Honda BF115A / BF130A 1998 Outboard Repair Manual Set (P/N 66ZW500)

Use the supplements with the base shop manual: they contain changed material rather than complete replacement instructions. The November supplement also refers to the March supplement for earlier service information.

Trim/tilt service limit: The manual covers hydraulic-unit disassembly but specifically instructs against internal disassembly of the pump assembly, free piston and piston-rod assembly.

PDF Search, Bookmarks and Wiring Detail

Search and diagram detail: Text search is limited mainly to the combined contents sheet and a few news headings; the service procedures are not text-searchable. Embedded chapter bookmarks navigate the base manual, supplements and news pages. Small pin numbers and wire-color codes in the large wiring diagrams require zooming.

The download is one printable, English-language 431-page PDF. That total includes all publications listed above and the combined contents sheet.

Engine Overhaul, PGM-FI Diagnosis and Gearcase Setup

The following selected coverage highlights outline the main workshop areas. Other topics include PCV-chamber operation checks and engine-cover hook adjustment.

• Engine repair: Step-by-step procedures for engine removal and installation, timing-belt setup, cylinder-head disassembly, valve-guide replacement, valve-seat reconditioning, and crankshaft/piston inspection.

• PGM-FI diagnostics: MIL blink-code diagnosis, ECM memory reset, sensor and IAC fault isolation, injector inspection, fuel-pressure testing, and vapor-separator/fuel-pump service.

• Gearcase work: Propeller, water-pump, shift-rod, propeller-shaft-holder and vertical-shaft repair, plus bevel-gear shimming, backlash adjustment and thrust-clearance checks for standard and counter-rotation units.

• Power trim/tilt: Swivel-case and stern-bracket removal, hydraulic-unit disassembly and assembly, ATF filling, ordered air-bleeding procedures, chamber blow-pressure testing, and power-tilt-motor repair.

• Electrical and controls: Starter-motor overhaul, relay, fuse, ignition-coil and switch checks, remote-control box and panel service, and shift/throttle cable adjustment.

• Maintenance and cooling: Engine and gear-oil changes, spark-plug and valve-clearance checks, belt adjustments, thermostat testing, and water-jacket and pressure-valve service.

• Shop reference: Component-specific torque tables, fluid capacities, service limits, inspection and adjustment data, electrical test specifications, and Honda special-tool numbers with stated applications.

Because the procedures assume special tools, pressure gauges, electrical test equipment, and established shop practices, this manual is best suited to marine technicians and experienced mechanics equipped for major outboard repair.

Engine Internals and PGM-FI Fault Isolation

Engine coverage extends to alternator and balancer service, flywheel and oil-pump work, crankcase teardown, and balancer-bearing replacement. Crankshaft main-bearing and connecting-rod bearing selection tables relate component markings to the required bearings.

The PGM-FI section combines 34-pin and 6-pin ECM terminal data with checks for MAP, TP, ECT, IAT and pulser-coil sensors. High-pressure fuel troubleshooting separates pump, regulator, relay, injector-power and harness faults, supporting fault isolation before replacement parts are selected.

Serial-Specific Gearcase and Fuel-System Updates

March supplement: Revised vertical-shaft and bevel-gear information covers bearing changes, shim selection and position, and backlash adjustment. Standard and counter-rotation gearcases have distinct setup requirements, including counter-rotation thrust-clearance checks.

November supplement: Changes address the cylinder-head water gallery and thermostat, fuel-pipe and water-separator layout, tube routing, maintenance schedule, high-pressure fuel strainer, vapor separator, and fuel-pressure procedures.

Matching the frame serial number to the applicable supplement helps distinguish the correct gearcase setup and revised cooling or fuel-system information.

Service news: The 2000 notices revise water-seal installation information and identify gearcase parts changes. The August notice distinguishes assemblies produced from April 1998 through May 2000 from revised parts used from June 2000 onward, with compatibility information for clutch shifters, bevel gears and propeller shafts.

Schematics, Test Charts and Special Tools

Visual references include the PGM-FI circuit diagram, ECM terminal arrangement, fuel/engine-control system diagram, side-mount remote-control-box wiring diagram, control-panel wiring diagram, and cable/harness and tube-routing views.

Troubleshooting flowcharts address hard starting, poor running, ignition and starter faults, idle control, alert circuits, high-pressure fuel delivery, and power trim/tilt problems.

Tool listings pair Honda numbers with their applications. ECM diagnosis uses the SCS short connector 07WPZ-0010100 and test harness 07WPZ-ZW50100. Gearcase setup references bearing preload tool 07SPJ-ZW0010Z, backlash indicator 07SPJ-ZW0030Z, and dial-indicator adapter kit 07SPJ-ZW0040Z.

Repair Notes and Safety

The cylinder-head section warns that removing the valves too quickly can damage the valve-stem seals. The power trim/tilt section also notes that overfilling the unit with ATF can damage the tilt-motor oil seal when the rods are compressed.

Fuel-system repair requires pressure relief and strict ignition-source control, and major engine, gearcase, and trim/tilt work requires proper support, lifting equipment, and trained handling.

Examples of Injector and Thermostat Test Data

For BF115A/BF130A fuel-injector inspection, the base manual specifies terminal resistance of 11.1–12.3 Ω. The accompanying diagnosis also covers injector operation and the related power and control circuits.

For the updated cooling configuration covered by the November supplement, the thermostat starts opening at 58–62°C (136–144°F) and is fully open at 70°C (158°F). These specifications accompany the revised cylinder-head and water-gallery information.