Troubleshooting Guide - Honda

ENTroubleshooting GuideBF40D, BF50DContents*Tap or click the relevant issue.- Indicator lamp turns on / off- Engine does not start- Engine stops after it's started / Enginestops when it's running- If the outboard motor was submerged- If the starting system does not operate(Start the engine with the emergencystarter rope)This troubleshooting guide is for reference purposes andsupplements the owner’s manual that came with youroutboard motor. Always refer to the Owner’s manual forclarification and more detail on the processes shown inthis document.Photos in this guide may not match your actual model.It is recommended that you download this PDF and storeit in your device.Web instruction manual, Official owner's manual PDF &Dealer locatorhttps://www.hondappsv.com

Indicator lamp turns on / off1/4Denotation of IndicatorsOil Pressure IndicatorDuring normal operation, this indicator remainsturned on.It turns off and the buzzer sounds when the oillevel is low and/or the engine lubrication systemis faulty. The engine speed slows down gradually.Overheat IndicatorDuring normal operation, this indicator is off.The overheat indicator turns on and the buzzersounds when the engine cooling circuit is faulty.The engine speed slows down.ACG IndicatorDuring normal operation, this indicator is off.The ACG indicator turns on and the buzzer soundswhen the charging system is faulty.PGM-FI IndicatorDuring normal operation, this indicator is off.The PGM-FI indicator turns on and the buzzersounds when the engine control system is faulty.When the engine key is turned on, all theindicators come on for a short time, and thebuzzer sounds twice.

Indicator lamp turns on / off2/4Symptom and solutionSYMPTOMOverheat warning system comes onOverheat warning system comes on.Overheat warning buzzer sounds.Engine speed decreases and stops.Engine speed cannot be increased by opening the throttle.Engine will stop whthin 20 seconds after engine speed islimited.POSSIBLE CAUSES & SOLUTIONSCooling water intake port clogged. Clean the cooling waterintake port.Spark plugs have incorrect heat range. Replace the sparkplugs. See method Faulty water pump.Thermostat clogged.Faulty thermostat.Cooling water passage clogged.Exhaust gas enters cooling system.Consult your dealer.

Indicator lamp turns on / off3/4SYMPTOMOil pressure indicator does not turn onOil pressure indicator does not come on.Oil pressure warning buzzer sounds.Engine speed decreases.Engine speed cannot be increased by opening the throttle.POSSIBLE CAUSES & SOLUTIONSInsufficient engine oil. Add engine oil to the specified level. See methodIncorrect engine oil is used. Change the engine oil. See method

Indicator lamp turns on / offSYMPTOMPGM-FI warning system comes onPGM-FI indicator turns on.PGM-FI warning buzzer soundsPOSSIBLE CAUSES & SOLUTIONSPGM-FI warning system is faulty. Consult your dealer.SYMPTOMACG warning system comes onACG indicator turns on.ACG warning buzzer sounds intermittently.POSSIBLE CAUSES & SOLUTIONSBattery voltage is too high or low. Check the battery. See methodFaulty ACG. Consult your dealer.4/4

Engine does not start1/4Starter motor operates but the enginedoes not startPOSSIBLECAUSESSOLUTIONSRefuel.No fuel in the fueltank. See methodFuel tank knob isclosed.Open the fuel tank knob.Fuel hose connectoris not connectedproperly.Re-connect the fuel hose connector.Clean the fuel tank filter.Fuel tank filter isclogged. See methodReplace the fuel filter.Fuel filter is clogged. See methodFuel hose is kinked.Re-locate the fuel hose.Using contaminatedor spoiled petrol.Dispose of the old fuel and clean thefuel tank. Fill with new petrol. See method

Engine does not startPOSSIBLECAUSESFuel pump is faulty.2/4SOLUTIONSConsult your dealer.Replace the blown fuse with a newone.Fuse has blown. See methodDirty spark plug.Consult your dealer.Spark plug gap isincorrect.Adjust the gap. See methodReplace the spark plug.Spark plug isdamaged. See methodCrank sensor isfaulty.Consult your dealer.ECU malfunction.Consult your dealer.Ignition coil is faulty.Consult your dealer.

Engine does not startPOSSIBLECAUSES3/4SOLUTIONSWire harness isfaulty.Consult your dealer.Electrical leak of theemergency stopswitch wire.Consult your dealer.Emergency stopswitch does notreturn to thestarting position.Consult your dealer.Tighten the spark plug.Spark plug is loose. See methodEmergency stopswitch is notinstalled correctly.Reinstall the emergency stop switch.

Engine does not start4/4Starter motor does not operatePOSSIBLECAUSESSOLUTIONSACG coil is faulty.Consult your dealer.Wire harness isfaulty.Consult your dealer.Shift lever is not inthe neutral position.Shift to the neutral position.Replace the blown fuse with a newone.Fuse has blown. See method

Engine stops after it's started /Engine stops when it's runningEngine stops; no fuel in the fuel tankPOSSIBLECAUSESSOLUTIONSRefuel.No fuel in the fueltank. See method1/2

Engine stops after it's started /Engine stops when it's running2/2Fuel tank contains fuel but engine stopsPOSSIBLECAUSESSOLUTIONSWater contaminationin the fuel.Consult your dealer.Fuel tank knob is notopen.Open the fuel tank knob.Replace the fuel filter.Fuel filter is clogged. See methodClean the fuel tank filter.Fuel tank filter isclogged. See methodEngine idling speedis too low.Consult your dealer.Fuel pump faulty.Consult your dealer.Sucking air from thefuel hose, hose joint,connector or primerbulb.Consult your dealer.

