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BF80A/BF90DK4/BF100A

INTRODUCTION ·······································2 CONTROL CABLE INSTALLATION ··········· 31

THE IMPORTANCE OF PROPER OPERATION CHECK AFTER

SERVICING ·············································3 INSTALLATION······································ 41

IMPORTANT SAFETY PRECAUTIONS·········3 METER INSTALLATION

(EQUIPPED TYPE)·································· 42
SERVICE RULES······································4
BATTERY AND CABLE CONNECTION ······ 45
SYMBOLS ···············································4
PROPELLER ········································· 46
UNPACKING············································5
ADJUSTMENT AFTER INSTALLATION······ 53
LIFT UP ··················································7
WHEN RADIO STATION/GPS
PARTS PACKAGE INSPECTION·················8 MOUNTED ON THE BOAT ······················· 54

TORQUE VALUES ·································· 11 BREAK-IN PROCEDURE ························· 55

MOTOR INSTALLATION ·························· 12 PRE-DELIVERY SERVICE CHECK LIST····· 56

REMOTE CONTROL BOX OPERATION CHECK LIST ······················· 57

INSTALLATION (EQUIPPED TYPE)··········· 20
WIRING DIAGRAMS ······························· 59
LONG TILLER HANDLE INSTALLATION
(EQUIPPED TYPE)·································· 28

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BF80A/BF90DK4/BF100A

INTRODUCTION
BF80A/BF90DK4/BF100A

This instruction covers set-up, installation and pre-delivery service for the Honda BF80A/BF90DK4/BF100A Outboard
Motors.
Set-up, installation and pre-delivery service must be performed by authorized Honda Marine Dealer.
These instructions are provided for dealer use only.
Proper set-up, installation and pre-delivery service are essential for safe, reliable operation. Your customer expects
the Outboard Motor to be correctly set up, installed, adjusted, and ready for use; test the outboard motor to be sure
that it functions properly.
All information, illustrations, directions and specifications included in this publication are based on the latest product
information available at the time of approval for printing. Honda Motor Co., Ltd. reserves the right to make changes
without incurring any obligations whatever.
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 instruction, you will find information that is preceded by a 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 judgement.
You will find important safety information in a variety of forms, including:
• Safety Labels – on the engine cover.
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING,
or CAUTION. These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
• Instructions – how to service these outboard motors correctly and safely.

© Honda Motor Co., Ltd.

Service publication office

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BF80A/BF90DK4/BF100A

THE IMPORTANCE OF PROPER SERVICING

The service information contained in this manual is intended for use by qualified, professional technicians. Attempting
service without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
the Outboard Motor or create an unsafe condition.
This manual describes the proper methods and procedures for performing service. Any person who intends to use
service procedure, or a tool that is not recommended by Honda, must determine the risks to their personal safety and
the safe operation of the Outboard Motor.
For Your Customer’s Safety
Proper service is essential to the customer’s safety and the reliability of the outboard motor. Any error or oversight
while servicing an Outboard Motor can result in faulty operation, damage to the outboard motor, or injury to others.

Improper service can create an unsafe

condition that can cause your customer or
others to be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic
shop safety practices (e.g., Sharp edges-wear gloves). If you have not received shop safety training or do not feel
confident about your knowledge of safe servicing practice, we recommend that you do not attempt to perform the
procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of
every conceivable hazard that can arise in performing service procedures. Only you can decide whether or not you
should perform a given task.

Failure to properly follow instructions and

precautions can cause you to be seriously
hurt or killed.
Follow the procedures and precautions in this
manual carefully.

IMPORTANT SAFETY PRECAUTIONS

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate
clothing and using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools and the skills required to perform
the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work
around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye
protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can
cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have engine-power equipment up in the air.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the
engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are
out of the way.
Gasoline vapors and hydrogen gasses from battery are explosive. To reduce the possibility of a fire or explosion, be
careful when working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.

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BF80A/BF90DK4/BF100A

SERVICE RULES
• Use Honda-recommended lubricants or their equivalents.
• When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque
diagonally, unless a particular sequence it specified.
• Lubricate any sliding surfaces before reassembly.
• After reassemble, check all parts for proper installation and operation.
• Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. The use of incorrect tools and
fasteners will damage the unit.
• Hold the connector body to disconnect the connector. Do not disconnect by pulling the wire harness. To disconnect
the locking connector, be sure to unlock first, then disconnect.
• Check the connector terminals for bend, excessive extrusion, missing terminal, or other abnormalities before
connecting the connector.
• To connect, insert the connector as far as it goes. If the connector is a locking type, be sure that it is locked
securely.
• Check the connector cover for breakage and check whether the connector female terminal is not open excessively.
Then, connect the connector securely. Check the connector terminal for rust. Remove the rust using an emery
paper or equivalent material before connecting the connector.
• Set the harness clips in the specified places securely, and secure the wire harness.
• Clamp the cables securely.
• Clamp the wire harnesses securely sot that they do not interfere with the rotating parts, moving parts and the hot
parts.
• Route and connect the wire harnesses properly. Be sure that the harnesses are not slack, twisted or pulled taut.
• Route the wire harnesses properly sot that they do not contact with the sharp edges and corners, and the end of
the bolts and screws on the body.
• If a wire harness contacts the end of the bolts/screws or sharp edges and corners, protect the contact part of the
wire harness with a tube or by winding with electrical insulating tape. If the wire harness has a grommet, set the
grommet securely.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required
pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.

Use marine grease (water resistant urea based grease).

x ( ) Indicates the diameter, length, and quantity of bolts used.

page 1 Indicates the reference page.

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BF80A/BF90DK4/BF100A

UNPACKING
• Wear the heavy gloves during unpacking to protect your hands
from the sharp edges and burrs on the steel crate frame.
WITHOUT LRTD/LHTD/XRTD TYPE
Remove the twelve bolts [1].
[2]
Slowly lift up the upper frame [2] with care not to strike on the
outboard motor. (Get an assistant to help remove the upper frame.)

[1]

Remove the carton [1] from the lower crate frame.

Remove the parts cartons [2] from the lower frame by removing the
band [3] and tape [4].
[1]
Check the parts list for the parts contained in the package (page 8).
After checking the parts against the parts list, lift up the outboard
motor.

[3]
[2]

[4]

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BF80A/BF90DK4/BF100A

LRTD/LHTD/XRTD TYPE
Remove the parts cartons [1] from the upper/lower frame [2] by
removing the bands [3] and tapes [4].
Check the parts list for the parts contained in the package (page 8).
After checking the parts against the parts list, lift up the outboard motor.

Remote control type: Long tiller handle type:

[1] [3] [1] [1]

[2] [2]

[3]

[4]

[3]
[1]

[4]
[1] [1]
[3] [3]
[4]

Remove the twelve bolts [1].

[2]
Slowly lift up the upper frame [2] with care not to strike on the
outboard motor. (Get an assistant to help remove the upper frame.)

[1]

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BF80A/BF90DK4/BF100A

LIFT UP
Remove the vinyl cover [1].

[1]

Remove the engine cover [1]. [2]

Connect engine lifting sling chains to the engine hangers [2], and lift
up the outboard motor with lower crate frame slowly using the hoist.
• Lift up the outboard motor with care not to damage the alternator
cover.

• Use a suitable hoist with a capacity rating of 250 kg (551 lbs) or

more. This outboard motor total height with the lower crate frame
is over 2 m (79 in).
• Get an assistant to help to lift up the outboard motor.

[1]

With the underside of the lower crate frame [1] set on the ground,
remove the nut [2] and washer [3]. [2]
Remove the nuts [4], washers [5], and resin washers [6] from the
stern bracket. [3]

[1] [6] [5] [4]

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BF80A/BF90DK4/BF100A

Remove the vinyl cover [1] from the starter cable [2] and fuel tube
[3]. [3]

While suspending the outboard motor from the hoist, install it on the
hull.

[2]
[1]

PARTS PACKAGE INSPECTION

No. Part name LRTL/ LRTU/ LRTD/ LHTD Remarks
XRTL XRTU/ XRTD
LRTR
1 Fuel tank 1 1
2 Fuel tube 1 1 1 1
3 Tube clip band 1 1 1 1 Use with Ref. No. 2
(12.5 mm)
4 Remote control cable plate 1 1 1 1
5 Remote control cable cover 1 1 1 1
6 Flange bolt (6 x 16 mm) 2 2 2 2 Use with Ref. No. 4, 5
7 Harness band clip 1 1 1 1 Use with Ref. No. 4
8 Shift pivot 2 2 2 2
9 Remote control box 1
10 Starter rope 1 1 1 1

(4)
(2)
(1)

(3)

(5)

(6)

(8)
(7)
(9)

(10)

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BF80A/BF90DK4/BF100A

No. Part name LRTL/ LRTU/ LRTD/ LHTD Remarks

XRTL XRTU/ XRTD
LRTR
11 Indicator harness 1
12 Meter harness 1
13 Switch panel harness 1
14 Tachometer 1
15 Trim meter 1
16 Cable grommet 1 1 1 1
17 Under case grommet band 1 1 1 1 Use with Ref. No. 16
18 Front separate cover 1 1 1 1
19 Special bolt (6 x 17 mm) 1 1 1 1 Use with Ref. No. 18
20 Special bolt (6 x 37 mm) 1 1 1 1 Use with Ref. No. 18
21 Bolt (6 x 20 mm) 1 1 1 1 Use with Ref. No. 18
22 Sensor nipple 1 1 1 1
23 Tiller handle 1
24 Washer (10 mm) 2 Use with Ref. No. 23
25 Bolt (10 x 32 mm) 2 Use with Ref. No. 23

(13)
(14)
(12)

(11)

(15)

(18)
(16)
(17) (19) (20) (21)

(23)

(22) (24) (25)

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BF80A/BF90DK4/BF100A

No. Part name LRTL/ LRTU/ LRTD/ LHTD Remarks

XRTL XRTU/ XRTD
LRTR
26 Friction bolt 1 Use with Ref. No. 27
27 Friction block 1
28 O-ring 1 Use with Ref. No. 27
29 Nut (6 mm) 1 Use with Ref. No. 27
30 Split pin (2.0 mm) 1 Use with Ref. No. 27
31 Steering friction rod 1 Use with Ref. No. 32
32 Steering friction shaft 1 Use with Ref. No. 27
33 Self-lock nut (8 mm) 2 Use with Ref. No. 31
34 Plain washer (8 mm) 2 Use with Ref. No. 31
35 Steering rod 1 1 1
36 Bolt (3/8-24UNF) 1 1 1 Use with Ref. No. 35
37 Washer (10 mm) 3 3 3 Use with Ref. No. 35
38 Steering rod collar 1 1 1 Use with Ref. No. 35
39 Self-lock nut (3/8-24UNF) 2 2 2 Use with Ref. No. 35
40 Declaration 1
41 Tool kit 1 1 1 1
42 Bolt (12 x 119 mm) 4 4 4 4
43 Plain washer (12 mm) 4 4 4 4
44 Plain washer (12 mm) 8 8 8 8
45 Nut (12 mm) 8 8 8 8
46 Propeller thrust washer 1 1 1 1
47 Plain washer (18.5 mm) 1 1 1 1
48 Castle nut (18 mm) 1 1 1 1
49 Split pin (4.0 mm) 1 1 1 1

(28) (35)
(26) (27) (31)

(30) (36) (37)

(29) (32)
(38) (39)
(33) (34)

(41) (42) (43)

(40) (45)

(44)

(46) (48)
(47) (49)

