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62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分
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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 up 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 GX270H

  • 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: Table Of Contents

    62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING COVER FUEL SYSTEM GOVERNOR SYSTEM CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL MUFFLER CYLINDER HEAD/VALVES CRANKCASE WIRING DIAGRAMS INDEX...
  • Page 3 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 4 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 5 62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated. term Full term Alternator American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment...
  • Page 6: Specifications

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ·····················1-2 ENGINE SPECIFICATIONS ·························· 1-5 TYPE CODE ··················································1-3 PERFORMANCE CURVES··························· 1-7 DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS························· 1-9 SPECIFICATIONS ·········································1-4 P.T.O. DIMENSIONAL DRAWINGS ··········· 1-13...
  • Page 7 62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS SERIAL NUMBER LOCATION SPECIFICATIONS The engine serial number [1], type [2] and model [3] is stamped on the crankcase. Refer to it when ordering parts or making technical inquiries.
  • Page 8 62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS TYPE CODE Model GX270H Type LHB5 QBE1 P. T. O. L type P type Q type Model GX270H Type QHB1 QHB5 QHP1 P. T. O. Q type Model GX270H Type QXC9 QXCK QXE9 P.
  • Page 9 62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS DIMENSIONS AND WEIGHTS SPECIFICATIONS Model GX270H GX390H1 Overall length E type* – 365 mm (14.4 in) L type* 405 mm (15.9 in) 440 mm (17.3 in) P type* 380 mm (15.0 in) 405 mm (15.9 in) Q type* 380 mm (15.0 in)
  • Page 10 62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS ENGINE SPECIFICATIONS GX270H Model GX270H Description code GCADH Type 4 stroke, overhead valve, single cylinder, inclined by 25° Displacement 270 cm (16.5 cu-in) Bore x stroke 77.0 x 58.0 mm (3.0 x 2.3 in) Net power (SAE J1349)* 6.0 kW (8.0 HP)/3,600 min...
  • Page 11 62Z7B000.book 6 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS GX390H1 Model GX390H1 Description code GCAFH Type 4 stroke, overhead valve, single cylinder, inclined by 25° Displacement 389 cm (23.7 cu-in) Bore x stroke 88.0 x 64.0 mm (3.5 x 2.5 in) Net power (SAE J1349)* 8.2 kW (11.0 HP)/3,600 min (rpm) Continuous rated power...
  • Page 12 62Z7B000.book 7 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS PERFORMANCE CURVES GX270H (kgf·m) (lbf·ft) (N·m) NET TORQUE (KW) (HP) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE 2000 3000 3600 4000 ENGINE SPEED (rpm)
  • Page 13 62Z7B000.book 8 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS GX390H1 (N·m) (lbf·ft) (kgf·m) NET TORQUE (KW) (HP) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE 2000 3000 3600 ENGINE SPEED (rpm)
  • Page 14 62Z7B000.book 9 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS DIMENSIONAL DRAWINGS *: P. T. O. type. (page 1-3) GX270H (WITHOUT REDUCTION) Unit: mm (in) Dual, Dual silent: 273 (10.8) Oil bath, Semi dry: 272 (10.7) Cyclone: 375 (14.8) 150 (5.9) With muffler cap: 448 (17.6) Without muffler cap: 430 (16.9)
  • Page 15 62Z7B000.book 10 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS GX270H (WITH REDUCTION) Unit: mm (in) Dual: 204.9 (8.07) Oil bath, Semi dry: 203.9 (8.03) 150 (5.9) 68.1 (2.7) With muffler cap: 448 (17.6) P. T. O. SHAFT Without muffler cap: 430 (16.9) Dual: 183 (7.2)
  • Page 16 62Z7B000.book 11 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS GX390H1 (WITHOUT REDUCTION) Unit: mm (in) Dual Silent: 297 (11.7) Oil bath: 295 (11.6) 156 (6.1) With muffler cap: 475 (18.7) Without muffler cap: 450 (17.7) CONTROL BOX With control box type: 491 (19.3) (If equipped) CRANKSHAFT (P.
  • Page 17 62Z7B000.book 12 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS GX390H1 (WITH REDUCTION) Unit: mm (in) With muffler cap: 475 (18.7) Without muffler cap: 450 (17.7) 140 (5.5) 212.9 (8.38) 84.1 (3.31) CONTROL BOX With control box type: 491 (19.3) (If equipped) P. T. O. SHAFT 141.5 (5.57) 194 (7.6) 155 (6.1)
  • Page 18 62Z7B000.book 13 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS P.T.O. DIMENSIONAL DRAWINGS *: P. T. O. type. (page 1-3) GX270H E TYPE* Unit: mm (in) 15° M6 x 1.0 (0.71) 53.5 (2.13) TAPER 1 / 5 35 (1.4) 15° 15° 28 (1.1) M10 x 1.25...
  • Page 19 62Z7B000.book 14 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS P TYPE* Unit: mm (in) 45° 45° 30° 30° 89 (3.5) 14NF2 Thread R. H. 5/16-24UNF-2B TAP (2) 26-27 (1.0-1.1) 5/16-24UNF-2B TAP (4) 72.5 (2.85) 3/8-16UNC-2B TAP (4) 103 (4.1) CRANKSHAFT (P. T. O.) Q TYPE* Unit: mm (in) 45°...
  • Page 20 62Z7B000.book 15 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS R TYPE* (1/2 REDUCTION CLUTCH TYPE) Unit: mm (in) M8 x 1.25 (4) 35 (1.4) 35 (1.4) M8 x 1.25 35 (1.3) 7.000 – 7.036 25 (1.0) (0.2756 – 0.2770) 50 (2.0) 53 (2.1) P.
  • Page 21 62Z7B000.book 16 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS V TYPE* Unit: mm (in) 2-1/4 TAPER 45° 45° 30° 30° 5/16-24UNF-2B TAP 106 (4.2) 18 (0.7) 5/16-24UNF-2B TAP (2) 46.5 (1.83) 25 (1.0) 5/16-24UNF-2B TAP (4) 76.5 (3.01) 3/8-16UNC-2B TAP (4) 103 (4.1) CRANKSHAFT (P.
  • Page 22 62Z7B000.book 17 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS L TYPE* (1/6 REDUCTION GEAR TYPE) Unit: mm (in) 45° 45° 64.8 (2.55) M8 x 1.25 (2) M8 x 1.25 (4) M8 x 1.25 7.00 – 7.03 (0.276 – 0.277) 41 (1.6) 28 (1.1) 60.0 (2.36) P.
  • Page 23 62Z7B000.book 18 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS Q TYPE* Unit: mm (in) 45° 45° 30° 30° 88.5 (3.48) 3/8-24UNF-2B TAP 5/16-24UNF-2B TAP (2) 56 (2.2) 6.30 – 6.35 (0.248 – 0.250) 28 (1.1) 5/16-24UNF-2B TAP (4) 72.2 (2.84) 3/8-16UNC-2B TAP (4) 103 (4.1) CRANKSHAFT (P.
  • Page 24 62Z7B000.book 19 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SPECIFICATIONS V TYPE* Unit: mm (in) 45° 45° 30° 30° 5/16-24UNF-2B TAP 105.5 (4.15) 5/16-24UNF-2B TAP (2) 18 (0.7) 5/16-24UNF-2B TAP (4) 75.5 (2.97) 46.5 (1.83) 3/8-16UNC-2B TAP (4) 103 (4.1) CRANKSHAFT (P. T. O.) 2-1/4 TAPER 1-19...
  • Page 25 62Z7B000.book 20 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MEMO...
  • Page 26: Service Information

