Honda GX120 manual

31Z0T600 00X31-Z0T -6000 31Z0T600 o 2002 Honda Motor Co., Ltd. -All Rights Reserved Owner’ s Manual GX120•GX160•GX200 Black DIC 157 N T1:GX120•GX160•GX200 2e Y 1 " GX120/160/200cover 2002.11.21 1:51 PM ページ 1[...]

The information and specifi cations included in this pub lication were in effect at the time of approval for p rinting. Illustrations are ba sed on the GX160. Only the QXE2 type is equipped for both electric and manual starting. Honda Motor Co., Ltd. reserves th e right, however, to discontinue or change specifications or design at any time without[...]

1 INTRODUCT ION Congratulations on your selection of a Honda engine. We are certain you will be pleased with your purchase of one of the finest engines on the market. We want to he lp you get t he best res ults f rom your new eng ine and to operate it safely. This manual contains the information on how to do that; please read it carefully. As you r[...]

2 INTRODUCTION A FEW WORDS ABOUT SAFETY Safety Labels Safety Messages Safety Headings Safety Section Instructio ns Your safety and the safety of others are ve ry important. And using this engine safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on lab[...]

3 CON TENTS ....................................................................................... ENGINE SAFETY . 5 ................................................ IMPORTANT SAFETY INFORMATION . 5 ........................................................................ CONTROLS & FEATURES . 7 ............................................ COMP[...]

4 CONTENTS SERVICING YOUR ENGINE (continued) ............................................................... SEDIMENT CUP CLEANING . 33 ....................................................................... SPARK PLUG SERVICE . 34 ............................................................... IDLE SPEED ADJUSTMENT . 35 ........................ SP[...]

5 IMPORTANT SAFETY INFORMATION Owner Responsibilities Refuel With Care Hot Exhaust ENGINE SAFE TY Most accidents with engines can be prevented if you follow all instructions in this manual and on the engine. Some of the most common hazards are discussed below, along with the best way to protect yourself and others. Honda engines are designed to giv[...]

6 ENGINE SAFETY Other Equipment Carbon Monoxide Hazard Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run the engine in a closed gar age or confined area. Review the instructions provided with the equipment powered by this engine for any additional safety precautions that should be observed in conjunction wit[...]

7 COMPONENT & CONTROL LOCATIONS CONTROLS & FEA TURES MUFFLER SPARK P LUG AIR CL EANER CHOK E LEVER START ER GRIP THROTTL E LEVER CIRCUIT BREAKE R (QXE2 ty pe) RECOIL STA RTER FUEL FILLER CA P FUEL TAN K OIL DR AIN PLU G FUEL VALVE LEVER ENGINE SWITCH (QXE2 ty pe) ENGINE OIL FILLER CAP/ DIPST ICK ELECTR IC STAR TER (QXE 2 type) 02/11/29 16:1[...]

8 CONTROLS & FEATURES CONTROLS Fuel Valve Lever FUEL VALVE LEVE R OFF O O N N The fuel valve opens and closes the passage between the fuel tank and 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 f uel valve leve r in the OFF position to prevent carburetor flooding [...]

9 CONTROLS & FEATURES Engine Switch QXE2 Type ALL ENGINE S EXCE PT QXE2 QXE2 T YPE CIRCUIT BREAKE R 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 the QX E2 ty[...]

10 CONTROLS & FEATURES Choke Lever CLOSED OPEN CHOK E LEVER The choke lever opens and closes the choke valve in the carburetor. The CLOSED position enriches the fuel mixture for starting a cold engine. The OPEN position provides the correct fuel mixture for operation after starting, and for restarting a warm engine. Some engine applications use[...]

11 CONTROLS & FEATURES Throttle Lever Recoil Starte r Grip THROTTL E LEVER START ER GRIP FAST SLOW The throttle lever controls engine speed. Moving the throttle lever in the dir ections shown makes the engine r u nf a s t e ro rs l o w e r . Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle[...]

