product update bf200a • bf225a engine will not start …
TRANSCRIPT
bf225 main relay pub.fm© 2005 American Honda Motor Co., Inc.— All
Rights Reserved Page 1 of 17 PTB53849 (TM027-2005.09)
CONSUMER INFORMATION: The information in this service bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely service and repair your Honda outboard motor. These procedures should not be attempted by “do-it-yourselfers”, and you should not assume that this bulletin applies to your equipment, or that your outboard motor has the condition described. To determine whether this information applies, contact an authorized Honda Marine dealer.
OUTBOARD MOTOR #49 SEPTEMBER 2005
PRODUCT UPDATE BF200A • BF225A
ENGINE WILL NOT START DUE TO MAIN RELAY FAILURE SYMPTOM The main relay may fail, causing the engine not to start.
AFFECTED UNITS
CORRECTIVE ACTION The main relay potting material separates from the main relay housing, allowing the electrical components inside the main relay to corrode due to exposure to moisture.
The potting material has been changed to eliminate cracking and moisture entering and corroding the relay contacts.
American Honda is performing a Product Update to install the new main relay on all affected units
Units in dealer inventory: Install the new main relay kit on ALL dealer inventory units in the affected frame serial number range prior to retail sale.
Retailed units: American Honda will notify all registered owners of affected units to contact their servicing dealer to arrange to have the main relay kit installed. Please contact owners of any unregistered units, as listed on the attached wholesale purchase report.
Warehouse units: Affected units in American Honda’s inventory will have the new main relay kit installed. These units can be identified by the green “•” mark on the crate serial number sticker and the white paint dot on the new main relay.
Install a new main relay kit on any affected unit by following the procedure starting on the next page.
MODEL FRAME SERIAL NUMBER RANGE
BF200A BAEJ-1000001~1400255 BAFJ-1000001~1400001
BF225A BAGJ-1000001~1400878 BAHJ-1000001~1400282
The engine will not start because the main relay has failed.
CRATE GREEN MARKING “•“
Nne
OUTBOARD #49 SEPTEMBER 2005
Page 2 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
INSTALLATION 1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Release the rubber strap securing the electric parts cover and remove the electric parts cover.
4. Disconnect the S terminal from the starter motor solenoid.
ENGINE COVER
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 3 of 17 PTB53849 (TM027-2005.09)
5. All except A6 models: Loosen the harness band clip and pull the S terminal cable from the harness band clip.
A6 models: Remove and discard the cable clip securing the S terminal cable.
6. Loosen the harness band clip located above the electric parts cover strap that secures the alternator fuse cable, fuse cable, and main wire harness.
HARNESS BAND CLIP
S TERMINAL CABLE
CABLE CLIP Discard.
S TERMINAL CABLE
HARNESS BAND CLIP
ELECTRIC PARTS COVER STRAP
OUTBOARD #49 SEPTEMBER 2005
Page 4 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
7. All except A6 models: Loosen the wire harness clip that secures the main wire harness, alternator B terminal cable, and service check connector cable.
A6 models: Loosen the harness band.
8. Pull off the boot of the alternator B terminal and remove the 10 mm nut. Remove the B terminal cable from the alternator.
9. Disconnect the green alternator 4P connector.
10. Remove the harness band clip securing the main wire harness to connector bracket A.
WIRE HARNESS CLIP
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 5 of 17 PTB53849 (TM027-2005.09)
11. Disconnect, then remove the following connectors from the connector bracket A.
PGM-FI main relay 6P connector PGM-FI main relay 2P connector Fuse box 4P connector PGM-FI main relay 4P connector Fuse box 3P connector
12. Position the connectors as shown.
PGM-FI MAIN RELAY 6P CONNECTOR
PGM-FI MAIN RELAY 2P CONNECTOR FUSE BOX 4P
CONNECTOR
CONNECTOR BRACKET A
FUSE BOX 4P CONNECTOR
FUSE BOX 3P CONNECTOR
OUTBOARD #49 SEPTEMBER 2005
Page 6 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
13. Remove the top two 6 × 10 mm flange bolts securing connector bracket A to connector bracket B.
Loosen the bottom 6 mm flange bolt securing connector bracket A to connector bracket B.
14. Pull connector bracket A as close to you as you can, and pull out the starter motor S terminal cable.
6 × 10 mm FLANGE BOLTS
Remove.
Loosen.