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-7 TORQUE VALUES ········································2-5 HARNESS AND TUBE ROUTING ·············· 2-10 LUBRICATION & SEAL POINT ····················2-6...
  • Page 27 62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION GX270H Unit: mm (in) Part Item Standard Service limit Engine Maximum speed (at no load) – 3,850 ± 150 min (rpm) Idle speed – 1,400 ± 150 min (rpm) 1.37 MPa (14.0 kgf/cm...
  • Page 28 62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SERVICE INFORMATION Part Item Standard Service limit Spark plug 0.70 – 0.80 (0.028 – 0.031) – Spark plug cap Resistance (20°C/68°F) 7.5 – 12.5 kΩ – Ignition coil Air gap 0.2 – 0.6 (0.01 – 0.02) –...
  • Page 29 62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SERVICE INFORMATION GX390H1 Unit: mm (in) Part Item Standard Service limit Engine Maximum speed (at no load) – 3,850 ± 150 min (rpm) Idle speed – 1,400 ± 150 min (rpm) 1.37 MPa (14.0 kgf/cm , 199 psi)/ Cylinder compression –...
  • Page 30 Air cleaner elbow nut M6 x 1.0 Muffler nut M8 x 1.25 Drive sprocket bolt M8 x 1.25 (With reduction, GX270H only) Gear case cover bolt M8 x 1.25 (With reduction, GX390H1 only) Primary drive gear bolt M8 x 1.25...
  • Page 31 62Z7B000.book 6 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SERVICE INFORMATION STANDARD TORQUE VALUES Torque values Item Tread Dia. (mm) N·m kgf·m lbf·ft Screw 4 mm 5 mm 6 mm Bolt and nut 5 mm 6 mm 8 mm 10 mm 12 mm Flange bolt and nut 5 mm 6 mm...
  • Page 32 62Z7B000.book 7 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SERVICE INFORMATION TOOLS Float level gauge Sliding hammer weight Valve guide driver, 6.45 x 11 mm 07401-0010000 07741-0010201 07742-0010200 Attachment, 32 x 35 mm Attachment, 42 x 47 mm Attachment, 52 x 55 mm 07746-0010100 07746-0010300 07746-0010400...
  • Page 33 62Z7B000.book 8 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SERVICE INFORMATION Pilot, 25 mm Pilot, 30 mm Pilot, 35 mm 07746-0040600 07746-0040700 07746-0040800 Pilot, 14 mm Driver handle Seat cutter, 29 mm (45° IN) 07746-0041200 07749-0010000 07780-0010300 Seat cutter, 27.5 mm (45° EX) Seat cutter, 35 mm (45°...
  • Page 34 62Z7B000.book 9 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SERVICE INFORMATION Flywheel puller set Bearing remover shaft set, 15 mm Bearing remover shaft set, 25 mm 07935-8050004 07936-KC10500 07936-ZV10100 Valve guide reamer, 6.612 mm Attachment, 45 x 50 mm Attachment, 62 x 64 mm 07984-ZE20001 07946-6920100 07947-6340400...
  • Page 35 62Z7B000.book 10 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SERVICE INFORMATION HARNESS AND TUBE ROUTING Connection of regulator/rectifier, charge/lamp coil, sub wire harness, and auto throttle solenoid are depending on the application of the engine, therefore, it does not indicate those parts in this manual. ALL TYPE GOVERNOR ARM ENGINE WIRE HARNESS...
  • Page 36 62Z7B000.book 11 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SERVICE INFORMATION COMBINATION SWITCH (CONTROL BOX) TYPE ENGINE WIRE HARNESS ENGINE WIRE HARNESS CONNECTOR OIL ALERT TERMINAL WIRE UNIT WIRE FASTENER TUBE TO STARTER MOTOR HARNESS CLIP STARTER MOTOR WIRE PURSE LOCK CLIP To starter motor 2-11...
  • Page 37 DIRECTION OF Do not contact with cylinder SWITCH CYLINDER BARREL barrel. HARNESS CLIP ENGINE STOP SWITCH WIRE Clamp engine stop switch wire at indicated position. GX270H: GX390H1: TO ENGINE TO OIL TO IGNITION TO ENGINE TO OIL STOP SWITCH ALERT UNIT...
  • Page 38 62Z7B000.book 13 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead SERVICE INFORMATION ENGINE STOP SWITCH ONLY: CLAMP ENGINE WIRE HARNESS ENGINE WIRE HARNESS CONNECTOR ENGINE STOP SWITCH WIRE WITH CHARGE COIL / LAMP COIL 1 A/3 A CHARGE COIL TYPE: 12 V-50 W LAMP COIL TYPE: 12 V-15 W/12 V-25 W LAMP COIL TYPE: CORD CORD...
  • Page 39 62Z7B000.book 14 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MEMO...
  • Page 40: Maintenance