12 CONTROLS & FEATURES FEATURES Circuit Breaker Oil Alert System (applicable engine types) (QXE2 type only) CIRCUIT BREAKE R If the engine stops and will not restart, check the engine oil le vel (page ) before troubleshooting in other ar eas. The circuit breaker prote cts the battery charging circuit. A short circuit, or a battery connected wit[...]

13 IS YOUR ENGINE READY TO GO? Check the General Condition of the Engine BEFORE OPERAT ION For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the engine to check its cond ition. Be sure to take care of a ny problem you find, or have your s ervicing dealer c orrect it, b[...]

14 BEFORE OPERATION Check the Engine Check the Equipment Power ed by This Engine The Oil Alert system (applicable engine types) will automatically stop the engine bef ore the oil level falls bel ow safe limits. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before star tup. Check the engine oil leve[...]

15 SAFE OPERATING PRECAUTIONS STARTING THE ENGINE OPERA TION ON FUEL VAL VE LEVE R B e f o r eo p e r a t i n gt h ee n g i n ef o rt h ef i r s tt i m e ,p l e a s er e v i e wt h e IMPORTANT SAFETY INFORMATION on page and the chapter titled BEFORE OPERATION . Review the instructions provided with the equipment powered by this engine for any sa fe[...]

16 OPERATION CHOK E LEVER CLOSE OPEN SLOW THROTTL E LEVER Move the throttle lever away from the SLOW position, about 1/ 3 of the way toward the FAST position. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown her e. To start a cold engi ne, m ove th e choke lever to th e CLOSED posi[...]

17 OPERATION START ER GRIP ENGINE SWITCH ON QXE2 TYPE ALL ENGINES EXCEPT QXE2 Turn the engine switch to the ON position. Operate the starter. Pull the starter grip lightly u ntil you feel re sistance, then pull briskly. Return the starter grip gently. RECOIL STARTER (all engine types): 4. 5. 02/11/29 16:18:55 31Z0T600_018[...]

18 OPERATION CHOK E LEVER OPEN ENGINE SWITCH (QXE2 type) ELECTRIC STARTER (QXE2 type): Turn the key to the START position, and hold it there until the engine starts. If the engin e fail s to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again. Using the electric starter for more than 5 seconds a [...]

19 OPERATION STOPPING THE ENGINE ALL ENGINES EXCEPT QXE2 QXE2 TYPE THROTTL E LEVER SLOW OFF ENGINE SWITCH To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal condi tions, use the foll owing procedure. Move the throttle lever to the SLOW position. Some engine applications use a remotely-mounted throttl[...]

20 OPERATION SETTING ENGINE SPEED OFF THROTTL E LEVER FAST SLOW FUEL VAL VE LEVE R Turn the fuel valve lever to the OFF position. Position the throttle lever for t he desired engine speed. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown her e. For engine speed recommendations, ref[...]

21 THE IMPORTANCE OF MAINTENANCE Maintenance, replacement or r epair of emission control devices and systems may be done by any engine repair establishment or individual, using parts that are ‘‘certified’’ t o EPA standards. SERVICING YOUR E NGINE Good maintenance is essential for saf e, economical, and trouble-free operation. It will also [...]

− − − 22 SERVICING YOUR ENGINE MAINTENANCE SAFETY Safety Precautions Carbon monoxide poisoning from engine exhaust . Burns from h ot parts. Injury from moving parts. Some of the most important safety pre cautions are as fo llows: However, we cannot warn you of every conceivable hazard that can arise in performing m aintenance. Only you can de[...]

− − − ＊ − ○ ○ ○○ ○ ○ ○ ○ ○ ○ ○ ○ ○＊ 23 SERVICING YOUR ENGINE MAINTENANCE SCHEDULE Engine oil Air filter Sediment cup Spark pl ug Spark arrester (optional parts) Idle speed Valve clearance Combustion chamber Fuel tank & filter Fuel tube REGULAR SERVICE P ERIOD (3) Perform at ever y indicated month or operati[...]

24 SERVICING YOUR ENGINE REFUELING 0.66 US gal (2.5 ) 0.95 US gal (3.6 ) 0.95 US gal (3.6 ) Fuel tank capacities GX120: GX160: GX200: MAXIMUM F UEL L EVEL With the engine stopped , remove the fuel tank c ap and check the fuel level. Refill the tank if the fuel level is low. Gasoline is highly flammable and explosive. You can be burned or seriously [...]

