honda owner's manual

Keep this owner’s manual handy, so you can refer to it at any time.This owner’s manual is considered a permanent part of the engine andshould remain with the engine if resold.

The information and specifications included in this publication were ineffect at the time of approval for printing. Illustrations are based on theGX160. Only certain types are equipped for both electric and manualstarting. Honda Motor Co., Ltd. reserves the right, however, todiscontinue or change specifications or design at any time withoutnotice and without incurring any obligation whatever. No part of thispublication may be reproduced without written permission.

The engine exhaust from this productcontains chemicals known to the State

of California to cause cancer, birthdefects or other reproductive harm.

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1

INTRODUCTION

Congratulations on your selection of a Honda engine. We are certainyou will be pleased with your purchase of one of the finest engines onthe market.

We want to help you get the best results from your new engine and tooperate it safely. This manual contains the information on how to dothat; please read it carefully.

As you read this manual, you will find information preceded by asymbol. That information is intended to help you avoid

damage to your engine, other property, or the environment.

We suggest you read the warranty policy to fully understand itscoverage and your responsibilities of ownership. The warranty policyis a separate document that should have been given to you by yourdealer.

When your engine needs scheduled maintenance, keep in mind thatyour Honda servicing dealer is specially trained in servicing Hondaengines. Your Honda servicing dealer is dedicated to your satisfactionand will be pleased to answer your questions and concerns.

Best Wishes,Honda Motor Co., Ltd.

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2

INTRODUCTION

A FEW WORDS ABOUT SAFETY

Safety Labels

Safety Messages

Safety Headings

Safety Section

Instructions

To help you make informed decisions about safety, we have providedoperating procedures and other information on labels and in thismanual. This information alerts you to potential hazards that couldhurt you or others.

Of course, it is not practical or possible to warn you about all thehazards associated with operating or maintaining an engine. You mustuse your own good judgment.

You will find important safety information in a variety of forms,including:

–– on the engine.

–– preceded by a safety alert symbol and oneof three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY HURT ifyou don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT ifyou don’t follow instructions.

You CAN be HURT if you don’t followinstructions.

–– such as IMPORTANT SAFETY INFORMATION.

–– such as ENGINE SAFETY.

–– how to use this engine correctly and safely.

This entire book is filled with important safety information –– pleaseread it carefully.

Your safety and the safety of others is very important. And using thisengine safely is an important responsibility.

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3

CONTENTS

.......................................................................................ENGINE SAFETY . 5................................................IMPORTANT SAFETY INFORMATION . 5

........................................................................CONTROLS & FEATURES . 7............................................COMPONENT & CONTROL LOCATIONS . 7

............................................................................................CONTROLS . 8................................................................................Fuel Valve Lever . 8

....................................................................................Engine Switch . 9.....................................................................................Choke Lever . 10

..................................................................................Throttle Lever . 11...........................................................................Recoil Starter Grip . 11

...........................................................................................FEATURES . 12.................................Oil Alert System (applicable engine types) . 12

..........................................Circuit Breaker (applicable types only) . 12

.............................................................................BEFORE OPERATION . 13.....................................................IS YOUR ENGINE READY TO GO? . 13

..................................Check the General Condition of the Engine . 13.............................................................................Check the Engine . 14

............................Check the Equipment Powered by This Engine . 14

............................................................................................OPERATION . 15...................................................SAFE OPERATING PRECAUTIONS . 15

....................................................................STARTING THE ENGINE . 15

....................................................................STOPPING THE ENGINE . 19...................................................................SETTING ENGINE SPEED . 20

....................................................................SERVICING YOUR ENGINE . 21............................................THE IMPORTANCE OF MAINTENANCE . 21

....................................................................MAINTENANCE SAFETY . 22..............................................................MAINTENANCE SCHEDULE . 23

..........................................................................................REFUELING . 24.............................................................FUEL RECOMMENDATIONS . 25

................................................................ENGINE OIL LEVEL CHECK . 26.........................................................................ENGINE OIL CHANGE . 27

..................................................ENGINE OIL RECOMMENDATIONS . 28...............TRANSMISSION OIL LEVEL CHECK (applicable models) . 29

........................TRANSMISSION OIL CHANGE (2:1 reduction type) . 30....................................................................AIR FILTER INSPECTION . 31

......................................................................AIR CLEANER SERVICE . 32..............................................................Dual-Filter-Element Types . 32

...................................................................................Oil-Bath Type . 34

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4

CONTENTS

SERVICING YOUR ENGINE (continued)...............................................................SEDIMENT CUP CLEANING . 35

.......................................................................SPARK PLUG SERVICE . 36...............................................................IDLE SPEED ADJUSTMENT . 37

........................SPARK ARRESTER MAINTENANCE (optional part) . 38

.........................................................HELPFUL TIPS & SUGGESTIONS . 39...................................................................STORING YOUR ENGINE . 39

........................................................................Storage Preparation . 39

........................................................................Storage Precautions . 42...................................................................Removal From Storage . 43

.................................................................................TRANSPORTING . 44

.....................................TAKING CARE OF UNEXPECTED PROBLEMS . 45.................................................................ENGINE WILL NOT START . 45

.....................................................................ENGINE LACKS POWER . 45.................................FUSE REPLACEMENT (applicable types only) . 46

........................................TECHNICAL & CONSUMER INFORMATION . 47...............................................................TECHNICAL INFORMATION . 47

..................................................................Serial Number Location . 47.Battery connections for Electric Starter (applicable types only) . 48

.................................................................Remote Control Linkage . 49....................................Carburetor Modification for High Altitude . 50

...........................................................................Oxygenated Fuels . 51..........................................Emission Control System Information . 52

...........................................................................................Air Index . 54..................................................................................Specifications . 55

.............................................................................Wiring Diagrams . 57..............................................................CONSUMER INFORMATION . 59

.........................................................................Honda Publications . 59........................................................Warranty Service Information . 60

............................QUICK REFERENCE INFORMATION . Inside back cover

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5

IMPORTANT SAFETY INFORMATION

Owner Responsibilities

Refuel With Care

Hot Exhaust

ENGINE SAFETY

Most accidents with engines can be prevented if you follow allinstructions in this manual and on the engine. Some of the mostcommon hazards are discussed below, along with the best way toprotect yourself and others.

Honda engines are designed to give safe and dependable service ifoperated according to instructions. Read and understand thisowner’s manual before operating the engine. Failure to do so couldresult in personal injury or equipment damage.

Know how to stop the engine quickly, and understand the operationof all controls. Never permit anyone to operate the engine withoutproper instructions.

Do not allow children to operate the engine. Keep children and petsaway from the area of operation.

Gasoline is extremely flammable, and gasoline vapor can explode.Refuel outdoors, in a well-ventilated area, with the engine stopped.Never smoke near gasoline, and keep other flames and sparks away.Always store gasoline in an approved container. If any fuel is spilled,make sure the area is dry before starting the engine.

