Honda GX390RT2 Shop Manual Download Page 5

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ABBREVIATIONS

Throughout this manual, the following abbreviations are used to identify the respective parts or systems

Abbrev. term

Full term

ACG

Alternator

API

American Petroleum institute

Approx.

Approximately

Assy.

Assembly

ATDC

After Top Dead Center

ATF

Automatic Transmission Fluid

ATT

Attachment

BAT

Battery

BDC

Bottom Dead Center

BTDC

Before Top Dead Center

BARO

Barometric Pressure

CKP

Crankshaft Position

Comp.

Complete

CMP

Camshaft Position

CYL

Cylinder

DLC

Data Link Connector

EBT

Engine Block Temperature

ECT

Engine Coolant Temperature

ECM

Engine Control Module

EMT

Exhaust Manifold Temperature

EOP

Engine Oil Pressure

Exhaust

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

Intake

INJ

Injection

Left

MAP

Manifold Absolute Pressure

MIL

Malfunction Indicator Lamp

O.D.

Outside Diameter

Optional Part

PGM-FI

Programmed-Fuel Injection

P/N

Part Number

Qty

Quantity

Right

SAE

Society of Automotive Engineers

SCS

Service Check Signal

STD

Standard

Switch

TDC

Top Dead Center

Throttle Position

VTEC

Variable Valve Timing & Valve Lift Electronic Control

Black

Green

Brown

Light green

Yellow

Red

Orange

Pink

Blue

White

Light blue

Gray

62Z5F000.book 5 ページ２０１０年３月２３日　火曜日　午後３時３１分

Summary of Contents for GX390RT2

Page 1: ...afety 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 pressurized air...

Page 2: ...NANCE 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 62Z5F000 book 2 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 3: ...rn 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 March 2010 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 These signal...

Page 4: ... 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 symbols Replace the part s with new one s before assembly Use the recommend...

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 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 Injection...

Page 6: ...RIAL NUMBER LOCATION 1 2 TYPE CODE 1 2 DIMENSIONS AND WEIGHTS SPECIFICATIONS 1 4 ENGINE SPECIFICATIONS 1 5 PERFORMANCE CURVES 1 6 DIMENSIONAL DRAWINGS 1 7 PTO DIMENSIONAL DRAWINGS 1 9 62Z5F000 book 1 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 7: ... 3 Model GX390RT2 Type QWA2 VAA1 VEP9 VKE4 VKX4 P T O Q type V type Model GX390RT2 Type VPE5 VPE9 VPX4 VPX9 VSD4 P T O V type Model GX390RT2 GX390T2 Type VTH4 VWC VWC9 VWT4 ES2 P T O V type E type Model GX390T2 Type LH LH2 LHB5 LHP1 LXE9 P T O L type Model GX390T2 Type PX QAPW QBE1 QH QHB1 P T O P type Q type Model GX390T2 Type QHB3 QHB5 QHP1 QMH QN P T O Q type 62Z5F000 book 2 ページ２０１０年３月２３日火曜日 ...

Page 8: ...E8 LXQ4 LXU PA2 PAE2 P T O L type P type Model GX390UT2 Type PXD8 PXE8 PXU QA26 QA4 P T O P type Q type Model GX390UT2 Type QAA6 QAE2 QAE4 QAE6 QC2 P T O Q type Model GX390UT2 Type QDW9 QE QHB4 QK4 QKA4 P T O Q type Model GX390UT2 Type QME0 QNE2 QNE6 QNE8 QNR2 P T O Q type Model GX390UT2 Type QNR6 QWC4 QXB7 QXB9 QXC4 P T O Q type Model GX390UT2 Type QXC6 QXC9 QXCU QXE4 QXE6 P T O Q type Model GX39...

Page 9: ...0 in 460 mm 18 1 in 460 mm 18 1 in S type 460 mm 18 1 in 460 mm 18 1 in V type 458 mm 18 0 in 460 mm 18 1 in 460 mm 18 1 in Overall height H type 448 mm 17 6 in L type 448 mm 17 6 in 448 mm 17 6 in P type 448 mm 17 6 in 448 mm 17 6 in Q type 448 mm 17 6 in 448 mm 17 6 in S type 448 mm 17 6 in 448 mm 17 6 in V type 448 mm 17 6 in 448 mm 17 6 in Dry weight H type 35 2 kg 77 6 lbs L type 35 2 kg 77 6...

Page 10: ...m Continuous rated power 7 0 kW 9 4 HP 3 600 min 1 rpm Maximum net torque SAE J1349 1 26 5 N m 2 7 kgf m 19 5 lbf ft 2 500 min 1 rpm Compression ratio 8 2 0 2 1 Fuel consumption at continuous rat ed power 3 5 Liters 0 92 US gal 0 77 Imp gal h Ignition system C D I Capacitor Discharge Ignition type magneto ignition Ignition timing B T D C 10 1 400min 1 rpm Spark advancer performance B T D C 10 22 S...