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 7 of 17 PTB53849 (TM027-2005.09)
15. Pull out the fuse box to PGM-FI main relay 4P female connector above the main wire harness.
16. Remove the two 6 × 22 mm flange bolts and two 6 mm washers, and remove the PGM-FI main relay assembly.
17. Install two new collars and two new grommets on the new PGM-FI main relay assembly.
MAIN WIRE HARNESS
6 × 22 mm FLANGE BOLT (2)
PGM-FI MAIN RELAY ASSEMBLY
6 mm WASHER (2)
OUTBOARD #49 SEPTEMBER 2005
Page 8 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
18. Set the PGM-FI main relay assembly to connector bracket A. Loosely tighten the 6 × 22 mm flange bolts and 6 mm washers, and then tighten the flange bolts to the specified torque.
TORQUE: 12 N•m (9 ft-lb)
19. Pull the connector bracket A toward you and route the starter cable S terminal cable as shown.
20. Route the S terminal cable through the harness band clip and connect the S terminal to the starter motor. Install the boot securely over the starter motor S terminal.
6 × 22 mm FLANGE BOLT (2)
PGM-FI MAIN RELAY ASSEMBLY
6 mm WASHER (2)
POWER TILT HARNESS
STARTER MOTOR S TERMINAL CABLE
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 9 of 17 PTB53849 (TM027-2005.09)
21. All except A6 models: Tighten the harness band clip
A6 types: Attach a new cable clip to secure the S terminal cable to connector bracket A.
HARNESS BAND CLIP
S TERMINAL CABLE
OUTBOARD #49 SEPTEMBER 2005
Page 10 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
22. Loosely install the two 6 x 10 mm flange bolts securing connector bracket A to connector bracket B, then tighten the three 6 mm bolts to the specified torque.
Torque: 12 N•m (9 ft-lb)
23. Route the fuse box to PGM-FI main relay 4P connector under the main wire harness as shown.
6 × 10 mm FLANGE BOLTS
MAIN WIRE HARNESS
PGM-FI MAIN RELAY 4P CONNECTOR
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 11 of 17 PTB53849 (TM027-2005.09)
24. Reconnect the following connectors, then secure them to connector bracket A in the order shown.
PGM-FI main relay 6P connector PGM-FI main relay 2P connector Fuse box 4P connector PGM-FI main relay 4P connector Fuse box 3P connector
25. Tighten the harness band clip.
PGM-FI MAIN RELAY 6P CONNECTOR
PGM-FI MAIN RELAY 2P CONNECTOR
FUSE BOX 4P CONNECTOR
FUSE BOX 3P CONNECTOR
CONNECTOR BRACKET A
HARNESS BAND CLIP
MAIN WIRE HARNESS
A6 MODELS
FUSE BOX 4P CONNECTOR
FUSE BOX 3P CONNECTOR
CONNECTOR BRACKET A
HARNESS BAND CLIP
MAIN WIRE HARNESS
ANGLE SENSOR HARNESS
OUTBOARD #49 SEPTEMBER 2005
Page 12 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
26. Install the harness band clip securing the main wire harness to the connector bracket A.
27. Reconnect the green alternator 4P connector to the alternator.
28. Install the alternator B terminal cable and secure with the 10 mm nut. Make sure the B terminal cable is positioned as shown, then tighten the 6 mm nut to the specified torque.
Torque: 8 N•m (6 ft-lb) 29. Securely install the boot over the alternator B terminal.
HARNESS BAND CLIP
MAIN WIRE HARNESS
CONNECTOR BRACKET A
B TERMINAL CABLE
6 mm NUT
ALTERNATOR 4-PIN CONNECTOR
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 13 of 17 PTB53849 (TM027-2005.09)
30. All except A6 models: Tighten the wire harness clip that secures the main wire harness, alternator B terminal cable, and service check connector cable.
A6 models: Tighten the harness band.
WIRE HARNESS CLIP
OUTBOARD #49 SEPTEMBER 2005
Page 14 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
31. Reinstall the electric parts cover by aligning the knobs with the grommets.
32. Carefully push on the left side of the cover and hang the cover on the hook on the back left side of connector bracket A.
33. Install the lower right edge of the electric parts cover so that it is inside the inner of the engine under cover.
34. Secure the electric parts cover with the rubber strap.
35. Install the engine cover.
36. Connect the battery negative cable.
37. Start and test the outboard motor.
Viewed from top
ELECTRIC PARTS COVER
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 15 of 17 PTB53849 (TM027-2005.09)
PARTS INFORMATION
Kit Contents
WARRANTY INFORMATION In warranty: The normal warranty applies.
Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration. Please contact Techline or your District Service Manager. You must request consideration and receive a decision before starting work.