The muffler becomes very hot during operation and remains hot fora while after stopping the engine. Be careful not to touch the mufflerwhile it is hot. Let the engine cool before storing it indoors.

To prevent fire hazards and to provide adequate ventilation forstationary equipment applications, keep the engine at least 3 feet (1meter) away from building walls and other equipment duringoperation. Do not place flammable objects close to the engine.

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6

ENGINE SAFETY

Other Equipment

Carbon Monoxide Hazard

Exhaust gas contains poisonous carbon monoxide. Avoid inhalation ofexhaust gas. Never run the engine in a closed garage or confined area.

Review the instructions provided with the equipment powered by thisengine for any additional safety precautions that should be observedin conjunction with engine startup, shutdown, operation, or protectiveapparel that may be needed to operate the equipment.

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7

COMPONENT & CONTROL LOCATIONS

[Inner vent type]

CONTROLS & FEATURES

MUFFLER

SPARK PLUG

AIR CLEANER

CHOKE LEVER

STARTER GRIP

THROTTLE LEVER

RECOIL STARTER

FUEL FILLER CAP

FUEL TANK

OIL DRAIN PLUG

BREATHER TUBE

TUBE CLIP

FUEL VALVE LEVER

OIL FILLER CAP

ELECTRIC STARTER(applicable types only)

ENGINE SWITCH(applicabletypes only)

CIRCUIT BREAKER(applicabletypes only)

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8

CONTROLS & FEATURES

CONTROLS

Fuel Valve Lever

FUELVALVELEVER

OFF

OONN

The fuel valve opens and closes the passage between the fuel tankand the carburetor.

The fuel valve lever must be in the ON position for the engine to run.

When the engine is not in use, leave the fuel valve lever in the OFFposition to prevent carburetor flooding and to reduce the possibility offuel leakage.

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9

CONTROLS & FEATURES

Engine Switch

Applicable Types

ELECTRIC STARTER TYPESALL ENGINES EXCEPTELECTRIC STARTER TYPES

CIRCUIT BREAKER

ENGINE SWITCH

ON

OFF

The engine switch enables and disables the ignition system.

The engine switch must be in the ON position for the engine to run.

Turning the engine switch to the OFF position stops the engine.

The engine switch on electric starter types includes a START positionfor operating the electric starter. The key automatically returns to theON position when released from the START position.

The circuit breaker, which is located below the key, protects thebattery charging circuit (see page 12).

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10

CONTROLS & FEATURES

Choke Lever

CLOSED

OPEN

CHOKE LEVER

The choke lever opens and closes the choke valve in the carburetor.

The CLOSED position enriches the fuel mixture for starting a coldengine.

The OPEN position provides the correct fuel mixture for operationafter starting, and for restarting a warm engine.

Some engine applications use a remote-mounted choke control ratherthan the engine-mounted choke lever shown here.

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11

CONTROLS & FEATURES

Throttle Lever

Recoil Starter Grip

THROTTLE LEVER

STARTER GRIP

FAST

SLOW

The throttle lever controls engine speed.

Moving the throttle lever in the directions shown makes the enginerun faster or slower.

Some engine applications use a remote-mounted throttle controlrather than the engine-mounted throttle lever shown here.

Pulling the starter grip operates the recoil starter to crank the engine.

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12

CONTROLS & FEATURES

FEATURES

Circuit Breaker

Oil Alert System (applicable engine types)

(applicable types only)

CIRCUITBREAKER

If the engine stops and will not restart, check the engine oil level (page) before troubleshooting in other areas.

The circuit breaker protects thebattery charging circuit. A shortcircuit, or a battery connected withreverse polarity, will trip the circuitbreaker.

The green indicator inside thecircuit breaker will pop out to showthat the circuit breaker has switchedoff. If this occurs, determine thecause of the problem, and correct itbefore resetting the circuit breaker.

The Oil Alert system is designed to prevent engine damage causedby an insufficient amount of oil in the crankcase. Before the oil level inthe crankcase can fall below a safe limit, the Oil Alert system willautomatically stop the engine (the engine switch will remain in the ONposition).

Push the circuit breaker button toreset.

26

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13

IS YOUR ENGINE READY TO GO?

Check the General Condition of the Engine

BEFORE OPERATION

For your safety, and to maximize the service life of your equipment, itis very important to take a few moments before you operate theengine to check its condition. Be sure to take care of any problem youfind, or have your servicing dealer correct it, before you operate theengine.

Before beginning your preoperation checks, be sure the engine is leveland the engine switch is in the OFF position.

Look around and underneath the engine for signs of oil or gasolineleaks.

Remove any excessive dirt or debris, especially around the mufflerand recoil starter.

Look for signs of damage.

Check that all shields and covers are in place, and all nuts, bolts, andscrews are tightened.

Improperly maintaining this engine,or failing to correct a problembefore operation, could cause amalfunction in which you could beseriously injured.

Always perform a preoperationinspection before each operation,and correct any problem.

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14

BEFORE OPERATION

Check the Engine

Check the Equipment Powered by This Engine

The Oil Alert system (applicable engine types) will automaticallystop the engine before the oil level falls below safe limits. However,to avoid the inconvenience of an unexpected shutdown, alwayscheck the engine oil level before startup.

Check the engine oil level (see page ). Running the engine with alow oil level can cause engine damage.

Review the instructions provided with the equipment powered by thisengine for any precautions and procedures that should be followedbefore engine startup.

Check the fuel level (see page ). Starting with a full tank will helpto eliminate or reduce operating interruptions for refueling.

Check the air filter (see page ). A dirty air filter will restrict air flowto the carburetor, reducing engine performance.

Check the transmission oil level on applicable engine types (seepage ). Oil is essential to transmission operation and long life.

26

31

24

29

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15

SAFE OPERATING PRECAUTIONS

STARTING THE ENGINE

OPERATION

ON

FUEL VALVELEVER

OFF

Before operating the engine for the first time, please review theIMPORTANT SAFETY INFORMATION on page and the chapter titledBEFORE OPERATION.

Review the instructions provided with the equipment powered by thisengine for any safety precautions that should be observed inconjunction with engine startup, shutdown, or operation.

Move the fuel valve lever to the ON position.

Carbon monoxide gas is toxic.Breathing it can causeunconsciousness and even kill you.

Avoid any areas or actions thatexpose you to carbon monoxide.

1.

5

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16

OPERATION

CHOKE LEVER

CLOSEOPEN

SLOW

THROTTLE LEVER

To start a cold engine, move the choke lever to the CLOSED position.

To restart a warm engine, leave the choke lever in the OPEN position.

Some engine applications use a remote-mounted choke controlrather than the engine-mounted choke lever shown here.

Move the throttle lever away from the SLOW position, about 1/3 ofthe way toward the FAST position.


2.

3.

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17

OPERATION

STARTER GRIP

ENGINE SWITCH

ON


Turn the engine switch to the ON position.

