH SHS SR LH LHS LR
Overall length 650 mm 640 mm 650 mm 640 mm
(25.6 in) (25.2in) (25.6 in) (25.2 in)
Overall width
Overall height 1,110 mm (43.7 in) 1,240 mm (48.8 in)
Dry weight 46.5 kg 50.0 kg 50.5 kg 49.5 kg 53.0 kg 52.0 kg
(With propeller mounted) (103 Ib) (110 Ib) (111 Ib) (109 Ib) (117 Ib) (115 Ib)
Operating weight 47.9 kg 51.4 kg 51.9 kg 50.9 kg 54.4 kg 53.4 kg
(106 Ib) (113 Ib) (114 Ib) (112 Ib) (120 Ib) (118 Ib)
Transom height 433 mm (17.0 in) 563 mm (22.2 in)
Transom angle 5 stage adjustment (4" , 8" , 12" , 16" , 20" )
Tilting angle 71" 72"
Swivel angle 45" right and left
BF20D
Model BF20D
Description Code BAMJ
SH I SHS I SR 1 LH 1 LHS I LR
Overall length 650 mm 640 mm 650 mm
(25.6 in) (25.2 in) (25.6 in)
Overall width 350mm (13.8 in1
Overall heiaht 1.110 mm (43.7 in) I 1.240 mm (48.8 in)
Dry weight
Operating weight
46.5 kg
(103 Ib)
47.9 kg
I50.0 kg
(110 Ib)
51.4 kg 51.9 kg 50.9 kg
1 E;k? I
54.4 kg
52.0 kg
(1151b)
53.4 kg
(106 Ib) (113 Ib) (114 Ib) (112 Ib) (120 Ib) (118 Ib)
Transom height 433 mm (17.0 in) 563 mm (22.2 in)
Transom anale
Tilting angle 71 I 72"
Swivel angle 45" right and left
1-I
, BF15D-BF20D
Model BFl5D BF20D
Tvpe I Water cooled 4-stroke, overhead valve, vertical twin
Displacement I ' 350 cm3 (21.5 cu. in)
Bore x stroke I 59 x 64 mm (2.3 x 2.5 in)
Rated horsepower 11.O kW (15 PS) 14.7 kW (20 PS)
at 5.500 min-l (ram)
Maximum torque 25.2 N.m (2.6 kgf.m, 18.8 Ibf.ft) 25.8 N.m (2.6 kgf.m, 18.8 Ibf.ft)
at 3.500 min-I (rpm) at 5,000 min-l (rpm)
Compression ratio I 9.2: 1
Fuel consumption I 313 g (11.O oz.)/kWh 337 g (11.9 oz.)/kWh
Cooling system
Ignition system
I Forced water circulation by impeller pump with thermostat
CDI
Ignition timing 0'12" B.T.D.C.
Spark plua CR5EH-9 (NGK). U16FER9 (DENSO)
Carburetor I Horizontal butterflv valve type sinale carburetor
Lubricating system Forced lubrication by trochoid pump
Oil capacity 1.O e (1.06 US qt, 0.88 Imp qt) at oil change
1.3 e (1.37 US qt, 1.14 Imp qt) with oil filter replacement
Recommended oil SAE 1OW-30, API Service classification SG/SH/SJ
Starting system SH, LH Type: Recoil starter
SHS, SR, LHS, LR Type: Electric starter and recoil starter
Stopping system
Fuel used
L Ignition primary circuit ground
Automotive unleaded gasoline (minimum 86 pump octane)
Fuel tank capacity Steel tank: 13 e (3.43 US gal, 2.86 Imp gal)
Plastic tank: 12 e (3.17 US gal, 2.64 Imp gal)
Fuel pump Mechanical plunger type
Exhaust system I Under water type
LOWER UNIT
Model BF15D, BF20D
Clutch Dog clutch (Forward-neutral-reverse)
Gear ratio 0.48 (13/27)
Reduction type Spiral bevel gear
Gear case oil capacity 0.285 e (0.27 US qt, 0.23 Imp qt)
PropeIler Number of blades 4
Diameter 235 mm (9-1/4 in)
1 Pitch 203 mm (8.0 in)
Rotating direction Clockwise (viewed from rear)
I -2
PREFACE CONTENTS
This manual covers the construction, function and ser-
vicing procedures of the Honda BF15D, BF20D SPECIFICATIONS
Outboard Motors.