25 SERVICING YOUR ENGINE FUEL RECOMMENDATIONS Use unleaded gasoline with a pump octane r ating of 86 or higher. Refuel in a well-ventilated area before starting the engine. If the engine has been r unnin g, allow it to cool . Refuel care fully t o avoid s pill ing fuel. Do not fill above the fuel strainer shoulder. After refue ling, tighten the fue[...]

26 SERVICING YOUR ENGINE ENGINE OIL LEVEL CHECK FILLER CAP /DIP STICK UPPER LI MIT LOWER LIMIT Check the engine oil level with the engine stopped and in a level position. Running the engine with a low oil level can cause engine damage. The Oil Alert system (applicable engine types) will automatically stop the engine before the oil level falls below[...]

27 SERVICING YOUR ENGINE ENGINE OIL CHANGE Engine oil capacities FILLER CAP / DIPSTI CK DRAIN B OLT OIL LEVE L Drain the used oil while the engine is warm. Warm oil drains quickly and completely. Place a suitable container below the engine to catch the used oil, then remove the filler cap/ dipstick and the drain plug. Allow the used oil to drain co[...]

28 SERVICING YOUR ENGINE ENGINE OIL RECOMMENDATIONS AMBIEN T TEMPERATUR E Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range. The SAE [...]

29 SERVICING YOUR ENGINE AIR FILTER INSPECTION STANDER D DUAL-F ILTER - ELEMENT TY PE (see p. 30- 31) OIL-BAT H TYPE (see p. 32) PAPER FIL TER ELEMENT FOAM FILTE R ELEMENT FILTER Remove the air clea ner cover and insp ect the f ilter. Clean or replace dirty filter elements. Always replace damaged filter elements. If equipped with an oil-bath air cl[...]

30 SERVICING YOUR ENGINE AIR CLEANER SERVICE Dual-Filter-Element Types STANDER D DUAL-F ILTER -ELEMENT TYPE AIR CLEANE R COVER PAPER FILTER ELEMENT FOAM FILTER ELEMENT GASKET A dirty air filter w ill restrict air flow to the c arburetor, reducing engine performance. If you operate the engine in very dusty areas, clean the air filter more often than[...]

31 SERVICING YOUR ENGINE Paper air filter element: Tap the filter element several times on a hard surface to remove dirt, or blow comp ressed air [not exce eding 30 psi (207 kPa, 2.1 kgf cm )] thr ough the filter element from the inside. Never try to brush off dirt; brushing will force dirt into the fibers. Foam air filter element: Clean in warm so[...]

32 SERVICING YOUR ENGINE Oil-Bath Type WING NUT CAP AIR CLEANE R CASE AIR CLEANE R COVER FILTER GRID OIL LEVE L Reassemble the air cleaner, and ti ghten the wing nut secur ely. 2.0 US oz (60 cm ) Remove the wing nut, and remove the air cleaner cap and cover. Remove the air filter f rom the c over, Wash the cover and f ilter in warm, soapy water, ri[...]

33 SERVICING YOUR ENGINE SEDIMENT CUP CLEANING SEDIM ENT CUP O-RING Move the fuel valve to the OFF position, then remove the fuel sediment cup and O-ring. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Keep heat, sparks and flame away. Handle fuel only outdoors. Wipe up spills immediately. Was[...]

− − − − 34 SERVICING YOUR ENGINE SPARK PLUG SERVICE SPARK P LUG WRENCH 0.028 0.031 in (0.70 0.80 mm) Disconnect the spark plug cap, and remove any dirt from around the spark plug area. Remove the spark plug with a 13/16-inch spark plug wrench. An incorrect spark plug can cause engine damage. BPR6ES W20EPR-U Inspect the spark plug. Replace i[...]

− ＋ − 35 SERVICING YOUR ENGINE IDLE SPEED ADJUSTMENT THROT TLE STOP SCRE W After the spark plug seats, tighten with a 13/16-inch spark plug wrench to comp ress the water . If reinstalling the used spa rk plug, tighten 1/ 8 1/4 turn af ter the spark plug seat. if installing a new spark plug, tighten 1/ 2 turn after the spark plug seats. A loos[...]

