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Honda GX120UT2, Manual

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Honda GX120UT2 Manual Download Page 36

2-7

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SERVICE INFORMATION

LUBRICATION & SEAL POINTS

Material

Location

Remarks

Engine oil

Crankshaft pin and gear teeth
Piston outer surface, ring groove and piston pin hole
Piston pin outer surface
Piston ring entire surface
Cylinder inner surface
Connecting rod big and small end bearing
Connecting rod bolt threads and seating surface
Camshaft cam profile and journal
Valve lifter pivot, pivot end and slipper surface
Valve stem sliding surface and stem end
Valve rocker arm tappet surface and pivot
Rocker arm pivot threads and pivot
Flywheel nut threads and seating surface
Governor weight holder gear and sliding surface
Governor holder shaft journal
Governor arm shaft journal
Cylinder head bolt threads and seating surface
P.T.O. shaft gear teeth and journal

Reduction unit (gear type)

Drive sprocket, P.T.O. shaft gear teeth and journal

Reduction unit (chain type: 

without clutch)

Drive sprocket, P.T.O. shaft, clutch center gear teeth 

and journal

Reduction unit (chain type: 

with clutch)

Clutch disc, clutch plate entire surface

Multi-purpose grease

Oil seal lips
Control lever sliding surface
Recoil starter case pulley sliding surface
Recoil starter ratchet sliding surface
Recoil starter spring retainer inside

Use molybdenum oil solution 

(mixture of the engine oil and 

molybdenum grease in a ratio 

of 1:1)

Camshaft cam profile

When installing a new 

camshaft 

Threebond® 2430 or 

equivalent 

Recoil starter center screw threads

LOCTITE® 638 or equivalent

Limiter cap inside

62Z4H000.book  7 ページ  ２０１１年５月２０日　金曜日　午前１０時５分

Summary of Contents for GX120UT2

Page 1: ... and using safety 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 the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields anytime you hammer drill grind or work around pre...

Page 2: ...TION 2 MAINTENANCE 3 TROUBLESHOOTING 4 COVER 5 FUEL SYSTEM 6 GOVERNOR SYSTEM 7 CHARGING SYSTEM 8 IGNITION SYSTEM 9 STARTING SYSTEM 10 OTHER ELECTRICAL 11 MUFFLER 12 CYLINDER HEAD 13 CRANKCASE 14 REDUCTION UNIT 15 WIRING DIAGRAMS 16 INDEX 62Z4H000 book 2 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 3: ... possible to warn you about all the hazards associated with servicing these products You must use your own good judgement Honda Motor Co Ltd SERVICE PUBLICATION OFFICE Date of Issue May 2011 You will find important safety information in a variety of forms including Safety Labels on the product Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION...

Page 4: ...c tools when servicing this unit Metric bolts nuts and screws are not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the unit SYMBOLS The symbols used throughout this manual show specific service procedures If supplementary information is required pertaining to these symbols it would be explained specifically in the text without the use of the symbol...

Page 5: ...mperature ECM Engine Control Module EMT Exhaust Manifold Temperature EOP Engine Oil Pressure EX Exhaust F Front or Forward GND Ground HO2S Heated Oxygen sensor IAC Idle Air Control IAT Intake Air Temperature I D Inside diameter IG or IGN Ignition IN Intake INJ Injection L Left MAP Manifold Absolute Pressure MIL Malfunction Indicator Lamp O D Outside Diameter OP Optional Part PGM FI Programmed Fuel...

Page 6: ... NUMBER LOCATION 1 2 P T O TYPE VARIATION 1 2 DIMENSIONS AND WEIGHTS SPECIFICATIONS 1 10 ENGINE SPECIFICATIONS 1 11 PERFORMANCE CURVES 1 12 DIMENSIONAL DRAWINGS 1 15 P T O DIMENSIONAL DRAWINGS 1 21 62Z4H000 book 1 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 7: ...4 QX2 QX4 QX9 QX C9 QX S2 RH Q4 Air cleaner Dual Dual silent Cyclone Low profile Oil bath Semi dry Muffler Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal EXP Cyclone Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Starter motor combination switch Oil level switch Engine stop switch Oil ale...