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BF80A/BF90DK4/BF100A

TORQUE VALUES
Use standard torque values for fasteners that are not listed in this
table.
Item Thread Dia. (mm) and pitch TORQUE VALUES
(length) N·m kgf·m lbf·ft
Castle nut 18 mm *1 *1 *1
Outboard motor mounting bolt / 12 x 119 mm 54 5.5 40
nut
Steering rod nut 3/8-24 UNF 22 2.2 16
Neutral lock block screw M6 tapping screw 2.5 0.26 1.8
Power tilt cord clamp screw M5 tapping screw 0.7 0.07 0.5
Remote control box cover C screw M5 tapping screw 2.5 0.26 1.8
Control wheel bolt M8 x 1.25 23.5 2.4 17
Front separator cover bolt M6 x 1.0 (Special bolt) 10 1.0 7
Front separator cover bolt M6 x 1.0 (SH bolt) 5 0.51 3.7
*1: If the split pin can not be set by tightening the castle nuts to 1.0 N·m (0.10 kgf·m, 0.7 lbf·ft), tighten the castle
nut until the split pin can be set. Note that the maximum torque of the castle nut is 44.1 N·m (4.5 kgf·m, 33 lbf·ft).
STANDARD TORQUE VALUES
Item Thread Dia. (mm) and pitch Torque values
(length) N·m kgf·m lbf·ft
Screw 5 mm 4.2 0.43 3.1
6 mm 9 0.92 6.5
Bolt and nut 5 mm 5.2 0.53 3.7
6 mm 10 1.0 7
8 mm 21.5 2.2 16
10 mm 34 3.5 25
12 mm 54 5.5 40
Flange bolt and nut 6 mm (SH bolt) (*2) 10 1.0 7
6 mm (CT bolt) (*3) 12 1.2 9
6 mm 12 1.2 9
8 mm 26.5 2.7 20
10 mm 39 4.0 29
*2: Small head bolt
*3: Self-tapping bolt

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BF80A/BF90DK4/BF100A

MOTOR INSTALLATION
DIMENSIONAL DRAWINGS
REMOTE CONTROL TYPE
At 68° tilt up: Unit: mm (in)
(Boat transom angle: 12°)
76.2 (3.0) 454.8 (17.9)
30°
365 (14.4)

770 (30.3)
320 (12.6)
44 (1.7)
621.4 (24.5)
814 (32.0)
641 (25.2)

X type: 1,052 (41.4)

L type: 925 (36.4)

68°

12°

L type: 979 (38.5)

X type: 1,097(43.2) 531 (20.9)

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BF80A/BF90DK4/BF100A

LONG TILLER HANDLE TYPE

At 68° tilt up: Unit: mm (in)
(Boat transom angle: 12°)

76.2 (3.0) 454.8 (17.9)

1,407 (55.4)
365 (14.4)

30°

320 (12.6)
5.2)
5 (3

770 (30.3)
R 89
648 (25.5)

44 (1.7)
904 (35.6)
746 (29.4) 153 (6.0)
621.4 (24.5)
814 (32.0)
728 (28.7)
641 (25.2)

X type: 1,052 (41.4)

L type: 925 (36.4)

68°

12°

L type: 979 (38.5)

X type: 1,097(43.2) 531 (20.9)

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BF80A/BF90DK4/BF100A

MOTOR SELECTION
Secure and correct installation is essential for safe boating and good
performance. Follow the installation instructions provided in this
manual.

Improper set-up or pre-deliver service can

cause an unsafe condition that can cause
your customer to be seriously hurt or killed.
Follow the procedures and precautions in this
manual and shop manual carefully.

Before installation, check to be sure that the outboard motor does

not exceed the recommended maximum horsepower for the boat on
which it is to be installed.
Refer to the boat’s certification plate for recommended maximum
horsepower. For most applications, the outboard motor should
provide 80% of the recommended maximum horsepower for the
boat. If the certification plate information is not available, contact the
boat dealer or manufacturer.
Refer to the following dimensional drawings to be sure there is
nothing on the boat that will interfere with outboard motor tilt up and
steering.
The BF80A, BF90D and BF100A outboard motors are designed to
be installed on boat transom with the following transom board
thickness.
Boat transom board thickness [1]:
41 – 70 mm (1.6 – 2.8 in)

[1]

As a general rule, the outboard should be installed so the anti-

ventilation plate [1] is parallel to the boat bottom [2].
If the board transom angle [3] is less than 8°, the BF80A, BF90D
and BF100A anti-ventilation plate will not be parallel to the boat Parallel
bottom when trimmed to the lowest position.

[1] [2]

[3]

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BF80A/BF90DK4/BF100A

Install the outboard motor on the center of the transom securely and
be sure that the boat is well-balanced. CENTER LINE

BOAT TRANSOM

BOAT TRANSOM CENTER LINE

Use a pencil and tape measure to locate center line [1].
BOAT TRANSOM
Put one end of the tape measure on a chine and place the other end
on the upper edge of the transom, somewhere past the “visual”
center. Place a mark on the transom and record the distance
measured.

[1]
KEEL

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BF80A/BF90DK4/BF100A

INSTALLATION HEIGHT CHECK

The water can damage the outboard motor when it enters the idle
port. Be sure to set the outboard motor installation height according
to the following procedure.
• The outboard motor installation height shall be ± 25 mm (± 1.0 in)
when the transom height of the boat is subtracted from the
transom height of the outboard motor.
• Note that this dimension is just the standard. Optimal installation
height differs depending on the boat type and shape of the
bottom of the boat. Refer to the boat maker's recommended
installation height and determine the optimal installation height by
test cruising the boat.
• If the outboard motor is installed at too low (deep) position;
– It reduces operating stability.
– It reduces high speed sailing performance.
– Water splashed over the wash board can be jetted out and fan
out the stern of the board.
– It lacks airiness of the boat.
– It gets heavy steering.
• If the outboard motor is installed at too high (shallow) position, it
causes ventilation when sailing on the choppy water or sailing at
high speed, and the boat does not sail smoothly.
Measure the boat transom height.
Workable boat transom height [1]:
L Type: 512 – 562 mm (20.2 – 22.1 in)
X Type: 639 – 689 mm (25.2 – 27.1 in)

[1]

Calculate the outboard motor installation height [1].

Determine the outboard motor installation height by subtracting the [2]
boat transom height [2] from the outboard motor transom height.
Outboard motor transom height [3]:
L Type: 537 mm (21.1 in)
X Type: 664 mm (26.1 in)
Outboard motor installation height must be in the range between ±
25 mm (± 1.0 in). [1]

[3]

ANTI-VENTILATION PLATE

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BF80A/BF90DK4/BF100A

Operate the power trim/tilt switch and trim down the outboard motor
to the lowermost position with the boat fully loaded. Check that the
distance between the water surface [1] and the idle port [2] is 150
mm (5.9 in) or more.
[2]
If the outboard motor installation height does not conform to the
above specification, adjust the transom height of the boat.
150 mm
(5.9 in) or
more

[1]

BOAT TRANSOM HEIGHT ADJUSTMENT

• If the outboard motor installation height is too low, attach wood
block(s) to the top of the transom and increase the installation
Cut away
height by the amount it is required.
• If the outboard motor installation height is too high, reduce the
height by planing down the top of the transom by the required
amount.
• When increasing the installation height, attach the wood block(s)
to the transom of the boat securely.
• Be sure to plane off the boat transom by the amount of the
outboard motor width.
• Some boat manufacturers may require different mounting height.
Consult your boat manufacturer for specifics on your boat.
OUTBOARD MOTOR
WIDTH

FIXING STAYS REMOVAL

After installing the outboard motor on the hull, remove the two
washer-bolts [1], and two bolts [2]. [5] [3]
Then remove the fixing stays [3] from the swivel case [4] and the
mount frame [5].

[4]

[2] [1]

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BF80A/BF90DK4/BF100A

TRANSOM DRILLING
Verify no damage will occur when the motor mounting holes are
drilled. Lock for any structural impediments such as bulkheads,
braces, fuel cells, bilge pumps, or floor sections before drilling.
Ensure there is adequate space for the bolt, washer, and transom
support plate (if applicable), to bear on a flat surface.
Wear safety glasses and drill holes in the transom.
Drill upper holes at least 25 mm (1 in) below transom top edge.
Drill the lower holes in the positions where the top edge of the long
hole in the stern bracket comes in contact with the bolt.
Mark the center point of the 4 drilling holes (i.e. 2 holes at the right Unit: mm (in)
and left sides of the transom respectively that are in the symmetrical
position with regard to the center line of the outboard installation TRANSOM TOP EDGE
line). 0
327 (12.90)
53.5(2.11)
72(2.83)
90.5(3.56)
109(4.29)
13.5(0.53)

250.8 (9.87)
254 (10.00)

312.2
(12.28)

INSTALLATION STERN
CENTER LINE BRACKET

Using a 3 – 5 mm (0.1 – 0.2 in) diameter drill [1], drill the pilot holes [1] [3]
at the marked points at right angles with the boat transom surface
[2]. Then, drill the holes using the 13.5 mm (0.53 in) diameter drill
[3].
With the outboard motor resting on the boat transom, verify the
correct motor height. The outboard motor can be raised by using a
lower set of mounting holes.
Use vacuum cleaner to clean up after drilling. 90° 90°

[2]

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BF80A/BF90DK4/BF100A

BOLTING OUTBOARD MOTOR TO TRANSOM

Apply silicone sealant [1] or equivalent to the four mounting bolt
holes from both side as shown. Secure the motor by installing the
bolts (12 x 119 mm) [2], washers (small) [3] from the outboard motor
side and washers (large) [4], washers (small) and nuts [5]. [2] [1] [5]
[3]
[4] [3]
Tighten the nuts to the specified torque.
TORQUE: 55 N·m (5.6 kgf·m, 41 lbf·ft)

Using an air impact tool to tighten or loosen the transom bolts can
generate enough heat to damage the bolt threads. The air impact
tool can also produce enough tightening torque to damage the boat
transom.

If the molding [1] of the transom upper edge interferes with the
outboard stern bracket [2], add the plate [3] or reconditioning the
bump and install the outboard stern bracket to the boat transom [4] [1]
securely.
With outboard motor resting on the boat transom, verify correct
motor height. Motor can be raised by using a lower set of mounting
holes.
Connect the cables, codes, and tube to the cable/electrical
connection.

[4]

[2] [3]

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BF80A/BF90DK4/BF100A

REMOTE CONTROL BOX INSTALLATION (EQUIPPED TYPE)

COMPONENT IDENTIFICATION AND CONTROLS
GEARSHIFT/THROTTLE
CONTROL LEVER
POWER TRIM/TILT SWITCH
NEUTRAL RELEASE
LEVER

INDICATOR LIGHT

FAST IDLE LEVER

FRICTION ADJUSTING COMBINATION SWITCH

SCREW

EMERGENCY STOP
SWITCH

REMOTE CONTROL
CABLE
EMERGENCY STOP
SWITCH LANYARD

Gearshift/throttle control lever Controls gear selection and throttle opening position.
Indicator light Indicates the operating condition of the outboard motor.
(Oil indicator light, overheat indicator light, MIL, alternator indicator
light)
Fast idle lever For engine warm-up and throttle opening adjustment when restart the
warm engine. The BF80A, BF90D and BF100A models use
programmed fuel injection, so this lever will not be needed for starting.
Combination switch For starting and stopping the outboard motor.
Emergency stop switch Will be activated in case of an emergency stop, or when the operator
falls overboard.
Friction adjusting screw Use this screw to adjust the operating resistance of the control lever.
Neutral release lever To move the control lever out of the "N" (NEUTRAL) position, lift this
lever up.
Remote control cable Wire connecting control box to outboard motor.
Power trim/tilt switch Use this switch to tilt up/down and to trim up/down the outboard motor.
FAST IDLE LEVER OPERATION
• After the engine starts and if the outside temperature is below 41˚F (5˚C), the fast idle lever can be used to
accelerate engine warm up.
• The engine speed increases with the fast idle lever in the range shown, which promotes warming up of the engine.
Set the fast idle lever at the "MAXIMUM" position after warming up and at restart of the engine.
• The fast idle lever can be operated provided that the control lever is in the "N" (NEUTRAL) position.
• The control lever can be operated provided that the fast idle lever returned fully to the release position.

