GX120 User Manual - All Pumps Direct
Contents
1. For Canadian types only French label Labels come with the engine Gasoline is highly flammable and explosive Turn engine off and let cool before refueling The engine emits toxic poisonous carbon monoxide gas Do not run in an enclosed area Read Owner s Manual before operation ENGLISH HD AIR VENT TUBE COMPONENT amp CONTROL LOCATION SPARK PLUG CHOKE LEVER AIR CLEANER MUFFLER STARTER GRIP i Led OIL FILLER CAP S78 DIPSTICK LLZ MP OIL DRAIN PLUG RECOIL STARTER ENGINE CONTROLS ENGINE SWITCH 05 02 09 13 16 12 32Z4F800 003 BEFORE OPERATION CHECKS IS YOUR ENGINE READY TO GO For your safety and to maximize the service life of your equipment it is very important to take a few moments before you operate the engine to check its condition Be sure to take care of any problem you find or have your servicing dealer correct it before you operate the engine A WARNING Improperly maintaining this engine or failure to correct a problem before operation can cause a malfunction in which you can be seriously hurt or killed Always perform a preoperation inspection before each operation and correct any problem Before beginning your preoperation checks be sure the engine is level and the engine switch is in the OFF position Always check the following items before you start the engine Check the Ge2. If the fuel tank is equipped with a fuel valve and or a fuel filler cap vent valve turn them to the CLOSED or OFF position You can rest the equipment on its side if the fuel tank is equipped with a fuel valve and a fuel filler cap vent and both are in the CLOSED or OFF position Position the equipment so the carburetor is facing up as shown INCORRECT FRONT CORRECT RIGHT INCORRECT LEFT AA aoa 0 7 CARBURETOR REAR Operator s side INCORRECT As viewed from the above 10 ENGLISH HD AA ae 05 05 17 13 23 38 32Z4F800_011 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL Possible Cause Correction NOT START 1 Check control Fuel valve and Turn valve s ON positions or fuel filler cap vent valve OFF Choke open Move lever to CLOSED position unless the engine is warm Engine switch Turn engine switch OFF to ON position 2 Check fuel Out of fuel Refuel p 6 Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carburetor p 10 Refuel with fresh gasoline p 6 3 Remove and inspect spark plug Spark plug faulty Gap or replace fouled or spark plug p 8 improperly gapped Spark plug wet Dry and reinstall with fuel spark plug Start flooded engine engine with throttle lever in MAX position 4 Take engine to an author
3. SAFETY INFORMATION e Understand the operation of all controls and learn how to stop the engine quickly in case of emergency Make sure the operator receives adequate instruction before operating the equipment e Do not allow children to operate the engine Keep children and pets away from the area of operation e Your engine s exhaust contains poisonous carbon monoxide Do not run the engine without adequate ventilation and never run the engine indoors e The engine and exhaust become very hot during operation Keep the engine at least 1 meter 3 feet away from buildings and other equipment during operation Keep flammable materials away and do not place anything on the engine while it is running 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 A ATTENTION L essence est tr s inflammable et explosive A WARNING Gasoline is highly flammable and explosive Turn engine off and let cool before refueling Arr ter le moteur et le laisser refroidir avant de faire le plein d essence The engine emits toxic carbon monoxide Le moteur produit les vapeurs nocives de monoxyde de carbone Do not run in an enclosed area Ne pas utiliser dans un local enclos Read Owner s Manual before operation Lire le manuel de propri taire avant l utilisation
4. service procedures EPA standards 3 For commercial use log hours of operation to determine MAINTENANCE SAFETY proper maintenance intervals Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in Failure to follow this maintenance schedule could result in non performing maintenance Only you can decide whether or not you warrantable failures should perform a given task A WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in this owner s manual SAFETY PRECAUTIONS e Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so e Read the instructions before you begin and make sure you have the tools and skills required e To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Remember that an authorized Honda servicing dealer
