Honda FG110 Manual Download

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FG110

Date of Issue: February, 2005
© American Honda Motor Co., Inc.

8-1

8. CAM PULLEY/CYLINDER HEAD

COVER/LOWER CRANKCASE

1. CAM PULLEY/CYLINDER HEAD COVER

a. DISASSEMBLY/REASSEMBLY

1. CAM PULLEY/CYLINDER HEAD COVER

. . . .

8-1

2. LOWER CRANKCASE

. . . . . . . . . . . . . . . . . . . .

8-4

1. Remove the top cover

(P. 6-1)

2. Remove the recoil starter

(P. 5-1)

3. Remove the fuel tank

(P. 5-6)

5 x 12 mm
SOCKET BOLT (2)

BREATHER
FILTER

HEAD COVER SEAL

HEAD COVER

4 x 12 mm SELF-
TAPPING SCREW (2)

HEAD COVER GROMMET

HEAD INNER COVER

INSPECTION:

P. 8-3

CAM PULLEY SHAFT

CAM PULLEY

TIMING BELT

INSTALLATION:

Check that the belt is not worn
or cracked and do not bend or
twist the belt.



Summary of Contents for FG110

Page 1: ...ty equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and...

Page 2: ...afety information throughout this manual Of course it is not practical or possible to warn you about all the hazards associated with servicing this tiller You must use your own good judgement You will...

Page 3: ...Date of Issue February 2005 American Honda Motor Co Inc...

Page 4: ...out wheels 13 0 kg 28 8 lbs 11 3 kg 24 9 lbs Dry with wheels 13 9 kg 30 6 lbs 12 2 kg 26 8 lbs Wet with wheels 14 5 kg 31 9 lbs 12 6 kg 27 8 lbs Minimum ground clearance 47 mm 1 9 in Tilling width 230...

Page 5: ...rication system Oil mist Oil capacity 80 cc 2 7 US oz 2 8 Imp oz Recommended operating ambient temperature 5 C 40 C 23 F 104 F Starting system Recoil starter Stopping system Ignition primary circuit g...

Page 6: ...Date of Issue February 2005 American Honda Motor Co Inc 1 3 FG110 2 WIRING DIAGRAM GROUND IGNITION SWITCH GROUND GROUND SPARK PLUG IGNITION COIL BLACK BLACK GREEN...

Page 7: ...Date of Issue February 2005 1 4 American Honda Motor Co Inc FG110 NOTES...

Page 8: ...te sliding surfaces before reassembly After reassembly check parts installation and operation 2 SYMBOLS USED IN THIS MANUAL As you read this manual you may find the following symbols with the instruct...

Page 9: ...TIONS The engine serial number is located on the cylinder block near the carburetor Refer to the engine serial number when ordering parts and when making technical inquiries The frame serial number is...

Page 10: ...0 0362 in 0 120 mm 0 0047 in 0 60 mm 0 024 in Connecting rod Small end I D 7 978 7 989 mm 0 3141 0 3145 in Valves Valve clearance cold IN EX Stem OD IN EX Guide ID IN EX Stem to guide clearance IN EX...

Page 11: ...te M4 3 0 0 3 2 2 Ignition coil M4 3 9 0 4 2 9 Recoil starter pulley M6 6 4 0 7 5 1 Flywheel M7 14 7 1 49 10 8 Valve adjusting lock nut M5 4 9 0 5 3 6 Spark plug M10 11 8 1 2 8 7 Transmission M6 CT 10...

Page 12: ...ITEM TOOL NAME TOOL NUMBER APPLICATION Piston base 07VPF ZM3010B Piston pin removal installation Push rod 07VPF ZM3020A Guide 07VPF ZM3030A Piston pin installation Rocker arm replacement tool 070PF Z0...

Page 13: ...incorrect IGNITION COIL faulty SPARK PLUG faulty Engine lacks power SPARK PLUG faulty AIR CLEANER clogged VALVE CLEARANCE incorrect Inspect P 2 11 Inspect P 3 9 Inspect P 3 9 Readjust P 3 8 Disassembl...