All information contained in this manual is based on the SERVICE INFORMATION
latest product information available at the time of print-
ing. We reserve the right to make changes at anytime
without notice. MAINTENANCE
No part of this publication may be reproduced, stored in
a retrieval system, or transmitted, in any form, by any PROPELLEWGEAR CASElEXTENSION CASE
means, electronic, mechanical, photocopying, record-
ing, or otherwise, without prior written permission of the
publisher. This includes text, figures, and tables. ENGINE COVERS
As you read this manual, you will find information that is
preceded by alNOTlcE symbol. The purpose of this mes- FUEL SYSTEM
sage is to help prevent damage to the outboard motor,
other property, or the environment.
RECOIL STARTER
SAFETY MESSAGES
Your safety, and the safety of others, are very impor-
tant. To help you make informed decisions, we have ENGINE REMOVALANSTALLATION
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
FLYWHEEMIMING BELT
with servicing these outboard motors. You must use
your own good judgment. CYLINDER HEADNALVESIOIL PUMP
You will find important safety information in a variety of
forms, including:
CRANKCASWCRANKSHAFT/PISTON
Safety Messages -- preceded by a safety alert A
symbol and one of three signal words, DANGER,
WARNING, or CAUTION. OIL CASElSTERN BRACKETBWIVEL CASE
These signal words mean:
You WILL be KILLED or SERIOUSLY SHIFT MECHANISM
HURT if you don't follow instructions.
! 1 . You CAN be KILLED or SERIOUSLY STEERING ROD/REMOTE CONTROL BOX
HURT if you don't follow instructions.
You CAN be HURT if you don't follow TILLER HANDLE
instructions.
Instructions -- how to service this outboard motor
ELECTRICALEQUIPMENT
correctly and safely.
WIRING DIAGRAMS
Honda Motor Co., Ltd
Service Publication Office
Date of Issue: July 2002
0 Honda Motor Co., Ltd.
,INDEX
BF15DmBF20D
1. SPECIFICATIONS ...................................................... 1-1 .
10 CYLINDER HEADNALVESIOIL PUMP ..................... 10-1
1. SPECIFICATIONS................................................... 1-1 1. CYLINDER HEAD REMOVAL................................. 10-2
2. DIMENSIONAL DRAWINGS ................................... 1-4 2 . OIL PUMP ............................................................... 10-5
3 . CYLINDER HEAD DISASSEMBLY ......................... 10-8
2. SERVICE INFORMATION .......................................... 2-1 4. VALVE SEAT REFACING ....................... 10-14
1. THE IMPORTANCE OF PROPER SERVICING ..... 2-1 5. CYLINDER HEAD ASSEMBLY ........... 1016
2 . IMPORTANT SAFETY PRECAUTIONS ................. 2-1 6. CYLINDER HEAD INSTALLATION............................ 1@18
3 . SYMBOLS USED IN THIS MANUAL ...................... 2-2
4 . SERIAL NUMBER LOCATIONS ............................. 2-2 11.CRANKCASE/CRANKSHAFT/PISTON..................... 11-1
5 . MAINTENANCE STANDARDS ............................... 2-3 1. THERMOSTATNVATER JACKET .......................... 11-2
6 . TORQUE VALUES ................................................ 2-6 2 . OIL STRAINER ... ...................... 11-8
7. SPECIAL TOOLS .................................................. 2-9 3 . PISTON............... ...................... 11-9
8. TROUBLESHOOTING........................................... 2-1 1 4. CRANKSHAFT/CYLINDERBLOCK ......................... 11-15
9. CABLE & HARNESS ROUTING............................ 2-29
10. LUBRICATION POINTS ........................................ 2-41 12.OIL CAWSTERN BRACKETKWIVEL CASE ......... 12-1
1 . OIL CASE ............................. ...................... 12-2
3. MAINTENANCE.......................................................... 3-1 2 . FRICTION ADJUST ...................... 12-4
1. MAINTENANCE SCHEDULE.................................. 3-1 3 . MOUNT FRAME ..... ...................... 12-6
2 . ENGINE OIL .............................................. 4 . STERN BRACKET .................................. 12-7
3. OIL FILTER CARTRIDGE ......................... 5 . SWIVEL CASE........................................................ 12-11
4 . GEAR CASE OIL .........................................
