Honda Automobiles GX120 User Manual

Owner’s Manual  
GX120•GX160•GX200  
o2002 Honda Motor Co., Ltd. -All Rights Reserved  
The engine exhaust from this product  
contains chemicals known to the State  
of California to cause cancer, birth  
defects or other reproductive harm.  
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 and  
should remain with the engine if resold.  
The information and specifications included in this publication were in  
effect at the time of approval for printing. Illustrations are based on the  
GX160. Only the QXE2 type is equipped for both electric and manual  
starting. Honda Motor Co., Ltd. reserves the right, however, to  
discontinue or change specifications or design at any time without  
notice and without incurring any obligation whatever. No part of this  
publication may be reproduced without written permission.  
INTRODUCTION  
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 help you get the best results from your new engine and to  
operate it safely. This manual contains the information on how to do  
that; please read it carefully.  
As you read this manual, you will find information preceded by a  
symbol. 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 its  
coverage and your responsibilities of ownership. The warranty policy  
is a separate document that should have been given to you by your  
dealer.  
When your engine needs scheduled maintenance, keep in mind that  
your Honda servicing dealer is specially trained in servicing Honda  
engines. Your Honda servicing dealer is dedicated to your satisfaction  
and will be pleased to answer your questions and concerns.  
Best Wishes,  
Honda Motor Co., Ltd.  
1
INTRODUCTION  
A FEW WORDS ABOUT SAFETY  
Your safety and the safety of others are very 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 labels and in this  
manual. This information alerts you to potential hazards that could  
hurt you or others.  
Of course, it is not practical or possible to warn you about all the  
hazards associated with operating or maintaining an engine. You must  
use your own good judgment.  
You will find important safety information in a variety of forms,  
including:  
Safety Labels –– on the engine.  
Safety Messages –– preceded by a safety alert symbol  
of three signal words, DANGER, WARNING, or CAUTION.  
and one  
These signal words mean:  
You WILL be KILLED or SERIOUSLY HURT if  
you don’t follow instructions.  
You CAN be KILLED or SERIOUSLY HURT if  
you don’t follow instructions.  
You CAN be HURT if you don’t follow  
instructions.  
Safety Headings –– such as IMPORTANT SAFETY INFORMATION.  
Safety Section –– such as ENGINE SAFETY.  
Instructions –– how to use this engine correctly and safely.  
This entire book is filled with important safety information –– please  
read it carefully.  
2
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 (QXE2 type 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  
AIR FILTER INSPECTION ..................................................................... 29  
AIR CLEANER SERVICE ....................................................................... 30  
Dual-Filter-Element Types ............................................................... 30  
Oil-Bath Type .................................................................................... 32  
3
CONTENTS  
SERVICING YOUR ENGINE (continued)  
SEDIMENT CUP CLEANING ................................................................ 33  
SPARK PLUG SERVICE ........................................................................ 34  
IDLE SPEED ADJUSTMENT ................................................................ 35  
SPARK ARRESTER MAINTENANCE (optional part) ......................... 36  
HELPFUL TIPS & SUGGESTIONS .......................................................... 37  
STORING YOUR ENGINE .................................................................... 37  
Storage Preparation ......................................................................... 37  
Storage Precautions ......................................................................... 40  
Removal From Storage .................................................................... 41  
TRANSPORTING .................................................................................. 42  
TAKING CARE OF UNEXPECTED PROBLEMS ...................................... 43  
ENGINE WILL NOT START .................................................................. 43  
ENGINE LACKS POWER ...................................................................... 43  
FUSE REPLACEMENT (QXE2 type only) ............................................ 44  
TECHNICAL & CONSUMER INFORMATION ......................................... 45  
TECHNICAL INFORMATION ................................................................ 45  
Serial Number Location ................................................................... 45  
Battery connections for Electric Starter (QXE2 type only) ............ 46  
Remote Control Linkage .................................................................. 47  
Carburetor Modification for High Altitude ..................................... 48  
Oxygenated Fuels ............................................................................ 49  
Emission Control System Information ........................................... 50  
Air Index ............................................................................................ 52  
Specifications ................................................................................... 53  
CONSUMER INFORMATION ............................................................... 57  
Honda Publications .......................................................................... 57  
Warranty Service Information ......................................................... 58  
QUICK REFERENCE INFORMATION ............................. Inside back cover  
4
ENGINE SAFETY  
IMPORTANT SAFETY INFORMATION  
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.  
Owner Responsibilities  
Honda engines are designed to give safe and dependable service if  
operated according to instructions. Read and understand this  
owner’s manual before operating the engine. Failure to do so could  
result in personal injury or equipment damage.  
Know how to stop the engine quickly, and understand the operation  
of all controls. Never permit anyone to operate the engine without  
proper instructions.  
Do not allow children to operate the engine. Keep children and pets  
away from the area of operation.  
Refuel With Care  
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.  
Hot Exhaust  
The muffler becomes very hot during operation and remains hot for  
a while after stopping the engine. Be careful not to touch the muffler  
while it is hot. Let the engine cool before storing it indoors.  
To prevent fire hazards and to provide adequate ventilation for  
stationary equipment applications, keep the engine at least 3 feet (1  
meter) away from building walls and other equipment during  
operation. Do not place flammable objects close to the engine.  
5
 
ENGINE SAFETY  
Carbon Monoxide Hazard  
Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of  
exhaust gas. Never run the engine in a closed garage or confined area.  
Other Equipment  
Review the instructions provided with the equipment powered by this  
engine for any additional safety precautions that should be observed  
in conjunction with engine startup, shutdown, operation, or protective  
apparel that may be needed to operate the equipment.  
6
CONTROLS & FEATURES  
COMPONENT & CONTROL LOCATIONS  
MUFFLER  
THROTTLE LEVER  
ENGINE SWITCH  
(QXE2 type)  
SPARK PLUG  
AIR CLEANER  
CHOKE LEVER  
CIRCUIT BREAKER  
(QXE2 type)  
RECOIL STARTER  
FUEL VALVE LEVER  
STARTER GRIP  
FUEL FILLER CAP  
FUEL TANK  
ELECTRIC STARTER  
(QXE2 type)  
OIL DRAIN PLUG  
ENGINE OIL FILLER CAP/DIPSTICK  
7
 
CONTROLS & FEATURES  
CONTROLS  
Fuel Valve Lever  
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 fuel valve lever in the OFF  
position to prevent carburetor flooding and to reduce the possibility of  
fuel leakage.  
