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How to use this manual
A Few Words About Safety
How to use this manual
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
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Summary of Contents for Honda WB20XT2

  • Page 1 Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 2 dummyhead dummyhead OUTLINE OF CHANGES OUTLINE OF CHANGES Item Before modification After modification Pump (WB20XT3) Pump (WB30XT3)
  • Page 3: Table Of Contents

    dummyhead dummyhead CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING COVER FUEL SYSTEM GOVERNOR SYSTEM IGNITION SYSTEM STARTING SYSTEM PUMP ENGINE REMOVAL/INSTALLATION CYLINDER HEAD CRANKCASE MUFFLER WIRING DIAGRAM INDEX...
  • Page 4 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 5 How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product.
  • Page 6 dummyhead dummyhead How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated Full term term Alternator American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Auto Voltage Regulator...
  • Page 7: Specifications

    dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ·····················1-2 PERFORMANCE CURVES··························· 1-4 SPECIFICATIONS ·········································1-2 DIMENSIONAL DRAWINGS························· 1-5...
  • Page 8 SPECIFICATIONS WB20XT2•WB30XT2 SERIAL NUMBER LOCATION SPECIFICATIONS The engine serial number is located on the cylinder barrel. The frame serial number is located on the engine bed. Refer to these numbers when ordering parts and when making technical inquiries.
  • Page 9 WB20XT2•WB30XT2 SPECIFICATIONS ENGINE Model WB20XT2 WB30XT2 Engine model GX120T2 GX160T2 Description code GCBNT GCBRT Type 4 stroke, overhead valve, single cylinder, inclined by 25° Displacement 118 cm (7.2 cu–in) 163 cm (9.9 cu–in) Bore x stroke 60.0 x 42.0 mm (2.36 x 1.65 in) 68.0 x 45.0 mm (2.68 x 1.77 in)
  • Page 10 dummyhead dummyhead SPECIFICATIONS SPECIFICATIONS DIMENSIONS AND WEIGHTS Model WB20XT3 WB30XT3 Description code WABT WACT Type A, C A, C Overall length 490 mm (19.3 in) 510 mm (20.1 in) Overall width 365 mm (14.4 in) 385 mm (15.2 in) Overall height 420 mm (16.5 in) 455 mm (17.9 in) Dry weight...
  • Page 11 SPECIFICATIONS WB20XT2•WB30XT2 PERFORMANCE CURVES WB20XT2 Discharge Capacity (gallons per minute) WB30XT2 Discharge Capacity (gallons per minute)
  • Page 12 dummyhead dummyhead PERFORMANCE CURVES WB20XT3 (feet) liters/min 50.0 100.0 150.0 200.0 US gal/min DISCHARGE CAPACITY WB30XT3 (feet) 1000 1200 liters/min 50.0 100.0 150.0 200.0 250.0 300.0 US gal/min DISCHARGE CAPACITY...
  • Page 13 WB20XT2•WB30XT2 SPECIFICATIONS DIMENSIONAL DRAWINGS Unit: mm (in) 455 (17.9) (WB20XT2) 510 (20.1) (WB30XT2) 365 (14.4) (WB20XT2) 385 (15.2) (WB30XT2)
  • Page 14 dummyhead dummyhead DIMENSIONAL DRAWINGS Unit: mm (in) 490 (19.3) (WB20XT3) 510 (20.1) (WB30XT3) 365 (14.4) (WB20XT3) 385 (15.2) (WB30XT3)
  • Page 15 dummyhead dummyhead MEMO...
  • Page 16: Service Information

    dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-6 TORQUE VALUES ········································2-4 HARNESS AND TUBE ROUTING ················ 2-8 LUBRICATION & SEAL POINTS··················2-5...
  • Page 17 SERVICE INFORMATION WB20XT2•WB30XT2 MAINTENANCE STANDARDS SERVICE INFORMATION WB20XT2 Unit: mm (in) Part Item Standard Service limit Engine Maximum speed (at no load) – 3,900 ± 100 min (rpm) Idle speed + 200 1,400 – (rpm) – 150 Cylinder compression 0.49 –...
  • Page 18 WB20XT2•WB30XT2 SERVICE INFORMATION WB30XT2 Unit: mm (in) Part Item Standard Service limit Engine Maximum speed (at no load) – 3,900 ± 100 min (rpm) Idle speed + 200 1,400 – (rpm) – 150 Cylinder compression 0.49 – 0.69 MPa (5.0 – 7.0 kgf/cm , 71 –...
  • Page 19 ENGINE TORQUE VALUES Torque values Item Tread Dia. (mm) N·m kgf·m lbf·ft Crankcase cover bolt (WB20XT2 /GX120T2) M6 x 1.0 Crankcase cover bolt (WB30XT2 /GX160T2) M8 x 1.25 Cylinder head bolt M8 x 1.25 Engine oil drain plug bolt M10 x 1.25 Connecting rod bolt (WB20XT2 /GX120T2) M7 x 1.0...
  • Page 20 WB20XT2•WB30XT2 SERVICE INFORMATION LUBRICATION & SEAL POINTS ENGINE Location Material Remarks Crankshaft pin and gear teeth Engine oil Piston outer surface and piston ring Piston pin outer surface Cylinder barrel inner surface Connecting rod big and small end bearing...
  • Page 21 SERVICE INFORMATION WB20XT2•WB30XT2 TOOLS SPECIAL TOOLS Special tools used in this manual can be ordered using normal American Honda parts ordering procedures. Jet cleaner set Float level gauge Valve guide driver, 5.5 mm 07JPZ-001010B 07401-0010000 07742-0010100 or 07JPZ-001010A...
  • Page 22 WB20XT2•WB30XT2 SERVICE INFORMATION COMMERCIALLY AVAILABLE TOOLS Tool name Tool number Application Fuel line clip pliers HCP6A Carburetor removal Two-jaw puller OTC1035 Flywheel removal Valve seat cutter, 31° NWYCU115 Valve seat reconditioning Valve seat cutter, 45° NWYCU122 Valve seat cutter, 60°...
  • Page 23 SERVICE INFORMATION WB20XT2•WB30XT2 HARNESS AND TUBE ROUTING CYLINDER BARREL RIBS WB20XT2: ENGINE WIRE CARBURETOR INSULATOR HARNESS TO ENGINE STOP SWITCH HIGH-TENSION CORD WB30XT2: ENGINE WIRE HIGH-TENSION CORD CYLINDER BARREL RIBS HARNESS CARBURETOR INSULATOR CORD HOOK IGNITION COIL CONNECTOR...
  • Page 24 WB20XT2•WB30XT2 SERVICE INFORMATION BREATHER TUBE CARBURETOR INSULATOR HIGH-TENSION CORD WB30XT2: WB20XT2: CARBURETOR INSULATOR FAN COVER CLAMP FUEL TUBE...
  • Page 25 SERVICE INFORMATION WB20XT2•WB30XT2 ENGINE STOP SWITCH OIL LEVEL SWITCH ENGINE WIRE HARNESS WB30XT2: HARNESS CLIP CONNECTOR OIL ALERT UNIT CONNECTOR CLAMP ENGINE STOP SWITCH WIRE OIL LEVEL SWITCH CONNECTOR ENGINE WIRE ENGINE WIRE HARNESS HARNESS OIL LEVEL SWITCH...
  • Page 26: Maintenance

    dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE························3-2 VALVE CLEARANCE CHECK/ADJUSTMENT ································ 3-7 ENGINE OIL LEVEL CHECK/CHANGE ·······3-3 COMBUSTION CHAMBER CLEANING ······· 3-9 AIR CLEANER CHECK/CLEANING ·············3-4 FUEL TANK AND FILTER CLEANING ········ 3-9 SPARK PLUG CHECK/ADJUSTMENT ········3-5 FUEL TUBE CHECK ··································· 3-10 SPARK PLUG REPLACEMENT ···················3-5 IMPELLER CHECK ·····································...
  • Page 27: Maintenance Schedule

    MAINTENANCE WB20XT2•WB30XT2 MAINTENANCE SCHEDULE MAINTENANCE REGULAR SERVICE PERIOD (2) Perform at every indicated month or operating hour interval, whichever comes first. Refer to Item page First Every Every Every Each use month or 3 months or 6 months or year or 20 hrs.
  • Page 28: Engine Oil Level Check/Change

    TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft) Add the specified amount of recommended oil into the engine. ENGINE OIL CAPACITY: WB20XT2: 0.56 liter (0.59 US qt, 0.49 Imp qt) WB30XT2: 0.58 liter (0.61 US qt, 0.51 Imp qt) AMBIENT TEMPERATURE RECOMMENDED OIL: SAE 10W-30 API service classification SJ or later After adding the oil, check the oil level.
  • Page 29: Air Cleaner Check/Cleaning

    MAINTENANCE WB20XT2•WB30XT2 AIR CLEANER CHECK/CLEANING CHECK A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If the engine is operated in dusty areas, clean the air cleaner more often than specified in the MAINTENANCE SCHEDULE.
  • Page 30: Spark Plug Check/Adjustment

    WB20XT2•WB30XT2 MAINTENANCE SPARK PLUG CHECK/ADJUSTMENT Remove the spark plug (page 3-5). Check the following and replace if necessary. – Insulator (1) and sealing washer (2) for damage – Center electrode (3) and side electrode (4) for wear – Burning condition, coloration...
  • Page 31: Sediment Cup Cleaning

    MAINTENANCE WB20XT2•WB30XT2 SEDIMENT CUP CLEANING 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.
  • Page 32 WB20XT2•WB30XT2 MAINTENANCE VALVE CLEARANCE CHECK/ ADJUSTMENT Inspect and adjust the valve clearance while the engine is cold. CHECK Disconnect the spark plug cap (1) and remove the following: – Breather tube (2) – Head cover bolt (6 x 12 mm) (3) –...
  • Page 33: Valve Clearance

    MAINTENANCE WB20XT2•WB30XT2 Insert a thickness gauge (1) between the valve rocker arm (2) and valve stem (3) to measure the valve clearance. VALVE CLEARANCE: WB20XT2: IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in) EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in) WB30XT2: IN: 0.08 ±...
  • Page 34: Combustion Chamber Cleaning

    WB20XT2•WB30XT2 MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the cylinder head (page 12-3). Clean any carbon deposits from the combustion chamber (1). Installation is in the reverse order of removal. FUEL TANK AND FILTER CLEANING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
  • Page 35: Fuel Tube Check

    MAINTENANCE WB20XT2•WB30XT2 FUEL TUBE CHECK 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.
  • Page 36: Impeller Clearance Check

    WB20XT2•WB30XT2 MAINTENANCE IMPELLER CLEARANCE CHECK Remove the impeller cover (1) (page 10-5). Measure the depth of the impeller cover by using the depth gauge or vernier caliper. Measure the height of the impeller (1) vanes from the rib (2) of the end plate (3).
  • Page 37: Pump Inlet Valve Check

