This Seloc 1202 - Honda Outboard repair and service manual covers 2002-2014 Honda outboard motors, 2.0 to 225 HP, 1-4 cylinder and V6 models, including Jet Drives.
This high quality service manual / tome contains 744 pages of DIY stepwise instructions and photos for the home mechanic interested in saving money.
Step-by-step illustrated keyed procedures guide you through every conceivable job possible, including all adjustments necessary. Perfect for do-it-yourselfers, professional mechanics, or students.
Book Excerpt: 2002-2014 Honda Outboards 2.0-225 HP, 1-4 Cylinder, V6, Jet Drive
IGNITION & ELECTRICAL SYSTEMS
CHARGING CIRCUIT | DESCRIPTION & OPERATION
(See Figures 108 thru 113)
A charging system is standard (or at least an available option) on the vast majority of Honda 4-strokes, the one exception being the BF2D for which we could not locate such an option). When installed, a charging system provides an electrical current to maintain the battery and to operate other engine/boat mounted electrical components.
The charging systems used on these motors will have various outputs (from 3-90 amps) matched to appropriate capacities for the motor and loads from accessories due to anticipated boat size. Honda tends to do a lot of things their own way, and Charging Systems on their outboards are no exception.
Whereas other manufacturers might choose to provide AC accessory coils or unregulated system in addition to fully-regulated ones, almost all of the systems we could locate for these motors are fully regulated, using a combination regulator/rectifier (there's one exception as it seems some early BF5As may use an unregulated system containing only a rectifier).
The rectifier function of that component converts current from AC to DC, while the regulator function monitors battery load/condition to prevent possible overcharging.
Regardless of the particular system used on any given powerhead, all types start by generating an AC current in the same fashion.
A Stator Coil or Battery Charge Coil is mounted under a magnetized rotating mass (usually a flywheel on other brands of outboards, but on these Hondas you never know what it might be, it could be a flywheel or it could be separate rotor) in order to utilize its mechanical spinning motion when the engine is operating.
Permanent magnets (attached to the flywheel or rotor) generate a spinning magnetic field that cuts through the coil windings producing an alternating current. The coil wiring delivers current to charging system components (a regulator/rectifier on Hondas).
DESCRIPTION & OPERATION
(See Figures 1 thru 4)
The lower unit/gearcase is considered that part of the outboard below the mid-section/exhaust housing (sometimes known as the intermediate housing). If the powerhead is the equivalent of a car's engine, then the gearcase is the equivalent of a car's transmission and differential, "transmitting" the power made by the motor to the "wheel" (propeller) that moves the boat.
The unit contains the water pump, propeller shaft, driveshaft, pinion gear, forward gear, and usually reverse gear. The shifting capabilities, including the forward and, in all but the smallest gearcases, the reverse gears together with the clutch, shift assembly, and related linkage, are all housed within the lower unit.
The lower unit may be removed and serviced without disturbing the remainder of the outboard unit.
Rotational power from the powerhead is transferred through the vertical driveshaft to the lower unit. The driveshaft is splined to the crankshaft (or crankshaft driven gear on some models) on the upper end and a pinion gear is splined to the driveshaft (usually secured by a nut but sometimes by a clip on smaller motors) on the lower end.
The forward and reverse (if equipped) gears are in constant mesh with the pinion gear and rotate anytime the powerhead is operating.
Subject: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014 Honda Outboards 2.0-225 HP, 1-4 Cylinder and V6 Models, Including Jet Drives service, maintenance, and repair.
ISBN-10: 0893300780 | ISBN-13: 9780893300784