GX120 GX160 GX200 - Celtic Distributors Ltd
Contents
1. fy OPERATION 1 As the engine warms up gradually move the choke lever to the OPEN position CHOKE LEVER 2 Position the throttle control lever for the desired engine speed THROTTLE CONTROL LEVER 16 Oil alert system Where equipped The Oil Alert System is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase Before the oil level in the crankcase can fall below a safe limit the Oil Alert System will automatically stop the engine the engine switch will remain in the ON position NOTICE If the engine stops and will not restart check the engine oil level page 6 before troubleshooting in other areas Circuit breaker for electric starter The circuit breaker protects the battery charging circuit A short circuit or a battery connected in reverse polarity will trip the circuit breaker The green indicator inside the circuit breaker will pop out to show that the circuit breaker has switched off If this occurs determine the cause of the problem and correct it before resetting the circuit breaker Push the circuit breaker button to reset CIRCUIT BREAKER 17 STOPPING THE ENGINE To stop the engine in an emergency turn the engine switch to the OFF position Under normal conditions use the following procedure 1 Move the throttle control lever fully to the right THROTTLE CONTROL LEVER es _ LOW 2 Turn the engine switch to the OFF p2. and separate them ELEMENT Carefully check both elements for holes or tears and replace if damaged 2 Foam element Clean in warm soapy water rince and allow to dry thoroughly Or clean in high flash point solvent and allow to dry Dip the element in clean engine oil and squeeze out all the excess The engine will smoke during initial start up if too much oil is felt in the foam FOAM AIR GUIDE ELEMENT AIR INTAKE TAB CYCLONE 3 Paper element Tap the element lightly several times on a hard surface to remove excess dirt or blow compressed air through the filter from the inside out Never try to brush the dirt off brushing will force dirt into the fibers Replace the paper ele ment if it is excessively dirty Cleaning the cyclone housing 1 When the cyclone housing becomes dirty unscrew the three special pan screws and wipe or wash the components with water Next thoroughly dry the components and carefully reassemble them CAUTION e When reinstalling the cyclone ensure that the tab on the air intake fits properly into the groove in the pre cleaner cap e Be careful to install the air guide in the proper direction 22 lt Semi dry type gt 1 Unscrew the wing nut remove the air cleaner cover and remove the element 2 Wash the element in a nonflammable or high flash point solvent and dry it thoroughly 3 Soak the element in clean engine oil and squeeze out the excess oil 4 Reinstall the air clean
3. reinstall the spark plug 5 Pull the starter rope slowly until resistance is felt Continue polling until the notch on the starter pulley aligns with the hole on the recoil starter see illustration below At this point the intake and exhaust valves are closed and this will help to protect the engine from internal corrosion ONS SS Align the mark on the starter Nr pulley with the hole at the top SN N of recoil starter 6 Electric starter type Remove the battery and store it in a cool dry place Recharge it once a month 7 Cover the engine to keep out dust 29 i TROUBLESHOOTING Engine will not start using recoil starter 1 Is the engine switch in the ON position 2 Is there enough oil in the engine 3 Is the fuel valve ON 4 Is there fuel in the fuel tank 5 Is gasoline reaching the carburetor To check loosen the drain screw with the fuel valve ON AWARNING If any fuel is spilled make sure the area is dry before testing the spark plug or starting the engine Fuel vapor or spilled fuel may ignite DRAIN SCREW 6 Is there a spark at the spark plug a Remove the spark plug cap Clean any dirt from around the spark plug base then remove the spark plug b Install the spark plug in the plug cap c Turn the engine switch ON d Grounding the side electrode to any engine ground pull the recoil starter to see if sparks jump across the gap e If there is no spark replace the plug If OK reinstall the s