N (NEUTRAL)
F (FORWARD)
R (REVERSE)
55° MAXIMUM 30° 30° THROTTLE
THROTTLE OPENING
FAST IDLE OPENING MINIMUM
OPERATION MINIMUM
RANGE
MAXIMUM
0° IDLE POSITION

MAXIMUM
FAST IDLE LEVER

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BF80A/BF90DK4/BF100A

STEERING GUIDE CABLE INSTALLATION

• Attach the steering guide cable to the outboard motor first, then
install the outboard motor on the boat.
• Refer to the steering guide cable manufacturer’s manual for
cable handling procedures.
Remove the cap [1] from the tilting shaft.
[1]

Pass the steering guide cable [1] through the tilting shaft and tighten
the cap nut [2]. Install the outboard motor on the hull.
• Before installing the steering guide cable, apply marine grease to
the sliding surface of the cable and the inner side of the cap nut. [2]

[1]

Apply marine grease to the steering link rod collar [1].

Attach the steering link rod [2] to the hole in the mount frame and
loosely tighten it with the bolt [3], washer [4], collar and the self lock [3]
nut [5].
Connect the steering link rod to the steering guide cable [6] with the [6]
[4] [1]
washers [7] and self lock nut [8].
Tighten the nuts to the specified torque.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)

[7]
[2]
[7] [5] [8]

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CONTROL CABLE SELECTION

• The remote control cable must be of the correct length. Sharp
bend of the short cable causes “twist” in the cable. While, the
cable involves bend or loop, that is not required normally, when it
is too long. In either case, the cable can be deformed
excessively.
Select a mounting location of the remote control box where it allows
easy access and unrestricted operation of the control lever, and [2]
make sure that there are no other parts obstructing the remote
control cables [1] and all components between the remote control
box [2] and the outboard motor.
• The remote control box is normally mounted on the starboard
side, but can be adapted to a reversed control lever position (port
side installation).
• Recommended position to install the control is close to the corner
of the front seat with the control lever in the "N" (NEUTRAL)
position.
• The bottom of the remote control box should be level with the
upper surface of the seat.
• Insert a shim between the control box and the installation
surface, if the play of the operating lever is insufficient. [1]
• The remote control box is normally mounted on the starboard
side. The control lever can be reversed to accommodate port
side (page 23).
• Position the spacer plate between the control box and the
installation surface.
• If the thickness of the mounting location is 25 mm (0.98 in) or
more, this location is not suitable to mounting, select other
location.
Recommended control cable:
• Morse 33 C cable (commercially available)
– Type of cable end screws: SAE thread (10-32UNF-2A)
– Use the SAE type thread only
Calculate the control cable length.
Measure the distance of L1 [1] and L2 [2] and calculate the required
control cable length as follows.
[1]
• Required control cable length =
L1 + L2 + 300 to 450 mm (11.8 to 17.7 in)

[2]

• Do not bend the control cable sharp with the radius of the cable
bend being 300 mm (12 in) or below.
Bending the cable sharp will increase the operation load of the
control lever which deteriorates the operationability of the lever.
• It must be long enough that allows proper tilt-up or down of the
outboard motor and secure steering operation.
• Add the extra length to the cable if it is obliged to route the cable
with slackness or if it is not possible to route the cable in an
ordinary route.

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CONTROL LEVER DIRECTION CHANGE

This remote control box can be mounted on the starboard or part
side by reversing the installation direction of the control lever. [2]
Remove the two screws [1] and the housing cover C [2].

[1]

Remove the two screws [1] and the power tilt cord clamp [2].
Disconnect the power trim/tilt switch wire harness connector [3].

[1]

[2]

[3]

Remove the control lever's lock bolt [1] using the 12 mm box wrench
[2], from the control lever [3]. [3]
• Remove the lock bolt with the control lever set in the neutral "N"
(NEUTRAL) position.

[2]

[1]

Remove the control lever [1] from the remote control box.

Take care not to damage the power trim/tilt switch wire harness.

[1]

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BF80A/BF90DK4/BF100A

Remove the two screws [1] and remove the neutral lock block [2]
from the control housing A. [2]

[1]

Install the neutral lock block [1] on the control housing B and tighten
the two screws [2] to the specified torque. [1]
TORQUE: 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)

[2]

Install the control lever [1] on the remote control box.

• Install the control lever by setting it in the neutral "N" (NEUTRAL)
position.

[1]

Connect the switch wire harness connector [1].

[3]
Set the power trim/tilt switch wire harness [2] to the hanger [3] and [2]
tape end [4] of the wire harness to the groove as shown.
Install the power tilt cord clamp [5] and tighten the two screws [6] to
the specified torque.
TORQUE: 0.7 N·m (0.07 kgf·m, 0.5 lbf·ft)

[5]
[6]
[1]
[6]
[4]

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BF80A/BF90DK4/BF100A

Install the housing cover C [1]. [6]

• Set the grommet A [2] of the wire harness [3] by aligning it with
the cutout in the control housing B [4] and housing cover C [5].
• Do not overtighten the screws.
Tighten the two screws [6] to the specified torque.
TORQUE: 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)

[3]

[2]
[1]

[4] [5]

Tighten with the lock bolt [1] to the specified torque. [1]
TORQUE: 23.5 N·m (2.4 kgf·m, 17 lbf·ft)

CONTROL CABLE INSTALLATION

HOUSING COVER C SCREW (5 x 25 mm) (2)

COTTER PIN (6 mm) (2) THROTTLE CONTROL CABLE

WASHER (2)

EYE END (2)

CABLE CLAMP SPACER

LOCK NUT (2)

SHIFT CONTROL CABLE

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BF80A/BF90DK4/BF100A

Remove the two screws and housing cover C.

Screw the lock nuts [1] and eye ends [2] more than 8 mm (0.3 in)
onto the thread of the control cables and tighten the lock nuts
securely to hold the pivots.
More than 8 mm (0.3 in)
Apply marine grease to the hole of the eye end.

[1] [2]

Install the shift control cable [1] by aligning the groove of the control
cable with the cable guide plate [2]. Then connect the eye end [3] to [8]
the shift arm pin [4] using the washer [5] and lock pin [6].
• Install the washer on the lock pin side. [7]
Install the cable clamp spacer [7] and throttle control cable [8] by
aligning the groove with the cable guide plate. Then connect the eye
end to throttle arm pin [9] using the washer and lock pin.
Install the housing cover C and tighten the screws to the specified
torque. [9]
TORQUE: 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft) [4]

[6]
[5]

[1]
[2]
[4]

[3]

CONTROL LEVER FRICTION ADJUSTMENT

Adjust the friction by turning the control lever friction adjuster [1].

[1]

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CONTROL BOX INSTALLATION

• This remote control box is designed to be mounted on the starboard side. When it is mounted on the port side,
reverse the control lever installation for the port mount type (page 23).
• Set a spacer between the remote control box and the boat to obtain the clearance for operation of the control lever.
• Connect the control cable to the remote control box before installing the remote control box.
• Select the remote control box installation position for boat and suitable type of the remote control box.
• Recommended installation position:
– Convenient for the control lever operation
– Free from interference or restriction in routing the cables and harnesses between the remote control box and the
outboard motor.
– Near a corner of the driver’s seat.
– Underside of the remote control box is level with the upper surface of the seat.
Set the remote control box [1] at the installation position and mark
the drilling points for the remote control box mounting screws. [2]
Drill at the marked points using the 7 mm-diameter drill bit. [1]

Set the spacer [2] between the remote control box and the mounting
surface on the boat as shown to obtain the clearance for smooth
operation of the control lever.
Install the remote control box using the collars [3], washers [4], nuts
[5] and the screws [6].
• Install the remote control box with the control lever set in the
neutral position.

[5]
[6]

[3] [4]

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LONG TILLER HANDLE INSTALLATION (EQUIPPED TYPE)

COMPONENT IDENTIFICATION AND CONTROLS

EMERGENCY STOP
SWITCH
REMOTE CONTROL
CABLE
EMERGENCY STOP
SWITCH LANYARD
INDICATOR LIGHT
SHIFT LEVER

COMBINATION SWITCH

THROTTLE FRICTION
FIXING DIAL

HEIGHT ADJUSTMENT BLOCK

POWER TRIM/TILT SWITCH

THROTTLE GRIP

Shift lever Use this shift lever to shift the gear.

Indicator light Indicates the operating condition of the outboard motor.
(Oil indicator light, overheat indicator light, MIL, alternator indicator
light)
Throttle grip Use this throttle grip for throttle operation.
Combination switch For starting and stopping the outboard motor.
Emergency stop switch Will be activated in case of an emergency stop, or when the operator
falls overboard.
Throttle friction fixing dial Use this throttle friction fixing dial to adjust the operation preload of the
throttle grip.
Remote control cable Wire connecting long tiller handle to outboard motor.
Power trim/tilt switch Use this switch to tilt up/down and to trim up/down the outboard motor.
Height adjustment block Use this height adjustment block to adjust the tiller handle height
(angle).
LONG TILLER HANDLE INSTALLATION
Remove the cap [1] from the tilting shaft.

[1]

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BF80A/BF90DK4/BF100A

Apply marine grease to the inside of the hole in the tilting shaft [1]
and pass the steering friction shaft [2] through the hole.
Apply marine grease to the entire of the O-ring [3] and the inside of [1]
the friction block [4] and install them on the steering friction shaft.
Install the friction bolt [5], nut [6] and the split pin [7] on the friction [2]
block.
• Be sure to set the nut into the hex hole in the friction block
securely.

[4] [3]

[7]
[6]
[5]

Align the 10 mm holes in the outboard motor mount frame with the
holes in the tiller handle's steering handle bracket and install the
steering handle bracket using the two washers [1] and the two bolts
[2].

[1] [2]

Install the steering friction rod [1] on the steering handle bracket [2]
and the steering friction shaft [3] using the two washers [4] and the [5]
[4]
two self lock nuts [5]. [2]

• Note to install the long end [6] of the steering friction rod from the
bend on the steering friction shaft. [3]

Loosen the friction bolt. Operate the tiller handle and check that it
moves smoothly. Tighten the friction bolt until light resistance is felt
in operating the tiller handle.

[4]

[1]
[5]
[6]

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LONG TILLER HANDLE HEIGHT/ANGLE ADJUSTMENT

• The long tiller handle height and angle can be adjusted in three
positions by changing the installation direction of the height 21°
adjustment block. Select a suitable height and angle for the
operator and secure the block.
7°
Raise the long tiller handle and remove the bolt [1] and the height
adjustment block [2]. 13°
Pull down the long tiller handle.
Determine the height adjustment block installation direction and
secure the block with the bolt.

[1]

Install the height

adjustment block so that
the selected angle is in
this position.

[2]

298 mm
(11.7 in)
Height

Reference point

361 mm
(14.2 in)

438 mm
(17.2 in)

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CONTROL CABLE INSTALLATION

INSTALLATION
After installing the control cable to the remote control box (page 25), then install the control cable to the outboard
motor.

SPECIAL BOLT (6 x 17 mm) FRONT SEPARATE

COVER BOLT (6 x 20 mm)
10 N·m (1.0 kgf·m, 7 lbf·ft)
5 N·m (0.5 kgf·m, 3.7lbf·ft)

BOLT (6 x 16 mm) (2)

THROTTLE
CONTROL CABLE
REMOTE CONTROL
CABLE COVER
SHIFT CONTROL
CABLE

CABLE
GROMMET

SHIFT PIVOTS/
LOCK PLATE

14P CONNECTOR

6P CONNECTOR
(LONG TILLER
HANDLE TYPE)

UNDER CASE
GROMMET BAND

HARNESS BAND
CLIP

REMOTE
6P CONNECTOR CONTROL CABLE
(REMOTE PLATE
CONTROL TYPE)

FUEL TUBE
THROTTLE ARM
LINK PIN

SHIFT LINK PIN

SPECIAL BOLT (6 x 37 mm)

10 N·m (1.0 kgf·m, 7 lbf·ft)
STARTER CABLE

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BF80A/BF90DK4/BF100A

Set the starter cable [1] on the front bracket [2].

