Honda BF35A-BF45A Outboard Motor Service & Repair Manual (P/N 66ZV300)
431 Pages • 17.35 MB • Instant, Printable PDF
Honda Models Covered & Key Technical Specifications
Models: Honda BF35A, Honda BF45A
Sub-models / Variants: Short shaft (SH), Long shaft (LH), Long shaft remote (LR), Long shaft remote trim (LRT), Short shaft remote (SR), Tiller handle type, Remote control type
Model Years: 1990
Technical Data:
- Engine type: 4-stroke, O.H.C, 3-cylinder
- Displacement: 808 cc (49.4 cu in)
- Rated power (BF35A): 35 HP @ 4,600–5,600 RPM
- Rated power (BF45A): 45 HP @ 5,000–6,000 RPM
- Lubrication capacity: 2.4 L (2.54 US qt)
- Cylinder compression: 15 ± 1 kg/cm² (212 ± 14 psi) @ 500 RPM
- Spark plug gap: 0.6–0.7 mm (0.024–0.028 in)
- Ignition system: CDI
- Cooling system: Forced water circulation with thermostat
- Fuel type: Regular automotive gasoline (86 pump octane)
Honda Manual Features & Content Preview
- Covers 1990 Honda BF35A and BF45A outboard motors, including short and long shaft configurations with tiller or remote control options
- Official Honda publication P/N 66ZV300, issued October 1990
- Contains 431 pages of technical information, including detailed wiring diagrams, torque specification tables, and tool application guides for professional repair shops and home garages
Documentation Overview
The 1990 Honda BF35A and BF45A service manual organizes maintenance and technical tasks into seventeen key sections. Coverage spans from initial engine identification and baseline maintenance standards through detailed disassemblies of the fuel, lubrication, and cooling systems. Major chapters document the flywheel and timing belt assemblies, cylinder head, oil pump, and complete crankshaft architecture. You will also find specific guidance on propeller and gear case maintenance. Separate supplements break down the power tilt and remote control subsystems.
Technical Specifications
Engine documentation includes comprehensive tolerance charts for pistons, rings, valves, and camshaft journals. Cylinder head bolt torque values are mapped out in a multi-stage sequence. Final-stage angles are specified directly in the engine assembly data. The ignition system section provides resistance values for charging, exciter, and pulser coils to speed up electrical diagnostic workflows during any repair process.
Reference cooling data lists thermostat opening temperatures and lift heights inside the water jacket chapter. For example, coolant system temperatures rely on a thermostat starting to open at 52°C (126°F). Standard idle speed sits at 950 ± 50 RPM in the carburetor section, while intake valve clearance for the BF35A is documented at 0.13–0.17 mm.
Always prioritize shop safety. Verify all procedures against current industry standards and ensure your workspace is properly ventilated before handling fuel system components. The service data provided here reflects the original manufacturer engineering for these 3-cylinder powerheads; hands-on work should always rely on the complete original OEM documentation to ensure safe and accurate execution.
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