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14-13

dummyhead

dummyhead

CRANKCASE

PISTON DISASSEMBLY/ASSEMBLY

Remove the piston(page 14-6).

PISTON PIN CLIP

CUTOUT

END GAP

PISTON

CONNECTING ROD UPPER

ASSEMBLY:
Set the connecting rod upper with
the long end toward the mark on
the piston head.

LONG END

OIL RING
(COMBINATION
RING)

SIDE RAIL

SPACER

PISTON RING SET

TOP RING

SECOND RING

OIL RING

PISTON PIN CLIP (2)

PISTON PIN

TOP RING

SECOND RING

MAKER MARK

10 mm (0.4 in)

120°

120°

120°

ASSEMBLY:
Be sure that the top ring and second ring are
not interchanged.
Install the top ring and second ring on the
piston with the maker mark side facing up.
Check that the piston rings rotate smoothly
after installing them.
Space the piston ring end gaps 120 degrees
apart, and do not align the ring end gaps with
the piston pin bore.

10 mm (0.4 in)

PISTON

ASSEMBLY:
Install by setting one end of the piston pin
clip in the groove of the piston pin bore,
holding the other end with long needle
pliers, and rotating the clip in.
Do not align the end gap of the piston pin
clip with the cutout of the piston pin bore.

SIDE RAIL

(Chrome plated)

MARK

62Z7B000.book 13 ページ２０１２年９月２７日　木曜日　午前１０時２１分

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Summary of Contents for GX270H

Page 1: ...g 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 pr...

Page 2: ... 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 VALVES 13 CRANKCASE 14 WIRING DIAGRAMS 15 INDEX 62Z7B000 book 2 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 3: ...ble 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 September 2012 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 will be explained specifically in the text without the use of the symbols...

Page 5: ... ECM Engine Control Module EMT Exhaust Manifold Temperature EOP Engine Oil Pressure EX Exhaust F Front or Forward GND Ground HO2S Heated Oxygen sensor IAB Intake Air Bypass 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 Pr...

Page 6: ... SERIAL NUMBER LOCATION 1 2 TYPE CODE 1 3 DIMENSIONS AND WEIGHTS SPECIFICATIONS 1 4 ENGINE SPECIFICATIONS 1 5 PERFORMANCE CURVES 1 7 DIMENSIONAL DRAWINGS 1 9 P T O DIMENSIONAL DRAWINGS 1 13 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 7: ...ICATIONS SPECIFICATIONS SERIAL NUMBER LOCATION The engine serial number 1 type 2 and model 3 is stamped on the crankcase Refer to it when ordering parts or making technical inquiries 1 2 3 62Z7B000 book 2 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 8: ...S4 VSD4 VSP VX VX1 VXK P T O V type Model GX390H1 Type ES2 LH LH1 LH2 LHB5 LHP1 LXE9 P T O E type L type Model GX390H1 Type PX QA2 QBE1 QH QH1 QHB1 QHB3 P T O P type Q type Model GX390H1 Type QHB5 QHP1 QMH QN QP QX QXE P T O Q type Model GX390H1 Type QXEK QXK SH SH1 SHE SM11 SWE2 P T O Q type S type Model GX390H1 Type SWX2 SX SX1 SXC SXC1 SXE1 SXE P T O S type Model GX390H1 Type VMT3 VMQ3 VPX4 VS4...

Page 9: ... mm 17 6 in L type 410 mm 16 1 in 443 mm 17 4 in P type 410 mm 16 1 in 443 mm 17 4 in Q type 410 mm 16 1 in 443 mm 17 4 in R type 410 mm 16 1 in S type 410 mm 16 1 in 443 mm 17 4 in V type 410 mm 16 1 in VPX4 only 447 mm 17 6 in Othe type 443 mm 17 4 in Dry weight E type 31 7 kg 69 9 lbs L type 26 5 kg 58 4 lbs 35 0 kg 77 2 lbs P type 25 0 kg 55 1 lbs 31 5 kg 69 4 lbs Q type 25 0 kg 55 1 lbs 31 5 ...

Page 10: ...nuous rated power 5 3 Liters 1 40 US gal 1 17 Imp gal h Ignition system Transistorized magneto ignition Ignition timing B T D C 20 1 200 4 000 min 1 rpm Spark plug VKK VMT VS4 VSD4 BPR5ES NGK W16EPR U DENSO Other type BPR6ES NGK W20EPR U DENSO Lubrication system Forced splash Oil capacity 1 1 Liters 1 16 US qt 0 97 Imp qt Recommended oil SAE 10W 30 API service classification SE or higher Cooling s...

Page 11: ...min 1 rpm Maximum net torque SAE J1349 25 1 N m 2 56 kgf m 18 5 lbf ft 2 500 min 1 rpm Compression ratio 8 0 1 Fuel consumption at continuous rated power 6 1 Liters 1 61 US gal 1 34 Imp gal h Ignition system Transistorrized magneto ignition Ignition timing B T D C 25 1 200 4 000 min 1 rpm Spark plug ES2 VMT3 VMQ3 VS4 VS6 VSB4 BPR5ES NGK W16EPR U DENSO Other type BPR6ES NGK W20EPR U DENSO Lubricati...

Page 12: ...X270H 18 16 14 12 N m KW 8 6 4 2 0 2000 3600 3000 4000 RECOMMENDED OPERATING SPEED RANGE ENGINE SPEED rpm OUTPUT TORQUE NET TORQUE NET POWER 8 6 4 2 0 10 HP PS 8 6 4 2 0 10 lbf ft kgf m 12 14 10 8 2 0 1 8 1 6 1 4 1 2 62Z7B000 book 7 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 13: ...2 20 N m KW 9 8 7 6 4 2000 3600 3000 RECOMMENDED OPERATING SPEED RANGE ENGINE SPEED rpm OUTPUT TORQUE NET TORQUE NET POWER HP PS 9 6 12 lbf ft kgf m 17 18 16 2 6 2 5 2 4 2 3 2 2 5 15 19 11 10 7 8 9 6 12 11 10 7 8 62Z7B000 book 8 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 14: ...4 5 1 36 96 3 8 105 4 1 195 5 7 70 Dual Dual silent 273 10 8 Oil bath Semi dry 272 10 7 Cyclone 375 14 8 CRANKSHAFT P T O Dual Dual silent Oil bath Semi dry 407 16 0 Cyclone 429 16 9 Dual Dual silent 183 7 2 Oil bath Semi dry 180 7 1 Cyclone 193 7 6 STD 116 4 6 100DB 152 6 0 STARTER MOTOR If equipped CONTROL BOX If equipped 410 16 1 With muffler cap 448 17 6 Without muffler cap 430 16 9 62Z7B000 b...

Page 15: ...1 195 5 7 70 68 1 2 7 P T O SHAFT 140 5 52 407 16 0 13 0 5 34 5 1 36 96 3 8 REDUCTION UNIT 405 15 9 Dual 183 7 2 Oil bath Semi dry 180 7 1 410 16 1 With muffler cap 448 17 6 Without muffler cap 430 16 9 150 5 9 Dual 204 9 8 07 Oil bath Semi dry 203 9 8 03 62Z7B000 book 10 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 16: ...l 194 7 6 Oil bath 192 7 6 156 6 1 Dual Silent 297 11 7 Oil bath 295 11 6 S 380 15 0 P Q 405 15 9 V 425 16 7 With control box type 491 19 3 Dual silent 443 17 4 Oil bath 436 17 2 STARTER MOTOR If equipped CONTROL BOX If equipped 133 5 5 26 VPX4 447 17 6 Other type 443 17 4 With muffler cap 475 18 7 Without muffler cap 450 17 7 62Z7B000 book 11 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 17: ...84 1 3 31 P T O SHAFT 155 6 1 98 3 9 122 4 8 443 17 4 REDUCTION UNIT 440 17 3 140 5 5 212 9 8 38 194 7 6 17 0 7 27 1 1 103 4 1 With control box type 491 19 3 STARTER MOTOR If equipped CONTROL BOX If equipped With muffler cap 475 18 7 Without muffler cap 450 17 7 447 17 6 62Z7B000 book 12 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 18: ...0 TAPER 1 5 M10 x 1 25 28 1 1 35 1 4 Φ26 000 26 003 Φ1 0236 1 0237 Φ 1 8 4 Φ 7 2 4 18 0 71 Φ190 05 190 25 Φ7 482 7 490 CRANKSHAFT P T O M6 x 1 0 Unit mm in 45 45 103 4 1 70 2 8 66 7 2 63 P D 1 2 7 5 0 Φ24 947 24 980 Φ0 9821 0 9835 10 0 4 68 1 2 68 60 0 2 36 42 1 7 P T O SHAFT M8 x 1 25 2 M8 x 1 25 4 20 9 21 0 0 82 0 83 28 1 1 7 00 7 05 0 276 0 278 REDUCTION UNIT M8 x 1 25 62Z7B000 book 13 ページ２０１２...

Page 19: ... 3327 5 16 24UNF 2B TAP 2 3 8 16UNC 2B TAP 4 CRANKSHAFT P T O 5 16 24UNF 2B TAP 4 Unit mm in 30 30 45 45 103 4 1 70 2 8 88 5 3 48 56 2 2 Φ25 375 25 400 Φ0 9990 1 0000 28 1 1 72 2 2 84 P D 165 1 6 50 P D 1 2 7 5 0 6 30 6 35 0 248 0 250 21 69 21 82 0 854 0 859 Φ110 00 110 05 Φ4 331 4 333 3 8 16UNC 2B TAP 4 5 16 24UNF 2B TAP 4 5 16 24UNF 2B TAP 4 7 16 20UNF 2B TAP CRANKSHAFT P T O 62Z7B000 book 14 ペー...