Page 14: ...ogged Inspect P 3 5 Clean P 3 4 Poor performance at low speed CARBURETOR clogged AIR CLEANER clogged SPARK PLUG faulty Readjust P 3 8 Disassemble clean P 4 3 Clean P 3 4 Inspect P 3 5 Readjust P 3 7 V...

Page 15: ...procedure Check for correct valve clearance P 3 7 Check for defective valves P 9 5 Check for worn piston piston rings or cylinder P 9 6 Check for blockage of the fuel line or filter P 3 9 Check for l...

Page 16: ...P 2 11 Start the engine according to the starting procedure Adjust the plug gap replace if chipped cracked or fouled P 3 5 Straighten the fuel tube if it is bent or pinched Replace if necessary P 3 9...

Page 17: ...carburetor insulator Check inside the carburetor for abnormalities such as hard or stiff diaphragms P 4 3 Check for a plugged spark arrester Start the engine according to the starting procedure Adjust...

Page 18: ...ter to check for sparks f COMPRESSION TEST 1 Drain the fuel tank 2 Drain the gasoline by pressing the carburetor primer bulb 3 Remove the spark plug cap and spark plug and install a compression gauge...

Page 19: ...O O Fuel line clogged O O O O O O O Air in fuel passage O O O O O O O Incorrect deteriorated fuel O O O Pump diaphragm Vacuum pulse leaking O O Vacuum pulse passage clogged O O Loose pump cover screw...

Page 20: ...EANING 3 9 6 VALVE CLEARANCE ADJUSTMENT 3 7 12 TRANSMISSION LUBRICATION 3 10 REGULAR SERVICE PERIOD 3 ITEM Perform at every indicated month or operating hour interval whichever comes first Before each...

Page 21: ...cap dipstick securely 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 2 Remove the oi...

Page 22: ...ndition 4 If the air filter is dirty clean it as described under Air Filter Cleaning see P 3 4 Replace the air filter if it is damaged NOTICE Operating the engine without an air filter or with a damag...

Page 23: ...a Air Filter Oil into the bag Seal the bag closed and knead the bag for one minute or longer until the oil is completely distributed into the foam filter Squeeze excess oil from the filter 4 Remove th...

Page 24: ...the gap if necessary by carefully bending the side electrode 7 Make sure the sealing washer is attached and install the spark plug carefully by hand to avoid cross threading 8 After the spark plug sea...

Page 25: ...remove the fan cover 2 Remove the 3 x 6 mm self tapping screw from the spark arrester and remove the spark arrester from the muffler 3 Use a brush to remove carbon deposits from the spark arrester sc...

Page 26: ...e cam pulley with the cylinder head center 4 Insert a feeler gauge between the rocker arm and valve to measure the valve clearance 5 If adjustment is necessary a Loosen the adjusting screw lock nut an...

Page 27: ...Lever Free play 5 8 mm 3 16 5 16 inch If adjustment is needed use the Throttle Cable Adjustment procedure below 9 CARBURETOR ADJUSTMENT A tachometer is required to adjust the idle speed 1 Start the en...

Page 28: ...per clip 4 Inspect the fuel filter If the fuel filter is dirty wash it with nonflammable solvent Be careful to avoid damaging the filter 5 Replace the filter if it is damaged or excessively dirty 6 Ri...

Page 29: ...om the transmission case 5 Fill the transmission by using a grease gun or grease applicator at the fill hole screw opening Push the gun or applicator against the opening so as to seal the nozzle of th...

Page 30: ...CLEANER REMOVAL INSTALLATION 4 1 2 CARBURETOR REMOVAL INSTALLATION 4 2 AIR CLEANER HOUSING REASSEMBLY Before installation clean inside the case with compressed air BREATHER TUBE REASSEMBLY Before inst...

Page 31: ...aging the engine 1 Remove the top cover P 6 1 2 Remove the air cleaner P 4 1 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat spar...

Page 32: ...with compressed air before installation Replace the main jet if it is corroded MAIN JET NUMBER 34 O RING CARBURETOR BODY REASSEMBLY Blow compressed air through the main jet passage to clean the passag...