• Align the tape end [3] on he starter cable with the end of the front
bracket.
[3]

Remote control type only:

Remove the two tie wrap bands [4] from each 14P connector wire
harness [5] and 6P connector wire harness [6].

[1]

[2]

Remote control type only:

[4]

[4]
[5]

[6]

Remote control type:

Route the starter cable [1], fuel tube [2], 14P connector wire harness [5]
[3] and 6P connector wire harness [4] through the cable grommet
[5].
• Align the tie wrap band [6] on each of the 14P connector wire
harness and 6P connector wire harness with the end of the cable [4]
grommet. [3]

[1] [2]

[4] [6]

[3] [6] [5]

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BF80A/BF90DK4/BF100A

Long tiller handle type:

[4]
Route the starter cable [1], fuel tube [2] and 14P/6P connector wire
harness [3] through the cable grommet [4].
• Align the tape [5] on the 14P/6P connector wire harness with the
end of the cable grommet.
[3]

[1] [2]

[5]
[3]

[4]

Install the cable grommet [1] in the groove in the front bracket [2]
aligning the flat part [3] of the front bracket with the flat part [4] of the
cable grommet. [1]

[4]

[2] [3]

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BF80A/BF90DK4/BF100A

Connect the 14P connector [1] and 6P connector [2] to the engine
[3]
side connectors [3] and secure the connectors to the connector [1]
holders [4]. [8]
[7]
Install the remote control cable plate [5] and tighten the bolt [6].
Secure the 14P connector wire harness [7] and 6P connector wire [6]
harness [8] with the harness band clip [9] and install it to the remote
control cable plate.
After securing the 14P/6P connector wire harness, cut off the
excess of the band so it does not interfere with the neighboring [5]
parts. [2]

[9]

[4]

Route the throttle control cable [1] and shift control cable [2] through
the cable grommet [3]. [2] [1]
Align the groove [4] in the remote control cables (shift and throttle)
with the groove [5] in the remote control cable plate.
Install the remote control cable cover [6] on the remote control cable
plate with the projection [7] on the remote control cable cover set in
the cutout [8] in the remote control cable plate.
Tighten the bolt [9].
Install the lock nuts [10] and shift pivots [11] on the remote control
cables. [3]
Apply marine grease to the link pin installation port of the shift pivot.
Connect the shift pivots to the shift link pin [12] and the throttle arm [14] [11] [9] [6]
link pin [13]. (Slide the lock plates [14] to connect the remote control [10]
cables and lock.) [4]

[14]

[13] [12] [5]

[7]

[8]

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BF80A/BF90DK4/BF100A

Set the front separate cover [1] on the front bracket [2] and loosely
tighten the bolt (6 x 20 mm) [3], special bolt (6 x 17 mm) [4] and the [4] [1]
[3]
special bolt (6 x 37 mm) [5].
Check that each cable and tube are set in the holes in the cable
grommet [6] securely and secure the cable grommet with the
grommet band [7].
Tighten each front separate cover bolt to the specified torque.
(Tighten in the order of a. through c.)
TORQUE:
BOLT (6 x 20 mm): 5 N·m (0.51 kgf·m, 3.7 lbf·ft)
SPECIAL BOLT: 10 N·m (1.0 kgf·m, 7 lbf·ft)
• Tighten the bolts with care not to turn up the cable grommet.
[2]

[5]

c. [6]
b.

a.

[7]

THROTTLE CONTROL CABLE ADJUSTMENT

Remote control type: Remote control type:
Set the control lever [1] in the forward full open position.
"N" (Neutral)
• If it is hard to set the control lever in the "F" (Forward) or "R"
(Reverse) position, stop the engine and shift the gear by turning Throttle full
the propeller or propeller shaft. close position
• Do not try to shift the gear with force. Damage to the gear shift "F" (Forward)
system can occur. [1]

Long tiller handle type:

Set the throttle grip [2] in the forward full open position. Throttle full
open position
• Align the " " mark [3] on the throttle grip with the throttle mark’s
full open position [4] and secure the throttle grip using the throttle
friction fixing dial [5].
Long tiller handle type:

[5]
[2]

[4] [3]

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BF80A/BF90DK4/BF100A

1. With the control lever or throttle grip in the full open position,
[1] [3]
check that the throttle arm [1] is in contact with the full open
stopper [2] of the shift link bracket [3].
2. Holding the control lever or throttle grip in the position of the step
1, check the clearance between the throttle cam [4] and the
stopper (full open side) [5] of the throttle body. It must be 1 mm or
below.
3. Move the control lever or throttle grip to the full close position.
Check that the throttle cam [6] of the throttle body is in contact
with the stopper (full close side) [7] securely.
Adjust if either the step 1, 2 or 3 is not satisfied.
If the step 1 is not satisfied, go to the procedure of <Throttle arm
not in full open position> (page 37). [2]
If either the step 2 or 3 is not satisfied, go to the procedure of
<Throttle cam not in full open position> (page 37).
[5]

1 mm maximum
[4]

[7]

Must be in contact
securely.
[6]

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BF80A/BF90DK4/BF100A

<Throttle arm not in full open position>

1. Loosen the shift pivot lock nut [1] of the remote control cable
(throttle side) [2] and remove the shift pivot [3] from the throttle [4] [2]
arm link pin [4].
2. Screw in the shift pivot until the throttle arm comes in contact with
the full open stopper and loosely install the shift pivot on the
throttle arm.
3. Remote control type:
Set the control lever with the full open position (page 35).
Long tiller handle type:
Align the " " mark on the throttle grip with the full open position
of the throttle mark (page 35).
4. Check that the steps 1, 2 and 3 of the throttle control cable [3] [1]
adjustment are satisfied (page 36).
If the steps 1, 2 and 3 of the throttle control cable adjustment are
not satisfied, adjust the throttle control cable again starting with
the step 1.
If the throttle arm is in contact with the full open stopper but the
steps 2 and 3 are not satisfied, go to the procedure of <Throttle [1]
cam not in full open position>.
5. Remote control type:
Move the control lever in the "N" (Neutral) position, and tighten
the shift pivot lock nut securely.
Long tiller handle type:
Move the throttle grip to the full close position and the gear shift
lever in the "N" (Neutral) position, and tighten the shift pivot lock [3]
nut securely.

<Throttle cam not in full open position>

Adjust the throttle control cable with it connected to the throttle arm.
1. Remove the throttle rod linkage pivot [1] from the throttle plate [2] [2] [3]
and loosen the linkage pivot lock nut [3].
2. While holding the throttle arm in contact with the full open
stopper, adjust the clearance between the throttle cam and the
stopper (full open side) to 1 mm or below by turning the throttle
rod linkage pivot.
3. Loosely install the linkage pivot on the throttle plate.
4. Check that the steps 1, 2 and 3 of the throttle control cable
adjustment are satisfied (page 36).
5. Tighten the linkage pivot lock nut.
6. After tightening the lock nut, check that the throttle cam side pivot
[1]
of the throttle rod is not out of the throttle cam.

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BF80A/BF90DK4/BF100A

SHIFT CONTROL CABLE ADJUSTMENT

Check the following before connecting the shift control cable to the
outboard motor. [3]
[4]
Shift control cable adjustment procedure is the same when the long
tiller handle type is used.
– Remote control box side (Tiller handle side) cable is connected
properly (page 25).
– Control lever is in the "N" (Neutral) position.
– Tip [1] of the neutral switch is set in the detent assisted spring [2]
securely and the detent spring roller [3] is set in the groove [4] in
the shift arm.
When the detent spring roller is set in the groove in the shift arm
but the tip of the neutral switch is not in the detent assisted spring
securely, check the detent assisted spring. Replace the detent [2]
assisted spring with a new one if it is deformed or damaged.

[1]

1. Apply marine grease to the shift link pin installation part [1] of the
shift pivot and to the shift link pin. [5]
[4]
2. Check that the shift control cable is disconnected from the shift
link pin. [2] [3]
Move the control lever [2] to the "F" (Forward) position [3] and
return it to the "N" (Neutral) position [4] slowly.
3. While holding the shift control cable [5] and the control lever in
the position described in step 2, mark (A) [6] at the end of the
cable outer seal [7] on the inner cable.
[6]
[7]

[1]

4. Move the control lever [1] to the "R" (Reverse) position [2] and
return it slowly to the "N" (Neutral) position [3].
5. While holding the control lever in the position described in step 4, [3]
mark (B) [4] at the end of the cable outer seal on the inner cable.
[2] [1]

[4]

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BF80A/BF90DK4/BF100A

6. Mark (C) [1] at the midpoint between the mark (A) [2] and the
mark (B) [3] on the inner cable.
[1]

[2] [3]

7. Align the mark (C) [1] made in the step 6 with the end of the cable
outer seal.

[1]

8. Move the tip [1] of the shift link pin lightly to the right and left. If
there is a free play in the shift link pin, set the shift link pin at the [2]
center [2] of the free play.

[1]

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BF80A/BF90DK4/BF100A

9. While holding the shift control cable [1] in the position described
in the step 7 (i.e. the mark (C) aligned with the end of the cable
outer seal), adjust the shift control cable length by turning the
shift pivot [2] right or left until the shift pivot can be set on the shift
link pin [3] smoothly. Install the shift pivot on the shift link pin.
• Take care not to bring the mark (C) out of alignment with the end [4]
of the cable outer seal. Do not move the shift link pin out of the
center of the free play, either, during installation of the shift pivot
on the shift link pin.
Tighten the shift pivot lock nut [4] securely.
After connecting the shift control cable, move the control lever [2]
back and forth to check for gear shift.
[3]
• If it is hard to set the control lever in the "F" (Forward) or "R"
(Reverse) position, stop the engine and shift the gear by turning
the propeller or propeller shaft.
• Do not try to shift the gear with force. Damage to the gear shift
system can occur.

[2]

[1]

10.Move the control lever from the "F" (Forward) to the “N” (Neutral)
position. If the gear does not shift to the neutral, disconnect the
shift control cable from the shift link pin. Move the inner cable
toward the mark (A) [1] and repeat the procedure from the step 8. Adjustment range

[1]

11.Move the control lever from the "R" (Reverse) to the "N" (Neutral)
position. If the gear does not shift to the neutral, disconnect the
shift control cable from the shift link pin. Move the inner cable
Adjustment range
toward the mark (B) [1] and repeat the procedure from the step 8.
12.After adjustment, move the control lever to each gear position. If
the gear does not shift to the neutral properly, repeat the step 10
or step 11.
13.After installation, tighten the shift pivot lock nut [2].

[2] [1]

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BF80A/BF90DK4/BF100A

OPERATION CHECK AFTER INSTALLATION

• Check whether the control cable is adjusted properly and there is no twist or bend in the cable.
• Check the control lever for smooth operation and check the control cable for smooth movement without restriction.
Set the control lever in the “F” (Forward) position (approx. 30°) and check whether the shift shaft is in the forward
position.
Set the control lever in the “F” (Forward) full open position and check whether the throttle lever is in the full open
position.
Return the control lever to the “N” (Neutral) position and check whether the throttle lever is in the full close position.
If the throttle lever does not move to the full open and/or full close position, adjust the throttle control cable again.
• If the throttle arm and throttle control cable had been adjusted properly, the throttle lever should automatically move
to the full open/full close position accordingly by setting the control lever in the fully open/full close position. If the
throttle lever is not in the proper position, adjust as follows.
1. Remove the two screws (5 x 12 mm) [1] and remove the fast idle lever [2].
2. Remove the five screws (5 x 25 mm) [3] and remove the control housing B [4].
3. Remove the two screws (5 x 25 mm) [5] and remove the housing cover C [6].
4. Set the control lever in the throttle full open position.
5. Loosen the lock nut [7] on the link joint bracket [8], and adjust by turning the stopper bolt [9] to bring the throttle
valve to full open.