Page 20: ...5 4 35 1 4 REDUCTION UNIT M8 x 1 25 25 1 0 35 1 4 35 1 4 7 000 7 036 0 2756 0 2770 53 2 1 Unit mm in 103 4 1 70 2 8 63 2 5 42 1 7 Φ24 947 24 980 Φ0 9822 0 9835 28 1 1 60 2 4 P D 165 1 6 50 P D 1 2 7 5 0 7 00 7 03 0 276 0 277 20 9 21 0 0 82 0 83 Φ110 00 110 05 Φ4 331 4 333 CRANKSHAFT P T O M8 x 1 25 2 30 30 45 45 Φ8 5 Φ0 34 4 M8 x 1 25 4 M8 x 1 25 62Z7B000 book 15 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 21: ...4 333 5 16 24UNF 2B TAP 2 5 16 24UNF 2B TAP 4 3 8 16UNC 2B TAP 4 30 30 45 45 CRANKSHAFT P T O 5 16 24UNF 2B TAP 2 1 4 TAPER 18 0 7 Unit mm in 15 15 53 7 2 11 P D 2 0 7 8 1 Φ34 947 34 980 Φ1 3759 1 3772 15 15 M6 x 1 0 TAPER 1 5 M10 x 1 25 28 1 1 35 1 4 Φ26 000 26 003 Φ1 0236 1 0237 Φ 1 8 4 Φ 7 2 4 18 3 0 72 Φ190 05 190 25 Φ7 482 7 490 M6 x 1 0 CRANKSHAFT P T O 62Z7B000 book 16 ページ２０１２年９月２７日木曜日午前...

Page 22: ...41 1 6 REDUCTION UNIT P T O SHAFT M8 x 1 25 2 M8 x 1 25 4 20 9 21 0 0 82 0 83 28 1 1 7 00 7 03 0 276 0 277 Unit mm in 30 30 45 45 103 4 1 70 2 8 89 3 5 Φ25 375 25 400 Φ0 9990 1 0000 14NF2 Thread R H 1 0 1 1 72 5 2 85 P D 165 1 6 50 P D 1 2 7 5 0 Φ110 00 110 05 Φ4 3307 4 3327 5 16 24UNF 2B TAP 2 3 8 16UNC 2B TAP 4 5 16 24UNF 2B TAP 4 CRANKSHAFT P T O 26 27 62Z7B000 book 17 ページ２０１２年９月２７日木曜日午前１０時２...

Page 23: ...8591 CRANKSHAFT P T O Φ110 00 110 05 Φ4 331 4 333 5 16 24UNF 2B TAP 2 3 8 16UNC 2B TAP 4 5 16 24UNF 2B TAP 4 3 8 24UNF 2B TAP Unit mm in 103 4 1 70 2 8 63 2 5 41 1 6 Φ24 947 24 980 Φ0 9822 0 9835 28 1 1 60 2 4 P D 165 1 6 50 P D 1 2 7 5 0 7 00 7 03 0 276 0 277 20 9 21 0 0 82 0 83 Φ110 00 110 05 Φ4 331 4 333 CRANKSHAFT P T O 30 30 45 45 Φ8 5 Φ0 34 4 M8 x 1 25 4 M8 x 1 25 2 M8 x 1 25 62Z7B000 book 1...

Page 24: ...4 15 46 5 1 83 Φ22 136 22 161 Φ0 8715 0 8724 18 0 7 75 5 2 97 P D 165 1 6 50 P D 1 2 7 5 0 Φ110 00 110 05 Φ4 331 4 333 5 16 24UNF 2B TAP 2 5 16 24UNF 2B TAP 4 3 8 16UNC 2B TAP 4 30 30 45 45 CRANKSHAFT P T O 5 16 24UNF 2B TAP 2 1 4 TAPER 62Z7B000 book 19 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 25: ...MEMO dummyhead dummyhead 62Z7B000 book 20 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 26: ...2 1 2 dummytext 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 5 LUBRICATION SEAL POINT 2 6 TOOLS 2 7 HARNESS AND TUBE ROUTING 2 10 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 27: ...004 0 016 1 0 0 04 Big end I D 33 025 33 039 1 3002 1 3007 33 07 1 302 Big end oil clearance 0 040 0 064 0 0016 0 0025 0 12 0 005 Crankshaft Crankpin O D 32 975 32 985 1 2982 1 2986 32 92 1 296 Crankshaft runout 0 10 0 004 Cylinder barrel Crankcase Camshaft journal I D 16 000 16 018 0 6299 0 6306 16 05 0 632 Crankcase cover Camshaft journal I D 16 000 16 018 0 6299 0 6306 16 05 0 632 Valves Valve ...

Page 28: ...0 7 Ω Secondary resistance 8 9 13 5 kΩ Starter motor Brush length 7 0 0 28 3 5 0 14 Mica depth 1 0 0 04 0 2 0 01 Charge coil Resistance 1 A 3 00 4 00 Ω 3 A 0 62 0 93 Ω Lamp coil Resistance 12 V 50 W 0 29 0 44 Ω 1 2 reduction clutch type Clutch friction disc thickness 3 5 0 14 3 0 0 12 Clutch plate warpage 0 10 0 004 Part Item Standard Service limit 62Z7B000 book 3 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 29: ... oil clearance 0 040 0 064 0 0016 0 0025 0 12 0 005 Crankshaft Crankpin O D 35 975 35 985 1 4163 1 4167 35 93 1 415 Crankshaft runout 0 10 0 004 Cylinder barrel Crankcase Camshaft journal I D 16 000 16 018 0 6299 0 6306 16 05 0 632 Crankcase cover Camshaft journal I D 16 000 16 018 0 6299 0 6306 16 05 0 632 Valves Valve clearance IN 0 15 0 02 EX 0 20 0 02 Valve stem O D IN 6 575 6 590 0 2588 0 259...

Page 30: ... 7 Spark plug M14 x 1 25 Special 18 1 8 13 Oil level switch nut M10 x 1 25 10 1 0 7 Flywheel nut M16 x 1 5 Special nut 113 11 5 83 Apply engine oil to the threads and seating surface Flywheel nut With reduction GX390H1 only M16 x 1 5 Special nut 157 16 0 116 Fuel tank nut bolt M8 x 1 25 24 2 4 18 Fuel tank joint M10 x 1 25 2 0 0 2 1 5 Air cleaner elbow nut M6 x 1 0 9 0 0 9 6 6 Muffler nut M8 x 1 2...

Page 31: ...mshaft 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 Balancer s...

Page 32: ...742 0010200 Attachment 32 x 35 mm 07746 0010100 Attachment 42 x 47 mm 07746 0010300 Attachment 52 x 55 mm 07746 0010400 Attachment 72 x 75 mm 07746 0010600 Inner driver handle 40 mm 07746 0030100 Attachment 30 mm 07746 0030300 Attachment 35 mm 07746 0030400 Pilot 15 mm 07746 0040300 Pilot 20 mm 07746 0040500 62Z7B000 book 7 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 33: ...80 0010300 Seat cutter 27 5 mm 45 EX 07780 0010200 Seat cutter 35 mm 45 IN 07780 0010400 Seat cutter 33 mm 45 EX 07780 0010800 Flat cutter 30 mm 32 IN 07780 0012200 Flat cutter 28 mm 32 EX 07780 0012100 Flat cutter 35 mm 32 IN 07780 0012300 Flat cutter 33 mm 32 EX 07780 0012900 Interior cutter 37 5 mm 60 IN EX 07780 0014100 Cutter holder 6 6 mm 07781 0010202 62Z7B000 book 8 ページ２０１２年９月２７日木曜日午前１０...

Page 34: ... 07935 8050004 Bearing remover shaft set 15 mm 07936 KC10500 Bearing remover shaft set 25 mm 07936 ZV10100 Valve guide reamer 6 612 mm 07984 ZE20001 Attachment 45 x 50 mm 07946 6920100 Attachment 62 x 64 mm 07947 6340400 62Z7B000 book 9 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 35: ...ngine therefore it does not indicate those parts in this manual ALL TYPE FUEL TUBE BREATHER TUBE TUBE CLIP HIGH TENSION CORD GOVERNOR ARM ENGINE WIRE HARNESS IGNITION COIL CORD HOOK TO SPARK PLUG TO ENGINE STOP SWITCH Do not override on boss IGNITION COIL CONNECTOR CYLINDER BARREL RIBS Insert wire in the recesses of ribs ENGINE WIRE HARNESS ENGINE WIRE HARNESS 62Z7B000 book 10 ページ２０１２年９月２７日木曜日午...

Page 36: ...TION SWITCH CONTROL BOX TYPE ENGINE WIRE HARNESS CONNECTOR TERMINAL WIRE OIL ALERT UNIT WIRE To starter motor STARTER MOTOR WIRE TO STARTER MOTOR FASTENER TUBE HARNESS CLIP PURSE LOCK CLIP ENGINE WIRE HARNESS 62Z7B000 book 11 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 37: ... TO OIL LEVEL SWITCH TO OIL ALERT UNIT GX270H GX390H1 HARNESS CLIP TO ENGINE STOP SWITCH TO OIL ALERT UNIT Y Y Y Y Y Y Bl Bl Bl Bl Bl Bl Bl ENGINE STOP SWITCH DIRECTION OF CYLINDER BARREL ENGINE STOP SWITCH WIRE Clamp engine stop switch wire at indicated position HARNESS CLIP ENGINE STOP SWITCH WIRE ENGINE STOP SWITCH WIRE PREVENT SLACK Do not contact with cylinder barrel ENGINE WIRE HARNESS 62Z7B...