5. such as a furnace water heater or clothes dryer Also avoid any area with a spark producing electric motor or where power tools are operated If possible avoid storage areas with high humidity because that promotes rust and corrosion Keep the engine level in storage Tilting can cause fuel or oil leakage Unless all fuel has been drained from the fuel tank leave the fuel valve and fuel filler cap vent in the CLOSED or OFF position to reduce the possibility of fuel leakage With the engine and exhaust system cool cover the engine to keep out dust A hot engine and exhaust system can ignite or melt some materials Do not use sheet plastic as a dust cover A nonporous cover will trap moisture around the engine promoting rust and corrosion Removal from Storage Check your engine as described in the BEFORE OPERATION CHECKS section of this manual see page 3 If the fuel was drained during storage preparation fill the tank with fresh gasoline If you keep a container of gasoline for refueling be sure it contains only fresh gasoline Gasoline oxidizes and deteriorates over time causing hard starting If the cylinder was coated with oil during storage preparation the engine will smoke briefly at startup This is normal TRANSPORTING If the engine has been running allow it to cool for at least 15 minutes before storing or loading on the transport vehicle A hot engine and muffler can burn you and can ignite some materials
6. the spark plug and cause hard starting Operation at an altitude that differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by specific modifications to the carburetor If you always operate your engine at altitudes above 1 500 meters 5 000 feet have your servicing dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 5 for each 300 meter 1 000 foot increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made NOTICE When the carburetor has been modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 1 500 meters 5 000 feet with a modified carburetor may cause the engine to overheat and result in serious engine damage For use at low altitudes have your servicing dealer return the carburetor to original factory specifications ENGLISH 11 HD T T p 05 02 09 13 19 57 32Z4F800_012 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are collectively referred to as oxygenated fuels To m
7. 31 X 321 mm U S Pump octane rating 86 or higher Height 12 3 X 13 0 X 12 6 in Except Research octane rating 91 or higher Dry mass weight 16 5 kg 36 4 Ibs U S Pump octane rating 86 or higher Engine type 4 stroke overhead valve single cylinder Engine oil SAE 10W 30 API SJ or later for general use Displacement 118 cm 7 2 cu in Refer to page 6 Bore X Stroke 60 0 X 42 0 mm 2 4 X 1 7 in Spark plug BP4ES NGK Net power in accordance with SEA J1349 2 6 kW 3 5 PS 3 5 bhp at 3 600 rom Max Net torque in accordance with SEA J1349 7 3 N m 0 74 kgf m 5 4 Ibf ft at 2 500 rpm Engine oil capacity 0 40 2 0 42 US qt 0 35 Imp qt When mount for rammer is angle 14 Cooling system Forced air Ignition system Transistor magneto PTO shaft rotation Counterclockwise W14EP U DENSO Maintenance Before each use e Check engine oil level Refer to page 6 e Check air filter Refer to page 8 e Check all bolts and nuts First 20 hours e Change engine oil Refer to page 7 Subsequent e Refer to the maintenance schedule on page 5 GX160 Basic type Length X Width X 319 X 343 X 333 mm Height 12 6 X 13 5 X 13 1 in Dry mass weight 18 6 kg 41 0 Ibs Engine type 4 stroke overhead valve single cylinder Displacement Bore X Stroke 163 cm 9 9 cu in 68 0 X 45 0 mm 2 7 X 1 8 in Net power in accordance wi
8. System Information Source of Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons The U S Clean Air Acts and Environment Canada EPA and Canadian regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are e Removal or alteration of any part of the intake fuel or exhaust systems e Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters Problems That May Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer e Hard starting or stalling after starting e Rough idle e Misfir
9. _ ata qd 07 06 01 18 28 57 32Z4F800_001 INTRODUCTION Thank you for purchasing a Honda engine We want to help you to get the best results from your new engine and to operate it safely This manual contains information on how to do that please read it carefully before operating the engine If a problem should arise or if you have any questions about your engine consult an authorized Honda servicing dealer 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 the engine if resold Review the instructions provided with the equipment powered by this engine for any additional information regarding engine startup shutdown operation adjustments or any special maintenance instructions United States Puerto Rico and U S Virgin Islands We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership The warranty policy is a separate document that should have been given to you by your dealer SAFETY MESSAGES Your safety and the safety of others are very important We have provided important safety messages in this manual and on the engine Pl