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE························3-2 SPARK PLUG REPLACEMENT ················· 3-11 ENGINE OIL LEVEL CHECK/CHANGE ·······3-3 SPARK ARRESTER CLEANING················ 3-12 REDUCTION CASE OIL LEVEL CHECK/ IDLE SPEED CHECK/ADJUSTMENT ········ 3-13 CHANGE························································3-4 VALVE CLEARANCE CHECK/ AIR CLEANER CHECK/CLEANING/ ADJUSTMENT ············································...
  • Page 41: Maintenance Schedule

    62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE REGULAR SERVICE PERIOD (2) First Every Every Every month year ITEM Perform at every indicated Refer Each months months month or operating hour 20 hrs. 300 hrs. page interval, whichever comes 50 hrs.
  • Page 42: Engine Oil Level Check/Change

    62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MAINTENANCE ENGINE OIL LEVEL CHECK/CHANGE CHECK Place the engine on a level surface. Remove the oil filler cap [1] and check the oil level shown into the oil filler neck [2]. If the oil level is low, fill with recommended oil to the upper level of the oil filler neck (page 3-3).
  • Page 43: Reduction Case Oil Level Check

    ENGINE OIL LEVEL CHECK/CHANGE because it shares the reduction oil with the engine oil (page 3- CHECK 1/2 REDUCTION CLUTCH TYPE (GX270H ONLY) Place the engine on a level surface. Remove the oil filler cap/oil level gauge [1], and wipe the oil level gauge clean.
  • Page 44 MAINTENANCE CHANGE 1/2 REDUCTION CLUTCH TYPE (GX270H ONLY) Place the engine on a level surface and place a suitable container under the drain bolt [1]. Remove the oil filler cap/oil level gauge [2], drain bolt and sealing washer [3] and drain the oil into a suitable container.
  • Page 45: Air Cleaner Check/Cleaning

    62Z7B000.book 6 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MAINTENANCE AIR CLEANER CHECK/CLEANING/ REPLACEMENT DUAL/DUAL SILENT TYPE: 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 46 If the oil is dirty, clean the cleaner oil pan and add the recommended oil to the upper level of the cleaner oil pan. OIL CAPACITY: GX270H: 60 cc GX390H1: 80 cc Installation is in the reverse order of removal.
  • Page 47 62Z7B000.book 8 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MAINTENANCE SEMI DRY TYPE 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. Operating the engine without the air filters or with the filter installed loosely will allow dirt to enter the engine, causing rapid engine wear.
  • Page 48: Sediment Cup Cleaning

    62Z7B000.book 9 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MAINTENANCE 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. Turn the fuel valve lever [1] to the OFF position.
  • Page 49 Check the sealing washer [2] for damage. Replace the spark plug if the sealing washer is damaged (page 3-11). SPARK PLUG: GX270H (VKK, VMT, VS4, VSD4): BPR5ES (NGK)/W16EPR-U (DENSO) GX270H (OTHER TYPE): BPR6ES (NGK)/W20EPR-U (DENSO) GX390H1 (ES2, VMT3, VMQ3, VS4, VS6, VSB4):...
  • Page 50: Spark Plug Replacement

    INSTALLATION Install and hand tighten the spark plug to the cylinder head. SPARK PLUG: GX270H (VKK, VMT, VS4, VSD4): BPR5ES (NGK)/W16EPR-U (DENSO) GX270H (OTHER TYPE): BPR6ES (NGK)/W20EPR-U (DENSO) GX390H1 (ES2, VMT3, VMQ3, VS4, VS6, VSB4): BPR5ES (NGK)/W16EPR-U (DENSO)
  • Page 51: Spark Arrester Cleaning

    62Z7B000.book 12 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MAINTENANCE SPARK ARRESTER CLEANING The engine and 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 52: Idle Speed Check/Adjustment

    62Z7B000.book 13 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MAINTENANCE CLEANING Be careful to avoid damaging the screen. Clean the carbon deposits from the spark arrester screen [1] with a wire brush [2]. Check the spark arrester screen for damage. If the screen is damaged, replace the spark arrester. Install the spark arrester in the reverse order of removal.
  • Page 53 62Z7B000.book 14 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MAINTENANCE Set the piston near top dead center of the cylinder compression stroke (both valves fully closed) by pulling the recoil starter slowly. When the piston is near top dead center of the compression stroke, the cutout [1] on the starter pulley [2] will align with the top hole [3] on the Pull slowly.
  • Page 54: Combustion Chamber Cleaning