Page 38: ...MP COIL CLAMP ENGINE STOP SWITCH WIRE ENGINE WIRE HARNESS CONNECTOR ENGINE WIRE HARNESS 12 V 50 W LAMP COIL TYPE CORD CLAMPER CORD GROMMET CORD CLAMPER CORD GROMMET COIL CORD 12 V 15 W 12 V 25 W LAMP COIL TYPE 1 A 3 A CHARGE COIL TYPE COIL CORD 62Z7B000 book 13 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 39: ...MEMO dummyhead dummyhead 62Z7B000 book 14 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 40: ...ECK CLEANING REPLACEMENT 3 6 SEDIMENT CUP CLEANING 3 9 SPARK PLUG CHECK ADJUSTMENT 3 9 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 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 41: ... or 100 hrs Every year or 300 hrs Refer to page ITEM Perform at every indicated month or operating hour interval whichever comes first 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 6 Clean 1 1 3 6 Cyclone type Every 6 months or 150 hours 3 6 Replace 3 6 Cyclone type Every 2 years or 600 hours 3 6 Sediment cup Clean 3 9 Spar...

Page 42: ... ground or pour it down a drain Install the drain bolt with a new sealing 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...

Page 43: ...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 level 2 of the oil level gauge page 3 5 Check that the O ring 3 is in good condition replace it if necessary Install ...

Page 44: ...the 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 ...

Page 45: ...d Clean the filters if they are to be reused page 3 8 Install the elements in the reverse order of removal CYCLONE TYPE A dirty air filter will restrict air flow to the carburetor reducing engine performance If the engine is operated in dusty areas clean the air cleaner more often than specified in the MAINTENANCE SCHEDULE Operating the engine without the air filters or with the filter installed l...

Page 46: ...engine performance If the engine is operated in dusty areas clean the air cleaner more often than specified in the MAINTENANCE SCHEDULE Operating the engine without the air filters or with the filter installed loosely will allow dirt to enter the engine causing rapid engine wear Install the air filters securely Remove the following Wing nut 1 Air cleaner cap 2 Air cleaner cover 3 Air cleaner eleme...

Page 47: ... the element if it is to be reused page 3 8 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 clean with a non flammable solvent and allow to dry thoroughly Dip the filter in clean engine oil and squeeze out all the excess oil Excess oil will restrict air flow through the foam element and may cause the ...

Page 48: ...ion part of the sediment cup for any sign of fuel leakage SPARK PLUG CHECK ADJUSTMENT Remove the spark plug cap and then remove the spark plug 1 using a spark plug wrench 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 TORQUE 3 9 N m 0 4 kgf m 2 9 lbf ft 1 2 3...

Page 49: ...ding the side electrode Install the spark plug page 3 11 A loose spark plug can become very hot and can damage the engine Overtightening can damage the threads in the cylinder block Install the spark plug cap securely SPARK PLUG GX270H VKK VMT VS4 VSD4 BPR5ES NGK W16EPR U DENSO GX270H OTHER TYPE BPR6ES NGK W20EPR U DENSO GX390H1 ES2 VMT3 VMQ3 VS4 VS6 VSB4 BPR5ES NGK W16EPR U DENSO GX390H1 OTHER TY...

Page 50: ...inder head Tighten the spark plug to the specified torque Connect the spark plug cap The engine and 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 Allow it to cool before proceeding SPARK PLUG GX270H VKK VMT VS4 VSD4 BPR5ES NGK W16EPR U DENSO GX270H OTHER TYPE BPR6ES NGK W20EPR U DENSO GX390H1 ...

Page 51: ... 6 mm 4 and spark arrester 5 INNER OUTER PROTECTOR TYPE Remove the bolts 6 x 10 mm or 6 x 12 mm 1 and outer muffler protector 2 Remove the tapping screw 4 x 8 mm 3 and spark arrester 4 The engine and 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 Allow it to cool before proceeding 4 2 5 3 1 1 4...

Page 52: ...rk arrester in the reverse order of removal IDLE SPEED CHECK ADJUSTMENT Start the engine and allow it to warm up to normal operating temperature For units equipped with auto throttle turn the auto throttle switch ON Turn the throttle stop screw 1 to obtain the specified idle speed VALVE CLEARANCE CHECK ADJUSTMENT Remove the head cover bolt 1 the head cover 2 and the head cover packing 3 1 2 IDLE S...

Page 53: ...clearance If adjustment is necessary proceed as follows Hold the rocker arm pivot 1 and loosen the rocker arm pivot lock nut 2 Turn the rocker arm pivot to obtain the specified clearance Hold the rocker arm pivot and retighten the rocker arm pivot lock nut to the specified torque Recheck the valve clearance and if necessary readjust the clearance Check the head cover packing for damage or deterior...

Page 54: ...w 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 seriously i...

Page 55: ...for deterioration cracks or signs of leakage 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 62Z7B000 book 16 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 56: ...4 1 4 dummytext 4 TROUBLESHOOTING BEFORE TROUBLESHOOTING 4 2 TROUBLESHOOTING 4 2 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 57: ...nd dry the electrodes and then restart the engine taking care that the choke valve is not closed too much If the engine does not start and the electrode are wet again check the carburetor float valve page 6 16 Perform the IGNITION SYSTEM TROUBLESHOOTING page 9 3 Perform the STARTING SYSTEM TROUBLESHOOTING page 10 2 Disassemble the carburetor to clean the carburetor ports jets and nozzles page 6 15...

Page 58: ...on test If the cylinder compression is too low perform a leak down test If there is no air leakage in the engine check the following Valve spring free length page 13 7 Valve seat width page 13 5 Valve face irregularly worn page 13 6 Decompressor operation page 14 20 Piston ring side clearance page 14 16 Piston ring width page 14 17 Piston ring end gap page 14 17 Piston skirt O D page 14 15 Cylinde...

Page 59: ...n piston piston rings or cylinder inner surface page 14 6 14 12 Check for carbon deposits in the combustion chamber page 3 15 Check around the air intake joint and carburetor replace the insulator and or gasket if necessary Disassemble and clean the carburetor page 6 15 Inspect the spark plug and adjust the spark plug gap Replace if necessary page 3 10 Adjust the valve clearance page 3 13 Clear No...

Page 60: ... switch page 5 2 combination switch page 11 3 Check the engine stop switch If equipped page 11 6 combination switch If equipped page 11 6 Check the wire harness connecting the oil level switch and ignition coil for open or short circuit Replace the engine wire harness No continuity Abnormal Replace the oil level switch page 14 6 Normal Continuity Check the oil level switch page 11 5 Check the igni...

Page 61: ...MEMO dummyhead dummyhead 62Z7B000 book 6 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 62: ...5 1 5 dummytext 5 COVER FAN COVER REMOVAL INSTALLATION 5 2 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 63: ...and disconnect the engine wire harness connector Without control box type When installing refer to the HARNESS AND TUBE ROUTING page 2 10 FAN COVER ENGINE STOP SWITCH TUBE CLIP FLANGE BOLT 6 x 12 mm 6 REMOVAL The fan cover can be removed with the recoil starter assembly installed GX270H VSD4 ONLY HARNESS CLIP ENGINE STOP SWITCH 62Z7B000 book 2 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 64: ...MOVAL INSTALLATION 6 9 CARBURETOR DISASSEMBLY ASSEMBLY 6 11 CHOKE DIAPHRAGM DISASSEMBLY ASSEMBLY 6 14 CARBURETOR BODY CLEANING 6 15 CARBURETOR INSPECTION 6 15 CHOKE DIAPHRAGM INSPECTION 6 16 PILOT SCREW REPLACEMENT 6 17 CHOKE SET REPLACEMENT 6 18 CYLINDER STUD BOLT REPLACEMENT 6 18 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 65: ...6 2 dummyhead dummyhead FUEL SYSTEM FUEL SYSTEM TOOL Float level gauge 07401 0010000 62Z7B000 book 2 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 66: ... ft FUEL FILLER CAP O RING FUEL TANK JOINT B8 D8 TUBE CLAMP 2 FUEL TUBE TUBE CLIP 24 N m 2 4 kgf m 18 lbf ft INSTALLATION Before installing check for deterioration or cracks FUEL TANK 2 0 N m 0 2 kgf m 1 5 lbf ft INSTALLATION Before installing check for deterioration or cracks INSTALLATION Before installing check the screen of the fuel strainer for clogs or damage FUEL STRAINER FUEL TUBE 6 3 x 50 ...

Page 67: ... inside of the air cleaner elbow Viewed from air cleaner side INSTALLATION Before installing check for damage Note the installation direction AIR CLEANER ELEMENT PAPER WING NUT AIR CLEANER COLLAR 2 CARBURETOR SPACER FLANGE NUT 6 mm 2 AIR CLEANER ELBOW AIR CLEANER COVER NUT If equipped GX270H SLANT OUTSIDE HIGH TENSION CORD BREATHER TUBE INSTALLATION After installing the air cleaner elbow insert th...

Page 68: ...AIR CLEANER COVER SEAL RING AIR CLEANER ELBOW SEAL PRE AIR CLEANER CASE COVER TAB GROOVE CARBURETOR SPACER INSTALLATION Before installing check for damage Note the installation direction Viewed from air cleaner side WASHER BOLT 6 x 22 mm COLLAR FLANGE NUT 6 mm 2 9 0 N m 0 9 kgf m 6 6 lbf ft AIR CLEANER COLLAR 2 BREATHER TUBE INSTALLATION After installing the air cleaner elbow insert the breather t...