    MAINTENANCE WB20XT2•WB30XT2 Subtract the height of the impeller (1) from the depth of the impeller cover (2) to obtain the impeller clearance (3). IMPELLER CLEARANCE: WB20XT2: 0.30 – 0.70 mm (0.012 – 0.028 in) WB30XT2: 0.50 – 0.90 mm (0.020 – 0.035 in) If not, adjust clearance by adding or removing adjuster shims (4) (page 10-7).
  • Page 38 dummyhead dummyhead IMPELLER CLEARANCE CHECK MAINTENANCE Remove the volute case [1] (page 10-3). Measure the depth of the impeller cover by using the depth gauge or vernier caliper. Measure the height of the impeller vanes [1] from the casing cover [2].
  • Page 39 dummyhead dummyhead Subtract the height of the impeller [1] from the depth of the volute case [2] to obtain the impeller clearance [3]. IMPELLER CLEARANCE: WB20XT3: 0.30 – 0.70 mm (0.012 – 0.028 in) WB30XT3: 0.50 – 0.90 mm (0.020 – 0.035 in) If not, adjust clearance by adding or removing adjuster shims [4] (page...
  • Page 40: Troubleshooting

    dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING···················4-2 WATER PUMP TROUBLESHOOTING········· 4-6 ENGINE TROUBLESHOOTING····················4-2...
  • Page 41 TROUBLESHOOTING WB20XT2•WB30XT2 BEFORE TROUBLESHOOTING TROUBLESHOOTING • Check that the connectors are connected securely. • Check for sufficient fresh fuel in the fuel tank. • Read the circuit tester's operation instructions carefully, and observe the instructions during inspection. ENGINE TROUBLESHOOTING...
  • Page 42 WB20XT2•WB30XT2 TROUBLESHOOTING ENGINE WON’T START • Check the oil level before troubleshooting (page 3-3). Loosen the carburetor drain screw and check the Check for clogged fuel tank joint or fuel tube No fuel fuel flow from the fuel tank (page 6-3).
  • Page 43 TROUBLESHOOTING WB20XT2•WB30XT2 ENGINE SURGES Partially close the choke. Does the engine speed stabilize? Clogged or saturated Check the air cleaner element (page 3-4). Clean or replace the air cleaner element (page 3-4). Clean Check the spark plug (page 3-5).
  • Page 44 WB20XT2•WB30XT2 TROUBLESHOOTING ENGINE DOES NOT STOP WHEN ENGINE STOP SWITCH IS TURNED OFF Check the engine stop switch (page 8-10). Replace the engine stop switch (page 8-6). Abnormal Normal Check the wire harness connecting the engine Replace the engine wire harness.
  • Page 45 TROUBLESHOOTING WB20XT2•WB30XT2 WATER PUMP TROUBLESHOOTING Priming water too low Increase. Pump will not prime Replace (page 10-8). Mechanical seal damaged Inlet valve damaged Replace (page 10-3, 10-4). Suction hose damaged Replace (page 10-3, 10-4). Air leak Tighten parts.
  • Page 46 WB20XT2•WB30XT2 TROUBLESHOOTING Priming water too low Increase. Self-feed time too long Mechanical seal damaged Replace (page 10-8). Inlet valve damaged Replace (page 10-3, 10-4). Suction hose damaged Replace (page 10-3, 10-4). Air leak Tighten parts. Pump RPM too high Adjust throttle or governor (page 3-6, 7-4).
  • Page 47 dummyhead dummyhead MEMO...
  • Page 48: Cover

    dummytext 5. COVER FAN COVER REMOVAL/INSTALLATION····5-2...
  • Page 49 COVER WB20XT2•WB30XT2 FAN COVER REMOVAL/INSTALLATION COVER Remove the fuel tube from the clamp (WB20XT2 only). When installing, route the tube and wires properly (page 2-8). WB20XT2 only: CLAMP FUEL TUBE ENGINE WIRE HARNESS CONNECTOR OIL ALERT UNIT CONNECTOR...
  • Page 50: Fuel System

    dummytext 6. FUEL SYSTEM TOOLS···························································6-2 CARBURETOR BODY CLEANING ·············· 6-8 FUEL TANK CARBURETOR INSPECTION ······················ 6-8 REMOVAL/INSTALLATION··························6-3 PILOT SCREW REPLACEMENT ················· 6-9 AIR CLEANER REMOVAL/INSTALLATION··························6-5 CHOKE REPLACEMENT ··························· 6-10 CARBURETOR CARBURETOR STUD BOLT REMOVAL/INSTALLATION··························6-6 REPLACEMENT ········································· 6-10 CARBURETOR DISASSEMBLY/ASSEMBLY ························6-7...
  • Page 51 FUEL SYSTEM WB20XT2•WB30XT2 TOOLS FUEL SYSTEM Jet cleaner set Float level gauge 07JPZ-001010B 07401-0010000 or 07JPZ-001010A...
  • Page 52 WB20XT2•WB30XT2 FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION 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.
  • Page 53 FUEL SYSTEM WB20XT2•WB30XT2 FUEL FILTER HOLDER REMOVAL/INSTALLATION (A TYPE ONLY) Remove the fuel filler cap (1). Turn the fuel filter holder (2) to align it the tether hole (3) with the cutout (4) of the fuel filler neck, and then remove the fuel filler cap.
  • Page 54 WB20XT2•WB30XT2 FUEL SYSTEM AIR CLEANER REMOVAL/INSTALLATION When removing air cleaner elbow, remove the engine (WB20XT2 only) (page 11-2). WING NUT 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) CARBURETOR SPACER INSTALLATION: Before installing, check for damage. AIR CLEANER CAP Note the installation direction.
  • Page 55 FUEL SYSTEM WB20XT2•WB30XT2 CARBURETOR REMOVAL/INSTALLATION 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.
  • Page 56 WB20XT2•WB30XT2 FUEL SYSTEM CARBURETOR DISASSEMBLY/ASSEMBLY 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.
  • Page 57 Check container instructions. If you are in doubt, do not use these products to clean Honda carburetors. • High air pressure may damage the carburetor body. Use low air pressure (206 kPa (2.11 kgf/cm , 30 psi) or less) when cleaning passages and ports.
  • Page 58 WB20XT2•WB30XT2 FUEL SYSTEM FLOAT VALVE Check the float valve and its seat (1) for wear or contamination. Check the valve seat (2) for clogs. Before installation, check for wear or a weak float valve spring (3). Check the operation of the float valve.
  • Page 59 FUEL SYSTEM WB20XT2•WB30XT2 CHOKE REPLACEMENT Remove the carburetor (page 6-6). Pull out the choke valve plate (1). Remove the choke shaft (2) and install a new choke shaft. Insert a new choke valve plate into the slit (3) of the choke shaft.
  • Page 60: Governor System