    62Z7B000.book 15 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the cylinder head (page 13-3). Clean any carbon deposits from the combustion chamber [1]. FUEL TANK AND FILTER CLEANING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
  • Page 55: Fuel Tube Check

    62Z7B000.book 16 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MAINTENANCE 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. Check the fuel tube [1] for deterioration, cracks or signs of leakage.
  • Page 56: Troubleshooting

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING···················4-2 TROUBLESHOOTING ·································· 4-2...
  • Page 57 62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead TROUBLESHOOTING BEFORE TROUBLESHOOTING TROUBLESHOOTING • Use a known-good battery for 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. •...
  • Page 58 62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead TROUBLESHOOTING From page 4-2 Compression is too high Perform the cylinder compression test (page Check the valve clearance (page 3-13) and 13-5). then perform the cylinder compression test. If the cylinder compression is too high, remove carbon deposits in the combustion chamber (page 3-15).
  • Page 59 62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead TROUBLESHOOTING ENGINE SPEED DOES NOT INCREASE OR STABILIZE Clogged Check the air cleaner element (page 3-6). Clean the air cleaner element (page 3-8). Clean Inspect the spark plug and adjust the spark Check the spark plug (page 3-9). Abnormal plug gap.
  • Page 60 62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead TROUBLESHOOTING ENGINE DOES NOT STOP WHEN COMBINATION/ ENGINE STOP SWITCH IS TURNED OFF Replace the engine stop switch (page 5-2)/ Check the engine stop switch (If equipped) (page Abnormal combination switch (page 11-3). 11-6)/combination switch (If equipped) (page 11- Normal Check the wire harness connecting the Replace the engine wire harness.
  • Page 61 62Z7B000.book 6 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MEMO...
  • Page 62: Cover

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 5. COVER FAN COVER REMOVAL/INSTALLATION····5-2...
  • Page 63 When installing, refer to the HARNESS AND TUBE ROUTING (page 2-10). HARNESS CLIP TUBE CLIP FLANGE BOLT (6 x 12 mm) (6) FAN COVER REMOVAL: GX270H (VSD4 ONLY) The fan cover can be removed ENGINE STOP SWITCH with the recoil starter assembly installed. ENGINE STOP SWITCH...
  • Page 64: Fuel System

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 6. FUEL SYSTEM TOOL ·····························································6-2 CARBURETOR BODY CLEANING ············ 6-15 FUEL TANK REMOVAL/INSTALLATION ····6-3 CARBURETOR INSPECTION ···················· 6-15 AIR CLEANER REMOVAL/ CHOKE DIAPHRAGM INSPECTION·········· 6-16 INSTALLATION·············································6-4 PILOT SCREW REPLACEMENT ··············· 6-17 CARBURETOR REMOVAL/ INSTALLATION·············································6-9 CHOKE SET REPLACEMENT ··················· 6-18 CARBURETOR DISASSEMBLY/ CYLINDER STUD BOLT ASSEMBLY ·················································6-11...
  • Page 65 62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead FUEL SYSTEM TOOL FUEL SYSTEM Float level gauge 07401-0010000...
  • Page 66 62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead 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. Turn the fuel valve lever to the OFF position.
  • Page 67 AIR CLEANER ELEMENT (FOAM) AIR CLEANER ELEMENT (PAPER) HIGH-TENSION CORD WASHER BOLT (6 x 22 mm) SLANT OUTSIDE NOISE SILENCER COLLAR GX270H: AIR CLEANER ELBOW SEAL AIR CLEANER ELBOW REMOVAL/ INSTALLATION: CARBURETOR SPACER Remove and install the air (If equipped)
  • Page 68 62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead FUEL SYSTEM CYCLONE TYPE: PRE AIR CLEANER WING NUT CASE COVER SCREW(5 x 16.5 mm) (5) AIR CLEANER COVER PRE AIR CLEANER GUIDE WING NUT PRE AIR CLEANER CASE GROMMET ASSEMBLY: Align the pre air cleaner case cover tab with the groove in the pre air cleaner case.
  • Page 69 62Z7B000.book 6 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead FUEL SYSTEM LOW PROFILE TYPE: BREATHER TUBE INSTALLATION: After installing the air cleaner elbow, insert the breather tube to the hole of the cylinder head cover as shown. BREATHER TUBE HIGH-TENSION CARBURETOR SPACER CORD INSTALLATION: GROMMET Before installing, check for damage.
  • Page 70 WING NUT AIR CLEANER CAP After installing the air cleaner elbow, insert the breather tube to the hole AIR CLEANER CAP of the cylinder head cover as shown. GX270H: AIR CLEANER BREATHER TUBE COVER AIR CLEANER COVER CLEANER OIL PAN...
  • Page 71 62Z7B000.book 8 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead FUEL SYSTEM SEMI DRY TYPE: BREATHER TUBE INSTALLATION: After installing the air cleaner elbow, WING NUT insert the breather tube to the hole of the cylinder head cover as shown. BREATHER TUBE AIR CLEANER CAP WASHER BOLT (6 x 22 mm) AIR CLEANER COVER HIGH-TENSION CORD...
  • Page 72 62Z7B000.book 9 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead FUEL SYSTEM CARBURETOR REMOVAL/ INSTALLATION DUAL/DUAL SILENT/CYCLONE/OIL BATH/SEMI DRY TYPE AIR CLEANER: Gasoline is highly flammable and explosive.You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. •...
  • Page 73 62Z7B000.book 10 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead FUEL SYSTEM LOW PROFILE TYPE AIR CLEANER: 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. •...
  • Page 74 62Z7B000.book 11 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead FUEL SYSTEM CARBURETOR DISASSEMBLY/ ASSEMBLY DUAL/DUAL SILENT/CYCLONE/OIL BATH/SEMI DRY TYPE AIR CLEANER: Gasoline is highly flammable and explosive.You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. •...
  • Page 75 ASSEMBLY: clean thoroughly with Install the float chamber to the carburetor body DRAIN SCREW low-pressure at an angle as shown. compressed air. [1] GX270H VMT, VS4: 18° [2] GX270H VSD4: 290° GX390H1: 252° O-RING SET BOLT O-RING O-RING SOLENOID VALVE...
  • Page 76 62Z7B000.book 13 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead FUEL SYSTEM MAIN JET NUMBER: GX270H: Carburetor Main Jet identification Number [1] + [2] Number BE70L A BE70M A BE75B C BE75H A BE78B A BE98F A BE98G A BE98H A GX390H1: Carburetor Main Jet...
  • Page 77 62Z7B000.book 14 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead FUEL SYSTEM CHOKE DIAPHRAGM DISASSEMBLY/ ASSEMBLY MANUAL CHOKE ROD CHOKE ROD GROMMET DIAPHRAGM STAY E-RING CHOKE ROD GUIDE THRUST WASHER (2.7 x 8 mm) CHOKE ROD STOPPER CHOKE DIAPHRAGM E-RING RETURN SPRING LEVER COLLAR CHOKE LEVER SCREW (5 x 12 mm) (2) ROD JOINT...
  • Page 78 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 (30 psi or less) when cleaning passages and ports.
  • Page 79 62Z7B000.book 16 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead FUEL SYSTEM FLOAT VALVE Check the float valve [1] and its seat [2] for wear or GX390H1 (BE85T B, BE88Q A): contamination. CARBURETOR BODY Before installation, check for wear or a weak spring [3]. Check the operation of the float valve.
  • Page 80 Place the spring on the replacement pilot screw, and install it on the carburetor. Turn the pilot screw in until it is lightly seated, then turn the screw out the required number of turns. CARBURETOR GX270H: BODY Carburetor Pilot screw identification Number = [3] + [4]...
  • Page 81 Thread two nuts onto the stud bolt and tighten them together, and then use a wrench to turn the stud bolt out. Install new stud bolts. SPECIFIED LENGTH GX270H 8 x 98 mm: 82 mm (3.23 in) 8 x 123 mm: 107 mm (4.21 in)
  • Page 82: Governor System

