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 DOWNLOAD HONDA WORKSHOP MANUAL BELOW 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! 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.
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Keep this owner's manual handy, so you can refer to it at any time. This owner's manual is considered a permanent part of the engine and should remain with the.
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.
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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.
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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. For safety, disconnect the spark plug lead, then ground it to the cylinder head.
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If necessary for service or access, remove the propeller, for details refer to the procedure in the Maintenance and Tune-Up section. Remove the two screws securing the lower unit to the exhaust housing. Taking Care not to damage the driveshaft and the water tube, separate the lower unit from the exhaust housing by pulling straight downward. If necessary for service or overhaul, drain the gear oil from the gearcase.
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. Apply a light coat of clean liquid soap to the water tube grommet. Apply a light coating of OMC Nut Lock, or equivalent thread lock to the threads of the 2 gearcase mounting screws. Install the gearcase, while carefully aligning the water tube in the grommet and the driveshaft slinesto the crankshaft shaft. If necessary, turn the propeller shaft slowly clockwise (when viewed from the shaft end) in align the splines.