Page 11: ...2000 3600 3000 RECOMMENDED OPERATING SPEED RANGE min 1 TRO N m 28 KW HP lbf ft kgf m 9 8 7 OUTPUT TORQUE 6 6 19 2 6 2 7 2 8 20 21 7 8 9 10 11 12 5 4 26 24 NET POWER NET TORQUE 16 17 18 15 2 3 2 4 2 5 2 2 22 20 62Z5F000 book 6 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 12: ...6 7 With control box type 498 6 19 63 GX390RUT2 447 17 6 GX390T2 443 17 4 98 3 9 121 8 4 80 301 3 11 86 100 3 9 133 5 5 26 141 5 5 57 200 6 7 90 17 0 7 27 1 1 103 4 1 105 4 1 195 5 7 70 Without control box type 460 18 1 CRANKSHAFT P T O CONTROL BOX STARTER MOTOR If equipped If equipped 448 17 6 62Z5F000 book 7 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 13: ...5 26 141 5 5 57 200 6 7 9 17 0 7 27 1 1 103 4 1 105 4 1 195 5 7 70 REDUCTION UNIT 68 1 2 68 P T O SHAFT 155 6 1 L 440 17 3 98 3 9 121 8 4 80 With control box type 498 6 19 63 Without control box type 460 18 1 GX390RUT2 447 17 6 GX390T2 443 17 4 448 17 6 62Z5F000 book 8 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 14: ... TAPER 1 5 M10 x 1 25 28 1 1 35 1 4 Φ25 997 26 000 Φ1 0235 1 0236 Φ 1 8 4 Φ 7 2 4 P T O SHAFT 18 0 71 Φ190 05 190 25 Φ7 482 7 490 Unit mm in 45 45 103 4 1 70 2 8 85 7 3 37 P D 1 2 7 5 0 0 Φ25 374 25 400 Φ0 9990 1 0000 16 0 6 62 1 2 45 REDUCTION UNIT P T O SHAFT Φ7 15 Φ0 281 6PLACES 6 31 6 36 0 248 0 250 80 3 20 63 2 5 21 69 21 82 0 854 0 859 62Z5F000 book 9 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 15: ... O SHAFT M8 x 1 25 2PLACES M8 x 1 25 4PLACES 20 9 21 0 0 82 0 83 28 1 1 7 00 7 05 0 276 0 278 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 26 27 1 0 1 1 72 5 2 85 P D 165 1 6 50 P D 1 2 7 5 0 0 Φ110 00 110 05 Φ4 3307 4 3327 5 16 24UNF 2B 2 PLACES 5 16 24UNF 2B 4 PLACES 3 8 16UNC 2B 4 PLACES CRANKSHAFT P T O 62Z5F000 book 10 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 16: ... 16 24UNF 2B 4 PLACES 3 8 16UNC 2B 4 PLACES Unit mm in 30 30 45 45 103 4 1 70 2 8 63 2 5 41 1 6 Φ24 947 24 980 Φ0 9822 0 9835 M8 1 25 28 1 1 60 2 4 P D 165 1 6 50 P D 1 2 7 5 0 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 SNC TYPE 3 8 16UNC 2B TAP 4 PLACES CRANKSHAFT P T O SM32 TYPE M8 x 1 25 2PLACES SM32 TYPE Φ8 51 Φ0 34 4 PLACES SM32TYPE M8 x 1 25 4 PLACES SNC TYPE 5 1...

Page 17: ... 5 4 15 46 5 1 83 22 136 22 161 Φ0 8715 0 8724 5 16 24UNF 2B TAP 18 0 7 75 5 2 97 P D 165 1 6 50 P D 1 2 7 5 0 0 Φ110 00 110 05 Φ4 331 4 333 CRANKSHAFT P T O 5 16 24UNF 2B 2 PLACES 5 16 24UNF 2B 4 PLACES 3 8 16UNC 2B 4 PLACES 62Z5F000 book 12 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 18: ...2 1 2 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 4 LUBRICATION SEAL POINT 2 5 TOOLS 2 6 HARNESS AND TUBE ROUTING 2 8 62Z5F000 book 1 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 19: ...40 0 0449 Second 1 160 1 175 0 0457 0 0463 1 140 0 0449 Connecting rod Small end I D 20 005 20 020 0 7876 0 7882 20 07 0 790 Big end side clearance 0 1 0 4 0 004 0 016 1 0 0 04 Big end I D 36 025 36 039 1 4183 1 4189 36 07 1 420 Big end oil clearance 0 040 0 064 0 0016 0 0025 0 12 0 005 Crankshaft Crank pin O D 35 975 35 985 1 4163 1 4167 35 93 1 415 Crankshaft runout 0 1 0 003 Cylinder barrel Cra...