4. wire cable If using a braided wire cable add a return spring as shown It is necessary to loosen the throttle lever friction nut when operating the throttle with a remote cable RETURN SPRING THROTTLE LEVER FRICTION NUT WIRE HOLDER 4mm SCREW FLEXIBLE WIRE CORE MOUNTING 5S SOLID WIRE l CORE MOUNTING 5 NN 5 mm CIRCLIP i Peaasi THROTTLE LEVER e a gt sh WIRE HOLDER ie 5mm CIRCLIP E TRANSPORTING STORAGE When transporting the engine tum the fuel valve OFF and keep the engine level to prevent fuel spillage Fuel vapor or spilled fuel may ignite Befor storing the unit for an extended period 1 Be sure the storage area is free of excessive humidity and dust 2 Drain the fule AWARNING Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flames or sparks in the area a With the fuel valve in the OFF position SEDIMENT CUP remove and empty the sediment cup b Turn the fuel valve to the ON position and drain the gasoline from the fuel DRAIN tank into a suitable container SCREW c Replace the sediment cup and tighten securely d Drain the carbretor by loosening the drain screw Drain the gasoline into a suitable container 3 Change the engine oil page 20 4 Remove the spark plug and pour about a tablespoon of clean engine oil into the cylinder Crank the engine several revolutions to distribute the oil then
5. x 45mm 68 x 54mm 2 4 x 1 7 in 2 7 x 1 8 in 2 7 x 2 1 in Max output 2 9kW 4 000 rpm 4kW 4 000 rom 4 8 kW 3 600 rpm Max torque 0 75kg m 5 4 ft lb 1 1 kg m 8 0 ft Ib 1 35 kg m 9 8 ft Ib 2 500 rpm 2 500 rpm 2 500 rpm Fuel 230 g PSh consumption Cooling system Forced air Ignition system Transister magneto PTO shaft rotation Counterclockwise S type NOTE Specifications may vary according to the types and are subject to change without notice 31 With cyclone air cleaner Dimensions GX 120 GX 160 GX 200 Power equipment description code GCO1 GC02 GCAE Length Width Height Dry weight 310 mm 12 2 in 410 mm 16 1 in 325 mm 12 8 in 12 0 kg 26 5 Ibs Sr Sa Sa aS 345 mm 13 6 in 420 mm 16 5 in 335 mm 13 2 in 14 0 kg 30 9 Ibs 313 mm 12 3 in 430 mm 16 9 in 335 mm 13 2 in 16 0 kg 35 3 Ibs e a aS Engine Engine type 4 stroke over head valve 1 cylinder Displacement 118 cm 7 2 cu in 163 cm 9 9 cu in 196 cm 12 0 cu in Bore X Stroke 60 x 42 mm 68 x 45mm 68 x 54mm 2 4 x 1 7 in 2 7 x 1 8 in 2 7 x 2 1 in Max output 2 9kW 4 000 rpm 4kW 4 000 rom 4 8 kW 3 600 rom Max torque 0 75 kg m 5 4 ft lb 1 1 kg m 8 0 ft Ib 1 35 kg m 9 8 ft Ib 2 500 rpm 2 500 rpm 2 500 rpm Fuel 230 g PSh consumption Cooling system Forced air Ignition system Transi
6. HONDA GX120 GX160 GX200 Serial number and engine type OWNER S MANUAL 32ZH7620 C 00X32 ZH7 6201 HONDA EUROPE N V EEC 1 www honda engines eu com Thank you for purchasing a Honda engine This manual covers the operation and maintenance of your engine GX120 GX160 GX200 All information in this publication is based on the latest product information available at the time of printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission This manual should be considered a permanent part of the engine and should remain with it if itis resold Pay special attention to statements preceded by the following words Indicates a strong Lae ale of severe personal injury or death if instructions are not followed CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTICE indicates that equipment or property damage can result if instructions are not followed NOTE Gives helpful information If a problem should arise or if you have any questions about your engine consult an authorized Honda dealer The Honda engine is designed to give safe and dependable service if operated according to instructions Read and understand the Owners Manual before operating the engine Failure to do so could result in perso
7. and strainer _ Clean 2 Fuel line Check Every 2 years 2 Replace if necessary NOT E 1 Service more frequently when used in dusty areas 2 These items should be serviced by an authorized Honda dealer unless the owner has the proper tools and is mechanically proficient See the Honda Shop Manual 19 1 Oil change Drain the oil while the engine is still warm to assure rapid and complete draining 1 Remove the oil filler cap and drain plug to drain the oil 2 Install the drain plug and tighten it securely 3 Refill with the recommended oil see page 6 and check the oil level 4 Install the oil filler cap ENGINE OIL CAPACITY 0 60 2 0 63 US qt 0 53 Imp qt 2 REDUCTION GEAR OIL CAPACITY Bt 9 0 53 US qt 0 44 Imp at ENGINE OIL 1 6 REDUCTION GEAR OIL CAPACITY 0 15 2 0 16 US qt 0 13 Imp qt DRAIN PLUG OIL FILLER CAP CAUTION Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil NOTE Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station for reclamation Do not throw it in the trash pour iton the ground or down a drain 20 2 Air cleaner service A di