Page 33: ...r assembly check for any sign of fuel leakage METERING LEVER PIN PRIMER BULB COVER METERING LEVER SPRING PUMP BODY REASSEMBLY Wash the passage with nonflammable solvent to remove dust and other foreig...

Page 34: ...ering lever metering lever pin and the metering lever pin screw on the pump body P 4 4 2 Measure the gap between the metering lever surface and the pump body surface 3 If the measurement is outside th...

Page 35: ...Date of Issue February 2005 4 6 American Honda Motor Co Inc FG110 NOTES...

Page 36: ...rican Honda Motor Co Inc 5 1 5 RECOIL STARTER STARTER PULLEY FUEL TANK 1 RECOIL STARTER a REMOVAL INSTALLATION 1 RECOIL STARTER 5 1 3 FUEL TANK REMOVAL INSTALLATION 5 6 2 STARTER PULLEY 5 5 RECOIL STA...

Page 37: ...e return spring to come out RECOIL STARTER ROPE REASSEMBLY Check the rope for fraying or wearing before installation SWING ARM COLLAR SET SCREW SWING ARM RECOIL STARTER REEL RECOIL STARTER HANDLE RECO...

Page 38: ...starter rope through the starter reel and tie the rope so that it can be untied easily by pulling it as shown 4 Wind the starter rope around the recoil starter reel in the direction of the arrow 5 In...

Page 39: ...e starter handle and tie the rope so that it can be untied easily by pulling it as shown 9 Secure the starter reel with the set screw Make sure to align the projection of the swing arm collar and swin...

Page 40: ...ulley with a driver or equivalent tool and loosen the flywheel with a 10 mm wrench b REASSEMBLY 1 Hold the recoil starter pulley with a driver or equivalent tool and tighten the flywheel to the specif...

Page 41: ...r deterioration before installation and replace if necessary Verify that the tube is not kinked in the tank FUEL FILTER CLEANING P 3 9 TUBE CLIP 2 FUEL RETURN TUBE FUEL TANK CAP RECOIL STARTER ASSEMBL...

Page 42: ...c 6 1 6 TOP COVER MUFFLER 1 TOP COVER a REMOVAL 1 Loosen the 5 mm captive cover bolt 2 Slide the cover off the engine b INSTALLATION 1 Slide the cover onto the engine 2 Tighten the 5 mm captive cover...

Page 43: ...muffler and air exhaust guide on the two studs Do not tap on the muffler seal flange or you will damage it If the seal flange is dented or damaged replace the muffler 3 Install the two 5 mm self lock...

Page 44: ...Motor Co Inc 7 1 7 IGNITION COIL CLUTCH SHOE FLYWHEEL 1 IGNITION COIL a ASSEMBLY DISASSEMBLY 1 IGNITION COIL 7 1 3 FLYWHEEL 7 6 2 CLUTCH ASSEMBLY 7 4 IGNITION COIL INSPECTION P 7 3 ADJUSTMENT P 7 3 4...

Page 45: ...p switch wire and the other tester lead to the iron core 2 Measure the primary resistance of the ignition coil SECONDARY RESISTANCE 1 Attach one lead of the tester to the terminal inside the spark plu...

Page 46: ...agnets with the ignition coil 3 Insert a feeler gauge between the ignition coil and the magnets on the flywheel 4 Push the ignition coil firmly toward the flywheel and tighten the bolts 5 Adjust the c...

Page 47: ...P 7 6 Take care not to break or bend the fins during disassembly or reassembly 7 mm FLANGE NUT 14 7 N m 1 49 kgf m 10 7 lbf ft 5 x 20 mm SOCKET BOLT 3 6 4 N m 0 7 kgf m 4 6 lbf ft FAN COVER CLUTCH AS...

Page 48: ...CLUTCH REASSEMBLY 1 Install the clutch assembly so that the mark is visible as shown 2 Set the clutch washer between the clutch assembly and the flywheel 3 Hold the flywheel with a commercially availa...