5 . SPARK PLUG.......................................................... 3-6 13.SHIFT LINKAGE ........................................................ 13-1
1. SHIFT ARMnHROTTLE ARM ................................ 13-2
2 . SHIFT LEVER ......................................................... 13-3
8. FUEL FILTER ........ ......................................... 3-1 1 3. SHIFT SHAFT ......................................................... 13-4
14.STEERING ROD/REMOTE CONTROL BOX............. 14-1
1. STEERING ROD..................................................... 14-1
12. TIMING BELT ........................................................ 3-15 2. REMOTE CONTROL CABLE ..........................
13. CRANKCASE BREATHER.................................... 3-19 3. CONTROL BOX WIRE HARNESS ......................... 14-4
14. EXHAUST EMISSION (Bodensee model)............. 3-19 4 . REMOTE CONTROL BOX ..............................
4 . PROPELLEWGEAR CASElEXTENSlON CASE ....... 4-1 15.TILLER HANDLE ....................................................... 15-1
1. PROPELLER ........................................................... 4-2 1. TILLER HANDLE .................................................... 15-2
2 . PROPELLER SHAFT HOLDER .............................. 4-3 2 . TILLER HANDLE BRACKET ...................... 15-6
3 . GEAR CASE ASSEMBLY ...................... 3 . THROTTLE GRIP .............................
4 . WATER PUMP ........ .......................................... 4-1 1 4 . STARTER SWITCH ..............
5. VERTICAL SHAFT/BEVEL GEAR ......... 5. EMARGENCY STOP SWlTC
6. WATER PUMP HOUSING ...................................... 4-21
7. GEAR CASEIANODENVATER SCREEN ................ 4-27 16. ELECTRICAL EQUIPMENT....................................... 16-1
8. EXTENSION CASE ................................................. 4-28 1. STARTER MOTOR .......................... ...... 16-1
9. EXHAUST CHAMBER COVER . 2. STARTER CABLE (Type with 12A c ......16-13
3. CHARGE WIRE (Type with6A charge coil) ............. 16-17
5. ENGINE COVERS....................................................... 5-1 4. NEUTRAL SWITCH/INDICATOR ........................... 16-20
1. ENGINE COVER ..................................................... 5-1 5. IGNITION CONTRO
2 . LEFT ENGINE UNDER COVER ............................. 5-2 6. CONNECTOR BRACKET A .................................. 16-24
3 . RIGHT ENGINE UNDER COVER ........................... 5-3 7. IGNITION COIL ......... ...................... 16-27
8 . REGULATOR/RECTI
6. FUEL SYSTEM ........................................................... 6-1
1. SILENCER/CARBURETOR ................................... 6-2 17.WIRING DIAGRAMS .................................................. 17-1
2 . CHOKE CABLE ....................................................... 6-17
3. FUEL PUMP/FUEL FILTER .................................... 6-18
4 . FUEL TANK ............................................................. 6-21
7. RECOIL STARTER ..................................................... 7-1
1. NEUTRAL START CABLE ...................................... 7-1
2. RECOIL STARTER ................................................. 7-2
3 . STARTER CASE B.................................................. 7-10