36 SERVICING YOUR ENGINE SPARK ARRESTER SERVICE (optional equipment) SCREEN SPARK ARREST ER MUFFLER PROTEC TOR 4 mm SCREW 4m m SCREWS EXHAUST DEFLE CTOR 5 mm SCREWS Your engine is not factory-equipped with a spark arrester. In some areas, it is illegal to o perate a n engine without a s park arreste r. Check local laws and regulations. A spark arre[...]

37 STORING YOUR ENGINE Storage Pre paration Cleaning Fuel HELP FUL TIPS & SUGGE STIONS Proper storage preparation is essential for keeping your engine troublefree and looking good. The f ollowing steps will help to keep rust and corrosion from impairing your engine’s function and appearance, and will make the engine easier t o start after sto[...]

38 HELPFUL TIPS & SUGGESTIONS ADDING A FUEL STABILIZER TO EXTEND FUEL STORAGE LIFE FUEL VAL VE OFF The Distributor’s Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation. You can extend f uel storage life by add ing a fuel stabilizer that is formulated for that purpose,[...]

39 HELPFUL TIPS & SUGGESTIONS DRAINING THE FUEL TANK AND CARBURETOR DRAIN BOLT SEDIM ENT CUP Place an approved gasoline container below the carburetor, and use a funnel to avoid spilling fuel. Remove the carburetor drain bolt and s ediment cup, then move the fuel valve lever to the ON position. Gasoline is highly flammable and explosive. You ca[...]

− 40 HELPFUL TIPS & SUGGESTIONS Engine Oil Storage Precautions Align not ch on pull ey wit h hole a t top of c over . If your engine will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well-ventilated storage area away from any appliance that operates with a f[...]

41 HELPFUL TIPS & SUGGESTIONS Removal From Storage Position the equipment so the engine is level. T ilting can cause f uel or oil leakage. With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials. Do not use sheet plas tic as a dust c over. A nonporous c over w[...]

42 HELPFUL TIPS & SUGGESTIONS TRANSPORTING If the engine has been running, allow it to cool for at least 15 minutes before loading the engine-powered equipment on the transpor t vehicle. A hot engine and exhau st system can burn you and can ignite some materia ls. Keep the engine level when transporting to reduce the possibility of fuel leakage[...]

43 Possib le Cause ENGINE WILL NOT START Correction Possib le Cause ENGINE LACKS POWER Correction TAKING CARE OF UNEXPECTED PROBLEMS Batte ry dis char ged. Fuse burnt out. Fuel valve OFF. Choke O PEN. Engine s witch O FF. Out of fuel. Bad f uel; engine store d without tre ating or dra ining ga soli ne, or refueled wit h bad gasolin e. Spar k plugs [...]

× × × 44 TAKING CARE OF UNEXPECTED PROBLEMS FUSE REPLACEMENT (QXE2 type only) FUSE COVER 5AF U S E ENGINE SWITCH REAR COV ER 61 2 m m SPECIA L SCREW The electric starter relay circuit and battery charging circuit are protected by a 5-ampere fuse. If the fuse burns out, the electric starter will not operate. The engine can be started m anually if[...]

45 TECHNICAL INFORMATION Serial Number Location TECHNICAL & CONSUMER INFORMATION ELECTR IC STARTER (QXE2 ty pe only) SERIAL NUM BER & ENGINE TYPE Record the engine serial number in the space below. You will need this serial number w hen ordering parts, and when making technical or warranty inquires (see page ). Engine serial number: 58 02/1[...]

＋ − ＋ ＋ − ＋＋ −− ＋ − 46 TECHNICAL & CONSUMER INFORMATION Battery Connections for Elect ric Start er (QXE2 type only) STARTER SOLENOID POSI TIVE ( ) BATTERY CABL E NEGAT IVE ( ) BATTERY C ABLE 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 thi[...]