8. and the other containing methanol Do not use gasohol that contains more than 10 ethanol Do not use gasoline containing methanol methyl or wood alcohol that does not also contain cosolvents and corrosion inhibitors for methanol Never use gasoline containing more than 5 methanol even if it has cosolvents and corrosion inhibitors NOTE e Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete e Before buying fuel from an unfamiliar station try to find out if the fuel contains alcohol if it does confirm the type and percentage of alcohol used If you notice any undesirable operating symptoms while using a gasoline that contains alcohol or one that you think contains alcohol switch to a gasoline that you know does not contain alcohol 11 STARTING THE ENGINE 1 Turn the fuel valve to the ON position FUEL VALVE 2 Move the choke lever to the CLOSED position NOTE Do not use the choke if the engine is warm or the air temperature is high CHOKE LEVER 12 3 Move the throttle control lever slightly to the left THROTTLE CONTROL LEVER 4 Start the engine e With recoil starter Turn the engine switch to the ON position ENGINE SWITCH Pull the starter grip lightly until resistance is fel
9. e battery charging system and trip the circuit breaker 5 PRE OPERATION CHECK 1 Engine oil level CAUTION e Running the engine with insufficient oil can cause serious engine damage Be sure to check the engine on a level surface with the engine stopped 1 Remove the oil filler cap and wipe the dipstick clean 2 Insert the dipstick into the oil filler neck but do not screw it in 3 If the level is low fill to the top of the oil filler neck with the recommended oil Use Honda 4 stroke or an equivalent high detergent premium quality mo tor oil certified to meet or exceed U S automobile manufacturer s require ments for service classification SG SF Motor oils classified SG SF will show this designation on the container SAE 10W 30 is recommended for gen pe eral all temperature use If single vis cosity oil is used select the appropri Ambient temperature ate viscosity for the average tempera SINGLE VISCOSITY ture in your area MULTI VISCOSITY CAUTION Using nondetergent oil or 2 stroke engine oil could shorten the engine s service life OIL FILLER CAP LEVEL DIPSTICK 2 Reduction gear oil Check reduction gear oil level Fill with SG SF rated engine oil if necessary lt 1 2 reduction with automatic centrifugal clutch 1 Remove the oil filler cap and wipe the dipstick clean 2 Insert the dipstick into the filler neck but do not screw itin 3 If the level is low fill to t
10. er element and the cover lt Oil bath type gt 1 Unscrew the wing nut remove the air cleaner cover and remove the element 2 Wash the element in a solution of household detergent and warm water then rinse thoroughly or wash in non flammable or high flash point solvent Allow the element to dry thoroughly 3 Soak the element in clean engine oil and squeeze out the excess oil The engine will smoke during intial start up if too much oil is left in the element 4 Empty the oil from the air cleaner case and wash out any accumulated dirt with nonflammable or high flash point solvent Dry the case 5 Fill the air cleaner case to the level mark with the same oil that is recom mended for the engine See engine oil recommendations on page 6 6 Reinstall the element and the cover 23 WING NUT N AIRCLEANER gt COVER 0 ELEMENT WING NUT AIR ae COVER ELEMENT 3 Sediment cup cleaning AWARNING e Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flames or sparks in the area e After installing the sediment cup check for leaks and make sure the area is dry before starting the engine Turn the fuel valve to OFF Remove the sediment cup and O ring and wash them in nonflammable or high flash point solvent Dry them thoroughly and reinstall securely Turn the fuel valve ON and check for leaks c i ce O RING COZ af d S oi 4 Spark pl
11. he upper level mark with the same oil recommended for the engine see engine oil recommendations on page 6 Oil capacity 0 50 2 0 53 US qt 0 44 Imp qt DIPSTICK FILLER CAP UPPER LEVEL lt 1 6 reduction 1 Remove the oil level bolt 2 Check the oil level it should reach the edge of the oil level bolt hole If the oil level is low remove the filler bolt and add oil until it starts to flow out the oil level bolt hole Use the same oil recommended for the engine See engine oil recommendations on page 6 3 Install the oil level bolt and filler bolt Tighten them securely Oil capacity 0 15 2 0 16 US qt 0 13 Imp qt FILLER BOLT 3 Air cleaner CAUTION Never run the engine without the air cleaner Rapid engine wear will result lt Dual element type gt 1 Check the air cleaner elements to be ELEMENTS sure they are clean and in good con dition 2 Clean or replace the elements if necessary page 21 GX120 160 GX120 160 200 an lt Cyclone type 1 Check cleaner for dirt or obstruction of elements 2 Check the cyclone housing for any dirt build up clean it if necessary CYCLONE page 22 ELEMENTS lt Semi dry type gt Check cleaner for dirt or obstruction of element page 23 ELEMENT lt Oil bath type 1 Check the air cleaner element to be sure it is clean and in good condition Clean or replace the element if necessary page 23 2 Check oil level a