FUEL  
VALVE  
LEVER  
ON  
OFF  
8
 
CONTROLS & FEATURES  
Engine Switch  
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.  
ALL ENGINES EXCEPT QXE2  
QXE2 TYPE  
ENGINE SWITCH  
OFF  
ON  
CIRCUIT BREAKER  
QXE2 Type  
The engine switch on the QXE2 type includes a START position for  
operating the electric starter. The key automatically returns to the ON  
position when released from the START position.  
The circuit breaker, which is located below the key, protects the  
battery charging circuit (see page 12).  
9
 
CONTROLS & FEATURES  
Choke 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 a remotely-mounted choke control  
rather than the engine-mounted choke lever shown here.  
CHOKE LEVER  
OPEN  
CLOSED  
10  
CONTROLS & FEATURES  
Throttle Lever  
The throttle lever controls engine speed.  
Moving the throttle lever in the directions shown makes the engine  
run faster or slower.  
Some engine applications use a remotely-mounted throttle control  
rather than the engine-mounted throttle lever shown here.  
THROTTLE LEVER  
SLOW  
FAST  
Recoil Starter Grip  
Pulling the starter grip operates the recoil starter to crank the engine.  
STARTER GRIP  
11  
CONTROLS & FEATURES  
FEATURES  
Oil Alert System (applicable engine types)  
The Oil Alert system is designed to prevent engine damage caused  
by an insufficient amount of oil in the crankcase. Before the oil level in  
the crankcase can fall below a safe limit, the Oil Alert system will  
automatically stop the engine (the engine switch will remain in the ON  
position).  
If the engine stops and will not restart, check the engine oil level (page  
26 ) before troubleshooting in other areas.  
Circuit Breaker (QXE2 type only)  
The circuit breaker protects the  
battery charging circuit. A short  
circuit, or a battery connected with  
reverse polarity, will trip the circuit  
breaker.  
The green indicator inside the  
circuit breaker will pop out to show  
that the circuit breaker has switched  
off. If this occurs, determine the  
cause of the problem, and correct it  
before resetting the circuit breaker.  
CIRCUIT  
BREAKER  
Push the circuit breaker button to  
reset.  
12  
BEFORE OPERATION  
IS YOUR ENGINE READY TO GO?  
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 condition. Be sure to take care of any problem you  
find, or have your servicing dealer correct it, before you operate the  
engine.  
Improperly maintaining this engine,  
or failing to correct a problem  
before operation, could cause a  
malfunction in which you could be  
seriously injured.  
Always perform a preoperation  
inspection before each operation,  
and correct any problem.  
Before beginning your preoperation checks, be sure the engine is level  
and the engine switch is in the OFF position.  
Check the General Condition of the Engine  
Look around and underneath the engine for signs of oil or gasoline  
leaks.  
Remove any excessive dirt or debris, especially around the muffler  
and recoil starter.  
Look for signs of damage.  
Check that all shields and covers are in place, and all nuts, bolts, and  
screws are tightened.  
13  
BEFORE OPERATION  
Check the Engine  
Check the engine oil level (see page 26). 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 safe limits. However,  
to avoid the inconvenience of an unexpected shutdown, always  
check the engine oil level before startup.  
Check the air filter (see page 29 ). A dirty air filter will restrict air flow  
to the carburetor, reducing engine performance.  
Check the fuel level (see page 24 ). Starting with a full tank will help  
to eliminate or reduce operating interruptions for refueling.  
Check the Equipment Powered by This Engine  
Review the instructions provided with the equipment powered by this  
engine for any precautions and procedures that should be followed  
before engine startup.  
14  
OPERATION  
SAFE OPERATING PRECAUTIONS  
Before operating the engine for the first time, please review the  
IMPORTANT SAFETY INFORMATION on page 5 and the chapter titled  
BEFORE OPERATION.  
Carbon monoxide gas is toxic.  
Breathing it can cause  
unconsciousness and even kill you.  
Avoid any areas or actions that  
expose you to carbon monoxide.  
Review the instructions provided with the equipment powered by this  
engine for any safety precautions that should be observed in  
conjunction with engine startup, shutdown, or operation.  
STARTING THE ENGINE  
1. Move the fuel valve lever to the ON position.  
FUEL VALVE  
LEVER  
ON  
15  
OPERATION  
2. 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 remotely-mounted choke control  
rather than the engine-mounted choke lever shown here.  
CHOKE LEVER  
OPEN  
CLOSE  
3. 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 here.  
SLOW  
THROTTLE LEVER  
16  
OPERATION  
4. Turn the engine switch to the ON position.  
ALL ENGINES EXCEPT QXE2  
QXE2 TYPE  
ENGINE SWITCH  
ON  
5. Operate the starter.  
RECOIL STARTER (all engine types):  
Pull the starter grip lightly until you feel resistance, then pull briskly.  
Return the starter grip gently.  
STARTER GRIP  
17  
OPERATION  
ELECTRIC STARTER (QXE2 type):  
Turn the key to the START position,  
and hold it there until the engine starts.  
If the engine fails 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 at a time will overheat  
the starter motor and can damage it.  
When the engine starts, release the  
key, allowing it to return to the ON  
position.  
ENGINE SWITCH  
(QXE2 type)  
6. If the choke lever has been moved to the CLOSED position to start  
the engine, gradually move it to the OPEN position as the engine  
warms up.  
CHOKE LEVER  
OPEN  
18  
OPERATION  
STOPPING THE ENGINE  
To stop the engine in an emergency, simply turn the engine switch to  
the OFF position. Under normal conditions, use the following  
procedure.  
1. Move the throttle lever to the SLOW position.  
Some engine applications use a remotely-mounted throttle control  
rather than the engine-mounted throttle lever shown here.  