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 7. GOVERNOR SYSTEM GOVERNOR ARM/CONTROL BASE ASSY. CONTROL BASE ASSY. DISASSEMBLY/ REMOVAL/INSTALLATION··························7-2 ASSEMBLY ··················································· 7-6 AUTO THROTTLE (IF EQUIPPED) REMOVAL/ MAXIMUM SPEED ADJUSTMENT ·············· 7-8 INSTALLATION·············································7-5 SOLENOID (AUTO THROTTLE) INSPECTION················································· 7-9...
  • Page 83: Governor Arm/Control Base Assy

    62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead GOVERNOR SYSTEM GOVERNOR ARM/CONTROL BASE GOVERNOR SYSTEM ASSY. REMOVAL/INSTALLATION MANUAL OPERATION TYPE Remove the following parts. – Air cleaner (page 6-4) – Muffler (page 12-2) – Fuel tank (page 6-3) – Tube clamp (page 6-9) Installation is in the reverse of removal.
  • Page 84 62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead GOVERNOR SYSTEM MANUAL OPERATION A TYPE Remove the following parts. – Air cleaner (page 6-4) – Muffler (page 12-2) – Fuel tank (page 6-3) – Tube clamp (page 6-9) Installation is in the reverse of removal. Adjust the maximum speed (page 7-8).
  • Page 85 62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead GOVERNOR SYSTEM EXCEPT MANUAL OPERATION TYPE Remove the following parts. – Air cleaner (page 6-4) – Muffler (page 12-2) – Fuel tank (page 6-3) – Tube clamp (page 6-9) (If equipped) Installation is in the reverse of removal. Adjust the governor (page 7-8) GOVERNOR ROD/THROTTLE RETURN SPRING...
  • Page 86: Removal/Installation

    62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead GOVERNOR SYSTEM AUTO THROTTLE (IF EQUIPPED) REMOVAL/INSTALLATION Remove the fuel tank (page 6-3). CHOKE RETURN SPRING SCREW (5 x 8 mm) (2) BOLT (6 x 12 mm) (2) THROTTLE LEVER To the units connected from the engine.
  • Page 87: Installation

    CIRCLIP (5 mm) (If equipped) CONTROL LEVER CLAW CONTROL BASE CONTROL ADJUST SPRING SCREW (GX270H: 5 x 28 mm, GX390H1: 5 x 32 mm) (If equipped) ASSEMBLY: Adjust the maximum speed (page 7-8). CABLE RETURN SPRING INSTALLATION: Install with the short end of the spring toward the control base.
  • Page 88 NON-HANDY LEVER A TYPE Remove the control base assy (page 7-2). CONTROL BASE CONTROL ADJUST SPRING SCREW (GX270H: 5 x 35 mm, GX390H1: 5 x 45 mm) ASSEMBLY: Adjust the maximum speed (page 7-8). NON-HANDY LEVER B TYPE Remove the control base assy (page 7-2).
  • Page 89: Maximum Speed Adjustment