[8]
[9]

[4]

[3]

[7]

[1]

[2]

[6]

[5]

41
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BF80A/BF90DK4/BF100A

METER INSTALLATION (EQUIPPED TYPE)

INSTALLATION
Meters and other instruments should be installed on the instrument/
mounting panel. If any other location is selected, it will be necessary
to use a mounting plate with a thickness of 2 – 11 mm (1/16 – 7/16 MOUNTING NUT
in).
• If mounting plate thickness exceeds 11 mm (0.4 in), the mounting
bracket must be modified accordingly. Recommended
• Tighten the mounting nuts evenly on both sides. Installation angle
• Meter installation angle should be within 45˚ - 75˚.
• If the boat has a magnetic compass, install the tachometer a
minimum of 130 mm (5 in) away from the compass.
Installation hole diameter:
Tachometer: Ø 80.5 mm (3.2 in) MOUNTING
Trim meter: Ø 58 mm (2.3 in) BRACKET

TACHOMETER

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BF80A/BF90DK4/BF100A

METER WIRE CONNECTION

• Route and connect the wire harness properly, as shown in the wiring diagram.
Use Meter Wire Harness A for meter.
• Connect leads and terminals securely. Make sure terminals are waterproof.
• Use 19-gauge (1.25 mm diameter) wire.
• Connect the connectors securely. If a terminal is oxidized or corroded, remove the oxidation or corrosion with a
nonconductive plastic scrub pad or contact cleaner before reconnecting it.
• Make sure insulators surround their connectors completely and that the ends are not folded up.
• Do not break the wire harness coverings. If the covering of a wire is broken, either repair it with electrician’s tape or
replace it.
• Attach unused terminals to the adjacent main harness with a piece of vinyl tape so that the terminals don’t interfere
with the surrounding parts.
• Connect each wire properly as shown in the wiring diagram. After each wire and harness is connected, check for
proper connections by referring to the wiring diagram.
• Connect the battery and turn the main power on to check for proper operation.
• This is an independent engine-control system. Do not attempt to integrate it with the boat’s system or other
accessories, except for the instrument light switch. There are three ways to illuminate the instrument lights:
– Connect a commercially available switch (Teleflex 1A 16970 or equivalent) between the Bl/Y and R/W terminals.
– Connect 12V (+) from the boat’s instrument lights to the R/W terminal.
– Connect the Bl/Y and R/W terminals together for “lights on” with the engine switch.

TACHOMETER
TRIM METER

To LIGHTING
SWITCH
Y/Bu
R/W

R/W
Bl/Y

Bl/Y
Gr
Bl

Bl

Bl

Bl
C2
C3

C10

C11

C12

C13

C14

C15

C16

C17

C18
C5
C4

C7

C8

C9
C6

Y/Bu
R/W

R/W

R/W

R/W
Bl/Y

Y/Bl

Bl/Y

Bl/Y

Bl/Y
Gr
Bl

Bl

Bl

Bl

Bl

Bl

C19
Bl
C20 To METER HARNESS B
R/W
C21
Bl/Y
Bl/Y

10 A
Y/Bu
Bl/Y
Gr

Bl

Bl

6
C34

C35

C37

C39

C40

4 1 3 2 5 6
Bl BLACK Br BROWN
W/Bu
R/Bu
Y/Bl

Y YELLOW O ORANGE
Bu BLUE Lb LIGHT BLUE
G GREEN Lg LIGHT GREEN
R RED P PINK
W WHITE Gr GRAY

To REMOTE CONTROL BOX

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BF80A/BF90DK4/BF100A

SWITCH PANEL HARNESS/INDICATOR HARNESS CONNECTION

• Use switch panel harness and indicator harness for remote control box and outboard motor.
• Connect the wires as per the wiring diagram.
• Stake the lead wire against the terminal securely.
• Connect the connectors securely. If a terminal is oxidized or corroded, remove the oxidation or corrosion with a
nonconductive plastic scrub pad or contact cleaner before reconnecting it.
• Make sure insulators surround their connectors completely and that the ends are not folded up.
• Do not break the wire harness coverings. If the covering of a wire is broken, either repair it with electrician’s tape or
replace it.
• Attach unused terminals to the adjacent main harness with a piece of vinyl tape so that the terminals don’t interfere
with the surrounding parts.
• First, check whether the wire harnesses are connected as shown in the wiring diagram, then connect the battery
and turn the main power on to check for proper condition of the electrical parts and wire harness.

6
Bl BLACK Br BROWN
4 1 3 2 5 6
To REMOTE CONTROL BOX Y YELLOW O ORANGE
Bu BLUE Lb LIGHT BLUE

W/Bu
R/Bu
Y/Bl

Bu
Bl
G G GREEN Lg LIGHT GREEN
R RED P PINK
W WHITE Gr GRAY

G G
3
Bu Bu
2

Bl Bl
1

Y/Bl Y/Bl Y/Bl

1

W/Bu W/Bu W/Bu W/Bu

5
2

R/Bu R/Bu R/Bu R/Bu

3

39 INDICATOR LIGHT
Lg Lg 5
1

Lb Lb Lg Lg
7 11 10
2

R R Lb Lb
3

Y Y R R To OUTBOARD
4

40 Y Y MOTOR
Bl/W Bl/W WIRE
6

Bl/W Bl/W
3

Y/G Y/G HARNESS

8

Y/G Y/G
2

Bl Bl
4

Bl Bl
4

Br Br
3

Br Br
1

Y/Bu Y/Bu
5 13

Y/Bu Y/Bu
5

Bl/Y Bl/Y
Bl/Y Bl/Y
6

41
2

W/Bl W/Bl W/Bl W/Bl

1
1

Bl/R Bl/R Bl/R Bl/R

9
3

Gr Gr Gr Gr
12 14
4

Lg/Bl Lg/Bl Lg/Bl G/Bl

2

42
REMOTE CONTROL
Bl
CABLE

44
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BF80A/BF90DK4/BF100A

BATTERY AND CABLE CONNECTION

• The battery contains sulfuric acid. Avoid

contact with skin, eyes or clothing. Always
shield your eyes when working near
batteries.
• Antidote:
EXTERNAL — Flush with water.
INTERNAL — Drink large quantities of
water or milk. Follow with milk of
magnesia, beaten egg, or vegetable oil.
Call a physician immediately.
EYE — Flush with water and get prompt
medical attention.
• The battery produces flammable gas
which can explode under certain
conditions. Keep sparks and flames away
from the battery.

Minimum requirements:
12V-55Ah/5HR (CCA582A) or 12V – 65Ah/20HR (CCA582A)
marine cranking battery
• Install the battery in the correct size corrosion-resistant battery
box, in a dry, well-ventilated location protected from water and
direct sunlight.
• Connect the positive (+) battery cable [1] first, then connect the
negative (–) battery cable [2]. Tighten cable nuts securely. [1]
• To disconnect, disconnect at the negative (–) terminal first, then [2]
at positive (+) terminal. Never dis/connect the battery cables in
the reverse order.
• Coat the battery terminal ends with the non-conductive grease.
Cover the battery positive (+) terminal.
• Secure the corrosion-resistant battery box properly to the boat.
To keep potential sparks away from the fuel tank, do not secure
or place battery near the fuel tank.

45
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BF80A/BF90DK4/BF100A

PROPELLER
Propeller Selection
DIAMETER

PROPELLER DIMENSIONS (Diameter x Pitch)

(Indication location differs according to a maker.)

PITCH Pitch.............. Advanced Distance During One Turn (Apparent Advanced Distance)
P P: Pitch (mm)
Pitch Ratio.....
D D: Outer Diameter of Propeller
(Visual Advanced Distance – Measured Distance) x 100
Slip Ratio.......
Visual Advanced Distance
During running; the actually advanced distance is reduced by about 10 – 15% due
to propeller display pitch.

Recommended full throttle engine speed range: BF80A: 5,000 - 6,000 min-1 (rpm)
BF90D: 5,300 - 6,300 min-1 (rpm)
BF100A: 5,500 - 6,300 min-1 (rpm)
Engine speed varies with propeller size and boat condition.
A propeller must be selected to adjust maximum engine speed to the recommended engine speed range.
Using the wrong propeller can cause motor damage.
The proper propeller will assure powerful acceleration, top speed, good fuel economy, cruising comfort, and engine
service life.
Propeller Selection Precaution
• Outboard motor must be installed vertically in relation to boat bottom. Set moderate trim angle, and adjust power
trim angle to lowest setting.
• Set trim tab, so boat will run in a straight line.
• Protect propeller from foreign objects, check regularly for damage, and/or deformation, and aquatic plants wrapped
around propeller hub.
• Keep bottom clean of shells, algae froth and dirt.
These will cause a significant drop in top speed.
• When doing propeller checks, select a calm day with little waves action.
• Avoid strong winds. Wind speed should be less than 15 km/h (10 miles/h).
• The boat should carry its average load (crew, load arrangement, ballast).
Select the correct propeller so that full throttle engine speed is within the recommended range.
• If the engine min-1 is under the recommended min-1 range, lower the propeller pitch by one size (1 to 2 inches) or
more as needed.
• If the engine min-1 is over the recommended min-1 range, select a propeller with a pitch one size larger or as
needed.
• If the following conditions exist, acceleration will improve and outboard motor service life will increase by lowering
the propeller pitch.
– Heavy loads such as crew, load, equipment, water skiing, etc;
– High temperatures and high humidity conditions;
– When operating at high altitude;
– When boat bottom needs cleaning;
– When area around gear case is obstructed;
To increase motor service life and ensure safe navigation, do not use full throttle for extended periods, but run the
motor at 70 to 80% of full throttle.
• If full throttle engine min-1 exceeds the recommended range, it can cause increased vibration, noise, reduced boat
performance, and possible engine wear damage.
• If full throttle engine min-1 is below the recommended range, it indicates that the engine is being overloaded.