THROTTLE LEVER  
SLOW  
2. Turn the engine switch to the OFF position.  
ALL ENGINES EXCEPT QXE2  
QXE2 TYPE  
ENGINE SWITCH  
OFF  
19  
OPERATION  
3. Turn the fuel valve lever to the OFF position.  
FUEL VALVE  
LEVER  
OFF  
SETTING ENGINE SPEED  
Position the throttle lever for the desired engine speed.  
Some engine applications use a remotely-mounted throttle control  
rather than the engine-mounted throttle lever shown here.  
For engine speed recommendations, refer to the instructions provided  
with the equipment powered by this engine.  
THROTTLE LEVER  
SLOW  
FAST  
20  
SERVICING YOUR ENGINE  
THE IMPORTANCE OF MAINTENANCE  
Good maintenance is essential for safe, economical, and trouble-free  
operation. It will also help reduce air pollution.  
Improperly maintaining this engine,  
or failure to correct a problem  
before operation, can cause a  
malfunction in which you can be  
seriously hurt or killed.  
Always follow the inspection and  
maintenance recommendations and  
schedules in this owner’s manual.  
To help you properly care for your engine, the following pages include  
a maintenance schedule, routine inspection procedures, and simple  
maintenance procedures using basic hand tools. Other service tasks  
that are more difficult, or require special tools, are best handled by  
professionals and are normally performed by a Honda technician or  
other qualified mechanic.  
The maintenance schedule applies to normal operating conditions. If  
you operate your engine under unusual conditions, such as sustained  
high-load or high-temperature operation, or use in unusually wet or  
dusty conditions, consult your servicing dealer for recommendations  
applicable to your individual needs and use.  
Maintenance, replacement or repair of emission control devices and  
systems may be done by any engine repair establishment or  
individual, using parts that are ‘‘certified’’ to EPA standards.  
21  
SERVICING YOUR ENGINE  
MAINTENANCE SAFETY  
Some of the most important safety precautions are as follows:  
However, we cannot warn you of every conceivable hazard that can  
arise in performing maintenance. Only you can decide whether or not  
you should perform a given task.  
Failure to properly follow  
maintenance instructions and  
precautions can cause you to be  
seriously hurt or killed.  
Always follow the procedures and  
precautions in the owner’s manual.  
Safety Precautions  
Make sure the engine is off before you begin any maintenance or  
repairs. This will eliminate several potential hazards:  
Carbon monoxide poisoning from engine exhaust.  
Be sure there is adequate ventilation whenever you operate the  
engine.  
Burns from hot parts.  
Let the engine and exhaust system cool before touching.  
Injury from moving parts.  
Do not run the engine unless instructed to do so.  
Read the instructions before you begin, and make sure you have the  
tools and skills required.  
To reduce the possibility of fire or explosion, be careful when  
working around gasoline. Use only a nonflammable solvent, not  
gasoline, to clean parts. Keep cigarettes, sparks and flames away  
from all fuel-related parts.  
Remember that your servicing dealer knows your engine best and is  
fully equipped to maintain and repair it.  
To ensure the best quality and reliability, use only new, genuine  
Honda parts or their equivalents for repair and replacement.  
22  
SERVICING YOUR ENGINE  
MAINTENANCE SCHEDULE  
REGULAR SERVICE PERIOD (3)  
ITEM  
First  
month 3 months6 months year  
or or or or  
20 Hrs. 50 Hrs. 100 Hrs. 300 Hrs.  
Every  
Every  
Every  
Refer  
to  
Each  
use  
Perform at every indicated  
month or operating hour interval,  
whichever comes first.  
page  
Engine oil  
Check level  
Change  
Check  
26  
27  
29  
30  
Air filter  
Clean  
(1)  
Replace  
Clean  
○ *  
Sediment cup  
Spark plug  
33  
34  
Check-adjust  
Replace  
Clean  
Spark arrester  
(optional parts)  
Idle speed  
36  
Check-adjust  
Check-adjust  
Clean  
(2)  
(2)  
35  
Valve clearance  
Combustion chamber  
Fuel tank & filter  
Fuel tube  
After every 500 Hrs. (2)  
Clean  
(2)  
Check  
Every 2 years (Replace if necessary) (2)  
Emission-related items.  
Replace the paper element type only.  
(1) Service more frequently when used in dusty areas.  
(2) These items should be serviced by your servicing dealer, unless  
you have the proper tools and are mechanically proficient. Refer  
to Honda shop manual for service procedures.  
(3) For commercial use, log hours of operation to determine proper  
maintenance intervals.  
23  
SERVICING YOUR ENGINE  
REFUELING  
Fuel tank capacities  
GX120: 0.66 US gal (2.5 )  
GX160: 0.95 US gal (3.6 )  
GX200: 0.95 US gal (3.6 )  
With the engine stopped, remove the fuel tank cap 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  
injured when handling fuel.  
Stop the engine and keep heat,  
sparks, and flame away.  
Handle fuel only outdoors.  
Wipe up spills immediately.  
MAXIMUM FUEL LEVEL  
24  
SERVICING YOUR ENGINE  
Refuel in a well-ventilated area before starting the engine. If the engine  
has been running, allow it to cool. Refuel carefully to avoid spilling fuel.  
Do not fill above the fuel strainer shoulder. After refueling, tighten the  
fuel tank cap securely.  
Never refuel the engine inside a building where gasoline fumes may  
reach 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 when  
filling your fuel tank. Damage caused by spilled fuel is not covered  
under warranty.  
FUEL RECOMMENDATIONS  
Use unleaded gasoline with a pump octane rating of 86 or higher.  
These engines are certified to operate on unleaded gasoline. Unleaded  
gasoline produces fewer engine and spark plug deposits and extends  
exhaust 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 no  
cause for concern.  
If spark knock or pinging occurs at a steady engine speed, under  
normal load, change brands of gasoline. If spark knock or pinging  
persists, see an authorized Honda servicing dealer.  
Running the engine with persistent spark knock or pinging can cause  
engine damage.  
Running the engine with persistent spark knock or pinging is  
considered misuse, and the Distributor’s Limited Warranty does not  
cover parts damaged by misuse.  