    62Z7B000.book 8 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead GOVERNOR SYSTEM MAXIMUM SPEED ADJUSTMENT MANUAL CONTROL TYPE Remove the fuel tank (page 6-3). Loosen the nut (6 mm) [1] of the governor arm. Turn the governor arm [2] counter 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 90: Solenoid (Auto Throttle)

    62Z7B000.book 9 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead GOVERNOR SYSTEM Move the governor rod [1] end [2] of the governor arm in the direction shown. Move the governor spring [3] end [4] of the governor arm in the direction shown. Holding both sections of the governor arm in alignment so that the two stops are in contact with one another, move the governor arm in the direction shown until the throttle is completely open, and hold it in that position.
  • Page 91 62Z7B000.book 10 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MEMO...
  • Page 92: Charging System

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 8. CHARGING SYSTEM TOOL ·····························································8-2 COOLING FAN/FLYWHEEL REMOVAL/ INSTALLATION ············································ 8-5 SYSTEM DIAGRAM ······································8-3 CHARGE/LAMP COIL (IF EQUIPPED) REMOVAL/INSTALLATION ························· 8-7 BEFORE TROUBLESHOOTING···················8-4 CHARGE/LAMP COIL INSPECTION ··········· 8-8 TROUBLESHOOTING···································8-4...
  • Page 93: Tool

    62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CHARGING SYSTEM TOOL CHARGING SYSTEM Flywheel puller set 07935-8050004...
  • Page 94: System Diagram

    62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CHARGING SYSTEM SYSTEM DIAGRAM 1 A/3 A CHARGE COIL TYPE: MAIN FUSE CIRCUIT SILICON PROTECTOR RECTIFIER CHARGE COIL BATTERY CONTROL BOX...
  • Page 95: Before Troubleshooting

    62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CHARGING SYSTEM BEFORE TROUBLESHOOTING • Use a known-good battery for troubleshooting. • Check that the connectors are connected securely. • Read the circuit tester's operation instructions carefully, and observe the instructions during inspection. • Disconnect the battery cable before continuity inspection. TROUBLESHOOTING Abnormal Replace the fuse (page 11-4).
  • Page 96: Cooling Fan/Flywheel Removal

    62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CHARGING SYSTEM COOLING FAN/FLYWHEEL REMOVAL/ INSTALLATION REMOVAL Remove the following parts: – Fan cover (page 5-2). – Ignition coil (page 9-4). FLYWHEEL (With starter) SPECIAL WOODRUFF KEY (25 x 18 mm) STARTER PULLEY (With screen) FLYWHEEL (Without starter) STARTER PULLEY...
  • Page 97 62Z7B000.book 6 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CHARGING 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. Set the special woodruff key (25 x 18 mm) [3] in the key groove [4] of the crankshaft securely.
  • Page 98: Charge/Lamp Coil (If Equipped)

    62Z7B000.book 7 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CHARGING SYSTEM CHARGE/LAMP COIL (IF EQUIPPED) REMOVAL/INSTALLATION Remove the following parts: – Fan cover (page 5-2). – Ignition coil (page 9-4). – Remove the flywheel (page 8-5). Remove the coil connector or connectors. Installation is in the reverse of removal. Install the cord clamp.
  • Page 99: Charge/Lamp Coil Inspection

    62Z7B000.book 8 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CHARGING SYSTEM CHARGE/LAMP COIL INSPECTION 12 V-15 W/12 V-25 W LAMP COIL TYPE Disconnect the lamp coil connectors [1]. Measure the resistance between the terminals of the charge/lamp coil. Resistance: lamp coil 12 V-15 W: 1.04 –...
  • Page 100: Ignition System

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 9. IGNITION SYSTEM SYSTEM DIAGRAM ······································9-2 IGNITION COIL AIR GAP CHECK/ ADJUSTMENT ·············································· 9-5 TROUBLESHOOTING···································9-3 SPARK TEST ················································ 9-5 IGNITION COIL REMOVAL/ INSTALLATION·············································9-4 SPARK PLUG CAP INSPECTION················ 9-5 IGNITION COIL INSPECTION ······················ 9-6...
  • Page 101 62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead IGNITION SYSTEM SYSTEM DIAGRAM IGNITION SYSTEM ENGINE STOP SWITCH TYPE: OIL LEVEL SWITCH SPARK PLUG IGNITION COIL ENGINE STOP OIL ALERT UNIT SWITCH CONTROL BOX TYPE: Bl/R MAIN FUSE COMBINATION SWITCH IGNITION COIL OIL LEVEL SPARK OIL ALERT UNIT BATTERY...
  • Page 102 62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead IGNITION SYSTEM TROUBLESHOOTING NO OR WEAK SPARK AT SPARK PLUG Check the following before troubleshooting: – Loose connectors – Spark plug (page 3-9) – Engine oil level (page 3-3) Replace the oil level switch (page 14-6). Check the oil level switch (If equipped) (page 11-5)/ Abnormal Replace the oil alert unit.
  • Page 103 62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead IGNITION SYSTEM IGNITION COIL REMOVAL/ INSTALLATION Remove the following parts: – Air cleaner (page 6-4) – Fuel tank (page 6-3) – Fan cover (page 5-2) IGNITION COIL WIRE INSTALLATION: Clamp the ignition coil wire to the ribs of the cylinder barrel as shown.
  • Page 104 62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead IGNITION SYSTEM IGNITION COIL AIR GAP CHECK/ ADJUSTMENT Remove the fan cover (page 5-2). 0.2 – 0.6 mm (0.01 – 0.02 in) Insert the feeler gauge [1] of proper thickness between the ignition coil [2] and the flywheel [3]. IGNITION COIL AIR GAP: 0.2 –...
  • Page 105 62Z7B000.book 6 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead IGNITION SYSTEM IGNITION COIL INSPECTION Remove the fan cover (page 5-2). PRIMARY SIDE Disconnect the ignition coil connector [1]. Measure the resistance of primary coil by attaching one ohmmeter probe to the ignition coil terminal [2] and the other at the iron core [3].
  • Page 106: Starting System