    dummytext 7. GOVERNOR SYSTEM GOVERNOR ARM/CONTROL BASE GOVERNOR ADJUSTMENT ························ 7-4 REMOVAL/INSTALLATION··························7-2 GOVERNOR CONTROL BASE DISASSEMBLY/ASSEMBLY ························ 7-5 DISASSEMBLY/ASSEMBLY ························7-3 MAXIMUM SPEED ADJUSTMENT ·············· 7-6...
  • Page 61 GOVERNOR ARM BOLT is normal as shown. as shown. More than 0.5 mm (0.02 in) WB20XT2 WB30XT2 BOLT WB20XT2: (6 x 20 mm) WB30XT2: (6 x 12 mm) BOLT (6 x 12 mm) GOVERNOR ARM GOVERNOR ROD/ THROTTLE RETURN SPRING REMOVAL/INSTALLATION:...
  • Page 62 WB20XT2•WB30XT2 GOVERNOR SYSTEM CONTROL BASE DISASSEMBLY/ASSEMBLY Remove the control base Assy (page 7-2). CONTROL LEVER WASHER LOCK NUT (6 mm) INSTALLATION: INSTALLATION: After installation the control base Assy., Install the control lever washer measure force at 10 mm (0.4 in) from by aligning the cutout of the the tip of the control lever (1) by pulling.
  • Page 63 GOVERNOR SYSTEM WB20XT2•WB30XT2 GOVERNOR ADJUSTMENT Loosen the nut (6 mm) (1) of the governor arm. Turn the governor arm (2) clockwise to fully open the carburetor throttle valve (3). Rotate the governor arm shaft (4) as far as it will go in the same direction the governor arm moved to open the throttle valve.
  • Page 64 LOCK PIN INSTALLATION: Install firmly into the groove of the governor arm shaft. WASHER (6 mm) GOVERNOR ARM SHAFT WASHER (6 mm) (WB20XT2 only) (Journal) GOVERNOR HOLDER SHAFT (Journal) GOVERNOR SLIDER INSTALLATION: Spread the governor weights to install the governor slider.
  • Page 65 GOVERNOR SYSTEM WB20XT2•WB30XT2 MAXIMUM SPEED ADJUSTMENT Use a tachometer with graduations of 50 min (rpm) or smaller that will accurately indicate 50 min (rpm) changes. Start the engine and allow it to warm up to normal operating temperature.
  • Page 66: Ignition System

