Sorry I'm a bit late responding - been traveling.
I have a 2007 with over 1600 hours on it and have had absolutely no significant issues except a manufacturing problem with the block early on. Honda replaced it at no charge, and she has run like a precision clock ever since. These are great engines if maintained well.
The 2007 and later models BF 200 and 225's have most of the serious problems fixed. Two that were highly publicized and discussed were (1) exhaust tubes that blew the HO2 sensor and (2) lack of lubrication on the mid-shaft bearing, causing it to fail and eat through the lower cowling.
Here are two other registered issues that occasionally occur:
HO2 sensor failure (cracks internally), SN: 1000001 - 1509999 (per Service Bulleting#70). The fix is to replace HO2 with an upgraded type. Some units require new ECM per SB#70.
ECM does not detect HO2 sensor failure, SN 1600001 - 1600527 (per Service Bulletin #71). The fix is to replace ECM.
There are several irritating issues that I have personally encountered:
1. You must remove the exhaust manifolds to check/replace internal anodes. A fix might be to install bolt-in anodes on the manifolds. BTW - the internal anodes are an aluminum alloy. I replaced my internal anodes at 1500 hours and they were near done for. BTW - I operate in saltwater. I suspect that fresh water operation would not cause a significant problem with those internal anodes.
2. Upper cowling tends to warp and not fit together well. I've used a heat gun and ratchet strap to re-seat it properly, but that doesn't permanently fix the issue. It is very important to bolt the upper cowling back on in the sequence described in the shop manual, but even that does not always work.
3. I believe that the fresh water flushing system is inadequate - it does not seem to flush everything out. Best to flush a minimum of 20 minutes after each use and occasionally use Salt Away while idling in a barrel.
4. At some speed between 4200 and 4600 rpm the motor changes rpm's +/- 100 rpm or so (i.e. hunts.) This affects 225's only. Apparently the VTEC kicks in and out at that rpm, trying to figure out which mode it should be in. After a long run, it tends to sort itself out.
5. There is no NMEA 2000 interface on the pre-2010 models. About every other manufacturer had that by 2002, but it took Honda until 2010 to do it.
6. There is no gauge-able heat sensor. When the engine overheats the alarm goes off and it just goes into SLOW mode or shuts down altogether with no warning. I fabricated my own heat sensors tied to gauges on my console so I can monitor heat on each manifold. If you are interested, send me an e-mail at
[email protected], and I will sent the instructions for doing it.
7. There is no gauge-able water pressure sensor. One could probably be fabricated.
If you are going to do any of your own maintenance or diagnostics, I highly recommend that you purchase the official Helm Shop Manual. It is available on Amazon or eBay and costs about $116, but it is worth every penny and a bunch more.