VIN Information
Description Qty. Part Number Honda Code
Kit, main relay 1 06380-ZY3-303 8139941
Description Qty. Part Number Honda Code
PGM-FI main relay 1 38580-ZY3-013 8104093
Grommet 2 38551-ZW1-000 4899761
Collar 2 91553-ZV5-010 7492846
Harness band clip 1 91541-SOA-003 6283873
VIN Prefix Affected Serial Number Range Model BAEJ 1000001~1400255
BF200A BAFJ 1000001~1400001 BAGJ 1000001~1400878
BF225A BAHJ 1000001~1400282
OUTBOARD #49 SEPTEMBER 2005
Page 16 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
The following is a copy of the letter sent to registered customers.
September 2005
What is the reason for this notice?
American Honda Motor Co., Inc. is conducting a product update of certain Honda BF200A and BF225A
outboard motors. Our records indicate that you may own one of these products.
What is the problem?
The main relay is sealed with potting material to prevent corrosion. Over time, the potting material
may separate from the relay housing causing the electrical components inside the relay to corrode. As a
result of the corrosion, the outboard may not start.
What should you do?
The main relay potting material has been improved to correct this situation. Please contact your
authorized Honda Marine servicing dealer to make an appointment to have your BF200A or BF225A
updated. Be aware that not all selling boat dealers are authorized Honda dealers. The dealer will
complete the main relay update procedure, without cost to you for parts or labor. Transportation of the
boat to the dealer and/or related hauling expenses are the responsibility of the owner.
If you need information regarding the location and phone number of your nearest authorized Honda
Marine servicing dealer, please access our dealer locator on our website at:
www.honda-marine.com/dea.aspx, or contact us at: (800) 426-7701.
Whom to contact if you experience problems.
If you are not satisfied with the service you receive from your Honda dealer, you may contact:
American Honda Motor Co., Inc. Marine Group Customer Relations Department 4900 Marconi Drive Alpharetta, GA 30005 (770) 497-6400
If you have questions.
Should you have any questions or concerns regarding this matter that your Honda servicing dealer
cannot answer, please call Honda Marine Customer Relations at (770) 497-6400.
American Honda Motor Co., Inc.
4900 Marconi Drive
Alpharetta, GA 30005
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 17 of 17 PTB53849 (TM027-2005.09)
It is our goal to provide you with the highest quality products and the best after-sale service. We
apologize for any inconvenience this situation may cause.
We thank you for your purchase of a Honda product.
Sincerely,
Wade E. Terry
CONSUMER INFORMATION: The information in this service bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely service and repair your Honda outboard motor. These procedures should not be attempted by “do-it-yourselfers”, and you should not assume that this bulletin applies to your equipment, or that your outboard motor has the condition described. To determine whether this information applies, contact an authorized Honda Marine dealer.
OUTBOARD MOTOR #49 SEPTEMBER 2005
PRODUCT UPDATE BF200A • BF225A
ENGINE WILL NOT START DUE TO MAIN RELAY FAILURE SYMPTOM The main relay may fail, causing the engine not to start.
AFFECTED UNITS
CORRECTIVE ACTION The main relay potting material separates from the main relay housing, allowing the electrical components inside the main relay to corrode due to exposure to moisture.
The potting material has been changed to eliminate cracking and moisture entering and corroding the relay contacts.
American Honda is performing a Product Update to install the new main relay on all affected units
Units in dealer inventory: Install the new main relay kit on ALL dealer inventory units in the affected frame serial number range prior to retail sale.
Retailed units: American Honda will notify all registered owners of affected units to contact their servicing dealer to arrange to have the main relay kit installed. Please contact owners of any unregistered units, as listed on the attached wholesale purchase report.
Warehouse units: Affected units in American Honda’s inventory will have the new main relay kit installed. These units can be identified by the green “•” mark on the crate serial number sticker and the white paint dot on the new main relay.
Install a new main relay kit on any affected unit by following the procedure starting on the next page.
MODEL FRAME SERIAL NUMBER RANGE
BF200A BAEJ-1000001~1400255 BAFJ-1000001~1400001
BF225A BAGJ-1000001~1400878 BAHJ-1000001~1400282
The engine will not start because the main relay has failed.
CRATE GREEN MARKING “•“
Nne
OUTBOARD #49 SEPTEMBER 2005
Page 2 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
INSTALLATION 1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Release the rubber strap securing the electric parts cover and remove the electric parts cover.
4. Disconnect the S terminal from the starter motor solenoid.
ENGINE COVER
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 3 of 17 PTB53849 (TM027-2005.09)
5. All except A6 models: Loosen the harness band clip and pull the S terminal cable from the harness band clip.
A6 models: Remove and discard the cable clip securing the S terminal cable.
6. Loosen the harness band clip located above the electric parts cover strap that secures the alternator fuse cable, fuse cable, and main wire harness.