10. a dealer Other No other adjustments needed specifications ENGLISH pe 13 AD RS 05 02 09 13 20 56 32Z4F800 014 CONSUMER INFORMATION Distributor Dealer Locator Information United States Puerto Rico and U S Virgin Islands Call 800 426 7701 or visit our website www honda engines com Canada Call 888 SHONDAY or visit our website www honda ca For European Area visit our website http www honda engines eu com Customer Service Information Servicing dealership personnel are trained professionals They should be able to answer any question you may have If you encounter a problem that your dealer does not solve to your satisfaction please discuss it with the dealership s management The Service Manager General Manager or Owner can help Almost all problems are solved in this way United States Puerto Rico and U S Virgin Islands If you are dissatisfied with the decision made by the dealership s management contact the Honda Regional Engine Distributor for your area If you are still dissatisfied after speaking with the Regional Engine Distributor you may contact the Honda s Office as shown All Other Areas If you are dissatisfied with the decision made by the dealership s management contact the Honda s Office as shown Honda s Office When you write or call please provide this information e Equipment manufacturer s name and model number that the engine is mounted o
11. ature 2 With the engine idling turn the throttle stop screw to obtain the standard idle speed P RETAINERS THROTTLE STOP SCREW Standard idle speed 1 500 150 rpm HELPFUL TIPS amp SUGGESTIONS STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine trouble free and looking good The following steps will help to keep rust and corrosion from impairing your engine s function and appearance and will make the engine easier to start when you use it again Cleaning If the engine has been running allow it to cool for at least half an hour before cleaning Clean all exterior surfaces touch up any damaged paint and coat other areas that may rust with a light film of oil NOTICE Using a garden hose or pressure washing equipment can force water into the air cleaner or muffler opening Water in the air cleaner will soak the air filter and water that passes through the air filter or muffler can enter the cylinder causing damage Fuel Gasoline will oxidize and deteriorate in storage Deteriorated gasoline will cause hard starting and it leaves gum deposits that clog the fuel system If the gasoline in your engine deteriorates during storage you may need to have the carburetor and other fuel system components serviced or replaced The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems wi
12. commendations and schedules in this owner s Spark plug Check adjust o 8 manual Replace o Idle speed Check adjust O 2 9 To help you properly care for your engine the following pages Valve clearance Check adjust O 2 Shop include a maintenance schedule routine inspection procedures manual and simple maintenance procedures using basic hand tools Other Combustion Clean After every 500 Hrs 2 Shop service tasks that are more difficult or require special tools are chamber manual best handled by professionals and are normally performed by a Fuel tank amp Clean o 2 Shop Honda technician or other qualified mechanic filter manual Fuel tube Check Every 2 years Shop The maintenance schedule applies to normal operating conditions Replace if necessary 2 manual If you operate your engine under severe conditions such as sustained high load or high temperature operation or use in Replace the paper air filter element only unusually wet or dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use 1 Service more frequently when used in dusty areas Maintenance replacement or repair of the emission control 2 These items should be serviced by your servicing dealer devices and systems may be performed by any engine repair unless you have the proper tools and are mechanically establishment or individual using parts that are certified to proficient Refer to Honda shop manual for
13. ease read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message is preceded by a safety alert symbol and one of three words DANGER WARNING or CAUTION These signal words mean A DANGER A CAUTION Each message tells you what the hazard is what can happen and what you can do to avoid or reduce injury You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instructions DAMAGE PREVENTION MESSAGES You will also see other important messages that are preceded by the word NOTICE This word means NOTICE Your engine or other property can be damaged if you don t follow instructions The purpose of these messages is to help prevent damage to your engine other property or the environment 2007 Honda Motor Co Ltd All Rights Reserved GX120U1 GX160U1 RAMMER 37Z4F802 00X37 Z4F 8020 HONDA OWNER S MANUAL MANUEL DE L UTILISATEUR MANUAL DEL PROPIETARIO GX120 GX160 FOR RAMMER TYPE COMPACTORS The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CONTENTS INTRODUCTION c eeeeeeeeeees SAFETY MESSAGEG 00 SAFETY INFORMATION SAFETY LABEL cec