    dummytext 8. IGNITION SYSTEM SYSTEM DIAGRAM ······································8-2 OIL ALERT UNIT REMOVAL/INSTALLATION ························· 8-7 IGNITION SYSTEM TROUBLESHOOTING···································8-2 IGNITION COIL AIR GAP CHECK/ADJUSTMENT ································ 8-7 IGNITION COIL REMOVAL/INSTALLATION··························8-3 SPARK TEST ················································ 8-8 COOLING FAN/FLYWHEEL SPARK PLUG CAP INSPECTION················ 8-8 REMOVAL/INSTALLATION··························8-4 IGNITION COIL INSPECTION ······················ 8-9 OIL LEVEL SWITCH REMOVAL/INSTALLATION··························8-6 OIL LEVEL SWITCH INSPECTION ··············...
  • Page 67 IGNITION SYSTEM WB20XT2•WB30XT2 SYSTEM DIAGRAM IGNITION SYSTEM ENGINE STOP SWITCH Black Brown Yellow Orange Blue Light blue SPARK PLUG IGNITION COIL ENGINE STOP SWITCH OIL ALERT UNIT OIL LEVEL SWITCH Green Light green Pink White Gray IGNITION SYSTEM TROUBLESHOOTING...
  • Page 68 WB20XT2•WB30XT2 IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Remove the following: – Fan cover (page 5-2) – Carburetor (page 6-6) When installing, route the engine wire harness and high-tension cord properly (page 2-8). After installation, check the ignition coil air gap (page 8-7).
  • Page 69 IGNITION SYSTEM WB20XT2•WB30XT2 COOLING FAN/FLYWHEEL REMOVAL/INSTALLATION REMOVAL Remove the ignition coil (page 8-3). GROMMET (WB20XT2 only) WOODRUFF KEY SIDE PLATE MAGNET PART BOLT (6 × 22 mm) STARTER PULLEY COOLING FAN NUT (14 mm) (Threads and seating surface) 75 N·m (7.6 kgf·m, 55 lbf·ft)
  • Page 70 WB20XT2•WB30XT2 IGNITION SYSTEM INSTALLATION • Clean the tapered parts (1) of dirt, oil, grease, and other foreign material before installation. • Be sure there are no metal parts or other foreign material on the magnet part (2) of the flywheel.
  • Page 71 IGNITION SYSTEM WB20XT2•WB30XT2 OIL LEVEL SWITCH REMOVAL/INSTALLATION Disconnect the Oil Alert unit connector. Remove the camshaft (page 13-4). Take care not to drop the valve lifter. OIL LEVEL SWITCH O-RING NUT (10 mm) 10 N·m (1.0 kgf·m, 7 lbf·ft)
  • Page 72 WB20XT2•WB30XT2 IGNITION SYSTEM OIL ALERT UNIT REMOVAL/INSTALLATION Disconnect the Oil Alert unit connectors (1). Remove the 6 x 12 mm bolt (2) and Oil Alert unit (3). Install the Oil Alert unit and bolt. Hold the Oil Alert unit against the boss (4) of the stay, and then tighten the bolt.
  • Page 73 IGNITION SYSTEM WB20XT2•WB30XT2 SPARK TEST Never hold the high-tension cord with wet hands while performing this test. Check for the following before conducting the spark test. • Faulty spark plug • Loose spark plug cap • Water in the spark plug cap (leaking the ignition coil secondary voltage) •...
  • Page 74 WB20XT2•WB30XT2 IGNITION SYSTEM IGNITION COIL INSPECTION Remove the fan cover (page 5-2). PRIMARY SIDE Disconnect the ignition coil connector (1). Measure the resistance of the primary coil by attaching one ohmmeter probe to the ignition coil wire terminal (2) and the other at the iron core (3).
  • Page 75 IGNITION SYSTEM WB20XT2•WB30XT2 ENGINE STOP SWITCH INSPECTION Remove the engine stop switch connector (1) from the engine wire harness. Check the continuity between the terminals at each switch position. Switch position Continuity If the correct continuity is not obtained, replace the engine stop switch (page 8-6).
  • Page 76: Starting System

    dummytext 9. STARTING SYSTEM RECOIL STARTER RECOIL STARTER REMOVAL/INSTALLATION··························9-2 DISASSEMBLY/ASSEMBLY ························ 9-3 RECOIL STARTER INSPECTION ················ 9-6...
  • Page 77 STARTING SYSTEM WB20XT2•WB30XT2 RECOIL STARTER STARTING SYSTEM REMOVAL/INSTALLATION RECOIL STARTER BOLT (6 x 10 mm) (3)
  • Page 78 WB20XT2•WB30XT2 STARTING SYSTEM RECOIL STARTER DISASSEMBLY/ASSEMBLY • Wear gloves and eye protection. • During disassembly/assembly, take care not to allow the return spring to come out. DISASSEMBLY Remove the recoil starter (page 9-2). SPRING RETAINER RECOIL STARTER CENTER SCREW (Inside) 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
  • Page 79 STARTING SYSTEM WB20XT2•WB30XT2 ASSEMBLY Pass the recoil starter rope (1) through the hole (2) of the recoil starter pulley (3), and then tie the rope as shown. Wind the recoil starter rope onto the recoil starter pulley counterclockwise as shown.
  • Page 80 WB20XT2•WB30XT2 STARTING SYSTEM Apply grease to the inside of the spring retainer (1). Apply locking agent (Hondalock 1 or equivalent) to the threads of the center screw (2). Set the friction spring (3), friction plate (4), and spring retainer to the recoil starter pulley in the direction as shown.
  • Page 81 STARTING SYSTEM WB20XT2•WB30XT2 RECOIL STARTER INSPECTION RECOIL STARTER OPERATION Remove the recoil starter Assy. (page 9-2). Pull the starter grip (1) several times to inspect that the ratchets (2) are operated properly (the ratchet ends come out from the spring retainer (3)).
  • Page 82: Pump