25  
SERVICING YOUR ENGINE  
ENGINE OIL LEVEL CHECK  
Check the engine oil level with the engine stopped and in a level  
position.  
1. Remove the filler cap/dipstick and wipe it clean.  
2. Insert and remove the dipstick with out screwing it into the filler  
neck. Check the oil level shown on the dipstick.  
3. If the oil level is low, fill to the edge of the oil filler hole with the  
recommended oil (see page 28).  
4. Screw in the filler cap/dipstick securely.  
FILLER CAP/DIPSTICK  
UPPER LIMIT  
LOWER LIMIT  
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 safe limit. However, to avoid  
the inconvenience of an unexpected shutdown, always check the  
engine oil level before startup.  
26  
 
SERVICING YOUR ENGINE  
ENGINE OIL CHANGE  
Drain the used oil while the engine is warm. Warm oil drains quickly  
and completely.  
1. Place a suitable container below the engine to catch the used oil,  
then remove the filler cap/dipstick and the drain plug.  
2. 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 with  
the environment. We suggest you take used oil in a sealed container  
to your local recycling center or service station for reclamation. Do  
not throw it in the trash, pour it on the ground, or down a drain.  
3. With the engine in a level position, fill to the outer edge of the oil  
filler hole with the recommended oil (see page 28).  
Engine oil capacities  
GX120 : 0.59 US qt (0.56 )  
GX160 : 0.63 US qt (0.60 )  
GX200 : 0.63 US qt (0.60 )  
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 the safe limit.  
However, to avoid the inconvenience of an unexpected shutdown,  
fill to the upper limit, and check the oil level regularly.  
4. Screw in the filler cap/dipstick securely.  
FILLER CAP/  
DIPSTICK  
OIL LEVEL  
DRAIN BOLT  
27  
 
SERVICING YOUR ENGINE  
ENGINE OIL RECOMMENDATIONS  
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.  
AMBIENT TEMPERATURE  
The SAE oil viscosity and service classification are in the API label on  
the oil container. Honda recommends that you use API SERVICE  
category SJ oil.  
28  
SERVICING YOUR ENGINE  
AIR FILTER INSPECTION  
Remove the air cleaner cover and inspect the filter. Clean or replace  
dirty filter elements. Always replace damaged filter elements. If  
equipped with an oil-bath air cleaner, also check the oil level.  
Refer to pages 30-32 for instructions that apply to the air cleaner and  
filter on your type of engine.  
PAPER FILTER  
ELEMENT  
FILTER  
FOAM FILTER  
ELEMENT  
STANDERD  
OIL-BATH TYPE  
(see p. 32)  
DUAL-FILTER-  
ELEMENT TYPE  
(see p. 30-31)  
29  
 
SERVICING YOUR ENGINE  
AIR CLEANER SERVICE  
A dirty air filter will restrict air flow to the carburetor, reducing engine  
performance. If you operate the engine in very dusty areas, clean the  
air 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 type  
of damage is not covered by the Distributor’s Limited Warranty.  
Dual-Filter-Element Types  
STANDERD DUAL-FILTER-ELEMENT  
TYPE  
1. Remove the wing nut from the  
air cleaner cover, and remove  
AIR  
CLEANER  
COVER  
the cover.  
2. Remove the wing nut from the  
air filter, and remove the filter.  
PAPER  
3. Remove the foam filter from the  
FILTER  
paper filter.  
ELEMENT  
4. Inspect both air filter elements,  
and replace them if they are  
damaged. Always replace the  
FOAM  
paper air filter element at the  
FILTER  
scheduled interval (see page  
ELEMENT  
23).  
GASKET  
5. Clean the air filter elements if  
they are to be reused.  
30  
 
SERVICING YOUR ENGINE  
Paper air filter element: Tap the filter element several times on a hard  
surface to remove dirt, or blow compressed air [not exceeding 30 psi  
(207 kPa, 2.1 kgf cm2)] through 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 soapy water, rinse, and allow to  
dry thoroughly. Or clean in nonflammable solvent and allow to dry.  
Dip the filter element in clean engine oil, then squeeze out all excess  
oil. The engine will smoke when started if too much oil is left in the  
foam.  
6. Wipe dirt from the inside of the air cleaner base and cover, using a  
moist rag. Be careful to prevent dirt from entering the air duct that  
leads to the carburetor.  
7. Place the foam air filter element over the paper element, and  
reinstall the assembled air filter. Be sure the gasket is in place  
beneath the air filter. Tighten the air filter wing nut securely.  
8. Install the air cleaner cover, and tighten the cover wing nut securely.  
31  
SERVICING YOUR ENGINE  
Oil-Bath Type  
1. Remove the wing nut, and remove the air cleaner cap and cover.  
2. Remove the air filter from the cover, Wash the cover and filter in  
warm, soapy water, rinse, and allow to dry thoroughly. Or clean in  
nonflammable solvent and allow to dry.  
3. Dip the filter in clean engine oil, then squeeze out all excess oil. The  
engine will smoke if too much oil is left in the foam.  
4. Empty the used oil from the air cleaner case, wash out any  
accumulated dirt with nonflammable solvent, and dry the case.  
5. Fill the air cleaner case to the OIL LEVEL mark with the same oil that  
is recommended for the engine (see page28).  
Oil capacity: 2.0 US oz (60 cm )  
6. Reassemble the air cleaner, and tighten the wing nut securely.  
WING  
NUT  
CAP  
AIR  
CLEANER  
COVER  
FILTER  
GRID  
AIR  
CLEANER  
CASE  
OIL LEVEL  
32  
SERVICING YOUR ENGINE  
SEDIMENT CUP CLEANING  
1. 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.  
2. Wash the sediment cup and O-ring in nonflammable solvent, and  
dry them thoroughly.  
3. Place the O-ring in the fuel valve, and install the sediment cup.  
Tighten the sediment cup securely.  
4. Move the fuel valve to the ON position, and check for leaks.Replace  
the O-ring if there is any leakage.  