14. eeeeeeeeeees COMPONENT amp CONTROL LOCATION cisien BEFORE OPERATION CHECKS isiin OPERATION c eeeeeeeeeeeeeeeeee SAFE OPERATING PRECAUTIONS 2 eeeeeeees STARTING THE ENGINE STOPPING THE ENGINE SERVICING YOUR ENGINE THE IMPORTANCE OF MAINTENANCE ossee MAINTENANCE SAFETYV SAFETY PRECAUTIONG MAINTENANCE SCHEDULE siririna REFUELING c eeeseeeeeeeees ENGINE Ol Lesvivesscetssteveceesseees Recommended Oil Oil Level Check Oil Change eeceeseeeees AIR CLEANER INSPECTION cceeeeeeeeeeeees Cleaning nis ENGLISH HD SPARK PLUG cee ee 8 AIR VENT TUBE cess 9 IDLE SPEED innin 9 HELPFUL TIPS amp SUGGESTIONS vice cccescessncsccsnnieas 9 STORING YOUR ENGINE 9 TRANSPORTING ceeeee 10 TAKING CARE OF UNEXPECTED PROBLEMS 11 TECHNICAL INFORMATION 11 Serial Number Location 11 Carburetor Modifications for High Altitude Operation 12 Emission Control System Afortissi reiissi 12 Specifications sses 13 Tuneup Specifications 13 Quick Reference Information cceceeeeeeeeeeees 13 Wiring Diagram eee 13 6 CONSUMER INFORMATION 14 Distributor Dealer Locator Information ccceeeeeeeeeeeeee 14 Customer Service Informatia Misiin 14 1 ENGLISH FRAN AIS 2 lt a 22 Ww LD ae S WW GIs 05 02 09 13 15 45 32Z4F800 002
15. eet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirements Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL _ ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE methyl tertiary butyl ether 15 by volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under the Distributor s Limited Warranty Emission Control
16. ing or backfiring under load e Afterburning backfiring e Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your Honda engine were designed built and certified to conform with EPA and Canadian emission regulations We recommend the use of genuine Honda parts whenever you have maintenance done These original design replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations Maintenance Follow the maintenance schedule on page 5 Remember that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature operation or use in unusually wet or dusty conditions will require more frequent service 12 ENGLISH HD AVA as Specifications D 07 06 01 18 30 38 32Z4F800_013 Quick Reference Information GX120 Basic type Fuel Unleaded gasoline Refer to page 6 Length X Width X 313 X 3
17. ions refer to the instructions provided with the equipment powered by this engine MIN THROTTLE LEVER on the equipment STOPPING THE ENGINE To stop the engine in an emergency simply turn the engine switch to the OFF position Under normal conditions use the following procedure 1 Move the throttle lever to the MIN position THROTTLE LEVER on the equipment i MIN 2 Turn the engine switch to the OFF position ENGINE SWITCH 3 If the fuel tank is equipped with a valve turn the fuel valve and fuel filler cap vent to the CLOSED or OFF position ENGLISH HD WZ as 05 05 17 13 23 11 32Z4F800 005 SERVICING YOUR ENGINE MAINTENANCE SCHEDULE THE IMPORTANCE OF MAINTENANCE REGULAR SERVICE PERIOD 3 Each First Every 3 Every 6 Every Refer Good maintenance is essential for safe economical and trouble Perform at every Use Month Months Months Year to free operation It will also help reduce pollution indicated month or or or or or Page operating hour interval 20 Hrs 50 Hrs 100 Hrs 300 Hrs A WA R N l N G whichever comes first ITEM Improper maintenance or failure to correct a Engine oil Check level fe 6 problem before operation can cause a malfunction in Change 0 o 7 which you can be seriously hurt or killed Air filter Check o 8 Clean oO 1 8 Always follow the inspection and maintenance Replace O re
18. it mark bottom edge of the oil fill hole on the dipstick NOTICE Running the engine with a low oil level can cause engine damage This type of damage is not covered by the Distributor s Limited Warranty 4 Install the oil filler cap dipstick and tighten securely OIL FILLER CAP DIPSTICK UPPER LIMIT DRAIN PLUG ENGLISH Aa LD as PS p 07 06 01 18 30 11 32Z4F800_008 AIR CLEANER A dirty air cleaner will restrict air flow to the carburetor reducing engine performance If you operate the engine in very dusty areas clean the air filter more often than specified in the MAINTENANCE SCHEDULE NOTICE Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine causing rapid engine wear This type of damage is not covered by the Distributor s Limited Warranty Inspection 1 Release the retaining clip and remove the air cleaner cover 2 Remove and inspect the air filter elements If the air filter element is dirty clean the air filter elements as described below Replace damaged filter elements Always replace the paper air filter element at the scheduled interval see page 5 3 Place the foam air filter element over the paper element and reinstall the assembled air filter elements Insert the open end of the air filter elements into the case as shown so the closed end is toward the air cleaner cover 4 Ho