Page 20: ...4 turns out BE89U A 2 1 4 turns out BE94B A 1 3 4 turns out BE94A A 2 1 4 turns out Float height 13 2 0 52 Spark plug Gap 0 7 0 8 0 028 0 031 Ignition coil Air gap 0 2 0 6 0 01 0 02 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 1A 3 00 4 00 Ω 3A 0 62 0 93 Ω 10A 0 16 0 24 Ω 18A 0 10 0 30 Ω Lamp coil Resistance 12V 15 W 1 04 1 56 Ω 12V 25 W 0 30 0 4...

Page 21: ... 0 9 0 9 6 6 Muffler nut M8 x 1 25 24 2 4 17 Exhaust pipe nut M8 x 1 25 24 2 4 17 Gear case cover bolt With reduction M8 x 1 25 24 2 4 17 Primary drive gear bolt With reduction M8 x 1 25 24 2 4 17 Engine stop switch tapping screw M3 x 1 06 0 45 0 046 0 33 Recoil starter center screw M5 x 0 8 Special bolt 3 9 0 40 2 9 Fuel strainer cup M24 x 1 0 3 9 0 40 2 9 Item Tread Dia mm Torque values N m kgf ...

Page 22: ...reads and seating surface Rocker arm shaft Flywheel nut threads and seating surface Governor weight holder gear and journal Governor holder shaft Governor slider Governor arm shaft Cylinder head bolt threads and seating surface Rocker arm pivot threads and pivot Balancer shaft bearing and gear P T O shaft bearing and gear Counter shaft bearing and gears Oil seal lip Multi purpose grease O ring Rec...

Page 23: ...achment 42 47 in combination with 07749 0010000 07746 0010300 Bearing driver attachment 52 55 in combination with 07749 0010000 07746 0010400 Bearing driver attachment 72 75 in combination with 07749 0010000 07746 0010600 Inner driver handle 40 07746 0030100 Inner bearing driver attachment 35 in combination with 07746 0030100 07746 0030400 Pilot 15 in combination with 07749 0010000 07746 0040300 P...

Page 24: ... cutter 35 07780 0012300 Flat cutter 38 5 07780 0012400 Interior cutter 37 5 07780 0014100 Cutter holder 6 6 07781 0010202 Flywheel puller set 07935 8050004 Bearing remover shaft 15 07936 KC10500 Valve guide reamer 6 612 07984 ZE20001 Bearing driver attachment 45 50 in combination with 07749 0010000 07946 6920100 Bearing driver attachment 62 64 in combination with 07749 0010000 07947 6340400 62Z5F...

Page 25: ... the application of the engine therefore it does not indicate those parts in this manual ENGINE STOP SWITCH TYPE ENGINE WIRE HARNESS OIL LEVEL SWITCH ENGINE STOP SWITCH HARNESS CLIP To engine stop switch To ignition coil To oil level switch YELLOW YELLOW RED BLACK BLACK RED INSIDE HARNESS CLIP ENGINE STOP SWITCH CORD 62Z5F000 book 8 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 26: ...LOCK CLIP To starter motor To ignition coil YELLOW To ignition coil RED To ignition coil BLACK To starter motor CABLE STRAP FASTENER TUBE YELLOW RED BLACK To starter motor GRAY To control box WHITE BLACK WHITE CABLE STRAP FASTENE R TUBE CABLE STRAP FASTENER TUBE To charge coil STOP SWITCH CORD HOLDER OIL LEVEL SWITCH INSIDE COMBINATION SWITCH WIRE WHITE 62Z5F000 book 9 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 27: ...NGINE WIRE HARNESS IGNITION COIL CYLINDER BARREL RIB FUEL TUBE BREATHER TUBE CARBURETOR INSULATOR CONTROL BASE ASSY CONTROL BASE ASSY GOVERNOR ARM TUBE CLIP HIGH TENSION CORD HIGH TENSION CORD 62Z5F000 book 10 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 28: ...MP COIL TYPE 18A CHARGE COIL TYPE CORD CLAMPER CORD GROMMET COIL CORD CORD CLAMPER CORD GROMMET COIL CORD CORD CLAMPER CORD GROMMET COIL CORD 12 V 15 W 12 V 25 W LAMP COIL TYPE 1 A 3 A CHARGE COIL TYPE 10A CHARGE COIL TYPE 62Z5F000 book 11 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 29: ...MEMO 62Z5F000 book 12 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 30: ...ACEMENT 3 4 SEDIMENT CUP CLEANING 3 6 SPARK PLUG CHECK ADJUSTMENT 3 7 SPARK PLUG REPLACEMENT 3 8 SPARK ARRESTER CLEANING 3 8 IDLE SPEED CHECK ADJUSTMENT 3 10 VALVE CLEARANCE CHECK ADJUSTMENT 3 10 COMBUSTION CHAMBER CLEANING 3 12 FUEL TANK AND FILTER CLEANING 3 12 FUEL TUBE CHECK 3 13 62Z5F000 book 1 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 31: ...age ITEM Perform at every indicated month or operating hour inter val whichever comes first Engine oil Check level 3 3 Change 3 3 Air cleaner Check 3 4 Clean 1 1 3 4 Cyclone type Every 6 months or 150 hours 3 4 Replace 3 4 Cyclone type Every 2 years or 600 hours 3 4 Sediment cup Clean 3 6 Spark plug Check adjust 3 7 Replace 3 8 Spark arrester If equipped Clean 3 8 Idle speed Check adjust 3 10 Valv...