47 TECHNICAL & CONSUMER INFORMATION Remote Contro l Linkage RETUR N SPRING THROTTL E LEVER PIVOT NUT WIRE 5m m CIRCLIP THROTTL E LEVE R WIRE HOLDE R CHOK E LEVER WIRE HOLDE R 4 mm SCREW REMOT E CHOKE LINKAGE Solid wire core mounting OPTIONA L Flexible wire core mounting REMOTE THR OTTLE L INK AGE The throttle and choke control levers are provid[...]

48 TECHNICAL & CONSUMER INFORMATION Carburetor Modificati on for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an a ltitude that dif fers f [...]

49 TECHNICAL & CONSUMER INFORMATION ETHANOL METHANOL MTBE Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If yo[...]

50 TECHNICAL & CONSUMER INFORMATION Emission Control System Inform ation Source of Emissions The U.S. and California Clean Air Acts Tampering and Altering The combustion process produces car bon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, the[...]

51 TECHNICAL & CONSUMER INFORMATION Problems That May Affect Emissions Replacement Parts Maintenance If you are aware of any of the follow ing symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exha[...]

− − − 52 TECHNICAL & CONSUMER INFORMATION Air Index The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution. The durability description is intended to provide you with information relating to the engine’s emission durabilit[...]

×× × ×× × ×× × × ×× ×× × × ×× 53 TECHNICAL & CONSUMER INFORMATION Specifications GX 120 GX 160 Length W idth Hei ght Dry wei ght Engine type Displacem ent [Bore S troke ] Max. output Max. to rque Fuel c onsumption Coolin g system Igniti on sys tem PTO sha ft rota tion Length W idth Hei ght Dry wei ght Engine type Displacem ent[...]

×× × ± ± − − ×× × × ×× 54 TECHNICAL & CONSUMER INFORMATION GX200 GX120/GX160/GX200 Tuneup ITEM SPECIFICA TION MA INTE NANCE Length W idth Hei ght Dry wei ght Engine type Displacem ent [Bore S troke ] Max. output Max. to rque Fuel c onsumption Coolin g system Igniti on sys tem PTO sha ft rota tion 0.15 0.02 mm 0.20 0.02 mm 0.028 0[...]

55 TECHNICAL & CONSUMER INFORMATION Wiring Diagra ms QXE2 Type with Oil Alert and Ele ctric Starter 02/11/29 16:25:04 31Z0T600_056[...]

56 TECHNICAL & CONSUMER INFORMATION Engine Type With Oil Alert and Without Electric Starter 02/11/29 16:25:09 31Z0T600_057[...]

57 TECHNICAL & CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications Shop Manual Parts Catalog These publications will give you additional information for maintaining and repairing your engine. You may order them from your Honda engine dealer. This manual covers complete maintenance and overhaul procedures. It is intended to be used by a[...]

58 TECHNICAL & CONSUMER INFORMATION Warranty Service Infor mation Servicing dealership personnel are trained pr ofessionals. They should be able to answer any qu estions you may have. If you e ncounter a problem that your dealer does not solve to your satisfac tion, please discuss it with the dealership’s management. The Service Manager or Ge[...]

59 MEMO 02/11/29 16:25:30 31Z0T600_060[...]

60 MEMO 02/11/29 16:25:32 31Z0T600_061[...]

−− ＋ − QUICK REFERENCE INFORMATION Unleaded gasoline with a pump octane rating of 86 or higher SAE 10W-30, API SJ, for general use 0.95 US gal (3.6 ) 0.66 US gal (2.5 ) Fuel Engine Oil Spark Plug Carburetor Maintenance 0.028 0.031 in (0.70 0.80 mm) W20EPR-U BPR6ES 0.63 US qt (0.60 ) Check engine oil level. Check air filter. Change engine oi[...]

31Z0T600 00X31-Z0T -6000 31Z0T600 o 2002 Honda Motor Co., Ltd. -All Rights Reserved Owner’ s Manual GX120•GX160•GX200 Black DIC 157 N T1:GX120•GX160•GX200 2e Y 1 " GX120/160/200cover 2002.11.21 1:51 PM ページ 1 70000.2002.12  PRINTED IN THAILAND[...]