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 10. STARTING SYSTEM SYSTEM DIAGRAM ····································10-2 RECOIL STARTER INSPECTION ·············· 10-8 TROUBLESHOOTING·································10-2 STARTER MOTOR REMOVAL/ INSTALLATION ·········································· 10-9 RECOIL STARTER REMOVAL/ INSTALLATION···········································10-3 STARTER MOTOR DISASSEMBLY/ ASSEMBLY ··············································· 10-10 RECOIL STARTER Assy. DISASSEMBLY/ ASSEMBLY ·················································10-4 STARTER MOTOR INSPECTION ············ 10-12 10-1...
  • Page 107: System Diagram

    62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead STARTING SYSTEM SYSTEM DIAGRAM STARTING SYSTEM COMBINATION MAIN FUSE SWITCH STARTER BATTERY MOTOR CONTROL BOX TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE Check the battery condition. Replace with a known-good battery. Abnormal If the battery runs down again, perform the CHARGING SYSTEM TROUBLESHOOTING (page 8-4).
  • Page 108: Recoil Starter Removal

    62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER REMOVAL/ INSTALLATION RECOIL STARTER FLANGE BOLT (6 x 10 mm) (3) 10-3...
  • Page 109: Recoil Starter Assy. Disassembly

    62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER Assy. DISASSEMBLY/ASSEMBLY • Wear gloves and eye protection. • During disassembly/assembly, take care not to allow the spring to come out. DISASSEMBLY Remove the recoil starter Assy. (page 10-3). RECOIL STARTER SETTING SCREW RATCHET GUIDE FRICTION SPRING RATCHET (2)
  • Page 110: Assembly

    62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead STARTING SYSTEM ASSEMBLY • Wear gloves and eye protection. • During reassembly, take care not to allow the spring to come out. Hook the outer hook [1] of the recoil starter spring [2] to the groove [3] in the recoil starter reel [4], and install the spring by winding it.
  • Page 111 62Z7B000.book 6 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead STARTING SYSTEM Apply 1 – 2 g (0.04 – 0.07 oz) of grease to the shaft [1] of the case, and 1 – 2 g (0.04 – 0.07 oz) to the reel sliding surface [2] Install the reel [3] into the case by aligning the inner hook [4] of the spring with the boss [5] of the case as shown.
  • Page 112 62Z7B000.book 7 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead STARTING SYSTEM With the slack in the rope, turn the recoil starter reel [1] counterclockwise until the notch [2] align with the hole [3], then further turn it 3 turns to preload the recoil starter spring.
  • Page 113: Recoil Starter Inspection

    62Z7B000.book 8 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER INSPECTION RECOIL STARTER OPERATION Remove the recoil starter Assy. (page 10-3). Pull the starter grip [1] several times to inspect that the ratchets [2] are operated properly (the ratchet ends come out from the ratchet guide [3]).
  • Page 114: Starter Motor Removal

    STARTER MOTOR REMOVAL/ INSTALLATION Disconnect the starter motor wires from the starter motor. Remove the fan cover (page 5-2). STARTER MOTOR STARTER MOTOR TERMINAL WIRE STARTER MOTOR WIRE FLANGE BOLT (GX270H: 8 x 40 mm, GX390H1: 8 x 35 mm) (2) 10-9...
  • Page 115: Starter Motor Disassembly

    62Z7B000.book 10 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead STARTING SYSTEM STARTER MOTOR DISASSEMBLY/ ASSEMBLY Remove the starter motor (page 10-9). GX270H: HOUSING ASSEMBLY: WASHER Make sure there is no SCREW obstruction on the magnets. (5 x 14 mm) (2) INSULATOR INSPECTION: ARMATURE Check for cracks or damage.
  • Page 116 PINION GEAR HOUSING STARTER SOLENOID WIRE BRUSH HOLDER INSTALLATION (GX270H ONLY) Note the installation direction. Install the insulator [1], brush holder [2], negative brush terminals [3], and two 4 x 14 mm screws [4] to the center bracket as shown.
  • Page 117: Starter Motor Inspection

    If the positive brush length is less than the service limit, replace the center bracket and brush holder. STANDARD: GX270H: 7.0 mm (0.28 in) GX390H1: 10.5 mm (0.41 in) SERVICE LIMIT: GX270H: 3.5 mm (0.14 in) GX390H1: 4.0 mm (0.16 in)
  • Page 118 62Z7B000.book 13 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead STARTING SYSTEM BRUSH CONTINUITY CHECK Check for continuity between the positive (+) brushes [1] and negative (–) brushes [2]. There should be continuity between both the positive brushes. There should be continuity between both the negative brushes.
  • Page 119 62Z7B000.book 14 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead STARTING SYSTEM STARTER SOLENOID WIRE Check the starter solenoid wire for continuity. 10-14...
  • Page 120: Other Electrical

