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PROVISIONAL FINAL
HTI NUMBER: TI-62002082
DATE OF ISSUE:2002/10/24
Honda Technical Information DATE OF REVISION:
MODEL: BF15D / BF20D YOUR REFERENCE NO.
N/A
SUBJECT:FUEL LEAK WHEN IN FULLY TILT UP POSITION
SYMPTOM:
Fuel may leak slightly out of the outboard motor under
the following conditions:
1. Engine is stopped after widely open throttle
operation.
2. The outboard motor is fully tilted up and tipped
to the right-turn position.
3. It is kept in that position for 1.5~8 minutes.
MARKET TREATMENT:
If the symptom mentioned on the left is confirmed,
replace the part with the countermeasure part listed
below.
CAUSE:
Due to vaporised Gasoline in the fuel pump, the
internal pressure of the fuel pump rose, allowing
liquid gasoline in the fuel chamber flow into the
carburettor. And the gasoline that flowed into the
carburettor leaked out of the carburettor through the
main nozzle.
ILLUSTRATION
SERVICE PARTS INFORMATION
PARTS NUMBER PARTS DESCRIPTION
COUNTERMEASURE:
1. The installation direction of the fuel pump has been
changed 180 degrees to prevent fuel from flowing
out even if it vaporizes.
2. The installation direction of the fuel chamber has
been changed not to drain liquid gasoline to the
carburettor, but to let vapour gasoline flow into the
chamber.
3. As the installation direction of the two above
components was changed, the length and shape of
the fuel hoses have been changed, too.
16861-ZY1-010 Fuel tube B
APPLICATION ON PRODUCTION LINE 17702-ZY1-010 Fuel tube C
MODEL SERIAL PREFIX SERIAL NO.FRT 17701-ZY1-010 Fuel tube D
BF15D3 BALJ 1002828 0.5 90503-ZV4-000 6mm washer
BF20D3 BAMJ 1002875 0.5 95005-1100130M 11x20 tube (Cutting to use)
90679-SG9-E01 Tie wrap
(91303-ZW9-000) O-ring (Replace new one)
WARRANTY APPLICATION:Ordinary
MAIN CAUSAL PART:16700-ZW9/16790-ZY1
PARTS AVAILABILITY:
Will be available in the middle of November.
WARRANTY DEFECT CODE:060
QIS NUMBER:AP2002090611151 PARTS TREATMENT:
Necessary
DEALER NOTICE:Bulletin Orally Not necessary
Issued by Manager
T. Warabi T. Kubota
Power Product Service Division
NOTES:
101, 120, 130, 23D, 231, 235, 237, 240, 25F, 26E, 267,
272, 28R, 350, 374, 41C, 430, 460, 504, 507, 522, 550,
741, 776 DISTRIBUTION:All
After C/M
Before C/M
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ANNEX
HTI NUMBER: TI-62002082
DATE OF ISSUE:2002/10/24
Honda Technical Information DATE OF REVISION:
MODEL: BF15D / BF20D YOUR REFERENCE NO.
N/A
SUBJECT:FUEL LEAK WHEN IN FULLY TILT UP POSITION
(A) Necessary parts.
(B) Preparation before work
Before
replacement After
replacement
2. Fuel tube B
8. 6 mm washer
9. 11 x 20 tube
(
2
)
11. O-ring
10.Tie wra
p
3. Fuel tube D
1. Fuel tube C
Fuel chamber
(not included)
No. Part Number Part Name Q'ty
1 16861-ZY1-010 Tube B, fuel 1
2 17702-ZY1-010 Tube C, fuel 1
3 17701-ZY1-010 Tube D, fuel 1
8 90503-ZV4-000 6 mm washer 1
9 95005-1100130M Tube, 11 x 20 (To be cut into 20mm) 2
10 90679-SG9-E01 Tie wrap 1
11 91303-ZW9-000 O-ring 1
NBecause this work involves changes of fuel tubes, fuel remaining in the related parts leaks. Be
careful not to allow fuel to leak to the outside using shop cloth.
NBefore starting work, make sure that there is no flame nearby. (Remove the terminals if a
battery is equipped.)
NBe careful not to allow dust to enter during work.
NRemove the fuel connector.
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ANNEX
HTI NUMBER: TI-62002082
DATE OF ISSUE:2002/10/24
Honda Technical Information DATE OF REVISION:
MODEL: BF15D / BF20D YOUR REFERENCE NO.
N/A
SUBJECT:FUEL LEAK WHEN IN FULLY TILT UP POSITION
(C) Work
1-1. Remove the undercover on the rear side.
1-2. Remove the water pilot tube and carburetor drain tube from
the undercover on the right.
2. Remove the engine side stopper, and then remove the fuel
chamber stay (not reusable).
3-1. Remove the fuel tubes B and C of the fuel pump, and remove the fuel pump from this unit.
[Note] Replace the O-ring of the fuel pump with the supplied O-ring.
3-2. Invert the direction of the fuel pump by 180 degrees, and install it.
Tightening torque of 6 x 22 flange bolt: 12 Nm
4-1. Pull out the oil level gauge, and insert the 11 x 20 mm tube into the oil level pipe as far as it will go.
4-2. Insert the slit of the fuel chamber suspension of the subassembled kit into the oil level pipe.
4-3. Similarly insert the second 11 x 20 mm tube into the oil level pipe, and install the oil level gauge.
Before
replacement After
replacement
Engine side
stopper
Installed position
and direction
Insert the chamber
with its direction as
shown in illustration.
Oil level
p
i
p
e
11 x 20 tube
Make 2 pcs at
20mm length
Sus
p
ension
Apply soap suds when installing the 11 x 20 mm tube and
rubber suspension. Be sure to insert them as far as they
will go without any clearance.
Sus
p
ension slit
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ANNEX
HTI NUMBER: TI-62002082
DATE OF ISSUE:2002/10/24
Honda Technical Information DATE OF REVISION:
MODEL: BF15D / BF20D YOUR REFERENCE NO.
N/A
SUBJECT:FUEL LEAK WHEN IN FULLY TILT UP POSITION
5-1. Install each fuel tube of the kit. Reuse the tube clip and clamp.
5-2. Install the fuel tube B on the joint on the upper side of the pump.
5.3 Adjust the chamber position so that clearance between the oil filter cartridge and fuel chamber will be
approx.
15 mm as shown in the illustration below, and then secure the chamber with a tie wrap. After
securing it with the tie wrap, cut the surplus end.
6. Mount a new 6 mm washer on the engine side stopper before installation.
Tightening torque of engine side stopper: 10 Nm
7. Installation of water check tube and carburetor drain tube
9. Install the undercover.
Tightening torque of 5 x 10 screw washer: 4.5 Nm
10. Check that the tube does not interfere with the undercover.
11. Install the battery terminals removed for preparation work.
[END]
Engine side stopper
6 mm washe
r
8. Connect the fuel connector from the fuel tank before installing
the rear undercover. Check for fuel leakage from each joint o
f
the tube by supplying fuel with the primary pump.
Pass the carburetor drain
tube between the fuel tube
B and fuel tube C.
Do not block the water pilot hole tube. (Avoid blockage by taking a large bend
radius through passing the tube under the chamber.)
Tube B for upper joint
Tube C for lower joint
15 mm
Oil filter
cartridge
Fuel
chambe
r
Tie wra
p
/