46
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BF80A/BF90DK4/BF100A
Propeller Selection Chart
Use the following table as the guide for propeller selection. Test run the outboard motor and check the maximum
speed. If it is not in the recommended maximum speed range shown in the table, replace the propeller and test run
again. Adjust to bring the maximum speed to the recommended speed range as needed.
BF80A
Propeller Speed (km/h) Speed in the recommended engine speed range (km/h)
size Dia. x 5,000 min–1 6,000 min–1
Propeller 0 10 20 30 40 50 60 70 80 90 100
pitch (rpm) (rpm)
(inch)
13.5 x 15 43 60
Stainless 13.25 x 17 46.8 66.1
Steel
(SUS) 13.25 x 19 58.1 77.5
13.25 x 21 61.3 83.5
14 x 11 8 28
13.75 x 13 20 39
13.5 x 14 25 44
13.5 x 15 41 58
Aluminum 13.25 x 17 53 69
(AL)
13 x 19 58 77
13 x 21 61 81
13.2 x 19 64 82
13.2 x 21 68 88

BF90D
Propeller Speed (km/h) Speed in the recommended engine speed range (km/h)
size Dia. x 5,300 min–1 6,300 min–1
Propeller 0 10 20 30 40 50 60 70 80 90 100
pitch (rpm) (rpm)
(inch)
13.5 x 15 45 62
Stainless 13.25 x 17 49 68
Steel
(SUS) 13.25 x 19 61 81
13.25 x 21 65 87
14 x 11 14 31
13.75 x 13 25 41
13.5 x 14 36 51
13.5 x 15 46 60
Aluminum 13.25 x 17
49 66
(AL)
13 x 19 56 74
13 x 21 62 82
13.2 x 19 57 76
13.2 x 21 65 85

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BF80A/BF90DK4/BF100A

BF100A
Propeller Speed (km/h) Speed in the recommended engine speed range (km/h)
size Dia. x 5,500 min–1 6,300 min–1
Propeller 0 10 20 30 40 50 60 70 80 90 100
pitch (rpm) (rpm)
(inch)
13.5 x 15 45 62
Stainless 13.25 x 17 49 68
Steel
(SUS) 13.25 x 19 61 81
13.25 x 21 65 87
14 x 11 14 31
13.75 x 13 25 41
13.5 x 14 36 51
13.5 x 15 46 59
Aluminum 13.25 x 17
52 66
(AL)
13 x 19 56 73
13 x 21 62 81
13.2 x 19 58 75
13.2 x 21 65 84

48
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BF80A/BF90DK4/BF100A
Boat Type and Applicable Size (Length and Weight)
BF80A 1 ft = 30.4 cm
Example
Weight
Hull Shape Overall Outb Overall Recommended
Boat Type (kg) Weight
(Example) length (ft) oard length full throttle
[lbs] (kg) [lbs]
motor (ft) speed (km/h)
640
Single 16.1 [1,411] 59.6
Fishing boat 495 –1,300
1,230
(off shore) 15.5 – 17.1 [1,091 – 2,866] Single 8.1 [2,712] 56.4
900
Single 15.2 [1,984] 54.8
600
Single 17 73
730 – 1,085 [1,323]
Bass boat 15.4 – 17
[1,609 – 2,392] 825
Single 17 62
[1,819]
500
Single 16.5 66
[1,102]
495 –1,300
Aluminum 550
16 – 18 [1,091 – 2,866] Single 17 62
boat [1,213]
1,200
Single 18 46
[2,646]
525
Single 18.1 64.9
[1,157]
Center 500 – 850 575
15.8 – 18.1 Single 16.6 61.3
console [1,102 – 1,874] [1,268]
800
Single 16.7 [1,764] 58.5
605
Single 16 59.9
[1,334]
625 – 1,500 850
Runabout 15 – 17 Single 15.8 56.3
[1,378 – 3,307] [1,874]
1,350
Single 15.7 51.3
[2,976]
825
Single 14.11 57
700 – 825 [1,819]
Water ski 4.11 – 15.1
[1,543 – 1,819] 700
Single 17 55
[1,543]
1,175
Single 19 24
1,175 – 3,000 [2,590]
Deck boat 19 – 26
[2,590 – 6,614] 3,000
Single 26 26
[6,614]
1,485
Single 24 [3,274] 29.7
Pontoon 1,050 – 2,013 1,850
18 – 24 Single 19 25.2
boat [2,315 – 4,438] [4,079]
1,380
Single 20 27.5
[3,042]

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BF80A/BF90DK4/BF100A

BF90D 1 ft = 30.4 cm
Example
Weight
Hull Shape Overall Outbo Overall
Boat Type (Example) length (ft)
(kg) Weight Recommended
[lbs] ard full throttle
length (ft) (kg) [lbs]
motor speed (km/h)
Single 16.5 500 69.5
[1,102]
495 –1,300
16 – 18 [1,091 – 2,866] Single 17 550 67.5
Aluminum boat [1,213]
1,300
Single 18 [2,866] 51.5
640
Single 16.1 61.0
Fishing [1,411]
495 –1,300
boat 1,230
15.5 – 17.1 [1,091 – 2,866] Single 18.1 58.0
(off shore) [2,712]
900
Single 15.2 56.5
[1,984]
600
Single 17 75.0
730 – 1,000 [1,323]
Bass boat 15.4 – 17
[1,609 – 2,205] 825
Single 17 64.0
[1,819]
525
Single 18.1 66.5
[1,157]
Center 500 – 1300 575
15.8 – 18.1 [1,102 Single 16.6 62.8
console – 2,866] [1,268]
F
800
R Single 16.7
[1,764]
60.0
P
605
Single 16 [1,334] 61.5
625 – 1,500 850
Runabout 15 – 17 [1,378 – 3,307] Single 15.8 [1,874] 57.8
1,350
Single 15.7 [2,976] 52.8
825
Single 14.1 [1,819] 62.5
700 – 825
Water ski 14.1 – 15.2 [1,543 – 1,819]
700
Single 17 [1,543] 61.5
1,175
Single 19 29.0
1,175 – 3,000 [2,590]
Deck boat 19 – 26
[2,590 – 6,614] 3,000
Single 26 27.0
[6,614]
660
Single 14.1 44.4
[1,455]
490 – 950 950
Inflatable boat 14.1 – 17.1 [1,080 Single 16.1 43.0
– 2,094] [2,094]
661
Single 17.1 47.5
[1,457]

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BF80A/BF90DK4/BF100A

BF100A 1 ft = 30.4 cm
Example
Weight
Hull Shape Overall Outboa Overall
Boat Type (Example) length (ft)
(kg) Weight Recommended
[lbs] rd full throttle
length (ft) (kg) [lbs]
motor speed (km/h)
Single 16.5 500 74.5
[1,102]
495 –1,300
16 – 18 [1,091 – 2,866] Single 17 550 70.5
Aluminum boat [1,213]
1,300
Single 18 [2,866] 54.5

Single 16.7 790 67.8

[1,742]
Fishing 750
495 –1,300 Single 15.6 [1,653] 66.2
boat
15.5 – 17.1 [1,091 – 2,866]
(off shore) 1,000
Single 17.1 [2,205] 66.1
1,100
Single 17.2 [2,425] 65.1

Single 18 730 76.0

730 – 1,085 [1,609]
Bass boat 15.1 – 18.0
[1,609 – 2,392] 570
Single 15.1 84.8
[1,257]
950
Single 18.4 [2,094] 68.2
Center 500 – 850 950
console 15.8 – 18.4 [1,102 – 1,874] Single 17.0 [2,094] 65.6
F
1,680
R Single 17.0 [3,704] 58.4
P
Single 16.2 665 65.7
[1,466]
625 – 1,500 800
Runabout 15 – 17 [1,378 – 3,307] Single 15.6 [1,764] 62.5
1,500
Single 17.0 57.9
[3,307]
825
Single 14.1 63.6
650 – 825 [1,819]
Water ski 14.1 – 15.1 [1,433 – 1,819]
650
Single 15.1 68.0
[1,433]
1,175
Single 19 30.0
[2,590]
Deck boat 19 – 26 1,175 – 3,000 Single 26 3,000 35.0
[2,590 – 6,614] [6,614]
Single 17 1,500 39.6
[3,307]
638
Single 17.3 54.9
[1,407]
661 – 1,050 760
Inflatable boat 16.1 – 19.8 Single 18.4 54.3
[1,457 – 2,315] [1,676]
1,050
Single 19.6 51.1
[2,315]

51
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BF80A/BF90DK4/BF100A

PROPELLER INSTALLATION
• Disconnect the battery cable terminal to prevent the engine from starting accidentally.
Wear heavy gloves to protect your hands from sharp or nicked propeller blades.
Apply marine grease to the propeller shaft [1].
Install the thrust washer [2] and the propeller (Not included) [3] on
the propeller shaft. [1]

Gear case
side
[3]
[2]

Install the propeller washer [1] and castle nut (18 mm) [2].
Tighten the castle nut (18 mm) and secure with the split pin [3].
TORQUE: 1.0 N·m (0.10 kgf·m, 0.7 lbf·ft) [3]

If the split pin does not align with the hole in the propeller shaft,
adjust by turning the nut in the tightening direction. Do not exceed
the maximum torque.
Maximum tightening torque:
44.1 N·m (4.5 kgf·m, 32 lbf·ft)

[1] [2]

After installation, bend the split pin [1] ends as shown to secure.
If the commercially available parts are used, select the stainless
steel parts. [1]

52
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BF80A/BF90DK4/BF100A

ADJUSTMENT AFTER INSTALLATION

Trim Tab Adjustment
After the engine break-in (page 55), run the boat at full speed and
check to see if the boat is drawn to the left or right. Adjust the trim
tab as required to ensure good and straight running characteristics.
When the boat is drawn to the left:
Remove the gear case grommet [1].
Loosen the bolt [2] and turn the trim tab [3] to the left. Fix the trim tab
in the position

[1]

[2]

[3]

When the boat is drawn to the right:

Remove the gear case grommet [1].
Loosen the bolt [2] and turn the trim tab [3] to the right. Fix the trim
tab in the position.

[1]

[2]

53
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BF80A/BF90DK4/BF100A

WHEN RADIO STATION/GPS

MOUNTED ON THE BOAT
The ECM and its wires are designed so that they are not affected by
the external jamming, but the ECM can function erroneously when it
receives the extremely strong electric wave. Check the ECM for
erroneous operation whenever a radio station or navigation system
is mounted on the boat.
Observe the following instructions to prevent erroneous operation.
• Set the antenna and radio station at least 50 cm (1.6 ft) or more
away from the ECM, switch panel cable, indicator cord, or remote
control box and control panel.
• Avoid routing the antenna wire lead too long compared to the
remote control wire leads.
• Do not install the radio station that does not conform with the
laws and regulations concerned. (10 W or below)
• Set the GPS antenna and navigation unit at least 3 m (9.8 ft) or
more away from the ECM.
• Ground the GPS antenna ground securely.

After installing a radio station or GPS, the ECM must be inspected

for erroneous operation.

INSTALLATION EXAMPLE:

GOOD
REMOTE
CONTROL BOX
At least
50 cm (1.6 ft)

RADIO UNIT
ANTENNA

NO GOOD
Radio unit too close Antenna too near
to remote control box REMOTE
outboard motor.
and control cable. CONTROL BOX

Routing antenna cable and

control cable together.

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BF80A/BF90DK4/BF100A

BREAK-IN PROCEDURE
Break-in period: 10 hours
Break-in operation allows the moving parts to wear-in evenly and
thus ensures proper performance and longer outboard motor
service life.
• First 15 minutes:
Run the outboard motor at trolling speed. Use the minimum
amount of throttle opening necessary to operate the boat at a
safe trolling speed.
• Next 45 minutes:
Run the outboard motor up to a maximum of 2,000 to 3,000 min-1
(rpm) or 10% to 30% throttle opening.
• Next 60 minutes:
Run the outboard motor up to a maximum of 4,000 to 5,000 min-1
(rpm) or 50% to 80% throttle opening. Short bursts of full throttle
are acceptable but do not operate the motor continuously at full
throttle.
• Next 8 hours:
Avoid continuous full throttle operation (100% throttle opening).
Do not run the outboard motor at full throttle for more than 5
minutes at a time.
For boats that plane easily, bring the boat up on plane then reduce
the throttle opening to the specified break-in settings called out
above.

Serious damage to the engine may occur in the area where the
lowest temperature becomes 0°C (32°F) or less, if a cooling system
freezes, and warm-up operation after starting is not performed but a
high-speed cruise is carried out.