    dummytext 10. PUMP TOOLS·························································10-2 IMPELLER/END PLATE REMOVAL/INSTALLATION ······················· 10-7 INLET PIPE/OUTLET PIPE REMOVAL/INSTALLATION························10-3 MECHANICAL SEAL REPLACEMENT······ 10-8 PUMP CASE/IMPELLER COVER WATER PUMP VACUUM TESTER ············ 10-9 REMOVAL/INSTALLATION························10-5 10-1...
  • Page 83 PUMP WB20XT2•WB30XT2 TOOLS PUMP Attachment, 32 x 35 mm Driver Mechanical seal attachment 07746-0010100 07749-0010000 07948-9540000 Water pump vacuum tester 07APJ-YB3A100 10-2...
  • Page 84 WB20XT2•WB30XT2 PUMP INLET PIPE/OUTLET PIPE REMOVAL/INSTALLATION WB20XT2 HOSE COUPLING PACKING FILLER CAP (Commercially available) SEAL RING OUTLET PIPE BOLT (8 x 25 mm) (4) HOSE COUPLING INLET VALVE (Commercially available) INSTALLATION: Check the inlet valve for breakage or damage.
  • Page 85 PUMP WB20XT2•WB30XT2 WB30XT2 HOSE COUPLING PACKING FILLER CAP (Commercially available) SEAL RING OUTLET PIPE BOLT (10 x 32 mm) (4) HOSE COUPLING INLET VALVE (Commercially available) INSTALLATION: Check the inlet valve for breakage or damage. Align the tab (1) on the inlet valve with the OUTLET groove (2) of the inlet pipe.
  • Page 86 dummyhead dummyhead INLET PIPE/OUTLET PIPE PUMP REMOVAL/INSTALLATION WB30XT3 HOSE COUPLING PACKING INSTALLATION: Install the hose coupling packing [1] FILLER CAP in the groove [2] of the hose clamp SEAL RING ring. OUTLET PIPE BOLT (10 x 32 mm) (4) INLET VALVE HOSE COUPLING (2) INSTALLATION: OUTLET...
  • Page 87 WB20XT2•WB30XT2 PUMP PUMP CASE/IMPELLER COVER REMOVAL/INSTALLATION WB20XT2 Remove the engine (page 11-2). STUD BOLT (6 x 50 mm) (2) VOLUTE CASE INSTALLATION: Check the mating surface SHORT for damage and nicks. LONG CAP NUT (6 mm) (3) STUD BOLT (6 x 63.5 mm) SEAL RING O-RING (49 x 5.7 mm)
  • Page 88 PUMP WB20XT2•WB30XT2 WB30XT2 Remove the engine (page 11-3). STUD BOLT (3) VOLUTE CASE INSTALLATION: Check the mating surface for damage and nicks. CAP NUT (6 mm) (3) SEAL RING O-RING (71 x 5.7 mm) CASING SEAL RING SERVICE BULLETIN #8...
  • Page 89 dummyhead dummyhead PUMP CASE/IMPELLER COVER REMOVAL/INSTALLATION WB20XT3 Remove the engine (page 11-2). STUD BOLT (3) VOLUTE CASE INSTALLATION: Check the mating surface for damage and nicks. SHORT LONG CAP NUT (6 mm) (3) SEAL RING O-RING (49 x 5.7 mm) O-RING (217.5 x 3.5 mm) DRAIN CAP CASING...
  • Page 90 dummyhead dummyhead WB30XT3 Remove the engine (page 11-3). STUD BOLT (3) VOLUTE CASE INSTALLATION: Check the mating surface for damage and nicks. SHORT LONG CAP NUT (6 mm) (3) SEAL RING O-RING (71 x 5.7 mm) CASING SEAL RING DRAIN CAP CASING BOLT (10 x 32 mm) (4) 10-4...
  • Page 91 PUMP IMPELLER/END PLATE REMOVAL/INSTALLATION Remove the casing (page 10-5). WB20XT2: CASING COVER SEALING WASHER (4) BOLT WB20XT2: (8 x 28 mm) (4) WB30XT2: (10 x 32 mm) (4) RUBBER RING ADJUSTER SHIM FLOATING SEAT INSTALLATION: Check the seat surface for damage, nicks.
  • Page 92 dummyhead dummyhead IMPELLER/END PLATE REMOVAL/INSTALLATION Remove the casing (page 10-3). WB20XT3: CASING COVER SEALING WASHER (4) BOLT (8 x 28 mm) (4) RUBBER RING ADJUSTER SHIM FLOATING SEAT INSTALLATION: Check the seat surface for damage, nicks. Apply soapy water to the rubber ring and install the floating seat in the rubber ring.
  • Page 93 PUMP WB20XT2•WB30XT2 MECHANICAL SEAL REPLACEMENT Drive out the mechanical seal (1) from the inside using the special tools. TOOLS: Driver (2) 07749-0010000 Attachment, 32 x 35 mm 07746-0010100 Apply liquid sealant (Hondabond HT or equivalent) to the outside surface of a new mechanical seal (1).
  • Page 94 WB20XT2•WB30XT2 PUMP WATER PUMP VACUUM TEST Use the water pump vacuum tester to confirm the pump develops the proper suction vacuum, ensuring it will prime and operate properly. TOOLS: Water Pump Vacuum Tester 07APJ-YB3A100 Install thread tape or sealant to the vacuum gauge and install in the base plate.
  • Page 95 dummyhead dummyhead MEMO...
  • Page 96: Engine Removal/Installation

    dummytext 11. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION ·········11-2 11-1...
  • Page 97 ENGINE REMOVAL/INSTALLATION WB20XT2•WB30XT2 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION WB20XT2 NUT (8 mm) (4) FRAME NUT (8 mm) (4) ENGINE MOUNT RUBBER (4) INSTALLATION: Check for cracking, deformation, or other damage before installation. Install by aligning with the hole in the frame.
  • Page 98 WB20XT2•WB30XT2 ENGINE REMOVAL/INSTALLATION WB30XT2 FRAME NUT (8 mm) (4) ENGINE MOUNT RUBBER (4) (Rubber mount type) INSTALLATION: Check for cracking, deformation, or other damage before installation. Install by aligning with the hole in the frame as shown. NUT (8 mm) (4)
  • Page 99 dummyhead dummyhead MEMO...
  • Page 100: Cylinder Head