Operate the starter.

Pull the starter grip lightly until you feel resistance, then pull briskly.Return the starter grip gently.

RECOIL STARTER (all engine types):

4.

5.

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18

OPERATION

CHOKE LEVER

OPEN

CCLLOOSSEE

ENGINE SWITCH(applicable types only)

Turn the key to the START position,and hold it there until the engine starts.

If the engine fails to start within 5seconds, release the key, and wait atleast 10 seconds before operating thestarter again.

Using the electric starter for morethan 5 seconds at a time will overheatthe starter motor and can damage it.

When the engine starts, release thekey, allowing it to return to the ONposition.

If the choke lever has been moved to the CLOSED position to startthe engine, gradually move it to the OPEN position as the enginewarms up.

ELECTRIC STARTER (applicable types only):

6.

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19

OPERATION

STOPPING THE ENGINE


THROTTLE LEVER

SLOW

OFF

ENGINE SWITCH

To stop the engine in an emergency, simply turn the engine switch tothe OFF position. Under normal conditions, use the followingprocedure.

Turn the engine switch to the OFF position.

Move the throttle lever to the SLOW position.


1.

2.

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20

OPERATION

SETTING ENGINE SPEED

OFF

THROTTLE LEVER

FAST

SLOW

FUEL VALVELEVER

ON

Turn the fuel valve lever to the OFF position.

Position the throttle lever for the desired engine speed.

For engine speed recommendations, refer to the instructions providedwith the equipment powered by this engine.


3.

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21

THE IMPORTANCE OF MAINTENANCE

Maintenance, replacement or repair of emission control devices andsystems may be done by any engine repair establishment orindividual, using parts that are ‘‘certified’’ to EPA standards.

SERVICING YOUR ENGINE

Good maintenance is essential for safe, economical, and trouble-freeoperation. It will also help reduce air pollution.

To help you properly care for your engine, the following pages includea maintenance schedule, routine inspection procedures, and simplemaintenance procedures using basic hand tools. Other service tasksthat are more difficult, or require special tools, are best handled byprofessionals and are normally performed by a Honda technician orother qualified mechanic.

The maintenance schedule applies to normal operating conditions. Ifyou operate your engine under unusual conditions, such as sustainedhigh-load or high-temperature operation, or use in unusually wet ordusty conditions, consult your servicing dealer for recommendationsapplicable to your individual needs and use.

Improperly maintaining this engine,or failure to correct a problembefore operation, can cause amalfunction in which you can beseriously hurt or killed.

Always follow the inspection andmaintenance recommendations andschedules in this owner’s manual.

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22


MAINTENANCE SAFETY

Safety Precautions

Carbon monoxide poisoning from engine exhaust.

Burns from hot parts.

Injury from moving parts.

Some of the most important safety precautions follow. However, wecannot warn you of every conceivable hazard that can arise inperforming maintenance. Only you can decide whether or not youshould perform a given task.

Make sure the engine is off before you begin any maintenance orrepairs. This will eliminate several potential hazards:

Be sure there is adequate ventilation whenever you operate theengine.

Let the engine and exhaust system cool before touching.

Do not run the engine unless instructed to do so.

Read the instructions before you begin, and make sure you have thetools and skills required.To reduce the possibility of fire or explosion, be careful whenworking around gasoline. Use only a nonflammable solvent, notgasoline, to clean parts. Keep cigarettes, sparks and flames awayfrom all fuel-related parts.

Remember that your servicing dealer knows your engine best and isfully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new, genuineHonda parts or their equivalents for repair and replacement.

Failure to properly followmaintenance instructions andprecautions can cause you to beseriously hurt or killed.

Always follow the procedures andprecautions in the owner’s manual.

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23


MAINTENANCE SCHEDULE

For commercial use, log hours of operation to determine propermaintenance intervals.

These items should be serviced by your servicing dealer, unlessyou have the proper tools and are mechanically proficient. Referto Honda shop manual for service procedures.

Service more frequently when used in dusty areas.

Replace paper element type only. Cyclone type every 2 years or600 hours.

Internal vent carburetor (See page ) with dual element type only.(Cyclone type every 6 months or 150 hours.)

Emission-related items.

(1)

(2)

(3)

7

Engine oil

Reduction gear oil

(applicable types)

Air filter

Sediment cup

Spark plug

Spark arrester

(optional parts)

Idle speed

Valve clearance

Combustion chamber

Fuel tank & filter

Fuel tube

REGULAR SERVICE PERIOD (3)

Perform at every indicated

month or operating hour interval,

whichever comes first.

ITEM

Change

Check level

Change

Check

Check

Clean

Clean

Clean

Clean

Replace

Replace

Every 2 years (Replace if necessary) (2)

(2)

(2)

(2)

(1)

26

27

29

30

31

32

35

36

38

37

Clean

(1)

After every 500 Hrs. (2)

First

month

or

20 Hrs.

Every

3 months

or

50 Hrs.

Every

6 months

or

100 Hrs.

Every

year

or

300 Hrs.

Refer

to

page

Each

use

Check level

Check-adjust

Check-adjust

Check-adjust

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24


REFUELING

MAXIMUMFUELLEVEL (strainer type) (non-strainer type)

FUEL TANK TOP

MAXIMUMFUELLEVEL

1 inch(25 mm)

Gasoline is highly flammable andexplosive.

You can be burned or seriouslyinjured when handling fuel.

Stop the engine and keep heat,sparks, and flame away.Handle fuel only outdoors.Wipe up spills immediately.

With the engine stopped and on a level surface, remove the fuel tankcap and check the fuel level. Refill the tank if the fuel level is low.

Refuel in a well-ventilated area before starting the engine. If the enginehas been running, allow it to cool. Refuel carefully to avoid spilling fuel.Do not fill the fuel tank completely. Fill tank to approximately 1 inch(25 mm) below the top of the fuel tank to allow for fuel expansion. Itmay be necessary to lower the fuel level depending on operatingconditions. After refueling, tighten the fuel tank cap securely.

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25


FUEL RECOMMENDATIONS

Use unleaded gasoline with a pump octane rating of 86 or higher.

Never refuel the engine inside a building where gasoline fumes mayreach flames or sparks. Keep gasoline away from appliance pilot lights,barbecues, electric appliances, power tools, etc.

Spilled fuel is not only a fire hazard, it causes environmental damage.Wipe up spills immediately.

Fuel can damage paint and plastic. Be careful not to spill fuel whenfilling your fuel tank. Damage caused by spilled fuel is not coveredunder warranty.

These engines are certified to operate on unleaded gasoline. Unleadedgasoline produces fewer engine and spark plug deposits and extendsexhaust system life.

Never use stale or contaminated gasoline or an oil/gasoline mixture.Avoid getting dirt or water in the fuel tank.

Occasionally you may hear a light ‘‘spark knock’’ or ‘‘pinging’’(metallic rapping noise) while operating under heavy loads. This is nocause for concern.