55
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BF80A/BF90DK4/BF100A

PRE-DELIVERY SERVICE CHECK LIST

Check all items on the following list. Refer to the Owner’s Manual or
Shop Manual for the specifications and the detailed procedures.
Test every unit to be sure it is functioning properly.
On land
EXTERNAL APPEARANCE
Check for Transport Damage
Check for paint scratches, touch up if necessary.
GEAR OIL
Check for proper gear oil level. Make sure the oil level and drain plugs are tight.
OIL CAPACITY: 0.95 (1.00 US qt, 0.84 lmp qt)
Recommended oil: SAE # 90 Hypoid gear oil
Use gear oil that meets or exceeds the requirement for API Service Classification GL-4.
INSTALLATION LOCATION
Check for correct installation location.
Check outboard motor for correct installation height.
Make sure the motor mounting bolts are tight with the double nuts.
Check to be sure sealant has been supplied to the transom mounting bolt holes.
FUEL SYSTEM
Be sure fuel lines are connected securely.
Check that there is no water in the gasoline.
Make sure the fuel tank is full of fresh gasoline.
Check for fuel leaks. If necessary, repair immediately.
STEERING SYSTEM
Check the steering system for smooth operation.
Make sure the outboard motor does not interfere with the steering cable and/or link arm,
control cables, wire harness etc. when the steering wheel is turned full left and full right
and with the motor in all tilt positions.
REMOTE CONTROL SYSTEM
Check the remote control for proper operation.
Make sure the control lever selects the forward, neutral, and the reverse gears.
Check that the throttle stopper functions when the gear is in “F” (Forward) and the throttle
is fully open.
TILLER HANDLE SYSTEM
Check that the tiller handle mounting bolt is tightened securely.
Check the tiller handle proper operation.
Make sure that gear shift operates properly with the shift lever.
Check that the throttle arm operates correctly with the throttle grip in full throttle.
ELECTRICAL SYSTEM
Check the wire harnesses for proper connections.
Check the battery connections for correct polarity and tightness.
Make sure the battery is fully charged and installed securely.
Make sure the meters, indicators and switches are connected correctly.
TILT MECHANISM
Push the power trim/tilt switch and make sure the outboard motor tilts up and down
smoothly.
Check for the tilt motor noise while tilting up or down.
Operate the steering with the outboard motor in the tilt-up position, and check to be sure
that the cables, harnesses, etc. do not interfere with the outboard motor.
Tilt up the outboard motor to the full tilt-up position and check the power trim/tilt oil level.
Make sure the tilt stopper sets in the lock position with the outboard motor in the full tilt-
up position.
Tilt down the outboard motor and check to see that the trim meter functions and indicates
“DOWN”.
Check the manual tilt valve for proper function.

56
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BF80A/BF90DK4/BF100A

ENGINE OIL
Check the engine oil level.
Engine oil capacity: 4.7 (4.97 US qt, 4.14 lmp qt)
Recommended oil: SAE 10W-30
Use 4-stroke motor oil that meets or exceeds the requirement for API Service Classification
SG, SH or SJ.
Always check the API SERVICE label on the oil container to be sure it includes the letters
SG, SH or SJ.
PROPELLER
Check for deformation (e.g. bend, etc.).
Check for excessive wear.
Check the castle nut for secure tightening.
Check the cotter pin for any abnormality.
ALL NUTS, BOLTS & OTHER FASTENERS
Check security and tighten if necessary.

OPERATION CHECK LIST

In the Water
OUTBOARD MOTOR INSTALLATION
Check that there are no water leaks from the motor mounting bolt holes.
Check for the balanced weight distribution in the boat.
OUTBOARD MOTOR OPERATION
Turn the combination switch to the START position and check whether the engine starts.
After the engine starts, make sure that the OIL indicator lamp should go on.
Check the outboard motor for any abnormal noise.
Check to be sure cooling water flows out of the cooling system indicator.
After the engine warms up:
Make sure the motor returns smoothly to idle.
Snap the throttle and check the engine response.
Check to see that the emergency stop switch functions securely.
LEAKS
Makes sure that there are no leaks from the fuel lines and/or connections. If necessary,
repair immediately.
Check the outboard motor for cooling water/oil leaks. Repair if necessary.
Check the exhaust system for gas leaks.
During Sea Trials
Check the idle speed.
IDLE SPEED: 750 ± 50 min-1 (rpm)
Check the gearshift operation with the gear shift lever or remote control lever.
Check the motor operation at trolling speed.
Check whether the outboard motor tilts up or water enters the boat from the transom
during cruising.
Check whether the adequate propeller has been selected.
Check the engine speed with the boat under way.
MAXIMUM RECOMMENDED ENGINE SPEED: BF80A: 5,000 – 6,000 min-1 (rpm)
BF90D: 5,300 – 6,300 min-1 (rpm)
BF100A: 5,500 – 6,300 min-1 (rpm)
Make sure that there is no propeller ventilation in a straight line. There is the possibility of
some propeller ventilation when turning at full throttle with the motor trimmed out.

57
 dummyhead

BF80A/BF90DK4/BF100A

After Sea Trials

CHECK & CLEAN THE OUTBOARD MOTOR
Check that there is no water in the gear oil.
Check that there are no signs of fuel, oil or water leaks. Repair if necessary.
After running in salty or dirty water, use a flushing kit to flush the cooling system with
clean water. Use a flushing kit, run the outboard motor at idle during flushing for
approximately 10 minutes.
Clean the entire outboard motor thoroughly with a cloth.
Check the outboard motor for external damage, defects, or cracks.

58
dummytext

WIRING DIAGRAMS
WIRING DIAGRAMS

FUSE BOX FUEL PUMP 29 ECM

EQUIPPED TYPE OPTIONAL PART
ALTERNATOR MAIN FUEL FUEL FUEL FUEL
TACHO METER TRIM METER ALTERNATOR W INJECTOR #4 INJECTOR #3 INJECTOR #2 INJECTOR #1 IGNITION COIL #4 IGNITION COIL #3 IGNITION COIL #2 IGNITION COIL #1 W/Bu ACGLP
COMBINATION SWITCH FUSE 70 A 30 A 6

