Message 3 of 3
Posted by member Kenny Clark on Sunday 1 February 2026

I hope photo uploaded this time.

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Message 1 of 3
Posted by member Kenny Clark on Saturday 31 January 2026

I've been paying for annual service for twelve years, with cost for parts/labour from £450 - £750. Although the expense is significant, keeping up with these checks reassures me while I'm on the water. Recently, I started looking at another option but still intend to maintain an annual service schedule.

I wanted to learn more about replacing outboard engine, parts and reduce service costs, so I serviced the engine myself for a second year. Is important to replace defective or end of life parts with an exact match (sound easy will explain this further on) I have Honda BF75D KO LRTU engine number BBAJ 1001242.

When the starter motor failed on the Firth of Clyde, I had to limp back to home port with the 5hp, a 5-mile trip in moderate conditions was an experience but a good learning. The marine engineer repaired the existing starter motor but warned that I should replace it soon as the solenoid may not last. Knowing what I have learned it would have been cheaper to fit a new starter motor - lesson No1.

New starter motor – was ordered with model, year, engine number. The starter duly arrived it looked identical to the old one. I shut off power, disconnected electrics, along with some other parts as it was a very tight fit to remove and install the starter. After trying everything to find a way to seat the new motor into position – it simply did not fit. I put both new and old starters together with the gears touching each other – it was clear the gear housings which are a circular metal protective cover around the gears were different. The old starter had a slight taper to the sides whilst the new version was straight – the tapered sides was essential to allow to tilt the starter into position. I got a refund from the supplier and got another one, which fitted without any problem. Double check dimensions spec etc of every replacement part and reference number – lesson No2.

Service and starter parts replaced
Starter motor (aftermarket used at £190, Honda version £1,300!)
4 stroke engine oil + oil pan drain plug
Oil filter
Gear oil + drain plug gaskets
High pressure fuel filter + ‘O’ ring
Low pressure oil filter + ‘O’ ring
4 iridium spark plugs
Water pump impeller kit – impeller, water pump gasket, seals, impeller key
Block thermostat 60c + ‘O’ ring
Cylinder head thermostat 50c + ‘O’ ring
2 gear box anodes alum.
1 power trim anode alum.
Marine grease – all moving parts and for corrosion protection

I stick labels on all replacement parts and date them for future reference. Family Pilot is stored in the boat shed during winter months, this makes things much easier. If possible, get the boat out of the water on blocks on trailer when replacing so many parts. I have tried to do work when at the pontoon but have said goodbye to my tools heading to the bottom – lesson No3.

I have watched Youtube videos extensively which I found very helpful to look at the practical side of working on the engine. Shop Manual (not Owners Manual) has diagrams with every engine part. I did not want to spend £100 to buy an original paper copy from the USA - there are some sites which have parts lists for free if you spend time on this.

Learning engine parts is time-consuming but doing the work even more so if you have the time. I used the savings from paying for a full service to order a new rope fender.

Regards,
Kenny

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