Page 69: ... COLLAR 2 DRAIN TUBE FILTER AIR CLEANER CASE AIR CLEANER SEAL AIR CLEANER ELEMENT AIR CLEANER COVER 9 0 N m 0 9 kgf m 6 6 lbf ft FLANGE NUT 6 mm FLANGE NUT 5 mm 6 AIR CLEANER SEPARATOR AIR CLEANER WIRE CLIP B 2 AIR CLEANER WIRE CLIP A 2 BREATHER TUBE HIGH TENSION CORD BREATHER TUBE INSTALLATION After installing the air cleaner elbow insert the breather tube to the hole of the cylinder head cover a...

Page 70: ...r elbow AIR CLEANER ELBOW INSTALLATION Before installing check for damage Note the installation direction Viewed from air cleaner side GX270H AIRCLEANER ELEMENT AIRCLEANER GRID WING NUT AIR CLEANER CAP AIR CLEANER COVER CLEANER OIL PAN AIR CLEANER ELBOW SEAL INSTALLATION After installing the air cleaner elbow insert the breather tube to the hole of the cylinder head cover as shown WASHER BOLT 6 x ...

Page 71: ... installation clean the inside of the air cleaner elbow AIR CLEANER ELBOW INSTALLATION Before installing check for damage Note the installation direction Viewed from air cleaner side WING NUT AIR CLEANER CAP AIR CLEANER COVER AIRCLEANER ELEMENT AIR CLEANER GRID BREATHER TUBE 9 0 N m 0 9 kgf m 6 6 lbf ft INSTALLATION After installing the air cleaner elbow insert the breather tube to the hole of the...

Page 72: ...CLAMP CARBURETOR REMOVAL INSTALLATION Remove the fuel tube FUEL TUBE B8 D8 TUBE CLAMP 2 1 REMOVAL INSTALLATION Pull the carburetor assembly to a point where the groove of the throttle arm lines up with the governor rod 1 and then lift the governor rod out of the hole of the throttle arm and unhook the throttle return spring 2 Installation is in the reverse order of removal INSTALLATION Before inst...

Page 73: ...arburetor After installing clamp the high tension cord 2 to the carburetor insulator CARBURETOR INSULATOR To control base stay NON HANDY LEVER B TYPE GOVERNOR ROD THROTTLE RETURN SPRING FUEL TUBE REMOVAL INSTALLATION Remove the fuel tube CARBURETOR To Choke diaphragm ASSEMBLY Install the dash pot into the tube clamp with the black end towards the choke diaphragm TUBE CLAMP DASH POT CHECK VALVE B8 ...

Page 74: ...ean thoroughly with low pressure compressed air Lightly lubricate the O ring 1 to ensure easy installation into the carburetor body ASSEMBLY Before installing clean thoroughly with low compressed air FLOAT CHAMBER ASSEMBLY Install the float chamber to the carburetor body at an angle as shown UPPER SIDE UPPER SIDE PILOT SCREW THROTTLE STOP SCREW ADJUSTMENT page 3 13 LIMITER CAP O RING 1 FLOAT FLOAT...

Page 75: ...AIN NOZZLE ASSEMBLY Before installing clean thoroughly with low pressure compressed air Lightly lubricate the O ring to ensure easy installation into the carburetor body FLOAT PIN SET BOLT UPPER SIDE O RING FLOAT VALVE SPRING ASSEMBLY Check for smooth movement after installation FLOAT VALVE PILOT SCREW ADJUSTMENT page 3 13 REPLACEMENT page 6 17 LIMITER CAP WASHER SCREW 5 x 12 mm 2 SOLENOID VALVE I...

Page 76: ...tion Number 1 2 Main Jet Number BE70L A 85 BE70M A 92 BE75B C 85 BE75H A 88 BE78B A 85 BE98F A 90 BE98G A 92 BE98H A 92 Carburetor identification Number 1 2 Main Jet Number BE85T B 92 BE85U A 95 BE88P A 105 BE88Q A 95 BE89K A 102 BE89L A 108 1 2 62Z7B000 book 13 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 77: ... CHOKE ROD STOPPER CHOKE ROD GUIDE CHOKE ROD GROMMET CHOKE LEVER ROD ROD JOINT DIAPHRAGM STAY E RING E RING SCREW 5 x 12 mm 2 PLAIN WASHER 5 mm CHOKE LEVER WASHER CHOKE LEVER SEAL ARM PIVOT BUSH CHOKE LEVER SEAL E RING THRUST WASHER 2 7 x 8 mm CHOKE DIAPHRAGM LEVER COLLAR 62Z7B000 book 14 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 78: ...le 1 Pilot jet hole 2 Pilot air jet 3 Main air jet 4 Transition ports 5 Pilot outlet 6 Main nozzle holder 7 External vent port 8 Internal vent port 9 CARBURETOR INSPECTION FLOAT LEVEL HEIGHT Place the carburetor in the position as shown Measure the distance between the float top and carburetor body when the float just contacts the seat without compressing the valve spring If the measured float hei...

Page 79: ... the float valve CHOKE DIAPHRAGM INSPECTION Check for smooth operation by pressing the rod with a finger Connect a vacuum pump to the choke diaphragm and apply vacuum The diaphragm should hold Replace the choke diaphragm if necessary 2 OK CLEAN REPLACE 1 3 OTHER TYPE GX390H1 BE85T B BE88Q A CARBURETOR BODY CARBURETOR BODY OK CLEAN REPLACE 2 1 3 62Z7B000 book 16 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 80: ...opening setting Apply LOCTITE 638 to the inside of the limiter cap then install the cap so the stop prevents the pilot screw from being turned counterclockwise Be careful to avoid turning the pilot screw while installing the limiter cap The pilot screw must stay at its required setting Carburetor identification Number 3 4 Pilot screw opening BE70L A 2 1 8 turns out BE70M A 2 3 4 turns out BE75B C ...

Page 81: ...ure the choke shaft is in the position between the projections 4 of the choke valve plate CYLINDER STUD BOLT REPLACEMENT Thread two nuts onto the stud bolt and tighten them together and then use a wrench to turn the stud bolt out Install new stud bolts 2 3 1 2 1 4 4 SPECIFIED LENGTH GX270H 8 x 98 mm 82 mm 3 23 in 8 x 123 mm 107 mm 4 21 in GX390H1 8 x 106 mm 90 0 mm 3 54 in 8 x 131 5 mm 115 5 mm 4 ...

Page 82: ... CONTROL BASE ASSY REMOVAL INSTALLATION 7 2 AUTO THROTTLE IF EQUIPPED REMOVAL INSTALLATION 7 5 CONTROL BASE ASSY DISASSEMBLY ASSEMBLY 7 6 MAXIMUM SPEED ADJUSTMENT 7 8 SOLENOID AUTO THROTTLE INSPECTION 7 9 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 83: ...LLATION Pull the carburetor assy 1 toward to a point where the groove 2 of the throttle arm lines up with the governor rod 3 and then lift the governor rod out of the hole of the throttle arm and unhook the throttle return spring 4 GOVERNOR ROD THROTTLE RETURN SPRING If equipped If equipped If equipped OUTER HOLE SCREW 4 x 6 mm INSTALLATION Install with the long end of the spring toward the contro...

Page 84: ...rottle arm lines up with the governor rod 3 and then lift the governor rod out of the hole of the throttle arm and unhook the throttle return spring 4 GOVERNOR ROD THROTTLE RETURN SPRING If equipped If equipped SCREW 4 x 6 mm If equipped INSTALLATION Install with the long end of the spring toward the control base assy Hook the governor spring to the outer hole of the governor arm OUTER HOLE NUT 6 ...

Page 85: ...spring to the outer hole of the governor arm CONTROL BASE ASSY GOVERNOR ARM GOVERNOR ARM BOLT NUT 6 mm BOLT 6 x 12 mm 3 If equipped GOVERNOR SPRING GOVERNOR ARM SHAFT REMOVAL INSTALLATION Pull the carburetor assy 1 to a point where the groove 2 of the throttle arm lines up with the governor rod 3 and then lift the governor rod out of the hole of the throttle arm and unhook the throttle return spri...

Page 86: ...M AUTO THROTTLE IF EQUIPPED REMOVAL INSTALLATION Remove the fuel tank page 6 3 SCREW 5 x 8 mm 2 BOLT 6 x 12 mm 2 SOLENOID THROTTLE LEVER CHOKE RETURN SPRING To the units connected from the engine 62Z7B000 book 5 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 87: ...m STOPPER COLLAR ASSEMBLY Note the installation direction ASSEMBLY After tightening the nut fully loosen it 1 1 2 turns SELF LOCK NUT 6 mm CLAW If equipped CIRCLIP 5 mm CONTROL ADJUST SPRING If equipped LEVER SPRING CONTROL LEVER SPACER SCREW 4 x 6 mm If equipped WIRE HOLDER INSTALLATION Install with the short end of the spring toward the control base Hook the cable return spring to the hole of th...

Page 88: ...DY LEVER B TYPE Remove the control base assy page 7 2 SCREW GX270H 5 x 35 mm GX390H1 5 x 45 mm ASSEMBLY Adjust the maximum speed page 7 8 CONTROL ADJUST SPRING CONTROL BASE CONTROL ADJUST SPRING CONTROL BASE ASSEMBLY Adjust the maximum speed page 7 8 SCREW 5 x 35 mm 62Z7B000 book 7 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 89: ...he nut 6 mm securely Install the fuel tank page 6 3 Start the engine and allow it to warm up to normal operating temperature Move the control lever 5 to run the engine at the specified maximum speed and hold the control lever Turn the screw 6 of the control to obtain the specified maximum speed AUTO THROTTLE TYPE Remove the fuel tank page 6 3 Loosen the two bolts 6 x 12 mm 1 and move the auto thro...

Page 90: ...ver 2 just contacts the governor arm 3 and tighten the two bolts 6 mm 4 Install the fuel tank page 6 3 Turn the auto throttle switch to the OFF position and start the engine Allow it to warm to normal operating temperature Move the control lever to run the engine at the specified maximum speed and hold the control lever Turn the screw 5 to obtain the specified maximum speed Check the auto throttle...