O-RING  
SEDIMENT CUP  
33  
 
SERVICING YOUR ENGINE  
SPARK PLUG SERVICE  
Recommended spark plugs: BPR6ES (NGK)  
W20EPR-U (DENSO)  
An incorrect spark plug can cause engine damage.  
1. Disconnect the spark plug cap, and remove any dirt from around the  
spark plug area.  
2. Remove the spark plug with a 13/16-inch spark plug wrench.  
SPARK PLUG WRENCH  
3. Inspect the spark plug. Replace it  
if the electrodes are worn, or if the  
insulator is cracked or chipped.  
0.0280.031 in  
(0.700.80 mm)  
4. Measure the spark plug electrode  
gap with a suitable gauge. The  
gap should be 0.0280.031 in  
(0.700.80 mm). Correct the gap,  
if necessary, by carefully bending  
the side electrode.  
5. Install the spark plug carefully, by  
hand, to avoid cross-threading.  
34  
 
SERVICING YOUR ENGINE  
6. After the spark plug seats, tighten with a 13/16-inch spark plug  
wrench to compress the water.  
If reinstalling the used spark plug, tighten 1/81/4 turn after the  
spark plug seat.  
if installing a new spark plug, tighten 1/2 turn after the spark plug  
seats.  
A loose spark plug can overheat and damage the engine.  
Overtightening the spark plug can damage the threads in the  
cylinder head.  
7. Attach the spark plug cap.  
IDLE SPEED ADJUSTMENT  
1. Start the engine outdoors, and allow it to warm up to operating  
temperature.  
2. Move the throttle lever to its slowest position.  
3. Turn the throttle stop screw to obtain the standerd idle speed.  
200  
150  
Standard idle speed: 1,400  
rpm  
THROTTLE STOP SCREW  
35  
 
SERVICING YOUR ENGINE  
SPARK ARRESTER SERVICE (optional equipment)  
Your engine is not factory-equipped with a spark arrester. In some  
areas, it is illegal to operate an engine without a spark arrester. Check  
local laws and regulations. A spark arrester is available from  
authorized Honda servicing dealers.  
The spark arrester must be serviced every 100 hours to keep it  
functioning as designed.  
If the engine has been running, the muffler will be very hot. Allow the  
muffler to cool before servicing the spark arrester.  
1. Remove the three 4 mm screws from the exhust deflector, and  
remove the deflector.  
2. Remove the four 5 mm screws from the muffler protector and  
remove the muffler protector.  
3. Remove the 4 mm screw from the spark arrester, and remove the  
spark arrester from the muffler.  
5 mm SCREWS  
MUFFLER  
PROTECTOR  
EXHAUST  
DEFLECTOR  
4 mm  
SCREWS  
4 mm SCREW  
SPARK  
ARRESTER  
4. Use a brush to remove carbon deposits  
from the spark arrester screen. Be careful  
to avoid damaging the screen.  
SCREEN  
The spark arrester must be free of breaks  
and holes. Replace the spark arrester if it is  
damaged.  
5. Install the spark arrester, muffler protector, and exhaust deflector in  
the reverse order of disassembly.  
36  
 
HELPFUL TIPS & SUGGESTIONS  
STORING YOUR ENGINE  
Storage Preparation  
Proper storage preparation is essential for keeping your engine  
troublefree and looking good. The following steps will help to keep  
rust and corrosion from impairing your engine’s function and  
appearance, and will make the engine easier to start after storage.  
Cleaning  
If the engine has been running, allow it to cool for at least half an hour  
before cleaning. Clean all exterior surfaces, touch up any damaged  
paint, and coat other areas that may rust with a light film of oil.  
Using a garden hose or pressure washing equipment can force  
water into the air cleaner or muffler opening. Water in the air cleaner  
will soak the air filter, and water that passes through the air filter or  
muffler can enter the cylinder, causing damage.  
Water contacting a hot engine can cause damage. If the engine has  
been running, allow it to cool for at least half an hour before  
washing.  
Fuel  
Gasoline will oxidize and deteriorate in storage. Old gasoline will  
cause hard starting, and it leaves gum deposits that clog the fuel  
system. If the gasoline in your engine deteriorates during storage, you  
may need to have the carburetor and other fuel system components  
serviced or replaced.  
The length of time that gasoline can be left in your fuel tank and  
carburetor without causing functional problems will vary with such  
factors as gasoline blend, your storage temperatures, and whether the  
fuel tank is partially or completely filled. The air in a partially filled fuel  
tank promotes fuel deterioration. Very warm storage/temperatures  
accelerate fuel deterioration. Fuel deterioration problems may occur  
within a few months, or even less if the gasoline was not fresh when  
you filled the fuel tank.  
37  
HELPFUL TIPS & SUGGESTIONS  
The Distributor’s Limited Warranty does not cover fuel system  
damage or engine performance problems resulting from neglected  
storage preparation.  
You can extend fuel storage life by adding a fuel stabilizer that is  
formulated for that purpose, or you can avoid fuel deterioration  
problems by draining the fuel tank and carburetor.  
ADDING A FUEL STABILIZER TO EXTEND FUEL STORAGE LIFE  
When adding a fuel stabilizer, fill the fuel tank with fresh gasoline. If  
only partially filled, air in the tank will promote fuel deterioration  
during storage. If you keep a container of gasoline for refueling, be  
sure that it contains only fresh gasoline.  
1. Add fuel stabilizer following the manufacturer’s instructions.  
2. After adding a fuel stabilizer, run the engine outdoors for 10 minutes  
to be sure that treated gasoline has replaced the untreated gasoline  
in the carburetor.  
3. Stop the engine, and move the fuel valve to the OFF position.  
FUEL VALVE  
OFF  
38  
HELPFUL TIPS & SUGGESTIONS  
DRAINING THE FUEL TANK AND CARBURETOR  
1. Place an approved gasoline container below the carburetor, and use  
a funnel to avoid spilling fuel.  
2. Remove the carburetor drain bolt and sediment cup, then move the  
fuel valve lever to the ON position.  
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.  
DRAIN  
BOLT  
SEDIMENT  
CUP  
3. After all the fuel has drain into the container, reinstall the drain bolt  
and sediment cup. Tighten them securely.  