    dummytext 12. CYLINDER HEAD TOOLS·························································12-2 CYLINDER HEAD/VALVES INSPECTION ··············································· 12-5 CYLINDER HEAD REMOVAL/INSTALLATION························12-3 VALVE GUIDE REPLACEMENT ················ 12-8 CYLINDER HEAD VALVE GUIDE REAMING ·························· 12-9 DISASSEMBLY/ASSEMBLY ······················12-4 VALVE SEAT RECONDITIONING············ 12-10 12-1...
  • Page 101 CYLINDER HEAD WB20XT2•WB30XT2 TOOLS CYLINDER HEAD Valve guide driver, 5.5 mm Valve guide reamer, 5.510 mm 07742-0010100 07984-2000001 12-2...
  • Page 102 After installation, inspect following: – Valve clearance (page 3-7) – Cylinder compression (page 12-5) BOLT (Threads and seating surface) WB20XT2: (8 x 55 mm) (4) WB30XT2: (8 x 60 mm) (4) 24 N·m (2.4 kgf·m, 18 lbf·ft) REMOVAL/INSTALLATION: CYLINDER HEAD COVER PACKING Loosen and tighten the bolts in a crisscross pattern in 2 –...
  • Page 103 CYLINDER HEAD WB20XT2•WB30XT2 CYLINDER HEAD DISASSEMBLY/ASSEMBLY Remove the cylinder head (page 12-3). (Sliding surface and stem end) INTAKE/EXHAUST VALVE SPRING RETAINER EXHAUST VALVE REMOVAL: INSTALLATION: Push down and slide the valve spring retainer (1) to Do not interchange with the the side so that the valve stem (2) slips through the intake valve.
  • Page 104 WB20XT2•WB30XT2 CYLINDER HEAD CYLINDER HEAD/VALVES INSPECTION CYLINDER COMPRESSION CHECK Start the engine and warm up to normal operating temperature. Turn off the engine stop switch to stop the engine. Turn the fuel valve lever to the OFF position, and then loosen the drain screw of the carburetor to drain the fuel completely (page 6-3).
  • Page 105 CYLINDER HEAD WB20XT2•WB30XT2 VALVE SEAT WIDTH Remove the carbon deposits from the combustion VALVE LAPPER chamber (page 3-9). (Commercially available) Inspect each valve face for irregularities. If necessary, replace the valve. Apply a light coat of Prussian Blue or erasable felt- tipped marker ink to each valve seat.
  • Page 106 WB20XT2•WB30XT2 CYLINDER HEAD Measure and record each valve guide I.D. STANDARD: 5.500 – 5.512 mm (0.2165 – 0.2170 in) SERVICE LIMIT: 5.572 mm (0.2194 in) If the measured valve guide I.D. is more than the service limit, replace the valve guide (page 12-8).
  • Page 107 CYLINDER HEAD WB20XT2•WB30XT2 VALVE SPRING FREE LENGTH/ PERPENDICULARITY Measure the valve spring free length. STANDARD: 30.5 mm (1.20 in) SERVICE LIMIT: 29.0 mm (1.14 in) If the measured length is less than the service limit, replace the valve spring (page 12-4).
  • Page 108 WB20XT2•WB30XT2 CYLINDER HEAD Remove the heated cylinder head from the hot plate and support it with wooden blocks. Drive the valve guides (1) out of the cylinder head from the combustion chamber side. TOOL: Valve guide driver 5.5 mm (2)
  • Page 109 CYLINDER HEAD WB20XT2•WB30XT2 Check the valve guide bore; it should be straight, round, and centered in the valve guide. Insert the valve and check operation. If the valve does not operate smoothly, the guide may have been bent during installation.
  • Page 110 WB20XT2•WB30XT2 CYLINDER HEAD Lap the valves into their seats, using a commercially VALVE LAPPER available valve lapper and lapping compound. (Commercially available) After lapping, wash all residual compound off the cylinder head and valve. • Do not push the valve against the seat with force during lapping.
  • Page 111 dummyhead dummyhead MEMO...
  • Page 112: Crankcase