Page 91: ...MEMO dummyhead dummyhead 62Z7B000 book 10 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 92: ...2 SYSTEM DIAGRAM 8 3 BEFORE TROUBLESHOOTING 8 4 TROUBLESHOOTING 8 4 COOLING FAN FLYWHEEL REMOVAL INSTALLATION 8 5 CHARGE LAMP COIL IF EQUIPPED REMOVAL INSTALLATION 8 7 CHARGE LAMP COIL INSPECTION 8 8 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 93: ...8 2 dummyhead dummyhead CHARGING SYSTEM CHARGING SYSTEM TOOL Flywheel puller set 07935 8050004 62Z7B000 book 2 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 94: ...ad dummyhead CHARGING SYSTEM SYSTEM DIAGRAM 1 A 3 A CHARGE COIL TYPE Gr W W W W W W W W Gr CHARGE COIL BATTERY MAIN FUSE CONTROL BOX CIRCUIT PROTECTOR SILICON RECTIFIER 62Z7B000 book 3 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 95: ...al Abnormal Check the charge lamp coil page 8 8 Replace the charge coil lamp coil page 8 7 Check the harness connecting the charge coil and battery for open or short circuit and for proper connection If necessary replace or repair the harness Check the fuse page 11 7 Replace the fuse page 11 4 Replace the circuit protector page 11 4 Replace the silicon rectifier page 11 4 Normal Normal Normal Abno...

Page 96: ...ODRUFF KEY 25 x 18 mm REMOVAL Hold the flywheel 1 with a commercially available strap wrench 2 and use the special tool to remove the flywheel Do not hit the flywheel with a hammer REMOVAL Hold the flywheel 1 with a commercially available strap wrench 2 and remove the special nut 16 mm 3 Take care not to damage the cooling fan 1 STARTER PULLEY With starter FLYWHEEL Without starter FLYWHEEL With sc...

Page 97: ... the flywheel 2 by aligning the three projections of the cooling fan with the holes of the flywheel Attach the starter pulley 3 by aligning the hole of the pulley with the projection at the center of the cooling fan Apply a light coat of oil to the threads and the seating surface of the special nut 16 mm 1 and loosely tighten the nut Hold the flywheel 2 with a commercially available strap wrench 3...

Page 98: ...maximum speed page 7 8 BOLT 6 x 40 mm 4 CORD GROMMET CORD CLAMP 1 A 3 A CHARGE COIL BOLT 6 x 12 mm CORD GROMMET CORD CLAMP 12 V 50 W LAMP COIL TYPE 1 A 3 A CHARGE COIL TYPE 12 V 15 W 12 V 25 W LAMP COIL BOLT 6 x 12 mm CORD CLAMP 12 V 15 W 12 V 25 W LAMP COIL TYPE CORD GROMMET 1 A CHARGE COIL TYPE BOLT 6 x 35 mm 2 BOLT 6 x 12 mm 3 A CHARGE COIL TYPE BOLT 6 x 40 mm 2 12 V 15 W LAMP COIL TYPE BOLT 6 ...

Page 99: ... ground replace the lamp coil page 8 7 If the resistance is good and the flywheel is ok replace the lamp coil and retest 1 A 3 A CHARGE COIL 12 V 50 W LAMP COIL TYPE Disconnect the charge lamp coil connector 1 Check for continuity between terminal and engine ground There should be no continuity If the resistance is good and the flywheel is ok replace the charge lamp coil and retest Resistance lamp...

Page 100: ...YSTEM DIAGRAM 9 2 TROUBLESHOOTING 9 3 IGNITION COIL REMOVAL INSTALLATION 9 4 IGNITION COIL AIR GAP CHECK ADJUSTMENT 9 5 SPARK TEST 9 5 SPARK PLUG CAP INSPECTION 9 5 IGNITION COIL INSPECTION 9 6 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 101: ...TYPE CONTROL BOX TYPE SPARK PLUG IGNITION COIL OIL ALERT UNIT OIL LEVEL SWITCH ENGINE STOP SWITCH Bl Bl Y Bl Y Y Y Bl Y Y Bl W W W W Bl Y Bl R SPARK PLUG IGNITION COIL OIL ALERT UNIT OIL LEVEL SWITCH MAIN FUSE COMBINATION SWITCH CONTROL BOX BATTERY 62Z7B000 book 2 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 102: ... engine wire harness Check the engine stop switch If equipped page 11 6 combination switch If equipped page 11 6 Replace the oil level switch page 14 6 Replace the oil alert unit Without control box page 11 5 With control box page 11 4 Check the ignition coil page 9 6 Replace the ignition coil page 9 4 Check the oil level switch If equipped page 11 5 oil alert unit If equipped page 11 5 Abnormal A...

Page 103: ...IGNITION COIL WIRE SPARK PLUG CAP INSTALLATION Clamp the ignition coil wire to the ribs of the cylinder barrel as shown IGNITION COIL WIRE Viewed from above RIBS IGNITION COIL FLANGE BOLT 6 x 28 mm 2 CARBURETOR INSULATOR BREATHER TUBE HIGH TENSION CORD HIGH TENSION CORD INSTALLATION Install the Ignition coil as shown 62Z7B000 book 4 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 104: ...ark test Faulty spark plug Loose spark plug cap Water in the spark plug cap Leaking the ignition coil secondary voltage Loose ignition coil connector Disconnect the spark plug cap from the spark plug Connect a known good spark plug to the spark plug cap and ground the spark plug to the cylinder head Crank the engine by pulling the recoil starter forcefully and check whether sparks jump across the ...

Page 105: ...r at the iron core 3 If measured resistance is out of specification replace the ignition coil SECONDARY SIDE Disconnect the spark plug cap from the high tension cord 1 Measure the resistance of secondary coil by attaching one ohmmeter probe to the high tension cord and the other at the iron core If measured resistance is out of specification replace the ignition coil RESISTANCE 0 4 0 7 Ω 2 3 1 RES...

Page 106: ... 2 RECOIL STARTER REMOVAL INSTALLATION 10 3 RECOIL STARTER Assy DISASSEMBLY ASSEMBLY 10 4 RECOIL STARTER INSPECTION 10 8 STARTER MOTOR REMOVAL INSTALLATION 10 9 STARTER MOTOR DISASSEMBLY ASSEMBLY 10 10 STARTER MOTOR INSPECTION 10 12 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 107: ...G page 8 4 Replace the fuse page 11 4 Replace the starter solenoid page 10 10 10 11 Disassemble the starter motor page 10 10 10 11 and check the each parts page 10 12 Check the battery condition Check the fuse page 11 7 Check the starter solenoid page 10 12 Abnormal Normal Normal Normal Abnormal Check the combination switch page 11 6 Abnormal Replace the combination switch page 11 4 Abnormal Norma...

Page 108: ...10 3 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER REMOVAL INSTALLATION FLANGE BOLT 6 x 10 mm 3 RECOIL STARTER 62Z7B000 book 3 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 109: ...0 3 Wear gloves and eye protection During disassembly assembly take care not to allow the spring to come out RATCHET GUIDE RECOIL STARTER SETTING SCREW FRICTION SPRING RETURN SPRING 2 RECOIL STARTER REEL STARTER GRIP RECOIL STARTER SPRING RATCHET 2 RECOIL STARTER CASE RECOIL STARTER ROPE 62Z7B000 book 4 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 110: ... Pass the rope through the hole 2 in the reel 3 and then tie the rope as shown Wind the rope onto the reel 1 3 4 turns counterclockwise as shown and hook it to the notch 4 in the reel Pass the rope 1 through hole 2 of the recoil starter case 3 and starter grip 4 and then tie the rope as shown Wear gloves and eye protection During reassembly take care not to allow the spring to come out 2 1 3 4 2 3...

Page 111: ...rease to the sliding surface of the ratchets 1 Install the return springs 2 and ratchets into the reel as shown Install the friction spring 1 so that the end gap 2 is positioned 90 from the cutout 3 in the ratchet guide 4 Install the ratchet guide 1 onto the reel Install the setting screw 2 and tighten it to the specified torque while holding the ratchet guide 5 4 3 1 2 2 2 1 1 2 4 1 90 2 3 TORQUE...

Page 112: ...to wind in the reel 3 Pull the rope out of the reel 1 completely and check that the knot 2 of the rope comes to the hole 3 in the case If the reel can be further turned from this position the assembly is normal If the knot does not come to the hole the recoil starter spring is excessively preloaded Pull the starter grip 1 several times to inspect that the ratchets 2 are operated properly the ratch...

Page 113: ...ge 10 3 Pull the starter grip 1 several times to inspect that the ratchets 2 are operated properly the ratchet ends come out from the ratchet guide 3 STARTER PULLEY Remove the recoil starter Assy page 10 3 Inspect the square dogs 1 of the starter pulley 2 for deformation 1 2 3 2 2 1 62Z7B000 book 8 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 114: ...OVAL INSTALLATION Disconnect the starter motor wires from the starter motor Remove the fan cover page 5 2 STARTER MOTOR FLANGE BOLT GX270H 8 x 40 mm GX390H1 8 x 35 mm 2 STARTER MOTOR STARTER MOTOR WIRE TERMINAL WIRE 62Z7B000 book 9 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 115: ...struction on the magnets NEGATIVE BRUSH 2 BRUSH SPRING 4 BRUSH HOLDER INSULATOR INSPECTION Check for cracks or damage STARTER SOLENOID OVERRUNNING CLUTCH DRIVE PINION GEAR REDUCTION GEAR SCREW 4 x 6 mm 2 FLANGE NUT 6 mm 2 WASHER SCREW WASHER 5 x 32 mm 4 GASKET PINION GEAR WASHER SCREW 5 x 14 mm 2 SCREW WASHER 4 x 14 mm 2 STARTER SOLENOID WIRE POSITIVE BRUSH 62Z7B000 book 10 ページ２０１２年９月２７日木曜日午前１０...