Page 49: ...lywheel 3 Remove the flywheel using a commercially available flywheel puller b REASSEMBLY 1 Clean the tapered portion of the crankshaft of dirt oil grease and other foreign material 2 Install the flyw...

Page 50: ...VER 8 1 2 LOWER CRANKCASE 8 4 1 Remove the top cover P 6 1 2 Remove the recoil starter P 5 1 3 Remove the fuel tank P 5 6 5 x 12 mm SOCKET BOLT 2 BREATHER FILTER HEAD COVER SEAL HEAD COVER 4 x 12 mm S...

Page 51: ...r bolt hole Also the cam pulley alignment marks will be positioned as shown 4 Push the cam pulley shaft out from the valve spring side using a pin approximately 2 mm in diameter 5 Remove the timing be...

Page 52: ...8 3 FG110 d CYLINDER HEAD INNER COVER INSPECTION Check the oil return passages of the cylinder head inner cover for restrictions If they are restricted clean with compressed air Arrows in this diagra...

Page 53: ...ATION Install the valve aligning the chamfer and projections CHAMFER PROJECTIONS 12 3 x 2 4 mm O RING 5 x 16 mm SOCKET BOLT 3 SHROUD REASSEMBLY Clean the socket bolt threads and apply liquid sealant L...

Page 54: ...kcase from the cylinder block c OIL OUTLET VALVE DISASSEMBLY 1 Remove the two 4 x 8 mm screws and oil outlet valve assembly 2 Remove the 3 x 5 mm screw stopper plate oil outlet valve and oil outlet va...

Page 55: ...3 minutes after applying the liquid gasket 4 Loosely tighten each of the two 5 x 20 mm and the four 5 x 30 mm socket bolts 5 Tighten the socket bolts in the numbered sequence shown in the diagram TORQ...

Page 56: ...12 x 24 x 5 mm OIL SEAL PISTON INSPECTION P 9 2 REASSEMBLY P 9 2 Install with the mark on the piston head facing the carburetor side CRANKSHAFT REASSEMBLY P 9 4 PISTON PIN DISASSEMBLY P 9 2 REASSEMBLY...

Page 57: ...the connecting rod small end is securely set in the cutout of the piston base special tool 3 Remove the piston pin from the connecting rod using a hydraulic press TOOLS Piston base 07VPF ZM3010B Push...

Page 58: ...ting rod small end is securely set in the cutout of the piston base special tool 5 Press fit the piston pin into the connecting rod using a hydraulic press Press in the piston pin until the piston pin...

Page 59: ...3 Apply a bead of liquid gasket to the cylinder block specifically to the mating surface of the crankcase cover 4 Install the crankcase cover on the cylinder block P 8 6 5 Install the cam pulley and...

Page 60: ...nto the cylinder REMOVAL Push down and slide the retainer to the side so the valve stem slips through the hole at the slide of the retainer Viewed from clutch side REMOVAL INSTALLATION P 9 11 Do not i...

Page 61: ...irt and 90 to the piston pin bore PISTON TO CYLINDER CLEARANCE PISTON RING WIDTH PISTON RING SIDE CLEARANCE When any piston ring exceeds the service limit replace all the piston rings as a set Standar...

Page 62: ...he piston rings as a set PISTON PIN O D PISTON PIN BORE I D PISTON PIN TO PISTON PIN BORE CLEARANCE CONNECTING ROD SMALL END I D Standard Service limit Top Second 0 10 0 25 mm 0 004 0 010 in 0 60 mm 0...

Page 63: ...FREE LENGTH Measure the free length of the valve spring Replace the springs if they are shorter than the service limit Standard Service limit 22 097 mm 0 8700 in 21 797 mm 0 8581 in Standard Service...

Page 64: ...uide I D 2 Replace the cylinder block if the measurement exceeds the service limit VALVE STEM TO GUIDE CLEARANCE For each valve stem subtract the O D from the corresponding guide I D to obtain the val...

Page 65: ...ner wall of the cylinder 2 Insert the thick paper into the cylinder to protect the cylinder wall during combustion chamber cleaning 3 Attach a commercially available combustion chamber cleaning brush...