If spark knock or pinging occurs at a steady engine speed, undernormal load, change brands of gasoline. If spark knock or pingingpersists, see an authorized Honda servicing dealer.

Running the engine with persistent spark knock or pinging can causeengine damage.

Running the engine with persistent spark knock or pinging isconsidered misuse, and the Distributor’s Limited Warranty does notcover parts damaged by misuse.

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26


ENGINE OIL LEVEL CHECK

FILLER CAP/DIPSTICK

UPPER LIMIT

LOWER LIMIT

Check the engine oil level with the engine stopped and in a levelposition.

Running the engine with a low oil level can cause engine damage.

The Oil Alert system (applicable engine types) will automatically stopthe engine before the oil level falls below safe limit. However, to avoidthe inconvenience of an unexpected shutdown, always check theengine oil level before startup.

Remove the filler cap/dipstick and wipe it clean.

Insert and remove the dipstick with out screwing it into the fillerneck. Check the oil level shown on the dipstick.

If the oil level is low, fill to the edge of the oil filler hole with therecommended oil (see page 28).

Screw in the filler cap/dipstick securely.

1.

2.

3.

4.

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27


ENGINE OIL CHANGE

DRAIN BOLT

OIL LEVEL

FILLER CAP/DIPSTICK

WASHER

Drain the used oil while the engine is warm. Warm oil drains quicklyand completely.

Place a suitable container below the engine to catch the used oil,then remove the filler cap/dipstick, drain plug, and washer.

Allow the used oil to drain completely, then reinstall the drain plug,washer, and tighten drain plug securely.

Please dispose of used motor oil in a manner that is compatible withthe environment. We suggest you take used oil in a sealed containerto your local recycling center or service station for reclamation. Donot throw it in the trash, pour it on the ground, or down a drain.

With the engine in a level position, fill to the outer edge of the oilfiller hole with the recommended oil (see page 28).

Running the engine with a low oil level can cause engine damage.

The Oil Alert system (applicable engine types) will automaticallystop the engine before the oil level falls below the safe limit.However, to avoid the inconvenience of an unexpected shutdown,fill to the upper limit, and check the oil level regularly.


1.

2.

3.

4.

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28


ENGINE OIL RECOMMENDATIONS

AMBIENT TEMPERATURE

Oil is a major factor affecting performance and service life. Use4-stroke automotive detergent oil.

SAE 10W-30 is recommended for general use. Other viscosities shownin the chart may be used when the average temperature in your area iswithin the recommended range.

The SAE oil viscosity and service classification are in the API label onthe oil container. Honda recommends that you use API SERVICEcategory SJ or SL oil.

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29


TRANSMISSION OIL LEVEL CHECK

2 : 1 Reduction Transmission With Centrifugal Clutch

6 : 1 Reduction Transmission

(applicable engine types)

LOWER LIMIT

UPPERLIMIT

FILLER CAP/DIPSTICK

FILLER BOLT

OIL-LEVEL-CHECK BOLT

DRAIN BOLT

Check the transmission oil level with the engine stopped and in a levelposition.

Remove the filler cap/dipstick and wipe it clean.

Insert and remove the dipstick with out screwing it into the filler hole.Check the oil level shown on the dipstick.

If the oil level is low, add oil to reach the upper limit mark on thedipstick. Use the same oil that is recommended for the engine (seepage 28).


Remove the oil-level-check bolt, andsee weather the oil level is at theedge of the bolt hole.

If the oil level is below the checkbolt hole, remove the filler bolt, andadd oil until it starts to flow out thecheck bolt hole. Use the same oilthat is recommended for the engine(see page 28).

Install the oil-level-check bolt andfiller bolt. Tighten them securely.

1.

2.

3.

4.

1.

2.

3.

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30


TRANSMISSION OIL CHANGE(2 : 1 reduction transmission with centrifugal clutch)

FILLER CAP/DIPSTICK

DRAIN BOLT

UPPERLIMIT

LOWER LIMIT

Drain the used oil while the engine is warm. Warm oil drains quicklyand completely.

Running the engine with a low transmission oil level can causetransmission damage.


0.53 US qt (0.50 )

Place a suitable container below the transmission to catch the usedoil, then remove the filler cap/dipstick and the drain plug.

Allow the used oil to drain completely, then reinstall the drain plug,and tighten it securely.

Please dispose of used motor oil in a manner that is compatible withthe environment. We suggest you take used oil in a sealed containerto your local recyling center or service station for reclamation. Donot throw it in the trash, pour it on the ground, or down a drain.

With the engine in a level position, fill to the upper limit mark on thedipstick with the same oil that is recommended for the engine (seepage ). To check the oil level, insert and remove the dipstickwithout screwing it into the filler hole.

1.

2.

3.

Transmission oil capacity:

4.

28

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31


AIR FILTER INSPECTION

PAPERFILTERELEMENT

PAPERFILTERELEMENT

FOAMFILTERELEMENT

FOAMFILTERELEMENT

FILTER

CYCLONE DUAL-FILTER-ELEMENTTYPE(see p. 32-33)

OIL-BATH TYPE(see p. 34)

STANDARDDUAL-FILTER-ELEMENT TYPE(see p. 32-33)

Remove the air cleaner cover and inspect the filter. Clean or replacedirty filter elements. Always replace damaged filter elements. Ifequipped with an oil-bath air cleaner, also check the oil level.

Refer to pages for instructions that apply to the air cleaner andfilter on your type of engine.

32-34

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32


AIR CLEANER SERVICE

Dual-Filter-Element Types

AIRCLEANERCOVER

PAPERFILTERELEMENT

FOAMFILTERELEMENT

GASKET

STANDARDDUAL-FILTER-ELEMENTTYPE

A dirty air filter will restrict air flow to the carburetor, reducing engineperformance. If you operate the engine in very dusty areas, clean theair filter more often than specified in the MAINTENANCE SCHEDULE.

Operating the engine without an air filter, or with a damaged air filter,will allow dirt to enter the engine, causing rapid engine wear. This typeof damage is not covered by the Distributor’s Limited Warranty.

Remove the wing nut from theair cleaner cover, and removethe cover.

Remove the wing nut from theair filter, and remove the filter.

Remove the foam filter from thepaper filter.

Inspect both air filter elements,and replace them if they aredamaged. Always replace thepaper air filter element at thescheduled interval (see page23).

Clean the air filter elements ifthey are to be reused.

1.

2.

3.

4.

5.

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33


CYCLONE DUAL-FILTER-ELEMENTTYPE

SPECIAL PAN SCREW (3)

PRECLEANER CAP

AIRCLEANERCOVER

PAPERFILTERELEMENT

FOAMFILTERELEMENT

GASKET

GROOVE

AIR GUIDE

TAB

CYCLONEHOUSING

Foam air filter element: Clean inwarm soapy water, rinse, and allowto dry thoroughly. Or clean innonflammable solvent and allow todry. Dip the filter element in cleanengine oil, then squeeze out allexcess oil. The engine will smokewhen started if too much oil is left inthe foam.