12. nal injury or equipment damage El SAFETY INSTRUCTIONS To ensure safe operation e Honda engine is designed to give safe and dependable service if operated according to instructions Read and understand the Owner s Manual before operating the engine Failure to do so could result in personal injury or equipment damage e Always make a pre operation inspection page 6 before you nasal the engine You may prevent an accident or equipment mage e To prevent fire hazards and to provide adequate ventilation keep the engine at least 1 meter 3 feet away from buildings and other equipment during operation Do not place flammable objects close to the engine e Children and pets must be kept away from the area of operation due to a possibility of burns from hot engine components or injury from any equipment the engine may be used to operate e Know how to stop the engine quickly and understand the operation of all controls Never permit anyone to operate the engine without proper instructions e Do not place flammable objects such as gasoline matches etc close to the engine while it is running e Refuel in a well ventilated area with the engine stopped Gasoline is highly flammable and explosive under certain conditions e Do nor overfill the fuel tank There should be no fuel in the filler nec Make sure that the filler cap is closed securely e If any fuel is spilled clean it up completely and allow petroleum vapou
13. nd condition CAUTION Never run the engine without the air cleaner Rapid engine wear will result OIL LEVEL 4 Fuel Use automotive gasoline Unleaded or lowleaded is preferred to minimize combustion chamber deposits FOR NEW SOUTH WALES ONLY Use unleaded fuel only Never use an oil gasoline mixture or dirty gasoline Avoid getting dirt dust or water in the fuel tank AWARNING e Gasoline is extremely flammable and is explosive under certain conditions e Refuel in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored e Do not overfill the fuel tank there should be no fuel in the filler neck After refueling make sure the tank cap is closed properly and securely e Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before starting the engine e Avoid repeated or prolonged contact with skin or breathing of vapor KEEP OUT OF REACH OF CHILDREN Fuel tank capacity GX120 2 5 2 0 66 US gal 0 55 Imp gal GX160 3 62 0 95 US gal 0 79 Imp gal GX200 3 62 0 95 US gal 0 79 Imp gal GASOLINES CONTAINING ALCOHOL If you decide to use a gasoline containing alcohol gasohol be sure it s octane rating is at least as high as that recommended by Honda There are two types of gasohol one containing ethanol
14. osition ENGINE SWITCH 3 Turn the fuel valve to the OFF position FUEL VALVE MAINTENANCE e Shut off the engine before performing any maintenance e To prevent accidental start up turn OFF the engine switch key and disconnect the spark plug cap e The engine should be serviced by an authorized Honda dealer unless the owner has proper tools and service data and feels he is mechanically qualified CAUTION Use only genuine Honda parts or their equivalent The use of replacement parts which are not of equivalent quality may damage the engine Periodic inspection and adjustment of the Honda engine is essential if high level performance is to be maintained Regular maintenance will also ensure a long service life The required service intervals and the kind of maintenance to be performed are described on the table below Maintenance Schedule REGULAR SERVICE PERIOD First Every Every Every Performed at every indicated month or Each use month 3month 6month year operating hour interval whichever comes first or or or or ITEM 20 Hrs 50 Hrs 100 Hrs 300 Hrs Engine oil Check level fe Change ie fe Reduction gear oil Check level fe applicable models only Change fe 0 Air cleaner Check 0 Clean o 1 Sediment cup Clean 0 Spark plug Check Clean fe Spark arrester Clean oO optional part Valve clearance Check Adjust O 2 Fuel tank