Page 66: ...3 Tighten the push rod 1 of the special tool by hand until the tip of the push rod comes to the center of the valve lifter shaft 2 Move the special tool left and right and check that it can be moved...

Page 67: ...de before installation Do not interchange them Check the rocker arm for IN or EX marks before installation Do not interchange them 2 Set the projection 1 of the valve lifter 2 in contact with the inst...

Page 68: ...d B 5 to be equal by moving the valve lifter and rocker arm right and left While holding the valve lifter and rocker arm in the position tighten the holder bolt 6 by hand until it contacts the valve l...

Page 69: ...mm 4 and then remove the special tool 8 Measure the clearance between the rocker arm and the cylinder head and make sure if the clearance are within the specification If the clearance is over the spec...

Page 70: ...R ENGINE STOP SWITCH THROTTLE LEVER ASSEMBLY 3 x 12 mm PAN SCREW 3 mm SPRING WASHER 3 mm PLAIN WASHER HANDLE GRIP 2 UPPER HANDLE PIPE HANDLE JOINT GRIP 2 FRAME JOINT WASHER 6 CABLE TIES 2 HANDLE HOLDE...

Page 71: ...ontinuity between the engine stop switch wires There should be continuity when the switch is in the OFF position There should be no continuity when the switch is in the ON position 3 TINES a DISASSEMB...

Page 72: ...slide onto the tine shaft in the order shown in the diagram above Do not force the tines onto the shaft 2 Install the lock pins through the tine shaft round side hole a then rotate the pin b to lock...

Page 73: ...Honda Motor Co Inc FG110 4 FENDER WHEELS ASSEMBLY DISASSEMBLY FG110 12 7 mm PUSH NUT 2 WHEEL 2 WHEEL BAR DRAG BAR 13 x 27 x 1 mm THRUST WASHER 2 LOCK PIN 6 35 mm LOCK PIN FRONT FENDER REAR FENDER 6 x...

Page 74: ...PUSH NUT 2 WHEEL 2 DRAG BAR LOCK PIN 6 x 177 5 mm HEX BOLT 2 FENDER COLLAR 4 6 mm NYLOCK NUT 2 FENDER 6 35 mm LOCK PIN LINCHPIN WHEEL BAR WHEEL SHAFT TORQUE 10 N m 7 ft lb Torque must not crush frame...

Page 75: ...on the unit can be stored upright It can also be transported over smooth ground or pavement When in the transport position the unit can be transported over rough ground This position also prevents the...

Page 76: ...transmission the driveshaft bushing will be damaged RADIAL BALL BEARING DRIVE GEAR 10 x 24 mm WASHER DRIVESHAFT BUSHING TINE SHAFT RADIAL BALL BEARING 2 LEFT TRANSMISSION CASE 17 x 40 x 8 mm OIL SEAL...

Page 77: ...E TRANSMISSION HALVES 1 Remove the eleven 6 x 23 mm flange bolts 2 Place a screwdriver or similar tool in each of the two recesses between the transmission halves 3 Pry the transmission halves apart c...

Page 78: ...ant from both halves of the transmission case 6 Clean the mating halves of the transmission case using a degreasing agent and a clean shop towel 7 Apply a thin bead of liquid gasket Hondabond 4 Three...

Page 79: ...Date of Issue February 2005 11 4 American Honda Motor Co Inc FG110...

Page 80: ...7 6 Fender Installation Removal 10 4 Flywheel Assembly Disassembly 7 6 Fuel 1 2 Fuel filter 5 6 Fuel return tube 5 6 Fuel tank Installation Removal 5 6 G Gear 11 1 Grass guard 11 2 Grease 3 10 H Hand...

Page 81: ...ter service 3 6 Spark plug service 3 5 Special tools 2 5 Specifications Dimensions 1 1 Engine 1 2 Service 2 3 Starter reel 5 3 Symbols 2 1 T Throttle lever cable inspection 3 8 Throttle stop screw 4 3...

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