Page 8: ... Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal EXP Cyclone Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Starter motor combination switch Oil level switch Engine stop switch Oil alert unit Circuit protector Reduction Gear Chain Without clutch With clutch 62Z4H000 book 3 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 9: ...ffler Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal EXP Cyclone Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Starter motor combination switch Oil level switch Engine stop switch Oil alert unit Circuit protector Reduction Gear Chain Without clutch With clutch 62Z4H000 book 4 ページ ２０１１年５月...

Page 10: ...Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal EXP Cyclone Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Starter motor combination switch Oil level switch Engine stop switch Oil alert unit Circuit protector Reduction Gear Chain Without clutch With clutch 62Z4H000 book 5 ページ ２０１１年５月２０日 金曜...

Page 11: ... Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal EXP Cyclone Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Starter motor combination switch Oil level switch Engine stop switch Oil alert unit Circuit protector Reduction Gear Chain Without clutch With clutch 62Z4H000 book 6 ページ ２０１１年５月２０日 金...

Page 12: ...profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal EXP Cyclone Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Starter motor combination switch Oil level switch Engine stop switch Oil alert unit Circuit protector Reduction Gear Chain Without clutch With clutch 62Z4H000 book 7 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 13: ...ffler Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal EXP Cyclone Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Starter motor combination switch Oil level switch Engine stop switch Oil alert unit Circuit protector Reduction Gear Chain Without clutch With clutch 62Z4H000 book 8 ページ ２０１１年５月...

Page 14: ...lent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal EXP Cyclone Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Starter motor combination switch Oil level switch Engine stop switch Oil alert unit Circuit protector Reduction Gear Chain Without clutch With clutch 62Z4H000 book 9 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 15: ...mm 12 5 in 346 mm 13 6 in 335 mm 13 2 in 346 mm 13 6 in 335 mm 13 2 in R 329 mm 13 0 in 318 mm 12 5 in 346 mm 13 6 in 335 mm 13 2 in 346 mm 13 6 in 335 mm 13 2 in S 329 mm 13 0 in 318 mm 12 5 in 346 mm 13 6 in 335 mm 13 2 in 346 mm 13 6 in 335 mm 13 2 in U 329 mm 13 0 in 318 mm 12 5 in 346 mm 13 6 in 335 mm 13 2 in V 329 mm 13 0 in 318 mm 12 5 in 346 mm 13 6 in 335 mm 13 2 in 346 mm 13 6 in 335 mm...

Page 16: ...1 rpm Compression ratio 8 5 1 9 0 1 8 5 1 Fuel consumption at continuous rated power 1 0 Liter 0 26 US gal 0 22 Imp gal h 1 4 Liters 0 37 US gal 0 31 Imp gal h 1 7 Liters 0 45 US gal 0 37 Imp gal h Ignition system C D I Capacitor Discharge Ignition type magneto ignition Ignition timing B T D C 20 1 400 min 1 rpm B T D C 18 1 400 min 1 rpm B T D C 20 1 400 min 1 rpm Recommended spark plug BPR6ES NG...