19. ized Honda servicing dealer or refer to shop manual Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Replace or repair faulty components as necessary ENGINE LACKS POWER Possible Cause Correction 1 Check air filter Filter element s restricted Clean or replace filter element s p 8 2 Check fuel Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carburetor p 10 Refuel with fresh gasoline p 6 3 Take engine to an authorized Honda servicing dealer or refer to shop manual Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Replace or repair faulty components as necessary TECHNICAL amp CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location Record the engine serial number type and purchase date in the space below You will need this information when ordering parts and when making technical or warranty inquiries SERIAL NUMBER amp ENGINE TYPE LOCATION Engine serial number Engine type Date Purchased Carburetor Modifications for High Altitude Operation At high altitude the standard carburetor air fuel mixture will be too rich Performance will decrease and fuel consumption will increase A very rich mixture will also foul
20. k plug cap and remove any dirt from around the spark plug area 2 Remove the spark plug with a 13 16 inch spark plug wrench 3 Inspect the spark plug Replace it if damaged or badly fouled if the sealing washer is in poor condition or if the electrode is worn 4 Measure the spark plug electrode gap with a wire type feeler gauge Correct the gap if necessary by carefully bending the side electrode The gap should be m 0 70 0 80 mm 0 028 0 031 in 0 70 0 80 mm 0 028 0 031 in SEALING WASHER 5 Install the spark plug carefully by hand to avoid cross threading 6 After the spark plug is seated tighten with a 13 16 inch spark plug wrench to compress the sealing washer 7 When installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer 8 When reinstalling the original spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer NOTICE A loose spark plug can overheat and damage the engine Overtightening the spark plug can damage the threads in the cylinder head 9 Attach the spark plug cap to the spark plug 8 ENGLISH HD AVA T 05 02 09 13 18 39 32Z4F800_009 AIR VENT TUBE Inspection Check that the air vent tube is secured by the tube retainers without collapsing or kinking IDLE SPEED Adjustment 1 Start the engine outdoors and allow it to warm up to operating temper
21. knows your engine best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair and replacement ENGLISH 5 LD as D 07 06 01 18 29 23 32Z4F800_006 REFUELING Recommended Fuel Unleaded gasoline U S Pump octane rating 86 or higher Except U S Research octane rating 91 or higher Pump octane rating 86 or higher This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher a research octane rating of 91 or higher Refuel in a well ventilated area with the engine stopped If the engine has been running allow it to cool first Never refuel the engine inside a building where gasoline fumes may reach flames or sparks You may use regular unleaded gasoline containing no more than 10 Ethanol E10 or 5 Methanol by volume In addition Methanol must contain cosolvents and corrosion inhibitors Use of fuels with content of Ethanol or Methanol greater than shown above may cause starting and or performance problems It may also damage metal rubber and plastic parts of the fuel system Engine damage or performance problems that result from using a fuel with percentages of Ethanol or Methanol greater than shown above are not covered under warranty A WARNING Gasoline is highly flammable and explosive and you can be burned or seriously inj
22. ll vary with such factors as gasoline blend your storage temperatures and whether the fuel tank is partially or completely filled The air ina partially filled fuel tank promotes fuel deterioration Very warm storage temperatures accelerate fuel deterioration Fuel problems may occur within a few months or even less if the gasoline was not fresh when you filled the fuel tank Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under the Distributor s Limited Warranty You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose or you can avoid fuel deterioration problems by draining the fuel tank and carburetor Adding a Gasoline Stabilizer to Extend Fuel Storage Life When adding a gasoline stabilizer fill the fuel tank with fresh gasoline If only partially filled air in the tank will promote fuel deterioration during storage If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline 1 Add gasoline stabilizer following the manufacturer s instructions 2 After adding a gasoline stabilizer run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor 3 Stop the engine ENGLISH 9 HD AA as D 05 02 09 13 19 07 32Z4F800_010 Draining the Fuel Tank and Carburetor A WARNING Gasoline is highly fla