Page 116: ... do not interfere with the commutator WASHER 4 5 0 N m 0 5 kgf m 3 7 lbf ft SCREW 5 x 14 mm 2 5 0 N m 0 5 kgf m 3 7 lbf ft SCREW 5 x 32 mm 4 ASSEMBLY Make sure there is no obstruction on the magnets HOUSING GASKET ARMATURE STARTER SOLENOID WIRE REDUCTION GEAR WASHER CENTER BRACKET ASSY PINION GEAR OVERRUNNING CLUTCH DRIVE PINION GEAR RETAINER RING 2 5 N m 0 3 kgf m 1 8 lbf ft LOCK WASHER 2 NUT 6 m...

Page 117: ...tive lead to the solenoid body Measure the resistance between the battery and starter motor terminals as shown Continuity should exist when the battery is connected and not exist when the battery is disconnected BRUSH LENGTH Measure the brush length If the negative brush length is less than the service limit replace the brush and brush holder If the positive brush length is less than the service l...

Page 118: ...cloth Measure the mica depth If the mica depth is less than the service limit replace the armature Check the continuity as follows There should be continuity between each segment 2 There should be no continuity between each segment and armature core 3 There should be no continuity between each segment and armature shaft 4 OVERRUNNING CLUTCH Check the pinion gear shaft 1 for smooth axial movement A...

Page 119: ...10 14 dummyhead dummyhead STARTING SYSTEM STARTER SOLENOID WIRE Check the starter solenoid wire for continuity 62Z7B000 book 14 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 120: ...Y ASSEMBLY 11 4 OIL ALERT UNIT REMOVAL INSTALLATION 11 5 OIL ALERT UNIT INSPECTION 11 5 OIL LEVEL SWITCH INSPECTION 11 5 ENGINE STOP SWITCH INSPECTION 11 6 COMBINATION SWITCH INSPECTION 11 6 SILICON RECTIFIER INSPECTION 11 6 CIRCUIT PROTECTOR INSPECTION 11 7 FUSE INSPECTION 11 7 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 121: ...ER ELECTRICAL OTHER ELECTRICAL COMPONENT LOCATION WITHOUT CONTROL BOX WITH CONTROL BOX OIL LEVEL SWITCH If equipped ENGINE STOP SWITCH If equipped OIL ALERT UNIT If equipped CONTROL BOX 62Z7B000 book 2 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 122: ...ect the control box wires When installing refer to the HARNESS AND TUBE ROUTING with circuit protector page 2 10 CONTROL BOX ENGINE WIRE HARNESS FLANGE BOLT 6 x 12 mm 2 OIL LEVEL SWITCH WIRE CHARGE COIL CORD STARTER MOTOR WIRE TERMINAL WIRE 62Z7B000 book 3 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 123: ...the control panel COMBINATION SWITCH NUT SILICON RECTIFIER SPECIAL SCREW 6 x 12 mm CONTROL BOX CASE MAIN FUSE CASE MOUNTING BRACKET OIL ALERT UNIT CONTROL PANEL COMBINATION SWITCH WASHER SCREW 3 x 12 mm 2 PROTECTOR LENS If equipped CIRCUIT PROTECTOR If equipped COMBINATION SWITCH 1 CONTROL PANEL INSPECTION page 11 6 INSPECTION page 11 7 GX270H QBE1 QXE9 5 A VKK 15 A GX390H1 5 A INSPECTION page 11 ...

Page 124: ...isconnect the oil alert unit connector 1 Disconnect the oil level switch connector 1 Check the continuity between the switch terminal and engine ground There should be no continuity when the engine is full of oil Drain the engine oil completely page 3 3 Check the continuity between the switch terminal and engine ground There should be continuity Check the continuity between the switch terminals wh...

Page 125: ...heck the continuity between the terminals at each switch position If the correct continuity is not obtained replace the combination switch page 11 4 SILICON RECTIFIER INSPECTION Remove the silicon rectifier page 11 4 Check continuity between the terminals There should be continuity in one direction only Replace the rectifier if there is continuity in both directions or in neither direction Switch ...

Page 126: ...ned replace the circuit protector FUSE INSPECTION Remove the main fuse page 11 4 Visually inspect the fuse to see if it is blown Check continuity across the two blades Replace the fuse if it is blown or there is no continuity across the blades Switch position Continuity ON Yes OFF No ON OFF MAIN FUSE GX270H QBE1 QXE9 5 A VKK 15 A GX390H1 5 A BLOWN 62Z7B000 book 7 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 127: ...MEMO dummyhead dummyhead 62Z7B000 book 8 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 128: ...12 1 12 dummytext 12 MUFFLER MUFFLER REMOVAL INSTALLATION 12 2 EXHAUST PIPE STUD BOLT REPLACEMENT 12 4 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 129: ...T 8 mm If equipped CLEANING Before installing clean the spark arrester If equipped MUFFLER GASKET TAPPING SCREW 6 x 10 mm MUFFLER PROTECTOR TAPPING SCREW 5 x 8 mm 4 TAPPING SCREW 5 x 8 mm TAPPING SCREW 4 x 6 mm GX270H GX390H1 NUT 8 mm 2 BOLT 6 x 12 mm If equipped EXHAUST PIPE PROTECTOR EXHAUST PIPE If equipped MUFFLER GASKET EXHAUST PIPE GASKET 24 N m 2 4 kgf m 18 lbf ft 24 N m 2 4 kgf m 18 lbf ft...

Page 130: ... If equipped If equipped CLEANING Before installing clean the spark arrester 24 N m 2 4 kgf m 18 lbf ft BOLT 8 x 20 mm 2 If equipped MUFFLER GASKET INNER MUFFLER PROTECTOR TAPPING SCREW 4 x 8 mm TAPPING SCREW 4 x 6 mm MUFFLER A BOLT 6 x 10 mm SPARK ARRESTER If equipped MUFFLER PROTECTOR SEALS BOLTS 6 x 10 mm 62Z7B000 book 3 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 131: ...T REPLACEMENT Thread two nuts onto the exhaust pipe stud bolt 1 and tighten them together then use a wrench to turn the stud bolt out Install new stud bolts SPECIFIED LENGTH 8 x 32 mm 16 mm 0 63 in SHORT LONG 1 1 62Z7B000 book 4 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 132: ...3 2 CYLINDER HEAD REMOVAL INSTALLATION 13 3 CYLINDER HEAD DISASSEMBLY ASSEMBLY 13 4 CYLINDER HEAD VALVES INSPECTION 13 5 VALVE GUIDE REPLACEMENT 13 8 VALVE GUIDE REAMING 13 9 VALVE SEAT RECONDITIONING 13 10 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 133: ...0 Seat cutter 35 mm 45 IN 07780 0010400 Seat cutter 33 mm 45 EX 07780 0012900 Flat cutter 30 mm 32 IN 07780 0012200 Flat cutter 28 mm 32 EX 07780 0012100 Flat cutter 35 mm 32 IN 07780 0012300 Flat cutter 33 mm 32 EX 07780 0010800 Interior cutter 37 5 mm 60 IN EX 07780 0014100 Cutter holder 6 6 mm 07781 0010202 Valve guide reamer 6 612 mm 07984 ZE20001 62Z7B000 book 2 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 134: ... HEAD GASKET HEAD COVER HEAD COVER PACKING INSTALLATION Note the installation direction HEAD COVER FLANGE BOLT 10 x 80 4 Apply to the threads and seating surface HEAD COVER BOLT INSTALLATION Before installing the cylinder head remove any carbon deposits from the combustion chamber and inspect the valve seat After installing the cylinder head measure the cylinder compression CYLINDER HEAD HEAD COVE...

Page 135: ...VOT BOLT 2 24 N m 2 4 kgf m 18 lbf ft ROCKER ARM PIVOT LOCK NUT 2 10 N m 1 0 kgf m 7 lbf ft ROCKER ARM PIVOT 2 Apply to the threads and pivot VALVE ROCKER ARM ASSEMBLY Before installing the rocker arm check for wear on the surfaces of the rocker arm that contact the pivot bolt push rod and valve stem Apply to the tappet surface and pivot Sliding surface and stem end Sliding surface and stem end VA...

Page 136: ...cylinder head page 13 4 VALVE SEAT WIDTH Remove the carbon deposits from the combustion chamber page 3 15 Inspect each valve for face irregularities If necessary replace the valve page 13 4 Apply a light coat of Prussian Blue or erasable felt tipped marker ink to each valve seat Insert the valve and snap it closed against its seat several times Be sure the valve does not rotate on the seat The tra...

Page 137: ...he measured valve guide I D is more than the service limit replace the valve guide page 13 8 VALVE FACE Inspect each valve for face irregularities If necessary replace the valve page 13 4 TOOL Valve guide reamer 6 612 mm 2 07984 ZE20001 COMBUSTION CHAMBER SIDE VALVE SPRING SIDE 1 2 HANDLE Commercially available GX270H STANDARD 6 600 6 612 mm 0 2598 0 2603 in SERVICE LIMIT 6 66 mm 0 262 in GX390H1 ...

Page 138: ...13 4 Valve guide page 13 8 VALVE SPRING FREE LENGTH Measure the valve spring free length If the measured length is less than the service limit replace the valve spring page 13 4 STANDARD IN 6 575 6 590 mm 0 2588 0 2594 in EX 6 535 6 550 mm 0 2573 0 2579 in SERVICE LIMIT IN 6 44 mm 0 254 in EX 6 40 mm 0 252 in GX270H STANDARD IN 0 010 0 037 mm 0 0004 0 0015 in EX 0 050 0 077 mm 0 0020 0 0032 in SER...