Page 17: ...MANCE CURVES GX120 lbf ft kgf m N m 7 5 7 0 6 5 kW 2 1 0 3 TORQUE OUTPUT HP PS 5 5 5 0 0 70 0 75 4 3 2 1 0 4 3 2 1 0 NET POWER NET TORQUE RECOMMENDED OPERATING SPEED RANGE 2000 3000 3600 ENGINE SPEED rpm 62Z4H000 book 12 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 18: ...GX160 lbf ft kgf m N m 11 10 9 kW 2 1 0 3 TORQUE OUTPUT HP PS 8 0 7 0 1 1 4 3 2 1 0 NET POWER NET TORQUE RECOMMENDED OPERATING SPEED RANGE 2000 3000 3600 ENGINE SPEED rpm 7 5 1 0 0 9 5 5 4 3 2 1 0 4 62Z4H000 book 13 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 19: ...bf ft kgf m N m 13 kW 2 1 0 3 TORQUE OUTPUT HP PS 9 5 1 1 4 3 2 1 0 6 3 2 1 0 NET POWER NET TORQUE RECOMMENDED OPERATING SPEED RANGE 2000 3000 3600 ENGINE SPEED rpm 5 6 4 5 4 5 12 11 10 9 0 8 5 8 0 1 2 1 3 62Z4H000 book 14 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 20: ...0 T2 318 12 5 S type 75 5 2 97 U W type 75 2 2 96 P type 305 5 12 03 Q type 305 5 12 03 S type 297 11 7 T type 305 5 12 03 U type 309 8 12 20 V type 315 5 12 42 W type 317 5 12 50 Standard 91 3 6 Silent 104 4 1 Dual dual silent 160 6 3 Cyclone 166 6 5 Oil bath 157 6 2 Semi dry 156 6 1 Dual dual silent 317 12 5 Cyclone Oil bath 330 13 0 Semi dry 314 12 4 62Z4H000 book 15 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 21: ... 0 2 39 5 5 56 80 3 1 UT2 329 13 0 T2 318 12 5 Unit mm in 317 12 5 H type 45 1 1 78 L type 66 1 2 60 R type 89 7 3 53 H type 185 9 7 32 L type 164 9 6 49 R type 141 3 5 56 91 3 6 160 6 3 H type 151 2 5 95 L type 110 4 3 R type 162 8 6 41 H type 370 14 6 L type 332 13 1 R type 384 15 1 62Z4H000 book 16 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 22: ...ype 75 2 2 96 P type 312 5 12 30 Q type 312 5 12 30 S type 304 12 0 T type 312 5 12 30 U type 316 8 12 47 V type 322 5 12 70 W type 329 5 12 97 Standard 93 3 7 Silent 106 4 2 Dual dual silent 160 6 3 Cyclone 168 6 6 Oil bath 159 6 3 Semi dry 156 6 1 Dual dual silent 337 13 3 Cyclone Oil bath Semi dry 333 13 1 123 4 8 362 14 3 121 4 8 70 2 8 62Z4H000 book 17 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 23: ...Unit mm in 337 13 3 H type 45 1 1 78 L type 66 1 2 60 R type 89 7 3 53 H type 193 9 7 63 L type 172 9 6 81 R type 149 3 5 88 93 3 7 160 6 3 H type 151 2 5 95 L type 114 5 4 51 R type 162 8 6 41 H type 377 14 8 L type 343 13 5 R type 391 15 4 419 16 5 UT2 346 13 6 T2 335 13 2 362 14 3 121 4 8 70 2 8 62Z4H000 book 18 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 24: ... U W type 75 2 2 96 P type 321 5 12 66 Q type 321 5 12 66 S type 313 12 3 T type 321 5 12 66 V type 331 5 13 05 Dual dual silent 160 6 3 Cyclone 168 6 6 Oil bath 159 6 3 Semi dry 156 6 1 Dual dual silent 339 13 3 Cyclone Oil bath Semi dry 335 13 2 123 4 8 UT2 346 13 6 T2 335 13 2 121 4 8 70 2 8 433 17 0 106 4 2 62Z4H000 book 19 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 25: ...n 339 13 3 H type 207 9 8 19 L type 186 9 7 36 R type 163 3 6 43 106 4 2 160 6 3 H type 386 15 2 L type 352 13 9 R type 400 15 7 123 4 8 121 4 8 70 2 8 H type 45 1 1 78 L type 66 1 2 60 R type 89 7 3 53 H type 151 2 5 95 L type 114 5 4 51 R type 162 8 6 41 376 14 8 UT2 346 13 6 T2 335 13 2 433 17 0 62Z4H000 book 20 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 26: ...it mm in 61 7 2 43 58 5 2 30 17 0 7 5 16 24UNF 2B 4 73 4 78 0 186 0 188 16 26 16 36 0 640 0 644 61 7 2 43 58 5 2 30 Unit mm in Q type P type 3 4 16UNF 2ARH 22 5 0 89 Φ 19 025 19 050 0 7490 0 4500 GX120 Φ 78 3 1 GX160 GX200 Φ 74 2 9 GX120 Φ 78 3 1 GX160 GX200 Φ 74 2 9 GX120 Φ 19 000 19 050 0 7480 0 7500 GX160 GX200 Φ 19 025 19 050 0 7490 0 7500 62Z4H000 book 21 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 27: ...7 0 7452 0 7550 71 7 2 82 Unit mm in U type V type Unit mm in 5 16 24UNF 2B TAPER 2 1 4 33 5 1 32 Φ 19 830 19 843 0 7807 0 7812 Φ 14 225 14 275 0 5600 0 5620 Φ 19 000 19 050 0 7480 0 7500 8 0 3 66 2 6 56 2 2 1 2 20UNF 2ARH 3 954 3 984 0 1557 0 1569 9 90 10 00 0 390 0 394 GX120 Φ 78 3 1 GX160 GX200 Φ 74 2 9 GX120 Φ 78 3 1 GX160 GX200 Φ 74 2 9 Unit mm in W type GX120 M14 x 1 5 GX160 M18 x 1 5 GX120 ...

