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

This 431-page PDF combines Honda's 19-section December 1998 BF115A/BF130A base shop manual with later OEM supplements and service-news updates. It covers BF115AX codes BZBD (standard rotation) and BZBG (counter-rotation), plus BF130AX codes BZBE (standard rotation) and BZBH (counter-rotation). Configurations are LD (long, standard rotation), XD (extra-long, standard rotation), LCD (long, counter-rotation), and XCD (extra-long, counter-rotation). 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.

• Document set: Base shop manual P/N 66ZW500, 392 pages; March 2002 supplement P/N 66ZW500Z, 20 pages; November 2002 supplement P/N 66ZW500Y, 15 pages; one-page combined contents; Shop Manual News P/P-068 and P/P-087, one page each; and one-page August 2000 Service News.
• Engine repair: Covers engine removal and installation, alternator and balancer service, timing-belt setup, cylinder-head disassembly, valve-guide replacement, valve-seat reconditioning, flywheel and oil-pump work, and crankcase, crankshaft, piston, balancer-bearing, and bearing-selection procedures.
• PGM-FI diagnostics: Provides MIL blink-code diagnosis, ECM memory reset, 34-pin and 6-pin terminal data, sensor and IAC fault isolation, high-pressure fuel troubleshooting, fuel-pressure testing, injector inspection, and vapor-separator and fuel-pump service.
• Gearcase work: Details propeller, water-pump, shift-rod, propeller-shaft-holder, vertical-shaft, and bevel-gear repair, followed by gear-shim selection, shim-position charts, backlash adjustment, and thrust-clearance checks for standard and counter-rotation units.
• Power trim/tilt: Includes swivel-case and stern-bracket removal, hydraulic unit disassembly and assembly, ATF filling, ordered air-bleeding procedures, upper- and lower-chamber blow-pressure testing, and power-tilt-motor repair.
• Electrical and controls: Handles starter-motor overhaul, relays, fuses, ignition coils, switches, remote-control box and panel components, shift and throttle cables, plus cable, harness, vacuum, fuel-tube, and cooling-tube routing.
• Shop reference: Supplies component-specific torque tables for engine, gearcase, frame, and electrical assemblies; service limits, inspection and adjustment data, electrical test values, and multi-page special-tool tables with Honda tool numbers and stated applications.

Serial-Specific Updates

The March 2002 supplement applies to BF115A BZBD-1300380 and later and BF130A BZBE-1302203 and later. It revises the vertical-shaft and bevel-gear setup, including bearing changes, shim selection and position, and the backlash sequence.

The November 2002 supplement covers BF115A BZBD-1300690/BZBG-1300035 and later and BF130A BZBE-1302748/BZBH-1300363 and later. Its changes address the cylinder-head water gallery and thermostat, fuel-pipe and water-separator layout, tube routing, the maintenance schedule, high-pressure fuel strainer, vapor separator, and fuel-pressure procedures. Both supplements contain only the changed material and are meant to be used with the included base manual.

The 2000 news pages add revised water-seal installation information and a production break for gearcase parts. That Service News distinguishes standard BZBD/BZBE and counter-rotation BZBG/BZBH assemblies built from April 1998 through May 2000 from the revised parts used from June 2000 onward, including clutch-shifter, bevel-gear, and propeller-shaft compatibility.

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 detailed cable/harness and tube-routing views. Troubleshooting flowcharts cover hard starting, poor running, ignition and starter faults, PGM-FI sensors, idle control, alert circuits, high-pressure fuel delivery, and power trim/tilt problems.

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

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.