15. park plug and try to start the engine again according to the instructions 7 If the engine still dose not start take the engine to an authorized Honda dealer Engine will not start using electric starter 1 Are the battery cables securely connected and free of corrosion 2 Is the battery fully charged NOTE If the engine does not charge the battery check the circuit breaker 3 If the starter motor operates but the engine wil not start follow the troubleshooting procedure described under recoil starter operation 30 il SPECIFICATIONS Dimensions GX 120 GX 160 GX 200 Power equipment description code GCO1 GC02 GCAE Length Width Height lt Length gt lt Width gt lt Height gt 300 mm 11 8 in 345 mm 13 6 in 320 mm 12 6 in 305 mm 12 0 in 365 mm 14 4 in 335 mm 13 2 in K 385 mm 15 2 in 335 mm 13 2 in 313 mm 12 3 in 376 mm 14 8 in 335 mm 13 2 in gt gt gt 395 mm 15 6 in gt gt 335 mm 13 2 in gt Dry weight 12 0 kg 26 5 Ibs K 305 mm 12 0 in 14 0 kg 30 9 Ibs lt 16 0 kg 35 3 Ibs K 313 mm 12 3 in 16 0 kg 35 3 Ibs gt 17 9 kg 39 5 Ibs gt lt gt Electric starter model Engine Engine type 4 stroke over head valve 1 cylinder Displacement 118 cm 7 2 cu in 163 cm 9 9 cu in 196 cm 12 0 cu in Borex Stroke 60 x 42 mm 68
16. rester maintenance optional part AWARNING If the engine has been running the muffler will be very hot Allow it to cool before proceeding CAUTION The spark arrester must be serviced every 100 hours to maintain its efficiency 1 Remove the two 4 mm screws from the exhaust deflector and remove the deflector 2 Remove the four 5 mm screws from the muffler protector and remove the muffler protector 3 Remove the two 4 mm screw from the spark arrester and remove the spark arrester from the muffler eat 5mm SCREWS EXHAUST DEFLECTOR 4mm SCREWS ica SPARK ARRESTER 4 Use a brush to remove carbon deposits from the spark arrester screen CAUTION Be careful not to damage the spark arrester screen MUFFLER PROTECTOR MUFFLER NOTE The spark arrester must be free of breaks and holes Replace if necessary 5 Install the spark arrester and the muffler in the reverse order of disassembly 26 6 Carburetor idle speed adjustment 1 Start the engine and allow it to warm up to normal operating temperature 2 With the engine idling turn the throttle stop screw to obtain the standard idle speed Standard idle speed 1 400 ca rpm THROTTLE STOP SCREW 27 E THROTTLE AND CHOKE CONTROL CABLE optional part The throttle and choke control levers are provided with holes for optional cable attachment The following illustrations show installation examples for a solid wire cable and for a braided
17. rs to dissipate before starting the engine e Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stored e Exhaust gas contains poisonous carbon monoxide Avoid inhalation of exhaust gases Never run the engine in a closed garage or confined area e Place the engine on a stable surface Do not tilt the engine more than 20 from horizontal Operating at excessive angles may result in fuel spillage 3 SAFETY INSTRUCTIONS To ensure safe operation e Do not place anything on the engine as it may create a fire hazard e A spark arrester is available as an optional part for this engine It is illegal in some areas to operate an engine without a spark arrester Check local laws and regulations before operating e 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 To avoid severe bums or fire hazards let the engine cool before transporting it or storing it indoors SAFETY LABEL LOCATION This label warns you of potential hazards that can cause serious injury Read it carefully If the label comes off or becomes hard to read contact your Honda dealer for replacement READ OWNER S MANUAL BATTERY CONNECTIONS for electric starter Usea 12 volt battery with an ampere hour rating of at least 18 AH Connect the battery positive cable to the starter solenoid terminal as shown Connect
18. rty air cleaner will restrict air flow to the carburetor To prevent carburetor malfunction service the air cleaner regularly Service more frequently when operating the engine in extremely dusty areas AWARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result CAUTION Never run the engine without the air cleaner Rapid engine wear will result WING NUT lt Dual element type gt 1 Remove the wing nut and the air cleaner cover Remove the elements and separate them Carefully check both elements for holes or tears and replace if damaged 2 Foam element Wash the element in a solution of household detergent and warm water then rinse thor oughly or wash innonflammable or PAPER high flash point solvent Allow the el ELEMENT ement to dry thoroughly Soak the element in clean engine oil FORM and squeeze out the excess oil The ELEMENT engine will smoke during initial start up if too much oil is left in the foam 3 Paper element Tap the element lightly several times on a hard sur face to remove excess dirt or blow compressed air through the filter from the inside out Never try to brush the dirt off brushing will force dirt into the fibers Replace the pa per element if it is excessively dirty GX120 160 GX120 160 200 21 Cyclone type 1 Remove the wing nut and the air WING NUT cleaner cover Remove the GROOVE PAPER elements