HARNESS BAND CLIP
S TERMINAL CABLE
CABLE CLIP Discard.
S TERMINAL CABLE
HARNESS BAND CLIP
ELECTRIC PARTS COVER STRAP
OUTBOARD #49 SEPTEMBER 2005
Page 4 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
7. All except A6 models: Loosen the wire harness clip that secures the main wire harness, alternator B terminal cable, and service check connector cable.
A6 models: Loosen the harness band.
8. Pull off the boot of the alternator B terminal and remove the 10 mm nut. Remove the B terminal cable from the alternator.
9. Disconnect the green alternator 4P connector.
10. Remove the harness band clip securing the main wire harness to connector bracket A.
WIRE HARNESS CLIP
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 5 of 17 PTB53849 (TM027-2005.09)
11. Disconnect, then remove the following connectors from the connector bracket A.
PGM-FI main relay 6P connector PGM-FI main relay 2P connector Fuse box 4P connector PGM-FI main relay 4P connector Fuse box 3P connector
12. Position the connectors as shown.
PGM-FI MAIN RELAY 6P CONNECTOR
PGM-FI MAIN RELAY 2P CONNECTOR FUSE BOX 4P
CONNECTOR
CONNECTOR BRACKET A
FUSE BOX 4P CONNECTOR
FUSE BOX 3P CONNECTOR
OUTBOARD #49 SEPTEMBER 2005
Page 6 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
13. Remove the top two 6 × 10 mm flange bolts securing connector bracket A to connector bracket B.
Loosen the bottom 6 mm flange bolt securing connector bracket A to connector bracket B.
14. Pull connector bracket A as close to you as you can, and pull out the starter motor S terminal cable.
6 × 10 mm FLANGE BOLTS
Remove.
Loosen.
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 7 of 17 PTB53849 (TM027-2005.09)
15. Pull out the fuse box to PGM-FI main relay 4P female connector above the main wire harness.
16. Remove the two 6 × 22 mm flange bolts and two 6 mm washers, and remove the PGM-FI main relay assembly.
17. Install two new collars and two new grommets on the new PGM-FI main relay assembly.
MAIN WIRE HARNESS
6 × 22 mm FLANGE BOLT (2)
PGM-FI MAIN RELAY ASSEMBLY
6 mm WASHER (2)
OUTBOARD #49 SEPTEMBER 2005
Page 8 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
18. Set the PGM-FI main relay assembly to connector bracket A. Loosely tighten the 6 × 22 mm flange bolts and 6 mm washers, and then tighten the flange bolts to the specified torque.
TORQUE: 12 N•m (9 ft-lb)
19. Pull the connector bracket A toward you and route the starter cable S terminal cable as shown.
20. Route the S terminal cable through the harness band clip and connect the S terminal to the starter motor. Install the boot securely over the starter motor S terminal.
6 × 22 mm FLANGE BOLT (2)
PGM-FI MAIN RELAY ASSEMBLY
6 mm WASHER (2)
POWER TILT HARNESS
STARTER MOTOR S TERMINAL CABLE
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 9 of 17 PTB53849 (TM027-2005.09)
21. All except A6 models: Tighten the harness band clip
A6 types: Attach a new cable clip to secure the S terminal cable to connector bracket A.
HARNESS BAND CLIP
S TERMINAL CABLE
OUTBOARD #49 SEPTEMBER 2005
Page 10 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
22. Loosely install the two 6 x 10 mm flange bolts securing connector bracket A to connector bracket B, then tighten the three 6 mm bolts to the specified torque.
Torque: 12 N•m (9 ft-lb)
23. Route the fuse box to PGM-FI main relay 4P connector under the main wire harness as shown.
6 × 10 mm FLANGE BOLTS
MAIN WIRE HARNESS
PGM-FI MAIN RELAY 4P CONNECTOR
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 11 of 17 PTB53849 (TM027-2005.09)
24. Reconnect the following connectors, then secure them to connector bracket A in the order shown.
PGM-FI main relay 6P connector PGM-FI main relay 2P connector Fuse box 4P connector PGM-FI main relay 4P connector Fuse box 3P connector
25. Tighten the harness band clip.
PGM-FI MAIN RELAY 6P CONNECTOR
PGM-FI MAIN RELAY 2P CONNECTOR
FUSE BOX 4P CONNECTOR
FUSE BOX 3P CONNECTOR
CONNECTOR BRACKET A
HARNESS BAND CLIP
MAIN WIRE HARNESS
A6 MODELS
FUSE BOX 4P CONNECTOR
FUSE BOX 3P CONNECTOR
CONNECTOR BRACKET A
HARNESS BAND CLIP
MAIN WIRE HARNESS
ANGLE SENSOR HARNESS
OUTBOARD #49 SEPTEMBER 2005
Page 12 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
26. Install the harness band clip securing the main wire harness to the connector bracket A.
27. Reconnect the green alternator 4P connector to the alternator.
28. Install the alternator B terminal cable and secure with the 10 mm nut. Make sure the B terminal cable is positioned as shown, then tighten the 6 mm nut to the specified torque.
