2002 Honda BF15D and BF20D Outboard Motor Service Manual Set (P/N 66ZY000)

The supplement is used with the base manual for power tilt and gas-assisted tilt service. The bulletin updates fuel pump orientation, fuel chamber mounting and tube routing for the applicable frame-number changes.

PDF Search, Bookmarks and Diagram Detail

Search and drawing detail: Text search is partial: some repair pages, supplement tables, the base-manual wiring sheets and the update bulletin have no searchable text. Chapter bookmarks cover the base manual and supplement, with a separate bulletin bookmark. Small wiring labels require zooming.

The set is supplied as one printable, English-language 398-page PDF. All prefaces, publication indexes, the update bulletin and the additional one-page chapter/page index are included in that total.

Engine, Lower Unit and Tilt Service

The following topics are selected highlights from the manual set. Other documented work includes engine-cover removal and Bodensee exhaust-emission testing.

• Engine and timing: Step-by-step procedures for engine removal, cylinder-head and piston work, oil-pump inspection, timing-belt replacement, and valve-clearance adjustment.

• Fuel system: Carburetor overhaul, manual and automatic Starting Enrichment checks, fuel-pump testing, and fuel-filter, tank-strainer and primer-bulb service.

• Lower unit and cooling: Propeller and gear case disassembly, shaft and bearing inspection, shim selection, water-pump impeller replacement, and thermostat service.

• Tilt mechanisms: Power tilt motor and valve-body overhaul, ATF filling, air bleeding, blow-pressure inspection, and gas-assisted-damper replacement.

• Mounts and controls: Oil case, stern bracket and swivel case disassembly, plus shift linkage, steering rod, remote control box and tiller handle bracket service.

• Electrical diagnosis: Ignition, starter, charging and alert-system troubleshooting, with wiring diagrams for tiller-handle, remote-control and power-tilt configurations.

Suited to technicians and experienced owners equipped for electrical testing and precision mechanical inspection; the manual assumes basic shop-safety knowledge.

Internal Engine Inspection and Valve Timing

The cylinder head can be serviced with the engine installed on the frame. Internal chapters cover camshaft and rocker-arm inspection, valve-seat refacing, oil-pump clearances, and crankcase/crankshaft assembly, with bolt-length-specific cylinder-head torque data.

Timing and flywheel sections identify crankshaft holder 07923-ZA00100 and the relevant alignment marks. The cylinder-head instructions warn that backward flywheel rotation can damage the water pump.

Wear-limit tables and test procedures can be cross-referenced on a shop tablet while working beside the motor.

Fuel Delivery and Production Changes

The tank sections distinguish the 13-liter steel and 12-liter plastic assemblies, including their strainers, hose connections and primer-bulb valves. Carburetor instructions cover float and float-valve inspection, with separate handling information for Canadian pilot-screw limiter caps.

The included bulletin’s revised pump, fuel chamber and tube illustrations help match replacement components and routing to the relevant frame-number change.

Gear Case, Mounting Assemblies and Tilt Repair

The Shim Selection Table relates the forward-bevel-gear taper-roller-bearing height to engagement marks on the gear case. Water-pump housings, shaft seals and extension-case assemblies receive separate disassembly and assembly coverage.

Power tilt instructions address the motor, cylinder, piston and valve body, including ATF filling and air bleeding because trapped air can cause faulty operation. The gear pump is replaced as an assembly rather than internally disassembled. The manual also identifies a sealing washer that can collapse if installed at an angle in the manual-valve opening.

Gas-assisted-damper coverage includes removal, installation, tilt-lever replacement and disposal procedures.

Electrical Tests and Workshop Drawings

Resistance matrices for the ignition control module and regulator/rectifier accompany starting, charging and alert-system fault charts. Dimensional drawings and shift-linkage exploded views show component relationships.

Cable & Harness Routing and Connector Location drawings support circuit tracing. The Faulty Power Tilt Assembly Quick Reference Chart links operating symptoms with component checks.

Before beginning any teardown or diagnostic work on marine equipment, always verify your workspace is well-ventilated and that battery connections are isolated to prevent accidental sparking.

Selected Compression, Shaft and Ignition Test Data

Engine test data include standard cylinder compression of 1,370 ± 98 kPa (199 ± 14 psi) at 600 rpm and a crankshaft main-journal oil-clearance range of 0.018–0.042 mm.

For lower-unit inspection, the standard propeller-shaft diameter at the forward-bevel-gear area is 16.973–16.984 mm. Ignition-coil testing specifies 0.8–1.0 Ω across the primary terminals.