39  
HELPFUL TIPS & SUGGESTIONS  
Engine Oil  
1. Change the engine oil (see page 27).  
2. Remove the spark plugs (see page 34).  
3. Pour a tablespoon (510 cc) of clean engine oil into the cylinder.  
4. Pull the starter rope several times to distribute the oil in the cylinder.  
5. Reinstall the spark plugs.  
6. Pull the starter rope slowly untill resistance is felt and the notch on  
the starter pulley aligns with the hole at the top of the recoil starter  
cover. This will close the valves so moisture cannot enter the engine  
cylinder. Return the starter rope gently.  
Align notch on pulley  
with hole at top of cover.  
Storage Precautions  
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 flame, such as a furnace, water heater, or clothes  
dryer. Also avoid any area with a spark-producing electric motor, or  
where power tools are operated.  
If possible, avoid storage areas with high humidity, because that  
promotes rust and corrosion.  
Unless all fuel has been drained from the fuel tank, leave the fuel valve  
lever in the OFF position to reduce the possibility of fuel leakage.  
40  
HELPFUL TIPS & SUGGESTIONS  
Position the equipment so the engine is level. Tilting can cause fuel 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 plastic as a dust cover. A nonporous cover  
will trap moisture around the engine, promoting rust and corrosion.  
If equipped with a battery for an electric starter (QXE2 type), recharge  
the battery once a month while the engine is in storage.  
This will help to extend the service life of the battery.  
Removal From Storage  
Check your engine as described in the BEFORE OPERATION chapter of  
this manual.  
If the fuel was drained during storage preparation, fill the tank with  
fresh gasoline. If you keep a container of gasoline for refueling, be  
sure that it contains only fresh gasoline. Gasoline oxidizes and  
deteriorates over time, causing hard starting.  
If the cylinders were coated with oil during storage preparation, the  
engine may smoke briefly at startup. This is normal.  
41  
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 transport  
vehicle. A hot engine and exhaust system can burn you and can ignite  
some materials.  
Keep the engine level when transporting to reduce the possibility of  
fuel leakage. Move the fuel valve lever to the OFF position.  
42  
TAKING CARE OF UNEXPECTED PROBLEMS  
ENGINE WILL NOT  
START  
Possible Cause  
Correction  
QXE2 electric  
starting: Check  
battery and fuse.  
Check control  
positions.  
Battery discharged.  
Fuse burnt out.  
Recharge battery.  
Replace fuse (p. 44).  
1.  
Fuel valve OFF.  
Choke OPEN.  
Move lever to ON.  
Move lever to CLOSED  
unless engine is warm.  
Turn engine switch to  
ON.  
2.  
Engine switch OFF.  
Check fuel.  
Out of fuel.  
Refuel (p. 24).  
3.  
4.  
Bad fuel; engine  
stored without treating  
or draining gasoline,  
or refueled with bad  
gasoline.  
Spark plugs faulty,  
fouled, or improperly  
gapped.  
Drain fuel tank and  
carburetor (p. 39).  
Refuel with fresh  
gasoline.(p. 24)  
Remove and  
inspect spark plugs.  
Gap, or replace spark  
plugs (p. 34).  
Spark plugs wet with  
fuel (flooded engine).  
Dry and reinstall spark  
plugs. Start engine  
with throttle lever  
in FAST position.  
Replace or repair  
faulty components as  
necessary.  
Take engine to an  
authorized Honda  
servicing dealer, or  
refer to shop manual.  
Fuel filter clogged,  
carburetor malfunction,  
ignition malfunction,  
valves stuck, etc.  
5.  
ENGINE LACKS  
POWER  
Possible Cause  
Correction  
Check air filter.  
Filter element(s)  
clogged.  
Clean or replace filter  
element(s) (p. 30-32).  
Drain fuel tank and  
carburetor (p. 39).  
Refuel with fresh  
1.  
Check fuel.  
Bad fuel; engine  
stored without treating  
or draining gasoline,  
or refueled with bad  
gasoline.  
2.  
gasoline (P. 24).  
Take engine to an  
authorized Honda  
servicing dealer, or  
refer to shop manual.  
Fuel filter clogged,  
carburetor malfunction,  
ignition malfunction,  
valves stuck, etc.  
Replace or repair  
faulty components as  
necessary.  
3.  
43  
TAKING CARE OF UNEXPECTED PROBLEMS  
FUSE REPLACEMENT (QXE2 type only)  
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 manually if the fuse burns  
out, but running the engine will not charge the battery.  
1. Remove the 6 × 12 mm screw from the rear cover of the engine  
switch box.  
2. Remove the fuse cover, and inspect the fuse.  
If the fuse is burnt out, remove the fuse cover, then pull out and  
discard the burnt-out fuse. Install a new 5-ampere fuse, and reinstall  
the fuse cover.  
Never use a fuse with a rating greater than 5 amperes. Serious  
damage to the electrical system or a fire could result.  
3. Reinstall the rear cover. Install the 6 × 12 mm screw and tighten it  
securely.  
ENGINE SWITCH  
REAR COVER  
FUSE  
COVER  
6 ×12 mm  
SPECIAL SCREW  
5 A FUSE  
Frequent fuse failure usually indicates a short circuit or an overload in  
the electrical system. If the fuse burns out frequently, take the engine  
to a servicing Honda dealer for repair.  
44  
TECHNICAL & CONSUMER INFORMATION  
TECHNICAL INFORMATION  
Serial Number Location  
ELECTRIC  
STARTER  
(QXE2 type  
only)  
SERIAL NUMBER  
& ENGINE TYPE  
Record the engine serial number in the space below. You will need this  
serial number when ordering parts, and when making technical or  
warranty inquires (see page 58 ).  
Engine serial number:  
45  
TECHNICAL & CONSUMER INFORMATION  
Battery Connections for Electric Starter (QXE2 type only)  
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 will  
short circuit the battery charging system. Always connect the positive  
() battery cable to the battery terminal before connecting the  
negative () battery cable, so your tools cannot cause a short circuit if  
they touch a grounded part while tightening the positive () battery  
cable end.  