Page 32: ... securely ENGINE OIL CHANGE Drain the oil in the engine while the engine is warm Warm oil drains quickly and completely Place the engine on a level surface and place a suitable container under the drain plug bolt Remove the oil filler cap 1 drain plug bolt 2 and drain plug washer 3 to drain the oil into the suitable container Please dispose of used motor oil in a manner that is compatible with the...

Page 33: ...nstalled loosely will allow dirt to enter the engine causing rapid engine wear Install the air filters securely Remove the nut 1 and the air cleaner cover 2 Remove the wing nut 3 and air filter assembly 4 5 Separate the inner filter Paper 4 from the outer filter Foam 5 Carefully check both filters for holes or tears and replace if damaged Clean the filters if they are to be reused Install the elem...

Page 34: ... 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 air cleaner case lid spring 1 and air cleaner cover 2 Remove the air cleaner element 3 Carefully check air cleaner element and replace if damaged Cle...

Page 35: ...ING Turn the fuel cock lever 1 to the OFF position Remove the sediment cup 2 and the O ring 3 Remove the cup filter 4 while releasing the tabs 5 Clean the sediment cup and the cup filter with non flammable solvent and allow them to dry thoroughly Install the cup filter as the direction shown in the illustration Install a new O ring and tighten the sediment cup to the specified torque Check the ins...

Page 36: ...urement is out of the specification adjust by bending the side electrode Install the spark plug finger tight to seat the washer and then tighten 1 8 1 4 turn with a spark plug wrench 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 If the engine has been running the engine will be very h...

Page 37: ...securely SPARK ARRESTER CLEANING SOLID PROTECTOR TYPE Remove the muffler cover page 12 6 If equipped Remove the 5 x 8 mm tapping screws 1 6 x 10 mm tapping screw 2 and muffler protector 3 Remove the 5 x 8 mm tapping screws 4 and spark arrester 5 If the engine has been running the engine will be very hot Allow it to cool before proceeding SPARK PLUG BPR6ES NGK W20EPR U DENSO 1 2 The engine and the ...

Page 38: ...move the 5 x 8 mm tapping screws 3 R muffler protector 4 and L muffler protector 5 Remove the 5 x 8 mm tapping screws 6 and spark arrester 7 INNER OUTER PROTECTOR TYPE Remove the 6 x 10 mm bolts 1 and outer muffler protector 2 Remove the 4 x 8 mm tapping screw 3 and spark arrester 4 1 3 3 5 2 3 4 6 7 1 3 2 4 1 1 1 62Z5F000 book 9 ページ２０１０年３月２３日火曜日午後３時３１分 ...

Page 39: ...k arrester Install the spark arrester in the reverse order of removal IDLE SPEED CHECK ADJUSTMENT Start the engine and allow it to warm up to normal operating temperature 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 SPEED 1 400 150 min 1 rpm 1 3 2 1 62Z5F000 boo...

Page 40: ...stem 3 to measure the valve clearance If adjustment is necessary proceed as follows Hold the rocker arm pivot 1 and loosen the pivot adjusting nut 2 Turn the rocker arm pivot to obtain the specified clearance Hold the rocker arm pivot and retighten the pivot adjusting nut to the specified torque Recheck the valve clearance and if necessary readjust the clearance Check the head cover packing for da...

Page 41: ...2 page 6 3 Clean the fuel tank joint and fuel tank with non flammable solvent and allow them to dry thoroughly Install the fuel tank page 6 3 Check the installation part of the fuel tank for any sign of fuel leakage 1 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 immediat...

Page 42: ...oration 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 62Z5F000 book 13 ページ２０１０年３月２３日火曜日午後３時３１分 ...

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