If the outboard motor wassubmerged1/8A submerged outboard motor must be servicedimmediately after it is recovered from the water inorder to minimize corrosion.If there is a Honda outboard motor dealer nearby,take the outboard motor immediately to the dealer.If doing so is not an option, proceed as follows:STEP 1 - Wash the outboard motor1. Remove the enginecover2. Rinse the outboardmotor with freshwater to remove saltwater, sand, mud, etc.

If the outboard motor wassubmerged2/8STEP 2 – Drain the fuel3. Release the draintube from theprojection of theintake manifold andbring the end of thedrain tube out frombeneath the cover.4. Tilt the outboardmotor up.5. Drain the petrol intothe drain pan as itflows out of the draintube.

If the outboard motor wassubmerged3/86. After draining, tightenthe drain screw.7. Secure the drain tubeto the projection ofthe intake manifold.8. Tilt the outboardmotor down.

If the outboard motor wassubmerged4/8STEP 3 – Change the engine oil9. Remove the oil fillercap.10. Place a suitablecontainer under theoil drain guide,remove the drainbolt cover, engine oildrain bolt andwasher. Drain theengine oil until theflow of old oilreduces to a trickle.11. After draining the oil,install the drain boltand new sealingwasher, and tightenthe bolt securely.Install the drain boltcover.

If the outboard motor wassubmerged5/812. Refill to the upperlevel mark on the oillevel dipstick withthe recommendedoil. Do not overfill.Too much engine oilmay adversely affectthe engine.13. Check the oil level,insert the dipstick allthe way to theengine then read thelevel. The oil levelmust be betweenthe upper level (A)and lower level (B).STEP 4 – Lubricate the engine cylinder14. Remove all the sparkplugs.

If the outboard motor wassubmerged6/815. Remove the ACGcover. Wind theemergency starterrope (Refer to theEmergency startingprocedure.) Drainthe water from thecylinder by pullingthe emergencystarter rope severaltimes.16. Pour a teaspoon ofengine oil into all thespark plug holes.17. Pull the emergencystarter rope severaltimes to lubricatethe inside of thecylinder. Thenremove theemergency starterrope.

If the outboard motor wassubmerged7/818. Carefully install thespark plugs by handto avoid crossthreading. Tighten1/8—1/4 turn afterthe spark plug seats.Install the ACG cover.STEP 5 – Attempt to start the engine19. Install the enginecover.NOTICEIf the outboard motor was running when itbecame submerged, there may be mechanicaldamage, such as bent connecting rods. If theengine binds when cranked, do not attempt torun the outboard motor until it has beenrepaired.

If the outboard motor wassubmerged8/819. Attempt to start the engine.---If the engine fails to start, remove the sparkplugs, clean and dry the electrodes, thenreinstall the spark plugs and attempt tostart the engine again.If used engine oil showed signs of watercontamination, then a second engine oilchange should be performed after runningthe engine for 1/2 hour.If the engine starts and no mechanicaldamage is evident, continue to run theengine for 1/2 hour or longer.Take the outboard motor to your dealer as soonas possible.

If the starting system does not operate(using the emergency starter rope)1/5If the starting system does not operate properly forsome reasons, the engine can be started using theemergency starter rope in the tool kit.1. Stop the engine.2. Remove the enginecover3. Remove the four boltsand the ACG cover.

If the starting system does not operate(using the emergency starter rope)2/54. Remove the bandclamp, harness andclamp bracket fromthe ACG cover. Thenre-install on theengine side.5. Set the shift lever or remote control lever tothe neutral position.WARNINGThe ‘‘Neutral Starting System’’ will not work foremergency starting. Attempting to start theengine in forward and reverse gear positionmay causes sudden unexpected accelerationand could result in serious injury or death.

If the starting system does not operate(using the emergency starter rope)3/56. Tiller handle type:Align the “start” markon the throttle gripwith the projectedend of the “ ” markon the tiller handle.Remote control type:Leave the fast idlelever in the “START”(fully lowered)position.7. Turn the ACgenerator rotor anticlockwise so that thearrow is lined up withthe starter motor asshown.

If the starting system does not operate(using the emergency starter rope)4/59. Set the knotted endof the emergencystarter rope in thenotch in the fly wheel.10. Wind the emergencystarter ropeclockwise 3 timesaround the fly wheelalong the groove inthe ACG rotor.11. Insert theemergency clip intothe emergency stopswitch. Attach theother end of theemergency stopswitch lanyardsecurely to theoperator.

If the starting system does not operate(using the emergency starter rope)5/512. Turn the engineswitch key to the ONposition.13. Pull the starter ropelightly untilresistance is felt,then pull firmly.14. Leave the ACgenerator cover offand install theengine cover. Lockthe engine coverfixing levers.

A submerged outboard motor must be serviced immediately after it is recovered from the water in order to minimize corrosion. If there is a Honda outboard motor dealer nearby, take the outboard motor immediately to the dealer. If doing so is not an option, proceed as follows: 1/8 1. Remove the engine cover 2. Rinse the outboard motor with fresh