    dummytext 13. CRANKCASE TOOLS·························································13-2 PISTON DISASSEMBLY/ASSEMBLY ······················ 13-5 CRANKCASE COVER REMOVAL/INSTALLATION························13-3 CRANKCASE COVER/CYLINDER BARREL/ PISTON/CONNECTING ROD/CRANKSHAFT/ CAMSHAFT INSPECTION·························· 13-6 CRANKSHAFT/PISTON REMOVAL/INSTALLATION························13-4 CRANKSHAFT BEARING/OIL SEAL REPLACEMENT ······································· 13-13 13-1...
  • Page 113 CRANKCASE WB20XT2•WB30XT2 TOOLS CRANKCASE Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 52 x 55 mm 07746-0010100 07746-0010200 07746-0010400 Pilot, 25 mm Pilot, 22 mm Driver 07746-0040600 07746-0041000 07749-0010000 Attachment, 45 x 50 mm 07946-6920100...
  • Page 114 (With oil level gauge) OIL FILLER CAP PACKING (2) CHECK: Replace if necessary. BOLT WB20XT2: (6 x 28 mm) (7) 12 N·m (1.2 kgf·m, 9 lbf·ft) WB30XT2: (8 x 32 mm) (6) CRANKCASE COVER 24 N·m (2.4 kgf·m, 18 lbf·ft) INSTALLATION: Be careful not to damage the oil seal lips.
  • Page 115 (2) by aligning the punch marks (3). CONNECTING ROD BOLT (2) (Threads and seating surface) CRANKSHAFT WB20XT2: (7 x 34 mm) (Pin and gear teeth) 12 N·m (1.2 kgf·m, 9 lbf·ft) INSTALLATION: WB30XT2: (6 x 34.5 mm) Be careful not to damage the oil seal lips.
  • Page 116 WB20XT2•WB30XT2 CRANKCASE PISTON DISASSEMBLY/ASSEMBLY Remove the piston. (page 13-4). MAKER MARK PISTON RING SET (Entire surface) TOP RING INSTALLATION: To install the oil ring, install the spacer (1) first, and then install the side rails (2). Be sure that the top ring (3) and second ring (4) are not interchanged.
  • Page 117 CRANKCASE WB20XT2•WB30XT2 CRANKCASE COVER/CYLINDER BARREL/PISTON/CONNECTING ROD/ CRANKSHAFT/CAMSHAFT INSPECTION CAMSHAFT HOLDER I.D. CRANKCASE COVER SIDE Measure the camshaft holder I.D. of the crankcase cover. STANDARD: 14.000 – 14.018 mm (0.5512 – 0.5519 in) SERVICE LIMIT: 14.048 mm (0.5531 in) If the measurement is more than the service limit, replace the crankcase cover (page 13-3).
  • Page 118 WB20XT2•WB30XT2 CRANKCASE PISTON SKIRT O.D. Measure and record the piston O.D. at a point 10 mm (0.4 in) from the bottom of the skirt and 90° to the piston 90° pin bore. WB20XT2: STANDARD: 59.965 – 59.985 mm (2.3608 –...
  • Page 119 CRANKCASE WB20XT2•WB30XT2 PISTON PIN O.D. Measure and record the piston pin O.D. at three points (both ends and middle). Take the minimum reading to determine piston pin O.D. WB20XT2: STANDARD: 12.994 – 13.000 mm (0.5116 – 0.5118 in) SERVICE LIMIT: 12.954 mm (0.5100 in)
  • Page 120 WB20XT2•WB30XT2 CRANKCASE PISTON RING WIDTH Measure each piston ring width. WB20XT2: STANDARD: Top: 0.950 – 0.970 mm (0.0374 – 0.0382 in) Second: 0.940 – 0.960 mm (0.0370 – 0.0378 in) SERVICE LIMIT: Top: 0.93 mm (0.037 in) Second: 0.92 mm (0.036 in)
  • Page 121 CRANKCASE WB20XT2•WB30XT2 CONNECTING ROD BIG END SIDE CLEARANCE Measure the clearance between the connecting rod big end and crankshaft using a feeler gauge. STANDARD: 0.1 – 0.4 mm (0.004 – 0.016 in) SERVICE LIMIT: 1.1 mm (0.04 in)
  • Page 122 WB20XT2•WB30XT2 CRANKCASE CRANK PIN O.D. Measure the crank pin O.D. of the crankshaft. WB20XT2: STANDARD: 25.970 – 25.980 mm (1.0224 – 1.0228 in) SERVICE LIMIT: 25.92 mm (1.020 in) WB30XT2: STANDARD: 29.970 – 29.980 mm (1.1799 – 1.1803 in) SERVICE LIMIT: 29.92 mm (1.178 in)
  • Page 123 CRANKCASE WB20XT2•WB30XT2 CAMSHAFT CAM HEIGHT Measure the cam height of the camshaft. WB20XT2: STANDARD: IN: 27.600 – 27.800 mm (1.0866 – 1.0945 in) EX: 27.647 – 27.847 mm (1.0885 – 1.0963 in) SERVICE LIMIT: IN: 27.450 mm (1.0807 in) EX: 27.500 mm (1.0827 in)
  • Page 124 Remove the oil seal and drive out the crankshaft bearing. Drive a new crankshaft bearing (1) until it is fully seated on the end using the special tools. TOOLS: WB20XT2 (62/22): Attachment, 45 x 50 mm (2) 07946-6920100 Pilot, 22 mm (3)
  • Page 125 CYLINDER BARREL SIDE Remove the oil seal. Drive a new oil seal (1) in the position as shown using the special tools. INSTALLATION HEIGHT: 1.5 mm (0.06 in) TOOLS: WB20XT2: Attachment, 32 x 35 mm (2) 07746-0010100 Driver (3) 07749-0010000...
  • Page 126: Muffler

    dummytext 14. MUFFLER MUFFLER REMOVAL/INSTALLATION······14-2 EXHAUST PIPE STUD BOLT REPLACEMENT ········································· 14-3 14-1...
  • Page 127 MUFFLER WB20XT2•WB30XT2 MUFFLER REMOVAL/INSTALLATION MUFFLER The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Allow it to cool before proceeding.
  • Page 128 WB20XT2•WB30XT2 MUFFLER EXHAUST PIPE STUD BOLT REPLACEMENT Remove the muffler (page 14-2). Thread two nuts onto the exhaust pipe stud bolt (1) and SPECIFIED LENGTH tighten them together, and then use a wrench to turn the stud bolt out.
  • Page 129 dummyhead dummyhead MEMO...
  • Page 130: Wiring Diagram

    dummytext 15. WIRING DIAGRAM WIRING DIAGRAM······································15-2 15-1...
  • Page 131 WIRING DIAGRAM WB20XT2•WB30XT2 WIRING DIAGRAM WIRING DIAGRAM ENGINE STOP SWITCH Black Brown Yellow Orange Blue Light blue SPARK PLUG IGNITION COIL ENGINE STOP SWITCH OIL ALERT UNIT OIL LEVEL SWITCH Green Light green Pink White Gray 15-2...
  • Page 132: Index

    INDEX dummytext INDEX AIR CLEANER CHECK/CLEANING ················ ··············· 3-4 IMPELLER CLEARANCE CHECK ······························· 3-11 AIR CLEANER REMOVAL/INSTALLATION ··················· 6-5 IMPELLER/END PLATE REMOVAL/INSTALLATION·· 10-7 BEFORE TROUBLESHOOTING ························ ············ 4-2 INLET PIPE/OUTLET PIPE REMOVAL/ CARBURETOR BODY CLEANING ················· ··············· 6-8 INSTALLATION ·············································· ··············...

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