CYCLONE TYPE ONLY: Remove the three pan-head screws from theprecleaner cap, then remove the cyclone housing and air guide.Wash the parts with water, dry them thoroughly, and reassemblethem.

Be sure to install the air guide as shown in the illustration.

Install the cyclone housing so the air intake tab fits into the groove inthe precleaner cap.

Wipe dirt from the inside of the air cleaner base and cover, using amoist rag. Be careful to prevent dirt from entering the air duct thatleads to the carburetor.

Place the foam air filter element over the paper element, andreinstall the assembled air filter. Be sure the gasket is in placebeneath the air filter. Tighten the air filter wing nut securely.

Install the air cleaner cover, and tighten the cover wing nut securely.

Paper air filter element: Tap thefilter element several times on ahard surface to remove dirt, or blowcompressed air [not exceeding 30psi (207 kPa, 2.1 kgf cm )] throughthe filter element from the inside.Never try to brush off dirt; brushingwill force dirt into the fibers.

6.

9.

8.

7.

2

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34


2.0 US oz (60 cm )

Oil-Bath Type

Oil capacity:

WINGNUT

CAP

AIRCLEANERCASE

AIRCLEANERCOVER

FILTER

GRID

OIL LEVEL

Reassemble the air cleaner, and tighten the wing nut securely.

Remove the wing nut, and remove the air cleaner cap and cover.

Remove the air filter from the cover, Wash the cover and filter inwarm, soapy water, rinse, and allow to dry thoroughly. Or clean innonflammable solvent and allow to dry.

Dip the filter in clean engine oil, then squeeze out all excess oil. Theengine will smoke if too much oil is left in the foam.

Empty the used oil from the air cleaner case, wash out anyaccumulated dirt with nonflammable solvent, and dry the case.

Fill the air cleaner case to the OIL LEVEL mark with the same oil thatis recommended for the engine (see page28).

1.

5.

4.

3.

2.

6.

03/06/09 15:00:13 31ZH7622_035

35


SEDIMENT CUP CLEANING

SEDIMENT CUP

O-RING

Move the fuel valve to the OFF position, then remove the fuelsediment cup and O-ring.



Keep heat, sparks and flame away.Handle fuel only outdoors.Wipe up spills immediately.

Wash the sediment cup and O-ring in nonflammable solvent, anddry them thoroughly.

Place the O-ring in the fuel valve, and install the sediment cup.Tighten the sediment cup securely.

Move the fuel valve to the ON position, and check for leaks. Replacethe O-ring if there is any leakage.

1.

2.

3.

4.

03/06/09 15:00:22 31ZH7622_036

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36


SPARK PLUG SERVICE

SPARK PLUG WRENCH

0.028 0.031 in(0.70 0.80 mm)

SEALINGWASHER

Disconnect the spark plug cap, and remove any dirt from around thespark plug area.

Remove the spark plug with a 13/16-inch spark plug wrench.

An incorrect spark plug can cause engine damage.

BPR6ESW20EPR-U

Inspect the spark plug. Replace itif the electrodes are worn, or if theinsulator is cracked or chipped.

Measure the spark plug electrodegap with a suitable gauge. Thegap shou ld be 0.028 0.031 in(0.70 0.80 mm). Correct the gap,if necessary, by carefully bendingthe side electrode.

Install the spark plug carefully, byhand, to avoid cross-threading.

1.

2.

3.

4.

5.

Recommended spark plugs: (NGK)(DENSO)

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37


IDLE SPEED ADJUSTMENT

THROTTLE STOP SCREW

A loose spark plug can overheat and damage the engine.Overtightening the spark plug can damage the threads in thecylinder head.

Attach the spark plug cap.

After the spark plug seats, tighten with a 13/16-inch spark plugwrench to compress the sealing washer.

If reinstalling the used spark plug, tighten 1/8 1/4 turn after thespark plug seats.

if installing a new spark plug, tighten 1/2 turn after the spark plugseats.

Start the engine outdoors, and allow it to warm up to operatingtemperature.

Move the throttle lever to its slowest position.

Turn the throttle stop screw to obtain the standard idle speed.

6.

7.

1.

2.

3.

rpmStandard idle speed: 1,400 200150

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38


SPARK ARRESTER SERVICE (optional equipment)

SCREEN

SPARKARRESTER

MUFFLERPROTECTOR

4 mm SCREW

4 mmSCREWS

EXHAUSTDEFLECTOR

5 mm SCREWS

Your engine is not factory-equipped with a spark arrester. In someareas, it is illegal to operate an engine without a spark arrester. Checklocal laws and regulations. A spark arrester is available fromauthorized Honda servicing dealers.

The spark arrester must be serviced every 100 hours to keep itfunctioning as designed.

If the engine has been running, the muffler will be very hot. Allow themuffler to cool before servicing the spark arrester.

Remove the three 4 mm screws from the exhust deflector, andremove the deflector.

Remove the four 5 mm screws from the muffler protector andremove the muffler protector.

Remove the 4 mm screw from the spark arrester, and remove thespark arrester from the muffler.

Use a brush to remove carbon depositsfrom the spark arrester screen. Be carefulto avoid damaging the screen.

The spark arrester must be free of breaksand holes. Replace the spark arrester if it isdamaged.

Install the spark arrester, muffler protector, and exhaust deflector inthe reverse order of disassembly.

1.

2.

3.

4.

5.

03/06/09 15:00:48 31ZH7622_039

39

STORING YOUR ENGINE

Storage Preparation

Cleaning

Fuel

HELPFUL TIPS & SUGGESTIONS

Proper storage preparation is essential for keeping your enginetroublefree and looking good. The following steps will help to keeprust and corrosion from impairing your engine’s function andappearance, and will make the engine easier to start after storage.

If the engine has been running, allow it to cool for at least half an hourbefore cleaning. Clean all exterior surfaces, touch up any damagedpaint, and coat other areas that may rust with a light film of oil.

Using a garden hose or pressure washing equipment can forcewater into the air cleaner or muffler opening. Water in the air cleanerwill soak the air filter, and water that passes through the air filter ormuffler can enter the cylinder, causing damage.

Water contacting a hot engine can cause damage. If the engine hasbeen running, allow it to cool for at least half an hour beforewashing.

Gasoline will oxidize and deteriorate in storage. Old gasoline willcause hard starting, and it leaves gum deposits that clog the fuelsystem. If the gasoline in your engine deteriorates during storage, youmay need to have the carburetor and other fuel system componentsserviced or replaced.

The length of time that gasoline can be left in your fuel tank andcarburetor without causing functional problems will vary with suchfactors as gasoline blend, your storage temperatures, and whether thefuel tank is partially or completely filled. The air in a partially filled fueltank promotes fuel deterioration. Very warm storage/temperaturesaccelerate fuel deterioration. Fuel deterioration problems may occurwithin a few months, or even less if the gasoline was not fresh whenyou filled the fuel tank.