Page 28: ...NIT P T O SHAFT 45 1 1 78 Unit mm in L type REDUCTION UNIT P T O SHAFT M8 x 1 25 53 2 2 09 50 2 0 23 0 9 5 00 5 03 0 197 0 198 54 2 1 Φ 41 25 1 624 66 1 2 60 45 45 M8 x 1 25 6 PLACES GX120 Φ 17 957 17 984 0 7070 0 7080 GX160 GX200 Φ 19 947 19 980 0 7853 0 7866 GX120 Φ 14 90 15 00 0 587 0 591 GX160 GX200 Φ 16 90 17 00 0 665 0 669 93 5 3 68 65 1 2 56 62Z4H000 book 23 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 29: ...n R type REDUCTION UNIT 89 7 3 53 45 45 M8 x 1 25 4 PLACES P T O SHAFT M8 x 1 25 7 000 7 036 0 2756 0 2770 17 90 18 00 0 705 0 709 52 7 2 07 50 2 0 25 1 0 Φ 50 2 0 Φ 21 947 21 980 0 8641 0 8654 70 2 8 70 2 8 62Z4H000 book 24 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 30: ...2 1 2 dummytext 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 6 LUBRICATION SEAL POINTS 2 7 TOOLS 2 8 HARNESS AND TUBE ROUTING 2 11 62Z4H000 book 1 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 31: ... 026 Big end oil clearance 0 040 0 063 0 0016 0 0025 0 12 0 005 Crankshaft Crankpin O D 25 970 25 980 1 0224 1 0228 25 92 1 020 Crankshaft runout 0 10 0 004 Cylinder barrel Camshaft journal I D 14 000 14 018 0 5512 0 5519 14 048 0 5531 Crankcase cover Camshaft journal I D 14 000 14 018 0 5512 0 5519 14 048 0 5531 Valves Valve clearance IN 0 15 0 02 0 006 0 001 EX 0 20 0 02 0 008 0 001 Valve stem O...

Page 32: ... 0 04 Second 0 350 0 500 0 0138 0 0197 1 0 0 04 Oil side rail 0 10 0 35 0 004 0 014 1 0 0 04 Ring width Top 0 925 0 945 0 0364 0 0372 0 905 0 0356 Second 0 940 0 960 0 0370 0 0378 0 92 0 036 Connecting rod Small end I D 18 005 18 020 0 7089 0 7094 18 07 0 711 Big end side clearance 0 1 0 7 0 004 0 028 1 1 0 04 Big end I D 30 020 30 033 1 1819 1 1824 30 066 1 1837 Big end oil clearance 0 040 0 063 ...

Page 33: ... 35 MPa 3 6 kgf cm2 51 psi 600 min 1 rpm Cylinder head Warpage 0 10 0 004 Cylinder Sleeve I D 68 000 68 015 2 6772 2 6778 68 165 2 6837 Piston Skirt O D 67 965 67 985 2 6758 2 6766 67 845 2 6711 Piston to cylinder clearance 0 015 0 050 0 0006 0 0020 0 12 0 005 Piston pin bore I D 18 002 18 008 0 7087 0 7090 18 048 0 7105 Piston pin Pin O D 17 994 18 000 0 7084 0 7087 17 954 0 7068 Piston pin to pi...