23. mmable and explosive and you can be burned or seriously injured when handling fuel e Stop engine and keep heat sparks and flame away e Handle fuel only outdoors e Wipe up spills immediately 1 Drain the fuel tank following the instructions of the equipment manufacturer 2 Place an approved gasoline container below the carburetor and use a funnel to avoid spilling fuel Loosen or remove the carburetor drain bolt and washer CARBURETOR WASHER DRAIN BOLT 3 After all fuel has drained into the container install the drain bolt and washer and tighten the drain bolt Engine Oil 1 Change the engine oil see page 7 2 Remove the spark plug see page 8 3 Pour a tablespoon 5 10 cm 5 10 cc of clean engine oil into the cylinder 4 Pull the starter rope several times to distribute the oil in the cylinder 5 Reinstall the spark plug 6 Pull the starter rope slowly until resistance is felt and the notch on the starter pulley aligns with the hole at the top of the recoil starter cover This will close the valves so moisture cannot enter the engine cylinder Return the starter rope gently Align notch on pulley with hole at top of cover Storage Precautions If your engine will be stored with gasoline in the fuel tank and carburetor it is important to reduce the hazard of gasoline vapor ignition Select a well ventilated storage area away from any appliance that operates with a flame
24. n e Engine model serial number and type see page 11 e Name of dealer who sold the engine to you e Name address and contact person of the dealer who services your engine e Date of purchase e Your name address and telephone number e A detailed description of the problem United States Puerto Rico and U S Virgin Islands American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta GA 30005 8847 Or telephone 770 497 6400 8 30 am 6 00 pm EST Canada Honda Canada Inc 715 Milner Avenue Toronto ON M1B 2K8 Telephone 888 JHONDAY 888 946 6329 English 416 299 3400 French 416 287 4776 Facsimile 877 939 0909 416 287 4776 Australia Toll free Local Toronto dialing area Local Toronto dialing area Toll free Local Toronto dialing area Honda Australia Motorcycle and Power Equipment Pty Ltd 1954 1956 Hume Highway Campbellfield Victoria 3061 Telephone 03 9270 1111 Facsimile 03 9270 1133 For European Area Honda Europe NV European Engine Center http www honda engines eu com All Other Areas Please contact the Honda distributor in your area for assistance HONDA The Power of Dreams 14 ENGLISH HD AA T WA IS 05 02 09 13 21 00 32Z4F800 015 HON DA The Power of Dreams
25. neral Condition of the Engine 1 Look around and underneath the engine for signs of oil or gasoline leaks 2 Remove any excessive dirt or debris especially around the muffler and recoil starter 3 Look for signs of damage 4 Check that all shields and covers are in place and all nuts bolts and screws are tightened Check the Engine 1 Check the fuel level Starting with a full tank will help to eliminate or reduce operating interruptions for refueling 2 Check the engine oil level see page 6 Running the engine with a low oil level can cause engine damage 3 Check the air filter element see page 8 A dirty air filter element will restrict air flow to the carburetor reducing engine performance 4 Check the equipment powered by this engine Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine startup ENGLISH OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time please review the SAFETY INFORMATION section on page 2 and the BEFORE OPERATION CHECKS A WARNING Carbon monoxide gas is toxic Breathing it can cause unconsciousness and even kill you Avoid any areas or actions that expose you to carbon monoxide Review the instructions provided with the equipment powered by this engine for any safety precautions that should be observed with engine startup shutdown or o
26. ok the bottom edge of the air cleaner cover onto the case then secure the cover with the retaining clip RETAINING CLIP AIR CLEANER CASE PAPER FILTER ELEMENT CLOSED END FOAM FILTER ELEMENT OPEN END INCORRECT CORRECT oQ oQ AIR CLEANER COVER PLATE a HOLE Cleaning 1 Clean the air filter elements if they are to be reused Paper air filter element Tap the filter element several times ona hard surface to remove dirt or blow compressed air not exceeding 207 kPa 2 1 kgf cm 30 psi through the filter element from the inside Never try to brush off dirt brushing will force dirt into the fibers Foam air filter element Clean in warm soapy water rinse and allow to dry thoroughly Or clean in non flammable solvent and allow to dry Dip the filter element in clean engine oil then squeeze out all excess oil The engine will smoke when started if too much oil is left in the foam 2 Wipe dirt from the inside of the air cleaner case and cover using a moist rag Be careful to prevent dirt from entering the air duct that leads to the carburetor SPARK PLUG Recommended Spark Plugs BP4ES NGK W14EP U DENSO The recommended spark plug has the correct heat range for normal engine operating temperatures NOTICE An incorrect spark plug can cause engine damage For good performance the spark plug must be properly gapped and free of deposits SPARK PLUG WRENCH 1 Disconnect the spar