A battery can explode if you do not  
follow the correct procedure,  
seriously injuring anyone nearby.  
Keep all sparks, open flames, and  
smoking materials away from the  
battery.  
1. Connect the battery positive () cable to the starter solenoid  
terminal as shown.  
2. Connect the battery negative () cable to an engine mounting bolt,  
frame bolt, or other good engine ground connection.  
3. Connect the battery positive () cable to the battery positive ()  
terminal as shown.  
4. Connect the battery negative () cable to the battery negative ()  
terminal as shown.  
5. Coat the terminals and cable ends with grease.  
NEGATIVE ()  
BATTERY CABLE  
STARTER  
SOLENOID  
POSITIVE () BATTERY CABLE  
46  
TECHNICAL & CONSUMER INFORMATION  
Remote Control Linkage  
The throttle and choke control levers are provided with holes for  
optional cable attachment. The following illustrations show  
installation examples for a solid wire cable and for a flexible, braided  
wire cable. If using a flexible, braided wire cable, add a return spring  
as shown.  
It is necessary to loosen the throttle lever friction nut when operating  
the throttle with a remotely-mounted control.  
REMOTE THROTTLE LINKAGE  
THROTTLE LEVER  
PIVOT NUT  
RETURN  
SPRING  
Flexible wire core  
mounting  
4 mm SCREW  
WIRE  
WIRE HOLDER  
OPTIONAL  
THROTTLE  
LEVER  
5 mm  
CIRCLIP  
Solid wire core  
mounting  
REMOTE CHOKE LINKAGE  
WIRE HOLDER  
CHOKE LEVER  
47  
TECHNICAL & CONSUMER INFORMATION  
Carburetor Modification 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 altitude that differs from that at which this engine was  
certified, for extended periods of time, may increase emissions.  
High altitude performance can be improved by specific modifications  
to the carburetor. If you always operate your engine at altitudes above  
5,000 feet (1,500 meters), have your servicing dealer perform this  
carburetor modification. This engine, when operated at high altitude  
with the carburetor modifications for high altitude use, will meet each  
emission standard throughout its useful life.  
Even with carburetor modification, engine horsepower will decrease  
about 3.5% for each 1,000-foot (300-meter) increase in altitude. The  
effect of altitude on horsepower will be greater than this if no  
carburetor modification is made.  
When the carburetor has been modified for high altitude operation,  
the air-fuel mixture will be too lean for low altitude use. Operation at  
altitudes below 5,000 feet (1,500 meters) with a modified carburetor  
may cause the engine to overheat and result in serious engine damage.  
For use at low altitudes, have your servicing dealer return the  
carburetor to original factory specifications.  
48  
TECHNICAL & CONSUMER INFORMATION  
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 you use an oxygenated fuel, be sure it is unleaded and meets the  
minimum 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 the  
pump.  
The following are the EPA approved percentages of oxygenates:  
ETHANOL ––––––––(ethyl or grain alcohol) 10% by volume  
You may use gasoline containing up to 10%  
ethanol by volume. Gasoline containing ethanol  
may be marketed under the name ‘‘Gasohol’’.  
MTBE ––––––––––––(methyl tertiary butyl ether) 15% by volume  
You may use gasoline containing up to 15% MTBE  
by volume.  
METHANOL ––––––(methyl or wood alcohol) 5% by volume  
You may use gasoline containing up to 5%  
methanol by volume, as long as it also contains  
cosolvents and corrosion inhibitors to protect the  
fuel system. Gasoline containing more than 5%  
methanol by volume may cause starting and/or  
performance problems. It may also damage metal,  
rubber, and plastic parts of your fuel system.  
If you notice any undesirable operating symptoms, try another service  
station, or switch to another brand of gasoline.  
Fuel system damage or performance problems resulting from the use  
of an oxygenated fuel containing more than the percentages of  
oxygenates mentioned above are not covered under warranty.  
49  
TECHNICAL & CONSUMER INFORMATION  
Emission Control System Information  
Source of Emissions  
The combustion process produces carbon monoxide, oxides of  
nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of  
nitrogen is very important because, under certain conditions, they  
react to form photochemical smog when subjected to sunlight. Carbon  
monoxide does not react in the same way, but it is toxic.  
Honda utilizes lean carburetor settings and other systems to reduce  
the emissions of carbon monoxide, oxides of nitrogen and  
hydrocarbons.  
The U.S. and California Clean Air Acts  
EPA and California regulations require all manufacturers to furnish  
written instructions describing the operation and maintenance of  
emission control systems.  
The following instructions and procedures must be followed in order  
to keep the emissions from your Honda engine within the emission  
standards.  
Tampering and Altering  
Tampering with or altering the emission control system may increase  
emissions beyond the legal limit. Among those acts that constitute  
tampering are:  
Removal or alteration of any part of the intake, fuel or exhaust  
systems.  
Altering or defeating the governor linkage or speed-adjusting  
mechanism to cause the engine to operate outside its design  
parameters.  
50  
TECHNICAL & CONSUMER INFORMATION  
Problems That May Affect Emissions  
If you are aware of any of the following 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 exhaust smoke or high fuel consumption.  
Replacement Parts  
The emission control systems on your Honda engine were designed,  
built, and certified to conform with EPA and California emission  
regulations. We recommend the use of genuine Honda parts  
whenever you have maintenance done. These original-design  
replacement parts are manufactured to the same standards as the  
original parts, so you can be confident of their performance. The use  
of replacement parts that are not of the original design and quality  
may impair the effectiveness of your emission control system.  
A manufacturer of an aftermarket part assumes the responsibility that  
the part will not adversely affect emission performance. The  
manufacturer or rebuilder of the part must certify that use of the part  
will not result in a failure of the engine to comply with emission  
regulations.  
Maintenance  
Follow the maintenance schedule on page 23. Remember that this  
schedule is based on the assumption that your machine will be used  
for its designed purpose. Sustained high-load or high-temperature  
operation, or use in unusually wet or dusty conditions, will require  
more frequent service.  
51  
TECHNICAL & CONSUMER INFORMATION  
Air Index  
An Air Index Information hang tag/label is applied to engines certified  
to an emission durability time period in accordance with the  
requirements of the California Air Resources Board.  