Page 34: ... 966 13 984 0 5498 0 5506 13 916 0 5479 Carburetor Main jet BE59L A 75 BE59N A 75 BE59U A 75 BE74Y A 78 Pilot screw opening BE59L A 1 7 8 turns out BE59N A 1 7 8 turns out BE59U A 2 1 4 turns out BE74Y A 2 3 4 turns out Float height 13 7 0 54 Spark plug Gap 0 70 0 80 0 028 0 031 Spark plug cap Resistance 20 C 68 F 7 5 12 5 kΩ Ignition coil Air gap 0 2 0 6 0 01 0 02 Primary resistance 0 6 0 9 Ω Sec...

Page 35: ...tank nut bolt M6 x 1 0 10 1 0 7 Fuel tank joint M10 x 1 25 2 0 2 1 5 Air cleaner elbow nut M6 x 1 0 9 0 9 6 6 Muffler nut M8 x 1 25 24 2 4 18 Drive sprocket bolt Reduction unit chain type without clutch M8 x 1 25 24 2 4 18 Reduction case oil drain plug bolt Reduction unit gear type chain type with clutch M12 x 1 5 23 2 3 17 Recoil starter center screw M6 x 1 0 Special bolt 5 4 0 6 4 0 Fuel straine...

Page 36: ...ft journal Governor arm shaft journal Cylinder head bolt threads and seating surface P T O shaft gear teeth and journal Reduction unit gear type Drive sprocket P T O shaft gear teeth and journal Reduction unit chain type without clutch Drive sprocket P T O shaft clutch center gear teeth and journal Reduction unit chain type with clutch Clutch disc clutch plate entire surface Multi purpose grease O...

Page 37: ...lve guide driver 5 5 mm 07742 0010100 Bearing driver attachment 32 x 35 mm 07746 0010100 Bearing driver attachment 37 x 40 mm 07746 0010200 Bearing driver attachment 40 x 42 mm 07746 0010900 Bearing driver attachment 42 x 47 mm 07746 0010300 Bearing driver attachment 52 x 55 mm 07746 0010400 Pilot 20 mm 07746 0040500 Pilot 22 mm 07746 0041000 Pilot 25 mm 07746 0040600 Pilot 30 mm 07746 0040700 62Z...

Page 38: ... cutter 22 mm 32 IN 07780 0012601 Flat cutter 24 mm 32 EX 07780 0012500 Flat cutter 28 mm 32 IN EX 07780 0012100 Flat cutter 30 mm 32 IN 07780 0012200 Interior cutter 20 5 mm 60 EX 07780 0014300 Interior cutter 22 mm 60 IN EX 07780 0014202 Interior cutter 26 mm 60 IN EX 07780 0014500 Interior cutter 30 mm 60 IN 07780 0014000 Cutter holder 5 5 mm 07781 0010101 Flywheel puller set 07935 8050004 62Z4...