Torque: 8 N•m (6 ft-lb) 29. Securely install the boot over the alternator B terminal.
HARNESS BAND CLIP
MAIN WIRE HARNESS
CONNECTOR BRACKET A
B TERMINAL CABLE
6 mm NUT
ALTERNATOR 4-PIN CONNECTOR
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 13 of 17 PTB53849 (TM027-2005.09)
30. All except A6 models: Tighten the wire harness clip that secures the main wire harness, alternator B terminal cable, and service check connector cable.
A6 models: Tighten the harness band.
WIRE HARNESS CLIP
OUTBOARD #49 SEPTEMBER 2005
Page 14 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
31. Reinstall the electric parts cover by aligning the knobs with the grommets.
32. Carefully push on the left side of the cover and hang the cover on the hook on the back left side of connector bracket A.
33. Install the lower right edge of the electric parts cover so that it is inside the inner of the engine under cover.
34. Secure the electric parts cover with the rubber strap.
35. Install the engine cover.
36. Connect the battery negative cable.
37. Start and test the outboard motor.
Viewed from top
ELECTRIC PARTS COVER
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 15 of 17 PTB53849 (TM027-2005.09)
PARTS INFORMATION
Kit Contents
WARRANTY INFORMATION In warranty: The normal warranty applies.
Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration. Please contact Techline or your District Service Manager. You must request consideration and receive a decision before starting work.
VIN Information
Description Qty. Part Number Honda Code
Kit, main relay 1 06380-ZY3-303 8139941
Description Qty. Part Number Honda Code
PGM-FI main relay 1 38580-ZY3-013 8104093
Grommet 2 38551-ZW1-000 4899761
Collar 2 91553-ZV5-010 7492846
Harness band clip 1 91541-SOA-003 6283873
VIN Prefix Affected Serial Number Range Model BAEJ 1000001~1400255
BF200A BAFJ 1000001~1400001 BAGJ 1000001~1400878
BF225A BAHJ 1000001~1400282
OUTBOARD #49 SEPTEMBER 2005
Page 16 of 17 © 2005 American Honda Motor Co., Inc.— All Rights Reserved PTB53849 (TM027-2005.09)
The following is a copy of the letter sent to registered customers.
September 2005
What is the reason for this notice?
American Honda Motor Co., Inc. is conducting a product update of certain Honda BF200A and BF225A
outboard motors. Our records indicate that you may own one of these products.
What is the problem?
The main relay is sealed with potting material to prevent corrosion. Over time, the potting material
may separate from the relay housing causing the electrical components inside the relay to corrode. As a
result of the corrosion, the outboard may not start.
What should you do?
The main relay potting material has been improved to correct this situation. Please contact your
authorized Honda Marine servicing dealer to make an appointment to have your BF200A or BF225A
updated. Be aware that not all selling boat dealers are authorized Honda dealers. The dealer will
complete the main relay update procedure, without cost to you for parts or labor. Transportation of the
boat to the dealer and/or related hauling expenses are the responsibility of the owner.
If you need information regarding the location and phone number of your nearest authorized Honda
Marine servicing dealer, please access our dealer locator on our website at:
www.honda-marine.com/dea.aspx, or contact us at: (800) 426-7701.
Whom to contact if you experience problems.
If you are not satisfied with the service you receive from your Honda dealer, you may contact:
American Honda Motor Co., Inc. Marine Group Customer Relations Department 4900 Marconi Drive Alpharetta, GA 30005 (770) 497-6400
If you have questions.
Should you have any questions or concerns regarding this matter that your Honda servicing dealer
cannot answer, please call Honda Marine Customer Relations at (770) 497-6400.
American Honda Motor Co., Inc.
4900 Marconi Drive
Alpharetta, GA 30005
OUTBOARD MOTOR #49 SEPTEMBER 2005
© 2005 American Honda Motor Co., Inc.— All Rights Reserved Page 17 of 17 PTB53849 (TM027-2005.09)
It is our goal to provide you with the highest quality products and the best after-sale service. We
apologize for any inconvenience this situation may cause.
We thank you for your purchase of a Honda product.
Sincerely,
Wade E. Terry