8. ENGINE REMOVAUINSTALLATION........................ 8-1
1. ENGINE REMOVAL ................................................ 8-1
2 . ENGINE INSTALLATION........................................ 8-6
9. FLYWHEEVTIMING BELT ......................................... 9-1
1. FLYWHEEUCOILS ................................................. 9-2
2 . TIMING BELT/PULLEYS ......................................... 9-8
, 1 SPECIFICATIONS
1. SPECIFICATIONS 2. DIMENSIONAL DRAWINGS
1. SPECIFICATIONS
DIMENSIONS AND WEIGHTS
BF15D
Model BF15D
Description Code I BALJ
TY Pe SH SHS SR LH LHS LR
Overall length 650 mm 640 mm 650 mm 640 mm
(25.6 in) (25.2in) (25.6 in) (25.2 in)
Overall width
Overall height 1,110 mm (43.7 in) 1,240 mm (48.8 in)
Dry weight 46.5 kg 50.0 kg 50.5 kg 49.5 kg 53.0 kg 52.0 kg
(With propeller mounted) (103 Ib) (110 Ib) (111 Ib) (109 Ib) (117 Ib) (115 Ib)
Operating weight 47.9 kg 51.4 kg 51.9 kg 50.9 kg 54.4 kg 53.4 kg
(106 Ib) (113 Ib) (114 Ib) (112 Ib) (120 Ib) (118 Ib)
Transom height 433 mm (17.0 in) 563 mm (22.2 in)
Transom angle 5 stage adjustment (4" , 8" , 12" , 16" , 20" )
Tilting angle 71" 72"
Swivel angle 45" right and left
BF20D
Model BF20D
Description Code BAMJ
SH I SHS I SR 1 LH 1 LHS I LR
Overall length 650 mm 640 mm 650 mm
(25.6 in) (25.2 in) (25.6 in)
Overall width 350mm (13.8 in1
Overall heiaht 1.110 mm (43.7 in) I 1.240 mm (48.8 in)
Dry weight
Operating weight
46.5 kg
(103 Ib)
47.9 kg
I50.0 kg
(110 Ib)
51.4 kg 51.9 kg 50.9 kg
1 E;k? I
54.4 kg
52.0 kg
(1151b)
53.4 kg
(106 Ib) (113 Ib) (114 Ib) (112 Ib) (120 Ib) (118 Ib)
Transom height 433 mm (17.0 in) 563 mm (22.2 in)
Transom anale
Tilting angle 71 I 72"
Swivel angle 45" right and left
1-I
, BF15D-BF20D
Model BFl5D BF20D
Tvpe I Water cooled 4-stroke, overhead valve, vertical twin
Displacement I ' 350 cm3 (21.5 cu. in)
Bore x stroke I 59 x 64 mm (2.3 x 2.5 in)
Rated horsepower 11.O kW (15 PS) 14.7 kW (20 PS)
at 5.500 min-l (ram)
Maximum torque 25.2 N.m (2.6 kgf.m, 18.8 Ibf.ft) 25.8 N.m (2.6 kgf.m, 18.8 Ibf.ft)
at 3.500 min-I (rpm) at 5,000 min-l (rpm)
Compression ratio I 9.2: 1
Fuel consumption I 313 g (11.O oz.)/kWh 337 g (11.9 oz.)/kWh
Cooling system
Ignition system
I Forced water circulation by impeller pump with thermostat
CDI
Ignition timing 0'12" B.T.D.C.
Spark plua CR5EH-9 (NGK). U16FER9 (DENSO)
Carburetor I Horizontal butterflv valve type sinale carburetor
Lubricating system Forced lubrication by trochoid pump
Oil capacity 1.O e (1.06 US qt, 0.88 Imp qt) at oil change
1.3 e (1.37 US qt, 1.14 Imp qt) with oil filter replacement
Recommended oil SAE 1OW-30, API Service classification SG/SH/SJ
Starting system SH, LH Type: Recoil starter
SHS, SR, LHS, LR Type: Electric starter and recoil starter
Stopping system
Fuel used
L Ignition primary circuit ground
Automotive unleaded gasoline (minimum 86 pump octane)
Fuel tank capacity Steel tank: 13 e (3.43 US gal, 2.86 Imp gal)
Plastic tank: 12 e (3.17 US gal, 2.64 Imp gal)
Fuel pump Mechanical plunger type
Exhaust system I Under water type
LOWER UNIT
Model BF15D, BF20D
Clutch Dog clutch (Forward-neutral-reverse)
Gear ratio 0.48 (13/27)
Reduction type Spiral bevel gear
Gear case oil capacity 0.285 e (0.27 US qt, 0.23 Imp qt)
PropeIler Number of blades 4
Diameter 235 mm (9-1/4 in)
1 Pitch 203 mm (8.0 in)
Rotating direction Clockwise (viewed from rear)
I -2