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40


ADDING A FUEL STABILIZER TO EXTEND FUEL STORAGE LIFE

FUEL VALVE

OFF

ON

The Distributor’s Limited Warranty does not cover fuel systemdamage or engine performance problems resulting from neglectedstorage preparation.

You can extend fuel storage life by adding a fuel stabilizer that isformulated for that purpose, or you can avoid fuel deteriorationproblems by draining the fuel tank and carburetor.

When adding a fuel stabilizer, fill the fuel tank with fresh gasoline. Ifonly partially filled, air in the tank will promote fuel deteriorationduring storage. If you keep a container of gasoline for refueling, besure that it contains only fresh gasoline.

Add fuel stabilizer following the manufacturer’s instructions.

After adding a fuel stabilizer, run the engine outdoors for 10 minutesto be sure that treated gasoline has replaced the untreated gasolinein the carburetor.

Stop the engine, and move the fuel valve to the OFF position.

1.

2.

3.

03/06/09 15:01:06 31ZH7622_041

41


DRAINING THE FUEL TANK AND CARBURETOR

DRAINBOLT SEDIMENT

CUP

Place an approved gasoline container below the carburetor, and usea funnel to avoid spilling fuel.

Remove the carburetor drain bolt and sediment cup, then move thefuel valve lever to the ON position.



Keep heat, sparks and flame away.Handle fuel only outdoors.Wipe up spills immediately.

After all the fuel has drain into the container, reinstall the drain boltand sediment cup. Tighten them securely.

1.

2.

3.

03/06/09 15:01:14 31ZH7622_042

－

42


Engine Oil

Storage Precautions

Align notch on pulleywith hole at top of cover.

If your engine will be stored with gasoline in the fuel tank andcarburetor, it is important to reduce the hazard of gasoline vaporignition. Select a well-ventilated storage area away from any appliancethat operates with a flame, such as a furnace, water heater, or clothesdryer. Also avoid any area with a spark-producing electric motor, orwhere power tools are operated.

If possible, avoid storage areas with high humidity, because thatpromotes rust and corrosion.

Unless all fuel has been drained from the fuel tank, leave the fuel valvelever in the OFF position to reduce the possibility of fuel leakage.

Change the engine oil (see page 27).

Remove the spark plugs (see page 36).

Pour a tablespoon (5 10 cc) of clean engine oil into the cylinder.

Pull the starter rope several times to distribute the oil in the cylinder.

Reinstall the spark plug.

Pull the starter rope slowly untill resistance is felt and the notch onthe starter pulley aligns with the hole at the top of the recoil startercover. This will close the valves so moisture cannot enter the enginecylinder. Return the starter rope gently.

1.

2.

3.

4.

5.

6.

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43


Removal From Storage

Position the equipment so the engine is level. Tilting can cause fuel oroil leakage.

With the engine and exhaust system cool, cover the engine to keep outdust. A hot engine and exhaust system can ignite or melt somematerials. Do not use sheet plastic as a dust cover. A nonporous coverwill trap moisture around the engine, promoting rust and corrosion.

Check your engine as described in the BEFORE OPERATION chapter ofthis manual.

If the fuel was drained during storage preparation, fill the tank withfresh gasoline. If you keep a container of gasoline for refueling, besure that it contains only fresh gasoline. Gasoline oxidizes anddeteriorates over time, causing hard starting.

If the cylinder was coated with oil during storage preparation, theengine may smoke briefly at startup. This is normal.

If equipped with a battery for electric starter types, recharge thebattery once a month while the engine is in storage.This will help to extend the service life of the battery.

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44


TRANSPORTING

If the engine has been running, allow it to cool for at least 15 minutesbefore loading the engine-powered equipment on the transportvehicle. A hot engine and exhaust system can burn you and can ignitesome materials.

Keep the engine level when transporting to reduce the possibility offuel leakage. Move the fuel valve lever to the OFF position.

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45

Possible CauseENGINE WILL NOT

START

Correction

Possible CauseENGINE LACKS

POWER

Correction

TAKING CARE OF UNEXPECTED PROBLEMS

Check air filter.

Check fuel.

Take engine to anauthorized Hondaservicing dealer, orrefer to shop manual.

Filter element(s)clogged.Bad fuel; enginestored without treatingor draining gasoline,or refueled with badgasoline.Fuel filter clogged,carburetor malfunction,ignition malfunction,valves stuck, etc.

Clean or replace filterelement(s) (p. 32-34).Drain fuel tank andcarburetor (p. 41).Refuel with freshgasoline (P. 24).

Replace or repairfaulty components asnecessary.

Electric starting(applicable types):

Check controlpositions.

Check fuel.

Remove andinspect spark plug.

Take engine to anauthorized Hondaservicing dealer, orrefer to shop manual.

Battery discharged.Fuse burnt out.

Fuel valve OFF.Choke OPEN.

Engine switch OFF.

Out of fuel.Bad fuel; enginestored without treatingor draining gasoline,or refueled with badgasoline.Spark plug faulty,fouled, or improperlygapped.Spark plug wet withfuel (flooded engine).

Fuel filter clogged,carburetor malfunction,ignition malfunction,valves stuck, etc.

Recharge battery.Replace fuse (p. 46).

Move lever to ON.Move lever to CLOSEDunless engine is warm.Turn engine switch toON.Refuel (p. 24).Drain fuel tank andcarburetor (p. 41).Refuel with freshgasoline.(p. 24)

Clean, gap, or replacespark plug (p. 36).

Dry and reinstall sparkplug. Start enginewith throttle leverin FAST position.Replace or repairfaulty components asnecessary.

1.

2.

3.

4.

3.

2.

1.

5.

Check battery and fuse.

03/06/09 15:01:48 31ZH7622_046

×

×

×

46

TAKING CARE OF UNEXPECTED PROBLEMS

FUSE REPLACEMENT (applicable types only)

FUSECOVER

5 A FUSE

ENGINE SWITCHREAR COVER

6 12 mmSPECIAL SCREW

The electric starter relay circuit and battery charging circuit areprotected by a 5-ampere fuse. If the fuse burns out, the electric starterwill not operate. The engine can be started manually if the fuse burnsout, but running the engine will not charge the battery.

Never use a fuse with a rating greater than 5 amperes. Seriousdamage to the electrical system or a fire could result.

Frequent fuse failure usually indicates a short circuit or an overload inthe electrical system. If the fuse burns out frequently, take the engineto a servicing Honda dealer for repair.

Remove the 6 12 mm screw from the rear cover of the engineswitch box.

Remove the fuse cover, and inspect the fuse.

If the fuse is burnt out, remove the fuse cover, then pull out anddiscard the burnt-out fuse. Install a new 5-ampere fuse, and reinstallthe fuse cover.

Reinstall the rear cover. Install the 6 12 mm screw and tighten itsecurely.