Page 39: ...3710600 Bearing remover shaft handle 07936 3710100 Bearing remover shaft set 25 mm 07936 ZV10100 Valve guide reamer 5 510 mm 07984 2000001 Bearing driver attachment 45 x 50 mm 07946 6920100 Bearing driver attachment 62 x 64 mm 07947 6340400 62Z4H000 book 10 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 40: ...on the application of the engine therefore the routing of these parts is not indicated in this manual CARBURETOR INSULATOR GX120 HIGH TENSION CORD HIGH TENSION CORD GX160 GX200 CARBURETOR INSULATOR ENGINE WIRE HARNESS IGNITION COIL CONNECTOR CORD HOOK ENGINE WIRE HARNESS CYLINDER BARREL RIBS CYLINDER BARREL RIBS 62Z4H000 book 11 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 41: ...2 12 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE BREATHER TUBE HIGH TENSION CORD GX120 GX160 GX200 62Z4H000 book 12 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 42: ...WIRE HARNESS GX160 GX200 GX120 CLAMP ENGINE WIRE HARNESS CONNECTOR ENGINE STOP SWITCH WIRE OIL LEVEL SWITCH WIRE HARNESS CLIP ENGINE STOP SWITCH WIRE ENGINE WIRE HARNESS CONNECTOR To ignition coil To oil level switch To engine stop switch ENGINE WIRE HARNESS HARNESS CLIP ENGINE STOP SWITCH WIRES ENGINE STOP SWITCH CONNECTOR To ignition coil Bl Bl Y Y Y 62Z4H000 book 13 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 43: ... HARNESS CLIP ENGINE STOP SWITCH CONNECTOR ENGINE WIRE HARNESS CONNECTOR ENGINE STOP SWITCH WIRE ENGINE STOP SWITCH WIRES ENGINE WIRE HARNESS CLAMP GX160 GX200 To ignition coil To oil alert unit To oil level switch To engine stop switch OIL ALERT UNIT WIRES OIL ALERT UNIT CONNECTOR Bl Y Bl Y Y Bl 62Z4H000 book 14 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 44: ...E STARTER SOLENOID WIRE ENGINE WIRE HARNESS To ignition coil Bl W HARNESS CLIP To starter motor starter solenoid W PURSE LOCK CLIP 45 5 OIL ALERT UNIT WIRE STARTER MOTOR CONNECTOR HARNESS CLIP TERMINAL WIRE OIL LEVEL SWITCH WIRE FASTENER TUBE HARNESS CLIP PURSE LOCK CLIP OIL LEVEL SWITCH CONNECTOR CHARGE COIL CORD STARTER MOTOR WIRE TERMINAL WIRE PURSE LOCK CLIP TERMINAL WIRE CHARGE COIL CONNECTOR...

Page 45: ... LAMP COIL 1 A 3 A CHARGE COIL 12 V 15 W 12 V 25 W LAMP COIL TYPE 7 A CHARGE COIL TYPE 12 V 50 W LAMP COIL TYPE COIL CORD CORD GROMMET CORD CLAMPER COIL CORD CORD GROMMET CORD CLAMPER COIL CORD CORD GROMMET CORD CLAMPER 62Z4H000 book 16 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 46: ...CK CLEANING REPLACEMENT 3 7 SEDIMENT CUP CLEANING 3 10 SPARK PLUG CHECK ADJUSTMENT 3 11 SPARK PLUG REPLACEMENT 3 11 SPARK ARRESTER CLEANING 3 12 IDLE SPEED CHECK ADJUSTMENT 3 13 VALVE CLEARANCE CHECK ADJUSTMENT 3 13 COMBUSTION CHAMBER CLEANING 3 15 FUEL TANK AND FILTER CLEANING 3 15 FUEL TUBE CHECK 3 16 62Z4H000 book 1 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

Page 47: ...months or 50 hrs Every 6 months or 100 hrs Every year or 300 hrs Engine oil Check level 3 3 Change 3 3 Reduction case oil applicable types Check level 3 4 Change 3 5 Air cleaner Check 3 7 Clean 1 1 3 7 Cyclone type Every 6 months or 150 hours 3 7 Replace 3 7 Cyclone type Every 2 years or 600 hours 3 7 Sediment cup Clean 3 10 Spark plug Check adjust 3 11 Replace 3 11 Spark arrester applicable types...

Page 48: ...the drain plug bolt with a new drain plug washer and tighten it to the specified torque Add the specified amount of recommended oil into the engine After adding the oil check the oil level Check that the oil filler packing 4 is in good condition replace it if necessary Install and tighten the oil filler cap securely Make sure there are no oil leaks 1 3 2 Used engine oil contains substances that ha...

Page 49: ...plug washer and tighten it to the specified torque CHAIN TYPE with clutch Place the engine on a level surface Remove the oil filler cap oil level gauge 1 and wipe the oil level gauge clean Insert the oil level gauge without screwing it into the oil filler neck Remove the oil level gauge and check oil level shown on the oil level gauge If the oil level is low fill with recommended oil to the upper ...

Page 50: ...r and tighten it to the specified torque Install and tighten the breathing bolt securely Make sure there are no oil leaks Used engine oil contains substances that have been identified as carcinogenic If repeatedly left in contact with the skin for prolonged periods it may cause skin cancer Wash your hands thoroughly with soap and water as soon as possible after contact with used engine oil SAE 10W...