19. ster magneto PTO Shaft rotation Counterclockwise S type NOTE Specifications may vary according to the types and are subject to change without notice 32 MEMO Head office United Kingdom selling agent HONDA EUROPE N V HONDA ENGINES European Engine Center Honda Logistic Centre UK Ltd Langerbruggestraat 104 B 9000 GENT Unit 3210 Wellington Parkway TEL 32 0 9 250 12 11 Magna Park Lutterworth FAX 32 0 9 250 14 24 Leicestershire LE 17 4JQ VAT BE 418 250 835 HRG 125 024 United Kingdom Fortis Bank BE33 2900 0170 0046 TEL 44 0 1 45 55 59 429 BIC GEBABEBB FAX 44 0 1 45 55 59 428 www honda engines eu com 33
20. t then pull briskly CAUTION Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter e With electric starter where equipped Turn the engine switch to the START position and hold it there until the engine starts NOTE Do not use the electric starter for more than 5 seconds at a time If the engine fails to start release the key and wait 10 seconds before operating the starter again When the engine starts return the switch to the ON position ENGINE SWITCH e High altitude operation At high altitude the standard carburetor air fuel mixture will be ex cessively rich Performance will decrease and fuel consumption will increase High altitude performance can be improved by specific modifica tions to the carburetor If you always operate the engine at altitudes higher than 1 830 m 6 000 feet above sea level have your authorized Honda dealer perform these carburetor modifi cations Even with suitable carburetor jetting engine horsepower will decrease approximately 3 5 for each 305 m 1 000 feet increase in altitude The affect of altitude on horsepower will be greater than this if no carburetor modification is made CAUTION Operation of the engine at an altitude lower than the carburetor is jetted for may result in reduced performance overheating and serious engine damage caused by an excessively lean air fuel mixture 15
21. the battery negative cable to an engine mounting bolt frame bolt or other good engine ground connection Check the battery cable connections to be sure the cables are tightened and free of corrosion Remove any corrosion and coat the terminals and cable ends oe grease NEGATIVE STARTER SOLENOID BATTERY CABLE to engine body US POSITIVE AWARNING BATTERY CABLE e The battery gives off explosive gases keep sparks flames and Cigarettes away Provide adequate ventilation when charging or using batteries in an enclosed e The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe bums Wear protective clothing and a face shield If electrolyte gets on your skin flush with water If electrolyte gets in your eyes flush with water for at least 15 minutes and call a physician immediately Electrolyte is poisonous If swallowed drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician immediately e KEEP OUT OF REACH OF CHILDREN NOTICE e Use only distilled water in the battery Tap water will shorten the service life of the battery e Filling the battery above the UPPER LEVEL line may cause the electrolyte to overflow resulting in corrosion to engine or nearby parts Immediately wash off any spilled electrolyte e Be careful not to connect the battery in reverse polarity as this will short circuit th
22. ug service SEDIMENT CUP Recommended spark plug BPR6ES NGK W20EPR U DENSO CAUTION Never use a spark plug of incorrect heat range To ensure proper engine operation the spark plug must be properly gapped and free of deposits 1 Remove the spark plug cap and use the proper size spark plug wrench to remove the spark plug AWARNING If the engine has been running the muffler will be very hot Be careful not to touch the muffler SN a S C 2 Visually inspect the spark plug Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped Clean the spark plug with a wire brush if itis to be reused 3 Measure the plug gap with a feeler gauge Correct as necessary by bending the side electrode The gap should be 0 70 0 80 mm 0 028 0 031 in 0 70 0 80 mm 0 028 0 031 in 4 Check that each spark plug washer is in good condition and thread the spark plug in by hand to prevent cross threading 5 After the spark plug is seated tighten with a spark plug wrench to compress the washer fw NOTE When installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer When reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer CAUTION The spark plug must be securely tightened An improperly tightened spark plug can become very hot and may damage the engine 25 5 Spark ar
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