1.

2.

3.

03/06/09 15:01:59 31ZH7622_047

47

TECHNICAL INFORMATION

Serial Number Location

TECHNICAL & CONSUMER INFORMATION

SERIAL NUMBER& ENGINE TYPE

ELECTRICSTARTER(applicabletypes only)

Record the engine serial number in the space below. You will need thisserial number when ordering parts, and when making technical orwarranty inquires (see page ).

Engine serial number:

60

03/06/09 15:02:09 31ZH7622_048

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＋

＋

－

＋＋

－－

＋

－

48


Battery Connections for Electric Starter (applicable types only)

STARTERSOLENOID

POSITIVE ( ) BATTERY CABLE

NEGATIVE ( )BATTERY CABLE

Use a 12-volt battery with an ampere-hour rating of at least 18 Ah.

Be careful not to connect the battery in reverse polarity, as this willshort circuit the battery charging system. Always connect the positive( ) battery cable to the battery terminal before connecting thenegative ( ) battery cable, so your tools cannot cause a short circuit ifthey touch a grounded part while tightening the positive ( ) batterycable end.

A battery can explode if you do notfollow the correct procedure,seriously injuring anyone nearby.

Keep all sparks, open flames, andsmoking materials away from thebattery.

Connect the battery positive ( ) cable to the starter solenoidterminal as shown.Connect the battery negative ( ) cable to an engine mounting bolt,frame bolt, or other good engine ground connection.Connect the battery positive ( ) cable to the battery positive ( )terminal as shown.Connect the battery negative ( ) cable to the battery negative ( )terminal as shown.Coat the terminals and cable ends with grease.

1.

2.

3.

4.

5.

03/06/09 15:02:18 31ZH7622_049

49


Remote Control Linkage

RETURNSPRING

THROTTLE LEVERPIVOT NUT

WIRE

5 mmCIRCLIP

THROTTLELEVER

WIRE HOLDER

CHOKE LEVER

WIRE HOLDER

4 mm SCREW

REMOTE CHOKE LINKAGE

Solid wire coremounting

OPTIONAL

Flexible wire coremounting

REMOTE THROTTLE LINKAGE

The throttle and choke control levers are provided with holes foroptional cable attachment. The following illustrations showinstallation examples for a solid wire cable and for a flexible, braidedwire cable. If using a flexible, braided wire cable, add a return springas shown.

It is necessary to loosen the throttle lever friction nut when operatingthe throttle with a remote-mounted control.

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50


Carburetor Modification for High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be toorich. Performance will decrease, and fuel consumption will increase. Avery rich mixture will also foul the spark plug and cause hard starting.Operation at an altitude that differs from that at which this engine wascertified, for extended periods of time, may increase emissions.

Even with carburetor modification, engine horsepower will decreaseabout 3.5% for each 1,000-foot (300-meter) increase in altitude. Theeffect of altitude on horsepower will be greater than this if nocarburetor modification is made.

High altitude performance can be improved by specific modificationsto the carburetor. If you always operate your engine at altitudes above5,000 feet (1,500 meters), have your servicing dealer perform thiscarburetor modification. This engine, when operated at high altitudewith the carburetor modifications for high altitude use, will meet eachemission standard throughout its useful life.

When the carburetor has been modified for high altitude operation,the air-fuel mixture will be too lean for low altitude use. Operation ataltitudes below 5,000 feet (1,500 meters) with a modified carburetormay cause the engine to overheat and result in serious engine damage.For use at low altitudes, have your servicing dealer return thecarburetor to original factory specifications.

03/06/09 15:02:38 31ZH7622_051

51


ETHANOL

METHANOL

MTBE

Oxygenated Fuels

Some conventional gasolines are being blended with alcohol or anether compound. These gasolines are collectively referred to asoxygenated fuels.To meet clean air standards, some areas of the United States andCanada use oxygenated fuels to help reduce emissions.

If you use an oxygenated fuel, be sure it is unleaded and meets theminimum octane rating requirement.

Before using an oxygenated fuel, try to confirm the fuel’s contents.Some states/provinces require this information to be posted on thepump.

The following are the EPA approved percentages of oxygenates:

––––––––

––––––

(ethyl or grain alcohol) 10% by volumeYou may use gasoline containing up to 10%ethanol by volume. Gasoline containing ethanolmay be marketed under the name ‘‘Gasohol’’.

––––––––––––(methyl tertiary butyl ether) 15% by volumeYou may use gasoline containing up to 15% MTBEby volume.

(methyl or wood alcohol) 5% by volumeYou may use gasoline containing up to 5%methanol by volume, as long as it also containscosolvents and corrosion inhibitors to protect thefuel system. Gasoline containing more than 5%methanol by volume may cause starting and/orperformance problems. It may also damage metal,rubber, and plastic parts of your fuel system.

If you notice any undesirable operating symptoms, try another servicestation, or switch to another brand of gasoline.

Fuel system damage or performance problems resulting from the useof an oxygenated fuel containing more than the percentages ofoxygenates mentioned above are not covered under warranty.

03/06/09 15:02:51 31ZH7622_052

52


Emission Control System Information

Source of Emissions

The U.S. and California Clean Air Acts

Tampering and Altering

The combustion process produces carbon monoxide, oxides ofnitrogen, and hydrocarbons. Control of hydrocarbons and oxides ofnitrogen is very important because, under certain conditions, theyreact to form photochemical smog when subjected to sunlight. Carbonmonoxide does not react in the same way, but it is toxic.

Honda utilizes lean carburetor settings and other systems to reducethe emissions of carbon monoxide, oxides of nitrogen andhydrocarbons.

EPA and California regulations require all manufacturers to furnishwritten instructions describing the operation and maintenance ofemission control systems.

The following instructions and procedures must be followed in orderto keep the emissions from your Honda engine within the emissionstandards.

Tampering with or altering the emission control system may increaseemissions beyond the legal limit. Among those acts that constitutetampering are:

Removal or alteration of any part of the intake, fuel or exhaustsystems.

Altering or defeating the governor linkage or speed-adjustingmechanism to cause the engine to operate outside its designparameters.

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53


Problems That May Affect Emissions

Replacement Parts

Maintenance

If you are aware of any of the following symptoms, have your engineinspected and repaired by your servicing dealer.

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

The emission control systems on your Honda engine were designed,built, and certified to conform with EPA and California emissionregulations. We recommend the use of genuine Honda partswhenever you have maintenance done. These original-designreplacement parts are manufactured to the same standards as theoriginal parts, so you can be confident of their performance. The useof replacement parts that are not of the original design and qualitymay impair the effectiveness of your emission control system.

A manufacturer of an aftermarket part assumes the responsibility thatthe part will not adversely affect emission performance. Themanufacturer or rebuilder of the part must certify that use of the partwill not result in a failure of the engine to comply with emissionregulations.