Page 51: ...he reduction case After adding the oil check the oil level Check that the O ring 4 is in good condition replace it if necessary Install and tighten the oil filler cap oil level gauge securely Make sure there are no oil leaks Used engine oil contains substances that have been identified as carcinogenic If repeatedly left in contact with the skin for prolonged periods it may cause skin cancer Wash y...

Page 52: ...lled loosely will allow dirt to enter the engine causing rapid engine wear Install the air filters securely DUAL DUAL SILENT TYPE Remove the following Nut 1 Air cleaner cover 2 Wing nut 3 Element Assy Grommet 4 Inner filter Paper 5 Outer filter Foam 6 Carefully check both filters for holes or tears and replace if damaged Clean the filters if they are to be reused page 3 9 Installation is in the re...

Page 53: ... cleaner guide Check that the air cleaner cover packing 10 is in good condition replace it if necessary Installation is in the reverse order of removal Install the pre air cleaner case by align it the groove 11 and tab 12 of the air cleaner cover Assy LOW PROFILE TYPE Remove the air cleaner case lid spring 1 and air cleaner cover 2 Remove the pre air cleaner element 3 Carefully check the air clean...

Page 54: ...he reverse order of removal SEMI DRY TYPE Remove the following Wing nut 1 Air cleaner cap 2 Air cleaner cover 3 Air cleaner element 4 Carefully check the element for holes or tears and replace if damaged Clean the element if it is to be reused page 3 9 Installation is in the reverse order of removal ELEMENT CLEANING FOAM Clean the filter 1 in warm soapy water rinse and allow to dry thoroughly or c...

Page 55: ... the cup filter with non flammable solvent and allow them to dry thoroughly Install the cup filter while aligning it with the tip with the groove of the carburetor and cup filter tab 5 with the mark 6 of the carburetor Install a new O ring and sediment cup Tighten the sediment cup to the specified torque Check the installation part of the sediment cup for any sign of fuel leakage 1 Gasoline is hig...

Page 56: ...ap 1 and remove the spark plug 2 Clean around the spark plug base with compressed air before removing the spark plug and be sure that no debris is allowed to enter into the combustion chamber INSTALLATION Install and hand tighten the spark plug to the cylinder head Tighten the spark plug to the specified torque Connect the spark plug cap RECOMMENDED SPARK PLUG BPR6ES NGK W20EPR U DENSO PLUG GAP 0 ...

Page 57: ...e order of removal LOW PROFILE TYPE Remove the two bolts 8 x 20 mm 1 muffler 2 and muffler gasket 3 Remove the spark arrester 4 Be careful to avoid damaging the screen Clean the carbon deposits from the spark arrester screen with a wire brush Check the spark arrester screen for damage If the screen is damaged replace the spark arrester Replace the muffler gasket with a new one and install the spar...

Page 58: ...ug cap 1 and remove the following Breather tube 2 Head cover bolt 6 x 12 mm 3 4 Head cover 4 Head cover packing 5 Set the piston near top dead center of the cylinder compression stroke both valves fully closed by pulling the recoil starter slowly When the piston is near top dead center of the compression stroke the triangle mark 1 on the starter pulley 2 will align with the top hole 3 on the recoi...

Page 59: ...sting nut to the specified torque Recheck the valve clearance and if necessary readjust the clearance Replace the head cover packing with a new one and install the removed parts in the reverse order of removal Route the high tension cord and breather tube properly page 2 11 VALVE CLEARANCE GX120 GX200 IN 0 15 0 02 mm 0 006 0 001 in EX 0 20 0 02 mm 0 008 0 001 in GX160 IN 0 08 0 02 mm 0 003 0 001 i...

Page 60: ... allow them to dry thoroughly Check the screen of the fuel tank joint for clogs or damage replace if necessary Install a new O rings to the fuel tank joint and install them to the fuel tank Tighten the fuel tank joint to the specified torque Install the fuel tank page 6 3 After installation check for any signs of fuel leakage 1 Gasoline is highly flammable and explosive You can be burned or seriou...

Page 61: ...eakage Replace if necessary When checking GX160 GX200 remove the fan cover page 5 2 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 1 62Z4H000 book 16 ページ ２０１１年５月２０日 金曜日 午前１０時５分 ...

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