1990 Honda BF35A-BF45A Outboard Motor Service Manual

Covers BF35A and BF45A models with procedures for engine cover, throttle cam, choke rod, and starter motor. Includes part number 66ZV300.

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Document Details

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Document Number / Seller:
30181 / Sharon Clark
File Size:
17.35 MB
File Type:
PDF
Language:
English
Pages:
431
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Jan 5, 2026

Models Covered & Key Technical Specifications

Essential Calibration Shop Manual: Honda BF35A-BF45A Outboard Full Workshop Manual

Honda BF35A-BF45A (66ZV300) — 1990 | Factory Guide. Details on engine, fuel system, and electrical components.

  • Calibrated Securement Values: For proper assembly, 27 N-m represents the specified torque for the cylinder head bolts.
  • Rated Fluid Capacity: For optimal lubrication, 2.4 L (2.54 US qt, 2.11 Imp qt) defines the required crankcase oil capacity.
  • Published Power Draw: The starter motor requires 8 x 12 mm bolts for secure mounting.
  • Authorized Gap Specs: For the spark plug, 0.6–0.7 mm (0.024–0.028 in) establishes the standard electrode gap.
  • Maximum Output: The BF35A engine produces 35 HP @ 4,600-5,600 RPM, signifying the peak operational output.
  • Documented Tension Specs: For the timing belt, 130 N·m (13.0 kg-m, 94.0 ft-lb) signifies the critical tightening torque.

Professional Workshop Service Manual & Technical Specifications

Essential Calibration Shop Manual: Honda BF35A-BF45A Outboard Full Workshop Manual (1990) – 431 Pages | OEM Specs Information-Suite

Asset-ID: 66ZV300 // Unit-Designations: BF35A / BF45A Outboard Motor Logic // System-Coverage: Engine, Fuel System, Electrical, and Maintenance Procedures.

Honda BF35A-BF45A Outboard Full Workshop Manual

Assessment-Element System-Path Framework
Year 1990 Original Release Date
Models Covered BF35A, BF45A Specific Engine Variants
Pages 431 Document Length
Language English Manual Language
File Size 17.3523 MB Digital File Size

Repair procedures are structured around the comprehensive documentation of various engine and system components. This manual provides detailed insights into the operation and maintenance of your Honda outboard motor.

Engine Cover/Throttle/Choke

This section documents procedures related to the engine cover, throttle cam, and choke rod, covering their disassembly, reassembly, and adjustment. It includes specifications for their proper functioning.

Fuel System

The manual details the fuel system, including the fuel pump, fuel strainer, and fuel tubes, providing clear instructions for inspection and replacement. It outlines the necessary steps for system maintenance.

Ignition & Electrical Architecture

This part of the manual covers the ignition system, CDI unit, and charging coils, explaining their inspection and installation. It details electrical component specifications for optimal performance.

This manual documents torque specifications for various fasteners to ensure proper vibration dampening and assembly integrity.

FAQ

What **essential** testing parameters are listed? keyboard_arrow_down

15 ± 1 kg/cm² @ 500 RPM is the specified cylinder compression value for the BF35A engine, detailed on page 2-3.

Check the **correct** diagnostic procedures. keyboard_arrow_down

The diagnostic flowcharts for "ENGINE", "IGNITION SYSTEM", and "STARTER MOTOR" are found starting on page 2-13, guiding through troubleshooting steps.

What does the **documented** fluid capacity requirements state? keyboard_arrow_down

2.0 L (2.11 US qt, 1.76 Imp qt) is the engine oil capacity for the BF35A, as listed on page 3-2, relevant for maintenance beyond page 366.

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Reviews (2)

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New
I appreciated the quick email response when I had questions. The download process was smooth and the manual is thorough. Perfect for DIY maintenance!
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New
The service manual is incredibly detailed and easy to follow. The illustrations helped me navigate complex repairs without hassle. Highly recommend!