Page 139: ...LACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour Use a hot plate or oven to heat the cylinder head evenly to 150 C 300 F Do not use a torch to heat the cylinder head warpage of the cylinder head may result Do not get the cylinder head hotter than 150 C 300 F excessive heat may loosen the valve seat Remove the heated cylinder head from the hot p...

Page 140: ...oom temperature Ream the valve guide VALVE GUIDE REAMING For best results be sure the cylinder head is at room temperature before reaming valve guides Coat the reamer and valve guide with cutting oil Rotate the reamer clockwise through the valve guide the full length of the reamer Turn the special tool valve guide reamer clockwise never counterclockwise Continue to rotate the special tool while re...

Page 141: ...inst its seat several times Be sure the valve does not rotate on the seat The transferred marking compound will show any area of the seat that is not concentric Measure the valve seat width of the cylinder head If the measurement is more than the service limit recondition the valve seat Check whether the valve seat contact area of the valve is too high If the valve seat is too high or too low reco...

Page 142: ... the valve against the seat with force during lapping Apply a light pass with the valve lapper Avoid lapping the valve in the same position as it causes uneven wear Lap the valve by turning the lapper slowly Take care not to allow the lapping compound to enter the gap between the stem and guide Adjust the valve clearance after assembly page 3 13 TOOLS GX270H Cutter holder 6 6 mm 07781 0010202 Flat...

Page 143: ...MEMO dummyhead dummyhead 62Z7B000 book 12 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 144: ...AFT BALANCER WEIGHT BEARING OIL SEAL REPLACEMENT CRANKCASE COVER SIDE 14 24 CRANKSHAFT BEARING REPLACEMENT FLYWHEEL SIDE 14 26 GX270H CRANKSHAFT OIL SEAL REPLACEMENT CYLINDER BARREL SIDE 14 27 GX390H1 BALANCER WEIGHT BEARING GOVERNOR ARM SHAFT OIL SEAL CRANKSHAFT OIL SEAL REPLACEMENT CYLINDER BARREL SIDE 14 27 GX270H CRANKSHAFT P T O SHAFT OIL SEAL REPLACEMENT 1 2 REDUCTION CLUTCH TYPE 14 28 GX390...

Page 145: ...t 42 x 47 mm 07746 0010300 Attachment 52 x 55 mm 07746 0010400 Attachment 72 x 75 mm 07746 0010600 Inner driver handle 40 mm 07746 0030100 Attachment 30 mm 07746 0030300 Attachment 35 mm 07746 0030400 Pilot 15 mm 07746 0040300 Pilot 20 mm 07746 0040500 Pilot 30 mm 07746 0040700 Pilot 35 mm 07746 0040800 62Z7B000 book 2 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 146: ...07746 0041200 Driver handle 07749 0010000 Bearing remover shaft set 15 mm 07936 KC10500 Bearing remover shaft set 25 mm 07936 ZV10100 Attachment 45 x 50 mm 07946 6920100 Attachment 62 x 64 mm 07947 6340400 62Z7B000 book 3 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 147: ...6 3 x 6 3 x 43 mm If equipped DOWEL PIN 8 x 12 mm 2 CASE COVER PACKING CRANKCASE COVER Without reduction OIL FILLER CAP OIL FILLER CAP PACKING 2 OIL FILLER CAP With oil level gauge 24 N m 2 4 kgf m 18 lbf ft BOLT 8 x 40 mm 7 CRANKCASE COVER With reduction KEY 7 x 7 x 33 mm 6 3 x 6 3 x 43 mm If equipped 62Z7B000 book 4 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 148: ...OTTOM RUBBER SMALL BOTTOM RUBBER LARGE 2 DUCT COVER BOLT 5 x 10 mm 3 If equipped DOWEL PIN 8 x 12 mm 2 CASE COVER PACKING CRANKCASE COVER OIL FILLER CAP OIL FILLER CAP PACKING 24 N m 2 4 kgf m 18 lbf ft BOLT 8 x 40 mm 7 If equipped 62Z7B000 book 5 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 149: ... The 10 mm lock pin must be installed with the straight side of the 10 mm lock pin against the groove of the governor arm shaft 23 N m 2 3 kgf m 17 lbf ft 14 N m 1 4 kgf m 10 lbf ft INSTALLATION Set the connecting rod lower with the oil dipper toward the camshaft INSTALLATION Before installing the crankshaft check the oil seal of the cylinder barrel for damage or hardening Be careful not to damage...

Page 150: ...ylinder barrel by aligning the punch marks 2 of the balancer weight and the crankshaft 3 marked on the balancer drive gear 4 Install the camshaft 1 to the cylinder barrel by aligning the punch marks 2 of the camshaft and the crankshaft 3 marked on the timing gear 4 1 4 3 2 3 1 4 2 62Z7B000 book 7 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 151: ... 8 mm KEY 7 x 7 x 33 mm INSPECTION page 14 21 ASSEMBLY Attach the P T O drive chain to the P T O shaft and sprocket and install in the crankcase cover as a set BOLT 8 x 40 mm 6 INSPECTION page 14 21 BEARING 6206 P T O SHAFT Gear teeth and journal INSPECTION page 14 21 OIL SEAL 30 x 46 x 8 mm CHAIN CASE COVER ASSEMBLY Be careful not to damage the oil seal lips CHAIN CASE COVER PACKING BOLT 8 x 25 m...

Page 152: ...G 6206 REDUCTION COVER ASSEMBLY Be careful not to damage the lip of the oil seal when installing the P T O shaft into the reduction cover SEALING WASHER OIL DRAIN BOLT 23 N m 2 3 kgf m 17 lbf ft BOLT 8 x 35 mm ASSEMBLY Align the groove of the clutch weight holder with clutch center key when installing CLUTCH PLATE 2 ASSEMBLY Note the installation sequence ASSEMBLY Note the installation sequence CL...

Page 153: ... O SHAFT COUNTERSHAFT GEAR CASE COVER CHAIN CASE COVER PACKING KEY 7 x 7 x 33mm 6 3 X 6 3 X 43mm DISASSEMBLY ASSEMBLY Hold the 16 mm special nut of the flywheel and remove install the 8 x 25 mm flange bolt 24 N m 2 4 kgf m 18 lbf ft FLANGE BOLT 8 x 40 mm 6 16 mm SPECIAL NUT 24 N m 2 4 kgf m 18 lbf ft 62Z7B000 book 10 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 154: ... HOLDER Assy DISASSEMBLY ASSEMBLY Remove the clutch weight holder Assy page 14 9 CLUTCH PRESSURE PLATE CLUTCH WEIGHT HOLDER CLUTCH WEIGHT CENTER CLUTCH WEIGHT 48 CLUTCH FREE SPRING 4 CLUTCH SPRING HOLDER 4 62Z7B000 book 11 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 155: ...overnor weight check to be sure they moves smoothly GROOVE CRANKCASE COVER GX270H PLAIN WASHER 6 mm GOVERNOR WEIGHT PIN 3 GOVERNOR WEIGHT HOLDER PLAIN WASHER 6 mm GOVERNOR WEIGHT HOLDER GOVERNOR WEIGHT PIN 2 GOVERNOR WEIGHT 2 REASSEMBLY After installing the governor weight check to be sure they moves smoothly GOVERNOR HOLDER CLIP ASSEMBLY Install firmly into the groove of the governor shaft GOVERN...

Page 156: ...top ring and second ring are not interchanged Install the top ring and second ring on the piston with the maker mark side facing up Check that the piston rings rotate smoothly after installing them Space the piston ring end gaps 120 degrees apart and do not align the ring end gaps with the piston pin bore 10 mm 0 4 in PISTON ASSEMBLY Install by setting one end of the piston pin clip in the groove ...

Page 157: ... this inspection page 14 20 CYLINDER SLEEVE I D Measure and record the cylinder I D at three levels in both the X axis perpendicular to crankshaft and the Y axis parallel to crankshaft Take the maximum reading to determine cylinder wear and taper GX270H GX390H1 If the measurement is more than the service limit replace the cylinder barrel page 14 6 Inspect the piston skirt O D with this inspection ...

Page 158: ...rance If the clearance is still more than the service limit with the new piston replace the cylinder barrel page 14 6 PISTON PIN BORE I D Measure and record the piston pin bore I D of the piston GX270H GX390H1 If the measurement is less than the service limit replace the piston page 14 13 Inspect the piston pin O D with this inspection page 14 16 STANDARD 76 975 76 985 mm 3 0305 3 0309 in SERVICE ...

Page 159: ...e piston page 14 13 PISTON RING SIDE CLEARANCE Measure the clearance between each piston ring and ring groove of the piston using a feeler gauge If any of the measurements is more than the service limit inspect the piston ring width If the piston ring width is normal replace the piston page 14 13 and reinspect the clearance If necessary replace the piston rings top second oil as a set page 14 13 a...

Page 160: ...cting rod big end and crankshaft using a feeler gauge If the measurement is more than the service limit replace the connecting rod page 14 13 and recheck the clearance If the clearance is still more than the service limit with the new connecting rod replace the crankshaft page 14 6 STANDARD Top 1 170 1 190 mm 0 0460 0 0469 in Second 1 155 1 175 mm 0 0455 0 0463 in SERVICE LIMIT Top 1 140 mm 0 0449...