2
Bu/Y
VOLT HOUR GND IG BAT LOAD ST W R/Bu WARNL

Bl
R/C

3
METER METER W/Bl Gr TACHO
COLOR Bl Bl/R W/Bl Bl/Y Bl/W 10 A 2

4
OFF W/Bl 5 1 2 37 1 2 36 1 2 35 1 2 34 1 2
FI 2 3 1 2 3 1 2 3 1 2 3 1
33 32 31 30
ON T5 T6 Y Y/Bu TRMA
15 A 3

6
START W/Bl R/W TE
To LIGHTING IGP

W/Bu
SPARK SPARK SPARK SPARK

Bu/R

Bu/R

7
W/G
Y/Bl

Y/Bl

Y/Bl

Y/Bl

Y/Bl

Y/Bl

Y/Bl

Y/Bl
Bu

Bu
Br
SWITCH

Bl

Bl

Bl

Bl

Bl
R
Y
Y R/Bl THL

Y/Bu

R/W

R/W
R/W

R/W
Bl/Y

Bl/Y
15 A 5 PLUG PLUG PLUG PLUG

Gr

Bl

Bl

Bl

Bl
Bl

Bl

Bl

Bl

8
EMERGENCY STOP SWITCH

Y
W/G W/R PB
C2
C3

W
W
W

W
Bl
SUB

9
COLOR Bl/R Bl Y Y/R
1 2 POIL

C10

C11

C12

C13

C14

C15

C16

C17

C18

C22

C23

C24

C25

C26

C27

C28

C29
10 A 4
C5
C4

C7

C8

C9
C6

10
PUSH or REMOVE THE CLIP 1 2 3 1 2 GND1 W/R Bu K-LINE
FFP

11
SET THE CLIP

Y/Bu
R/W

R/W

R/W

R/W
Bl/Y

Y/Bl

Bl/Y

Bl/Y

Bl/Y

R/W

R/W
W W/Bu

Gr
W/Bu IGN2
Bl

Bl

Bl

Bl

Bl

Bl

Bl

Bl

Bl

Bl
Y

Y
10 A 1
REGULATOR/

12
Bl W W/Bu Lg FLR1
C19
NEAUTRAL SWITCH RECTIFIER

13
C30
Bl Bl Bl T3 T4 Lg FLR2
To SPEED COLOR Bl/Bu Bl

14
C20 C31 METER GEAR IN Bu IGN1
LIGHT W

15
R/W R/W R/W
C21 NEUTRAL C1
Bl/Y Y T1 G PG3
W 3

17
Br POWER TRIM/TILT SWITCH W/Bl
Bl/Y TROLLING STARTER O2HT

3
Bl/W Bl/W

18
Bl CONTROL COLOR Lg W/Bl Lb Y/G BUZZ

5
SWITCH BATTERY

2
Lg/Bl Bl/Bu Bu

19
NORMAL Bu

1
CRK

6
10 A Bu/R Bu/R

20
38 UP STARTER

3
DOWN T2 MOTOR Lg/R Lg
R/Bl TOH1

1
Bl
Bl Bl

22
Y/Bu
Lg/Bl
Bl/Y

FUEL R/Y TA

4
TROLLING CONTROL SWITCH
Gr

Br

Bl

Bl
GND2 Bl/Y Bl/Y

23
6 MAIN G TDC

2
COLOR Lg/Bl Bl Br

24
C32

C33

C34

C35

C36

C37

C38

C39

4 1 3 2 5 6 C40 NEUTRAL W/Bu W/Bu

REMOTE CONTROL BOX R TOH2

1
UP W/Y W

26
W/Bu
R/Bu
Y/Bl

Bl/Y

5
DOWN O2
Bu
Bl
G

Bl W/Bl W/Bl

27
EMERGENCY
Lg/Bl
Y/Bu
Bl/Y
Bl/Y

4
STOP SWITCH
Gr

Br

C41
Bl
R
R
Y
Y

W/G W/G
Bl/R Bl/R

2
C42 W/R W/R
Y/G Y/G WARNING W/G IGN3

3
NMEA

30
Bl/Y BUZZER 2000 1 PGM-FI/MAIN RELAY 4 Y OPL

31
C43 O/Bu R
R OHL
Lb Lb

32
C44 POWER W/Bu Bl Bu/R IGN4
W/Bl W/Bl TRIM/TILT

33
C45 SWITCH Y Y G FUP

34
Lg Lg
C46 W W G PG4

35
Bl/Y Bl/Y O
C47
Bu

5
Bl/Y Bl/Y LOAD
C48 SHIELD
Bl Bl NMEA2000 W CAN1H
C49

1
Bl Bl GND COMBINATION R CAN 12V
SWITCH

2
C50 2
Bl/R Bl/R IG Bu Bl CAN GND
Bl/R Bl

3
C51

1
Bl/W Bl/W ST Gr
C52 Bu LG1

2
W/Bl W/Bl BAT ENGINE SPEED CHECK CONNECTOR

5
W/Bl
C53 3 Br/Y VCC1
Bl
Bl

6
Bl
C54 Y/Bl Bu VCC2
Bl R

7
Bl GND Bu Y/Bl IGP1
C55
Bl/Y

8
Bl/Y Bl/Y BAT Lg IGP2
Y/Bl
C56

9
R R OHL INDICATOR Bl G/Y VTS
C57 LIGHT

10
Y Y OPL G DLC G/Bl TLUP
C58

11
4
R/Bu R/Bu WARNL Br TLDN
G G

12
C59
Y INJ4
3

W/Bu W/Bu ACGLP

Bu Bu

13
Bu INJ3
2

Bl Bl

14
R INJ2
1

Y/Bl Y/Bl Y/Bl

15
Br INJ1
1

W/Bu W/Bu W/Bu W/Bu

16
G PG1
5
2

R/Bu R/Bu R/Bu R/Bu

17
G EACVP
3

39 INDICATOR LIGHT

18
Bu CAN1L
Lg Lg 5

19
Y SHIELD
1

Lb Lb Lg Lg

20
7 11 10
2

R R Lb Lb
Br/W VCC3
3

Y Y R R

22
Bu LG2
4

40 Y Y

23
Bl/W Bl/W G SG1
6

Bl/W Bl/W

24
3

Y/G Y/G G SG2

8

Y/G Y/G

25
2

Bl Bl
4

Bl Bl
4

Br Br Bu NT SW
3

Br Br

27
1

Y/Bu Y/Bu Br FFD

5 13

Y/Bu Y/Bu

28
5

Bl/Y Bl/Y R/Bu KS

Bl/Y Bl/Y
6

29
41
Bl/R EMS1
2

W/Bl W/Bl W/Bl W/Bl

30
Bl/R EMS2
1
1

Bl/R Bl/R Bl/R Bl/R

31
9
3

Gr Gr Gr Gr
Lg SCS
12 14
4

Lg/Bl Lg/Bl Lg/Bl G/Bl

33
2

Lb
Lg

W
Bl

42
REMOTE CONTROL

W/Bl

G/Y
Lb

Lg
Bl 7 8 G PG2
CABLE 9 11

35
Bl EACVM
Bl 3 2 1 1

36
G 3 2 1 1
6 Bl

R/Bu

Bu

W/Bl
Br

Bl/Y

Y/Bl
G

Bl

G
Bu 28

Br/W

G
Y/Bu
W

Bl
G G W/Bl 10 Bu 25

G/W
1

Lb
Lg

Lb

Bu Bu Lg 14 2 1 16 2 1
Bl
2

1 1 2 4 3
15 1 2 3

Bl/Bu

G/R
Bl

Gr
R/W

G/Bl

G/Bl

W/R
Br/Y
R/Bl

R/Bl

Y/Bl

Y/Bl

W
W
R/Y

Y/R
Br

Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl

Y/Bl
Y/Bl

Y/Bl
Y/Bl

Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl

Bu

Bu

Bu
EQUIPPED TYPE

Bl
Bu

Bu

G
R
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl

Bl
Bl
Bl

Bl

Bl
Bl
Bl
Bl
Bl
Bl
Bl

Y
G
G
G
G
G
G
G
G
G

Y
Bl BLACK Br BROWN

Lg/Bl
Y/Bu
12 13

Bl
17 18 19 20 21 22 23 24 26 27
Y YELLOW O ORANGE
KNOCK VTEC 21 17 23 15 24 13 22 19 18 1 2 3 6 5 4 8 9 12 11 10 4 6 1 9 3 8 7 2 5 21 20 19 18 24 23 22 15 14 16 17
Bu BLUE Lb LIGHT BLUE GND4 GND5 GND6 GND7 2 1 2 1 2 1 2 1 3 1 2 3 1 2 3 2 1 3 2 1 2 1 3 2 1
REMOTE CONTROL TYPE (When using the G GREEN Lg LIGHT GREEN POWER
SENSOR SOLENOID
VALVE
side mount remote control box) R RED P PINK
POWER GND3
TRIM/TILT GROUND GROUND NEUTRAL TRIM WATER LEVEL ECT ECT IAT EBT TP EOP CKP CMP H02S SENSOR MAP IAC
W WHITE Gr GRAY POWER TILT RELAY SWITCH SWITCH ANGLE SENSOR SENSOR 2 SENSOR 3 SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR VALVE
TILT MOTOR GROUND BF90D/100A only JOINT CONNECTOR 2 JOINT CONNECTOR 1 SENSOR

59
 dummytext

FUSE BOX FUEL PUMP 29 ECM

OPTIONAL PART
ALTERNATOR MAIN FUEL FUEL FUEL FUEL
ALTERNATOR W INJECTOR #4 INJECTOR #3 INJECTOR #2 INJECTOR #1 IGNITION COIL #4 IGNITION COIL #3 IGNITION COIL #2 IGNITION COIL #1 W/Bu ACGLP
TACHO METER TRIM METER COMBINATION SWITCH FUSE 70 A 30 A 6

2
Bu/Y
GND IG BAT LOAD ST W R/Bu WARNL

Bl
R/C

3
VOLT METER HOUR METER COLOR Bl Bl/R W/Bl Bl/Y Bl/W W/Bl Gr TACHO
10 A 2

4
OFF W/Bl 5 1 2 37 1 2 36 1 2 35 1 2 34 1 2
FI 2 3 1 2 3 1 2 3 1 2 3 1
33 32 31 30
ON T5 T6 Y Y/Bu TRMA
15 A 3

6
START W/Bl R/W TE
IGP

W/Bu
SPARK SPARK SPARK SPARK

Bu/R

Bu/R

7
W/G
Y/Bl

Y/Bl

Y/Bl

Y/Bl

Y/Bl

Y/Bl

Y/Bl

Y/Bl
To LIGHTING

Bu

Bu
Br
Bl

Bl

Bl

Bl

Bl
R
Y
Y R/Bl THL

Y/Bu

R/W

R/W
R/W

R/W
Bl/Y

Bl/Y
SWITCH 15 A 5 PLUG PLUG PLUG PLUG

Gr

Bl

Bl

Bl

Bl
Bl

Bl

Bl

Bl

8
EMERGENCY STOP SWITCH

Y
W/G W/R PB

W
W
W

W
Bl
SUB

9
COLOR Bl/R Bl
C3
C2

Y Y/R POIL

C17

C18
1 2

C28
C16

C29
C10

C11

C12

C13

C14

C15

C22

C23

C24

C25

C26

C27
10 A 4
C6
C5
C4

C9
C7

C8

10
PUSH or REMOVE THE CLIP 1 2 3 1 2 GND1 W/R Bu K-LINE
FFP

11
SET THE CLIP

Y/Bu
R/W

R/W

R/W

R/W
Bl/Y

Y/Bl

Bl/Y

Bl/Y

Bl/Y

R/W

R/W
W W/Bu

Gr
W/Bu IGN2
Bl

Bl

Bl

Bl

Bl

Bl

Bl

Bl

Bl

Bl
Y

Y
10 A 1
REGULATOR/

12
Bl W W/Bu Lg FLR1
NEAUTRAL SWITCH RECTIFIER
TO

13
C19 C30
Bl Bl Bl T3 T4 Lg FLR2
SPEED COLOR Bl/Bu Bl

14
C20 C31 METER GEAR IN Bu IGN1
LIGHT W

15
R/W R/W R/W
C21 NEUTRAL C1
Bl/Y

Bl/Y Y T1 G PG3
6 4 W 3

17
POWER TRIM/TILT SWITCH W/Bl O2HT
STARTER
Bl/W Bl/W

18
10 A COLOR Lg W/Bl Lb Y/G BUZZ

5
BATTERY Bl/Bu Bu

19
NORMAL Bu CRK

6
Bu/R Bu/R

20
UP STARTER

3
Y/Bu
Bl/Y

MOTOR
Gr

Bl

DOWN T2 Lg/R Lg
R/Bl TOH1

1
Bl
Bl Bl

22
C43

C44

FUEL R/Y
C32

C33

C34

C35

C36

C37

C38

C39

C40

C41

C42

TA

4
TROLLING CONTROL SWITCH GND2 Bl/Y Bl/Y

23
MAIN G TDC

2
TILLER HANDLE COLOR Lg/Bl Bl Br

24
Bl
NEUTRAL W/Bu W/Bu
EMERGENCY R TOH2

1
UP
W/Bu
W/Bu
R/Bu
R/Bu

Y/Bu

W/Bl
W/Bl
Bl/Y
Bl/Y

STOP SWITCH W/Y W

Bu

Gr

Lb

Lg

C45

26
Bl
Bl
G

R
R
Y
Y

Bl/R Bl/R Bl/Y

5
DOWN W/Bl W/Bl
O2

27
C46

4
Y/G Y/G WARNING W/G W/G

2
Bl/Y BUZZER W/R W/R
NMEA W/G IGN3

3
2000 1

30
C47 4 Y OPL
O/Bu R PGM-FI/MAIN RELAY
Lb

31
Lb

3
R OHL
C48 POWER W/Bu Bl

32
W/Bl W/Bl TRIM/TILT

2
Bu/R IGN4
SWITCH Y Y

33
4
C49 G FUP
W W

34
Lg

6
Lg G PG4
O Bu

35
C50

5
Bl/Y Bl/Y
SHIELD
C51 NMEA2000
Bl/Y Bl/Y LOAD
C52 2 W CAN1H
Bl Bl Bu

1
C53 Bl R CAN 12V
COMBINATION

2
Bl Bl GND Gr Bl CAN GND
Bl/R
C54 SWITCH

3
Bl/R IG
Bl/R
C55 ENGINE SPEED
Bl/W Bl/W ST CHECK CONNECTOR Bu LG1
C56 3

5
W/Bl W/Bl BAT
W/Bl Br/Y VCC1
Y/Bl

6
C57 R

3
Bl Bu VCC2
Bl Bl GND Bu

7
1
C58 Y/Bl IGP1
Bl/Y Lg
Bl/Y BAT

8
Bl/Y 4
C59 Y/Bl IGP2
R R OHL INDICATOR Bl

9
2

C60 LIGHT DLC G/Y VTS

Y Y OPL

10
G G/Bl TLUP
C61

11
R/Bu R/Bu WARNL 4
C62 Br TLDN
G G

12
W/Bu W/Bu ACGLP Y INJ4
3

Bu Bu

13
Bu INJ3
2

Bl

14
R INJ2
1

Y/Bl

15
Br INJ1
4

W/Bu W/Bu

16
G PG1
5

R/Bu R/Bu

17
G EACVP
6

INDICATOR LIGHT

18
Bu CAN1L
5

19
Y SHIELD
Lg Lg

20
7 11 10

Lb Lb
Br/W VCC3
R R

22
Bu LG2
Y Y

23
G SG1
6

Bl/W Bl/W

24
G SG2
8

Y/G Y/G

25
4

Bl Bl
Bu NT SW
3

Br

27
Br FFD
5 13

Y/Bu Y/Bu

28
R/Bu KS
Bl/Y Bl/Y

29
Bl/R EMS1
2

W/Bl W/Bl

30
Bl/R EMS2
1

Bl/R Bl/R

31
9

Gr Gr
Lg SCS
12 14

G/Bl

33
Lb
Lg

W
Bl

W/Bl

G/Y
Lb

Lg
Bl HANDLE CABLE 7 8 G PG2
9 11

35
Bl EACVM
Bl 3 2 1 1

36
G 3 2 1 1
6 Bl

R/Bu

Bu

W/Bl
Br

Bl/Y

Y/Bl
G

Bl

G
Bu 28

Br/W

G
Y/Bu
W

Bl
G G
EQUIPPED TYPE 25
W/Bl

10 Bu

G/W
1

Lb
Lg

Lb

Lg

Bu Bu
Bl 14 2 1 16 2 1
2

1 1 2 4 3
Bl BLACK Br BROWN 15 1 2 3

Bl/Bu

G/R
Bl

Gr
R/W

G/Bl

G/Bl

W/R
Br/Y
R/Bl

R/Bl

Y/Bl

Y/Bl

W
W
R/Y

Y/R
Y YELLOW O ORANGE

Br

Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl

Y/Bl
Y/Bl

Y/Bl
Y/Bl

Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl

Bu

Bu

Bu

Bl
Bu

Bu

G
R
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl

Bl
Bl
Bl

Bl

Bl
Bl
Bl
Bl
Bl
Bl
Bl

Y
G
G
G
G
G
G
G
G
G

Lg/Bl
Y/Bu
Bu BLUE Lb LIGHT BLUE 12 13

Bl
17 18 19 20 21 22 23 24 26 27
G GREEN Lg LIGHT GREEN 21 17 23 15 24 13 22 19 18 1 2 3 6 5 4 8 9 12 11 10 4 6 1 9 3 8 7 2 5 21 20 19 18 24 23 22 15 14 16 17
KNOCK VTEC GND4 GND5 GND6 GND7 2 1 2 1 2 1 2 1 3 1 2 3 1 2 3 2 1 3 2 1 2 1 3 2 1
R RED P PINK
SENSOR SOLENOID
W WHITE Gr GRAY POWER
TILLER HANDLE TYPE TRIM/TILT VALVE
GROUND GROUND NEUTRAL TRIM WATER LEVEL ECT ECT IAT EBT TP EOP CKP CMP H02S SENSOR MAP IAC
POWER POWER TILT RELAY
GND3
SWITCH SWITCH ANGLE SENSOR SENSOR 2 SENSOR 3 SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
TILT MOTOR BF90D/100A only VALVE
GROUND JOINT CONNECTOR 2 JOINT CONNECTOR 1 SENSOR

60