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 durability period. The descriptive  
term indicates the useful-life period for the engine’s emission control  
system. See your Emission Control Warranty for additional  
information.  
Descriptive Term  
Moderate  
Applicable to Emissions Durability Period  
50 hours (065 cc)  
125 hours (greater than 65 cc)  
Intermediate  
Extended  
125 hours (065 cc)  
250 hours (greater than 65 cc)  
300 hours (065 cc)  
500 hours (greater than 65 cc)  
The Air Index Information hang tag must remain on the engine until it  
is sold. Remove the hang tag before operating the engine.  
52  
TECHNICAL & CONSUMER INFORMATION  
Specifications  
GX 120  
Length × Width × Height  
Dry weight  
11.7 × 13.4 × 12.5 in (297 × 341 × 318 mm)  
28.7 lbs (13.0 kg)  
Engine type  
4-stroke, overhead valve, single cylinder  
7.2 cu-in (118 cm )  
Displacement  
[Bore × Stroke]  
Max. output  
[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  
0.51 lb/hph (313 g/kWh, 230 g/PSh)  
Forced air  
Max. torque  
Fuel consumption  
Cooling system  
Ignition system  
PTO shaft rotation  
Transistorized magneto  
Counterclockwise  
GX 160  
Length × Width × Height  
Dry weight  
12.0 × 14.3 × 13.2 in (304 × 362 × 335 mm)  
33.1 lbs (15.0 kg)  
Engine type  
Displacement  
4-stroke, overhead valve, single cylinder  
9.9 cu-in (163 cm )  
[Bore × Stroke]  
Max. output  
Max. torque  
Fuel consumption  
Cooling system  
Ignition system  
PTO shaft rotation  
[2.7 × 1.8 in (68 × 45 mm)]  
5.4 bhp (4.0 kW, 5.5 PS) at 3,600 rpm  
8.0 lbf·ft (10.8 N·m, 1.1 kgf·m) at 2,500 rpm  
0.51 lb/hph (313 g/kWh, 230 g/PSh)  
Forced air  
Transistorized magneto  
Counterclockwise  
53  
TECHNICAL & CONSUMER INFORMATION  
GX200  
Length × Width × Height  
Dry weight  
12.3 × 14.8 × 13.2 in (313 × 376 × 335 mm)  
35.3 lbs (16.0 kg)  
Engine type  
Displacement  
4-stroke, overhead valve, single cylinder  
12.0 cu-in (196 cm )  
[Bore × Stroke]  
Max. output  
Max. torque  
Fuel consumption  
Cooling system  
Ignition system  
PTO shaft rotation  
[ 2.7 × 2.1 in (68 × 54 mm)]  
6.5 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  
0.51 lb/hph (313 g/kWh, 230 g/PSh)  
Forced air  
Transistorized magneto  
Counterclockwise  
GX120/GX160/GX200 Tuneup  
ITEM  
SPECIFICATION  
MAINTENANCE  
Spark plug gap  
0.0280.031 in  
Refer to page: 34  
(0.700.80 mm)  
Valve clearance  
IN: 0.15±0.02 mm (cold)  
EX: 0.20±0.02 mm (cold)  
See your authorized  
Honda dealer  
Other specifications  
No other adjustments needed.  
54  
TECHNICAL & CONSUMER INFORMATION  
Wiring Diagrams  
QXE2 Type with Oil Alert and Electric Starter  
55  
TECHNICAL & CONSUMER INFORMATION  
Engine Type With Oil Alert and Without Electric Starter  
56  
TECHNICAL & CONSUMER INFORMATION  
CONSUMER INFORMATION  
Honda Publications  
These publications will give you additional information for  
maintaining and repairing your engine. You may order them from  
your Honda engine dealer.  
Shop Manual  
This manual covers complete maintenance and overhaul procedures.  
It is intended to be used by a skilled technician.  
Parts Catalog  
This manual provides complete, illustrated parts lists.  
57  
TECHNICAL & CONSUMER INFORMATION  
Warranty Service Information  
Servicing dealership personnel are trained professionals. They should  
be able to answer any questions you may have. If you encounter a  
problem that your dealer does not solve to your satisfaction, please  
discuss it with the dealership’s management. The Service Manager or  
General Manager can help. Almost all problems are solved in this way.  
If you are dissatisfied with the decision made by the dealership’s  
management, contact the Honda Power Equipment Customer  
Relations Office. You can write to:  
American Honda Motor Co., Inc.  
Power Equipment Division  
Customer Relations Office  
4900 Marconi Drive  
Alpharetta, Georgia 30005-8847  
Or telephone: (770) 497-6400  
When you write or call, please give us this information:  
Model and serial number (see page 45 )  
Name of dealer who sold the engine to you  
Name and address of dealer who services your engine  
Date of purchase  
Your name, address and telephone number  
A detailed description of the problem  
58  
MEMO  
59  
MEMO  
60  
QUICK REFERENCE INFORMATION  
Fuel  
Type  
Unleaded gasoline with a pump  
octane rating of 86 or higher  
(page 25)  
Capacity  
GX120:  
0.66 US gal (2.5 )  
GX160 & GX200:  
0.95 US gal (3.6 )  
SAE 10W-30, API SJ, for general  
use (page 28)  
Engine Oil  
Spark Plug  
Type  
Capacity  
GX120:  
0.59 US qt (0.56 )  
GX160 & GX200:  
0.63 US qt (0.60 )  
NGK: BPR6ES  
Type  
Gap  
DENSO: W20EPR-U  
0.0280.031 in (0.700.80 mm)  
(page 34)  
200  
150  
Carburetor  
Maintenance  
Idle speed  
Each use  
1,400  
rpm (page 35)  
Check engine oil level.  
Check air filter.  
First 20 hours  
Subsequent  
Change engine oil.  
Refer to the maintenance  
schedule on page 23.  
 
T1:GX120•GX160•GX200  
70000.2002.12  
PRINTED IN THAILAND  
31Z0T600  
00X31-Z0T-6000  
2eY1  
N
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