Follow the maintenance schedule on page . Remember that thisschedule is based on the assumption that your machine will be usedfor its designed purpose. Sustained high-load or high-temperatureoperation, or use in unusually wet or dusty conditions, will requiremore frequent service.

23

03/06/09 15:03:13 31ZH7622_054

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－

－

54


Air Index

The bar graph is intended to provide you, our customer, the ability tocompare the emissions performance of available engines. The lowerthe Air Index, the less pollution.

The durability description is intended to provide you with informationrelating to the engine’s emission durability period. The descriptiveterm indicates the useful-life period for the engine’s emission controlsystem. See your Emission Control Warranty for additionalinformation.

Descriptive Term Applicable to Emissions Durability Period

50 hours (0 65 cc)125 hours (greater than 65 cc)



The Air Index Information hang tag must remain on the engine until itis sold. Remove the hang tag before operating the engine.

Moderate

Intermediate

Extended

An Air Index Information hang tag/label is applied to engines certifiedto an emission durability time period in accordance with therequirements of the California Air Resources Board.

03/06/09 15:03:24 31ZH7622_055

× × × ×

× ×

× ×

×

× ×

× × × ×× ×

×

55


Specifications

GX 120

GX 160

11.7 13.4 12.5 in (297 341 318 mm)28.7 lbs (13.0 kg)

4-stroke, overhead valve, single cylinder7.3 cu-in (119 cm )

2.4 1.7 in (60 42 mm)3.9 bhp (2.9 kW, 4.0 PS) at 3,600 rpm

5.4 lbf·ft (7.4 N·m, 0.75 kgf·m) at 2,500 rpm

Length Width HeightDry weightEngine typeDisplacement[Bore Stroke]Max. outputMax. torqueEngine oil capacityFuel tank capacityFuel consumptionCooling systemIgnition systemPTO shaft rotation

CounterclockwiseTransistorized magneto

Forced air0.51 lb/hph (313 g/kWh, 230 g/PSh)

0.95 US gal (3.6 )

8.0 lbf·ft (10.8 N·m, 1.1 kgf·m) at 2,500 rpm5.4 bhp (4.0 kW, 5.5 PS) at 3,600 rpm

2.7 1.8 in (68 45 mm)9.9 cu-in (163 cm )

4-stroke, overhead valve, single cylinder33.1 lbs (15.0 kg)

12.0 14.3 13.2 in (304 362 335 mm)

CounterclockwiseTransistorized magneto

Forced air0.51 lb/hph (313 g/kWh, 230 g/PSh)

0.66 US gal (2.5 )

Length Width HeightDry weightEngine typeDisplacement[Bore Stroke]Max. outputMax. torqueEngine oil capacityFuel tank capacityFuel consumptionCooling systemIgnition systemPTO shaft rotation

0.63 US qt (0.60 )

0.63 US qt (0.60 )

[ ]

][

03/06/09 15:03:38 31ZH7622_056

× × × ×

× ×

－－

±±

× ×

×

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56


GX200

GX120/GX160/GX200 Tuneup

ITEM SPECIFICATION MAINTENANCE

12.3 14.8 13.2 in (313 376 335 mm)35.3 lbs (16.0 kg)

4-stroke, overhead valve, single cylinder12.0 cu-in (196 cm )

2.7 2.1 in (68 54 mm)6.4 bhp (4.8 kW, 6.5 PS) at 3,600 rpm

9.76 lbf·ft (13.2 N·m, 1.35 kgf·m) at 2,500 rpm

0.028 0.031 in(0.70 0.80 mm)

Spark plug gap

Idle speedValve clearance

Other specifications0.20 0.02 mm

Refer to page: 36

Refer to page: 37See your authorizedHonda dealer

0.15 0.02 mm

Length Width HeightDry weightEngine typeDisplacement[Bore Stroke]Max. outputMax. torqueEngine oil capacityFuel tank capacityFuel consumptionCooling systemIgnition systemPTO shaft rotation Counterclockwise

Transistorized magnetoForced air

0.51 lb/hph (313 g/kWh, 230 g/PSh)0.95 US gal (3.6 )0.63 US qt (0.60 )

IN:EX:

[ ]

No other adjustments needed.

(cold)(cold)

1,400 rpm200150

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57


Wiring Diagrams

Oil Alert and Electric Starter Types

03/06/09 15:03:59 31ZH7622_058

58


Engine Type With Oil Alert and Without Electric Starter

03/06/09 15:04:04 31ZH7622_059

59


CONSUMER INFORMATION

Honda Publications

Shop Manual

Parts Catalog

These publications will give you additional information formaintaining and repairing your engine. You may order them fromyour Honda engine dealer.

This manual covers complete maintenance and overhaul procedures.It is intended to be used by a skilled technician.

This manual provides complete, illustrated parts lists.

03/06/09 15:04:11 31ZH7622_060

60


Warranty Service Information

Servicing dealership personnel are trained professionals. They shouldbe able to answer any questions you may have. If you encounter aproblem that your dealer does not solve to your satisfaction, pleasediscuss it with the dealership’s management. The Service Manager,General Manager, or Owner can help. Almost all problems are solvedin this way.

Name, address, and contact person of dealer who services yourengine

If you are still dissatisfied after speaking with the Regional EngineDistributor, you may contact the Honda Power Equipment CustomerRelations Office. You can write to:

If you are dissatisfied with the decision made by the dealership’smanagement, contact the Honda Regional Engine Distributor for yourarea. You can find their name, address, and phone number using thedealer/distributor locator on our website at (www.honda-engines.com)or by calling 1-800-426-7701.

American Honda Motor Co., Inc.Power Equipment DivisionCustomer Relations Office4900 Marconi DriveAlpharetta, Georgia 30005-8847

Or telephone: (770) 497-6400

When you write or call, please give us this information:

Name of dealer who sold the engine to you

Name of Distributor you contacted and the contact personDate of purchase

A detailed description of the problemYour name, address and telephone number

Equipment manufacturer’s name and model number that the engineis mounted onEngine model and serial number (see page )47

03/06/09 15:04:24 31ZH7622_061

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QUICK REFERENCE INFORMATION

Unleaded gasoline with a pumpoctane rating of 86 or higher

SAE 10W-30, API SJ or SL, forgeneral use

Type

Type

Type

Gap

Idle speedEach use

First 20hours

Subsequent

Fuel

Engine Oil

Spark Plug

CarburetorMaintenance

BPR6ESW20EPR-U

0.028 0.031 in (0.70 0.80 mm)

Check engine oil level.Check transmission oil level ifapplicable.Check air filter.Change engine oil.Change transmission oil ifapplicable.Refer to the maintenanceschedule on page 23.

(page 25)

NGK:DENSO:

(page 36)1,400 rpm (page 37)

(page 28)

200150

03/06/09 15:04:32 31ZH7622_062

honda owner's manual

Documents

engine safety

honda engine

engine exhaust

new engine

engine andshould

engine ready

safety alert symbol

honda motor