27. peration STARTING THE ENGINE 1 If the fuel tank is equipped with a valve be sure the fuel valve and fuel filler cap vent are in the OPEN or ON position before attempting to start the engine For specific instructions on fuel valve and fuel filler cap vent operation refer to the instructions provided with the equipment powered by this engine 2 To start a cold engine move the choke lever to the CLOSED position To restart a warm engine leave the choke lever in the OPEN position 3 Move the throttle lever to the MIN position The throttle lever is mounted on the equipment powered by this engine Refer to the instructions provided with that equipment for information about your specific throttle control THROTTLE LEVER on the equipment HD LD ae 05 02 09 13 16 34 32Z4F800 004 4 Turn the engine switch to the ON position ENGINE SWITCH 5 Operate the starter Pull the starter grip lightly until you feel resistance then pull briskly Return the starter grip gently STARTER GRIP NOTICE Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter 6 If the choke lever has been moved to the CLOSED position to start the engine gradually move it to the OPEN position as the engine warms up CHOKE LEVER 7 Position the throttle lever for the desired engine speed For engine speed recommendat
28. th SEA J1349 3 6 kW 4 9 PS 4 8 bhp at 3 600 rpm Max Net torque in accordance with SEA J1349 10 3 N m 1 05 kgf m 7 6 Ibf ft at 2 500 rpm Engine oil capacity 0 37 2 0 39 US qt 0 33 Imp qt When mount for rammer is angle 20 Cooling system Forced air Ignition system Transistor magneto PTO shaft rotation Counterclockwise The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine model and measured in accordance with SAE J1349 at 3 600 rpm Net Power and at 2 500 rpm Max Net Torque Mass Wiring Diagram Wiring diagram may vary according to the type BI K BI it Ti G Q 2 1 SPARK PLUG 2 IGNITION COIL OFF OTO 3 ENGINE SWITCH production engines may vary from this value BI Black Actual power output for the engine installed in the final machine will vary depending on numerous factors including the operating speed of the engine in application environmental conditions maintenance and other variables Tuneup Specifications GX120 160 ITEM SPECIFICATION MAINTENANCE Spark plug gap 0 70 0 80 mm Refer to page 8 0 028 0 031 in Idle speed 1 500 150 rpm Refer to page 9 Valve clearance IN 0 15 0 02 mm See your cold EX 0 20 0 02 mm authorized Hond
29. ured when refueling e Stop engine and keep heat sparks and flame away e Refuel only outdoors e Wipe up spills immediately NOTICE Fuel can damage paint and some types of plastic Be careful not to spill fuel when filling your fuel tank Damage caused by spilled fuel is not covered under the Distributor s Limited Warranty Never use stale or contaminated gasoline or oil gasoline mixture Avoid getting dirt or water in the fuel tank Refuel carefully to avoid spilling fuel Keep gasoline away from appliance pilot lights barbecues electric appliances power tools etc Spilled fuel is not only a fire hazard it causes environmental damage Wipe up spills immediately ENGINE OIL Oil is a major factor affecting performance and service life Use 4 stroke automotive detergent oil Recommended Oil Use 4 stroke motor oil that meets or exceeds the requirements for API service classification SJ or later or equivalent Always check the API service label on the oil container to be sure it includes the letters SJ or later or equivalent 60 80 100 F 20 10 0 10 20 30 40 C AMBIENT TEMPERATURE SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range Oil Level Check Check the engine oil level with the engine stopped and in a level position 1 Remove the oil filler cap dipstick and
30. wipe it clean 2 Insert the oil filler cap dipstick into the oil filler neck as shown but do not screw it in then remove it to check the oil level 3 If the oil level is near or below the lower limit mark on the dipstick fill with the recommended oil to the upper limit mark bottom edge of the oil fill hole Do not overfill 4 Reinstall the oil filler cap dipstick OIL FILLER CAP DIPSTICK UPPER LIMIT LOWER LIMIT OIL FILL HOLE bottom edge NOTICE Running the engine with a low oil level can cause engine damage This type of damage is not covered by the Distributor s Limited Warranty 6 ENGLISH HD AVA T 07 06 01 18 29 36 32Z4F800_007 Oil Change Drain the used oil when the engine is warm Warm oil drains quickly and completely 1 Place a suitable container below the engine to catch the used oil then remove the oil filler cap dipstick oil drain plug and washer 2 Allow the used oil to drain completely then reinstall the oil drain plug and new washer and tighten the oil drain plug securely Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash pour it on the ground or pour it down a drain 3 With the engine in a level position fill with the recommended oil see page 6 to the upper lim
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