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FG110

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

9-1

9. CRANKSHAFT/PISTON/CYLINDER

BLOCK/VALVES

1. CRANKSHAFT/PISTON

a. DISASSEMBLY/REASSEMBLY

Remove the lower crankcase

(P. 8-4)

1. CRANKSHAFT/PISTON

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

9-1

2. CYLINDER BLOCK/ROCKER ARMS/VALVES

9-5

SECOND RING
(BLACK CIRCUMFERENCE)

OIL RINGS
(COMBINATION
RINGS)

SIDE RAIL
SPACER
SIDE RAIL

10 mm
(0.4 in)

120¡

TOP RING
(WHITE CIRCUMFERENCE)

CARBURETOR SIDE

TOP RING

SECOND RING

OIL RINGS

MARK

10 x 20 x 5 mm
OIL SEAL

12 x 24 x 5 mm
OIL SEAL

PISTON

INSPECTION:

(P. 9-2)

REASSEMBLY:

(P. 9-2)

Install with the

mark on

the piston head facing the
carburetor side.

CRANKSHAFT

REASSEMBLY:

(P. 9-4)

PISTON PIN

DISASSEMBLY:

(P. 9-2)

REASSEMBLY:

(P. 9-4)

INSPECTION:

(P. 9-2)

SECOND RING

OIL RINGS

(COMBINATION
RINGS

TOP RING

“ • ” MARK

INSPECTION:

(P. 9-2)

REASSEMBLY:

•

Install the second ring with the “ • “ mark facing up.

• Do not interchange the top ring and the second ring.

• After assembly, check for smooth movement of the

piston ring.

• Stagger the piston ring end gaps 120° apart. Do not

align with the piston end.

• Space the side rail end gaps at least 10 mm (0.4 in)

apart. Coat the oil ring with oil after assembly.

10 mm (0.04 in)

PISTON RING

Содержание FG110

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 21: ...cap dipstick securely Oil Change Drain the used oil while the engine is warm Warm oil drains quickly and completely 1 Place a suitable container below the engine to catch the used oil 2 Remove the oi...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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