Page 161: ... replace the connecting rod page 14 13 CRANKPIN O D Measure the crankpin O D of the crankshaft GX270H GX390H1 If the measurement is less than the service limit replace the crankshaft page 14 6 STANDARD 18 005 18 020 mm 0 7089 0 7094 in SERVICE LIMIT 18 07 mm 0 711 in STANDARD 20 005 20 020 mm 0 7876 0 7882 in SERVICE LIMIT 20 07 mm 0 790 in TORQUE 14 N m 1 4 kgf m 10 lbf ft STANDARD 33 025 33 039 ...

Page 162: ... limit inspect the connecting rod big end I D and the crankpin O D If necessary replace the part that is not within the service limit and reinspect the clearance CRANKSHAFT RUNOUT Set the crankshaft on V blocks and measure the runout using a dial indicator If the measured runout is more than the service limit replace the crankshaft page 14 6 TORQUE 14 N m 1 4 kgf m 10 lbf ft STANDARD 0 040 0 064 m...

Page 163: ...spring 1 is worn or weakened replace the weight return spring Check that the decompressor weight moves smoothly If the decompressor weight does not move correctly replace the camshaft page 14 6 STANDARD IN 31 945 32 145 mm 1 2577 1 2655 in EX 31 666 31 866 mm 1 2467 1 2546 in SERVICE LIMIT IN 31 35 mm 1 234 in EX 31 35 mm 1 234 in STANDARD IN 32 498 32 698 mm 1 2794 1 2873 in EX 31 985 32 185 mm 1...

Page 164: ...sive play REDUCTION UNIT INSPECTION RADIAL BALL BEARING Clean the bearing with solvent and dry it thoroughly Turn the inner race of the radial ball bearing with your finger and check for play Replace the radial ball bearing if it is noisy or has excessive play CHAIN TYPE P T O SHAFT DRIVE SPROCKET DRIVE CHAIN Check the following for wear or damage P T O shaft 1 Drive sprocket 2 Drive chain 3 Repla...

Page 165: ...mage P T O shaft 1 Drive sprocket 2 Drive chain 3 Clutch center 4 Replace the P T O shaft drive sprocket and drive chain as a set Check the grooves of the drive sprocket for damage or wear caused by the clutch plate replace it if necessary Check the drive sprocket bushing 5 for damage or excessive wear replace the drive sprocket if necessary STANDARD 3 5 mm 0 14 in SERVICE LIMIT 3 0 mm 0 12 in SER...

Page 166: ...ssary replace the primary drive gear page 14 10 P T O SHAFT Check for worn and weakened gear of the P T O shaft If necessary replace the P T O shaft page 14 10 COUNTERSHAFT Check for worn and weakened gears of the countershaft If necessary replace the countershaft page 14 10 62Z7B000 book 23 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 167: ... special tools Apply grease to the lip of a oil seal TOOLS GX270H 6206 Attachment 62 x 64 mm 3 07947 6340400 Pilot 30 mm 4 07746 0040700 Driver handle 5 07749 0010000 GX390H1 6207 Attachment 72 x 75 mm 3 07746 0010600 Pilot 35 mm 4 07746 0040800 Driver handle 5 07749 0010000 1 4 5 2 3 TOOLS GX270H 30 x 46 x 8 mm Attachment 45 x 50 mm 2 07946 6920100 Driver handle 3 07749 0010000 GX390H1 35 x 52 x ...

Page 168: ...s Drive a new bearing 4 until it is fully seated on the end using the special tools TOOLS Bearing remover shaft set 15 mm 2 07936 KC10500 Sliding hammer weight 3 07741 0010201 TOOLS Attachment 32 x 35 mm 5 07746 0010100 Pilot 15 mm 6 07746 0040300 Driver handle 7 07749 0010000 3 2 1 7 5 6 4 62Z7B000 book 25 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 169: ...radial ball bearing 2 using a commercially available bearing puller 3 Drive a new bearing 4 until it is fully seated on the end using the special tools and hydraulic press TOOLS GX270H 6206 Attachment 30 mm 5 07746 0030300 Inner driver handle 40 mm 6 07746 0030100 GX390H1 6207 Attachment 35 mm 5 07746 0030400 Inner driver handle 40 mm 6 07746 0030100 3 1 6 5 2 4 62Z7B000 book 26 ページ２０１２年９月２７日木曜日...

Page 170: ... SEAL REPLACEMENT CYLINDER BARREL SIDE BALANCER WEIGHT BEARING 6202 Pull out the radial ball bearing 1 using the special tools Drive a new bearing 4 until it is fully seated on the end using the special tools TOOLS Attachment 45 x 50 mm 2 07946 6920100 Driver handle 3 07749 0010000 2 2 0 mm 0 08 in 3 1 Lips TOOLS Bearing remover shaft set 15 mm 2 07936 KC10500 Sliding hammer weight 3 07741 0010201...

Page 171: ...ip of a oil seal GX270H CRANKSHAFT P T O SHAFT OIL SEAL REPLACEMENT 1 2 REDUCTION CLUTCH TYPE P T O SHAFT OIL SEAL 30 x 50 x 7 mm Remove the oil seal from the reduction cover Drive a new oil seal 1 in the position as shown using the special tools Apply grease to the lip of a oil seal TOOLS Pilot 14 mm 2 07746 0041200 Driver handle 3 07749 0010000 0 0 5 mm 0 0 02 in 3 Lips 2 1 TOOLS Attachment 52 x...

Page 172: ...OVER SIDE P T O SHAFT BEARING 6206 Remove the oil seal and drive out the P T O shaft bearing Drive a new P T O shaft bearing 1 until it is fully seated on the end using the special tools TOOLS Attachment 45 x 50 mm 2 07946 6920100 Driver handle 3 07749 0010000 3 2 1 Lips TOOLS Bearing remover shaft set 25 mm 2 07936 ZV10100 Sliding hammer weight 3 07741 0010201 TOOLS Bearing driver attachment 52 x...

Page 173: ... ball bearing 1 using the special tools Drive a new bearing 4 until it is fully seated on the end using the special tools TOOLS Bearing remover shaft set 15 mm 2 07936 KC10500 Sliding hammer weight 3 07741 0010201 TOOLS Attachment 32 x 35 mm 5 07746 0010100 Pilot 15 mm 6 07746 0040300 Driver handle 7 07749 0010000 2 5 3 7 1 4 6 62Z7B000 book 30 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 174: ...mm Remove the oil seal from the crankcase cover Drive a new oil seal 1 in the position as shown using the special tools Apply grease to the lip of a oil seal TOOLS Attachment 62 x 64 mm 3 07947 6340400 Pilot 30 mm 4 07746 0040700 Driver handle 5 07749 0010000 3 5 1 4 2 TOOLS Attachment 45 x 50 mm 2 07946 6920100 Driver handle 3 07749 0010000 2 2 0 mm 0 08 in Lips 3 1 62Z7B000 book 31 ページ２０１２年９月２７...

Page 175: ...EARING 6204 Remove the crankcase cover page 14 4 Drive out the radial ball bearing 1 Drive a new bearing 2 until it is fully seated on the end using the special tools TOOLS Attachment 42 x 47 mm 3 07746 0010300 Pilot 20 mm 4 07746 0040500 Driver handle 5 07749 0010000 3 5 1 2 4 62Z7B000 book 32 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 176: ... Remove the crankcase cover page 14 4 Drive out the radial ball bearing 1 using the special tools Drive a new bearing 2 until it is fully seated on the end using the special tools TOOLS Attachment 32 x 35 mm 3 07746 0010100 Pilot 15 mm 4 07746 0040300 Driver handle 5 07749 0010000 5 3 4 1 2 62Z7B000 book 33 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 177: ...er page 14 4 Drive out the radial ball bearing 1 Drive a new bearing 2 until it is fully seated on the end using the special tools TOOLS Attachment 42 x 47 mm 3 07746 0010300 Pilot 20 mm 4 07746 0040500 Driver handle 5 07749 0010000 3 5 1 4 2 62Z7B000 book 34 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 178: ...15 1 15 dummytext 15 WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM RELATED INFORMATION 15 2 WIRING DIAGRAMS 15 4 62Z7B000 book 1 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 179: ...ated connectors The double frame connectors represent the male connectors and the single frame connectors represent the female connectors Both the male and female connectors are shown by viewing them from the terminal side FEMALE CONNECTOR MALE CONNECTOR LOCK VIEWING DIRECTION VIEWING DIRECTION FEMALE CONNECTOR DRAWING SINGLE FRAME Female connector viewed from the terminal side CONNECTOR No MALE C...

Page 180: ...P Pink W White Gr Gray SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a male or female terminal TERMINAL No CONNECTOR TERMINAL No Every connector and terminal has a number to help the users find the location and shape of the connector and the terminal arrangement by referring to the Connector general layout drawing and or the Connector drawing All the connector te...

Page 181: ...15 4 dummyhead dummyhead WIRING DIAGRAMS WIRING DIAGRAMS NO CHARGE COIL TYPE 1 A 3 A CHARGE COIL TYPE 62Z7B000 book 4 ページ２０１２年９月２７日木曜日午前１０時２１分 ...

Page 182: ...0H CRANKSHAFT OIL SEAL REPLACEMENT CYLINDER BARREL SIDE 14 27 GX270H CRANKSHAFT P T O SHAFT OIL SEAL REPLACEMENT 1 2 REDUCTION CLUTCH TYPE 14 28 GX390H1 BALANCER WEIGHT BEARING GOVERNOR ARM SHAFT OIL SEAL CRANKSHAFT OIL SEAL REPLACEMENT CYLINDER BARREL SIDE 14 27 GX390H1 COUNTERSHAFT P T O SHAFT BEARING REPLACEMENT CRANKCASE COVER SIDE 14 33 GX390H1 COUNTERSHAFT P T O SHAFT BEARING OIL SEAL REPLAC...

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