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 11. OTHER ELECTRICAL COMPONENT LOCATION ··························11-2 OIL LEVEL SWITCH INSPECTION ············ 11-5 CONTROL BOX REMOVAL/ ENGINE STOP SWITCH INSPECTION ······ 11-6 INSTALLATION···········································11-3 COMBINATION SWITCH INSPECTION ····· 11-6 CONTROL BOX DISASSEMBLY/ ASSEMBLY ·················································11-4 SILICON RECTIFIER INSPECTION ··········· 11-6 OIL ALERT UNIT REMOVAL/ CIRCUIT PROTECTOR INSPECTION········...
  • Page 121: Component Location

    62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead OTHER ELECTRICAL COMPONENT LOCATION OTHER ELECTRICAL WITHOUT CONTROL BOX: OIL ALERT UNIT (If equipped) ENGINE STOP SWITCH (If equipped) OIL LEVEL SWITCH (If equipped) WITH CONTROL BOX: CONTROL BOX 11-2...
  • Page 122: Control Box Removal

    62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead OTHER ELECTRICAL CONTROL BOX REMOVAL/ INSTALLATION Disconnect the control box wires. When installing, refer to the HARNESS AND TUBE ROUTING (with circuit protector) (page 2-10). ENGINE WIRE HARNESS STARTER MOTOR WIRE TERMINAL WIRE OIL LEVEL SWITCH WIRE CHARGE COIL CORD FLANGE BOLT (6 x 12 mm) (2)
  • Page 123: Control Box Disassembly

    Remove the control box (page 11-3). SILICON RECTIFIER SPECIAL SCREW MAIN FUSE INSPECTION: (page 11-6) (6 x 12 mm) INSPECTION: (page 11-7) GX270H: QBE1, QXE9: 5 A CONTROL BOX CASE VKK: 15 A GX390H1: 5 A CASE MOUNTING BRACKET OIL ALERT UNIT...
  • Page 124: Oil Alert Unit Removal

    62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead OTHER ELECTRICAL OIL ALERT UNIT REMOVAL/ INSTALLATION Disassemble the control box (page 11-4). With control box: Disconnect the oil alert unit connectors [1]. Without control box: Remove the bolt (6 x 12 mm) [2] and oil alert unit [3]. Installation is in the reverse order of removal.
  • Page 125: Engine Stop Switch Inspection

    62Z7B000.book 6 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead OTHER ELECTRICAL ENGINE STOP SWITCH INSPECTION Remove the engine wire harness connector [1]. 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 5-2).
  • Page 126: Circuit Protector Inspection

    Visually inspect the fuse to see if it is blown. Check continuity across the two blades. Replace the fuse if it is blown or there is no continuity across the blades. MAIN FUSE: GX270H: QBE1, QXE9: 5 A VKK: 15 A GX390H1:...
  • Page 127 62Z7B000.book 8 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MEMO...
  • Page 128: Muffler

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 12. MUFFLER MUFFLER REMOVAL/INSTALLATION······12-2 EXHAUST PIPE STUD BOLT REPLACEMENT ········································· 12-4 12-1...
  • Page 129 (5 x 8 mm) (4) Before installing, clean the spark arrester. TAPPING SCREW MUFFLER PROTECTOR (4 x 6 mm) (3) (If equipped) TAPPING SCREW GX270H: (6 x 10 mm) TAPPING SCREW (4 x 6 mm) GX390H1: TAPPING SCREW MUFFLER CAP...
  • Page 130 62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MUFFLER INNER/OUTER PROTECTOR TYPE EXHAUST INNER MUFFLER PROTECTOR PIPE GASKET MUFFLER EXHAUST PROTECTOR PIPE SEALS NUT (8 mm) (2) 24 N·m (2.4 kgf·m, 18 lbf·ft) BOLT (8 x 20 mm) (2) MUFFLER GASKET TAPPING SCREW (4 x 8 mm) BOLT (6 x 10 mm) MUFFLER...
  • Page 131 62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MUFFLER EXHAUST PIPE STUD BOLT REPLACEMENT Thread two nuts onto the exhaust pipe stud bolt [1] and tighten them together, then use a wrench to turn the stud bolt out. Install new stud bolts. SPECIFIED LENGTH: 8 x 32 mm: 16 mm (0.63 in) SHORT...
  • Page 132: Cylinder Head/Valves

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 13. CYLINDER HEAD/VALVES TOOLS·························································13-2 CYLINDER HEAD/VALVES INSPECTION··············································· 13-5 CYLINDER HEAD REMOVAL/ INSTALLATION···········································13-3 VALVE GUIDE REPLACEMENT ················ 13-8 CYLINDER HEAD DISASSEMBLY/ VALVE GUIDE REAMING ·························· 13-9 ASSEMBLY ·················································13-4 VALVE SEAT RECONDITIONING············ 13-10 13-1...
  • Page 133 62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CYLINDER HEAD/VALVES TOOLS CYLINDER HEAD/VALVES Valve guide driver, 6.45 x 11 mm Seat cutter, 29 mm (45° IN) Seat cutter, 27.5 mm (45° EX) 07742-0010200 07780-0010300 07780-0010200 Seat cutter, 35 mm (45° IN) Seat cutter, 33 mm (45° EX) Flat cutter, 30 mm (32°...
  • Page 134 62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL/ INSTALLATION Set the piston at top dead center of the cylinder compression stroke (page 3-13). Remove the following parts: – Air cleaner (page 6-4) – Carburetor (page 6-9) – Control base assy (page 7-2) –...
  • Page 135 62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CYLINDER HEAD/VALVES CYLINDER HEAD DISASSEMBLY/ ASSEMBLY Remove the cylinder head (page 13-3). VALVE SPRING RETAINER REMOVAL: EXHAUST VALVE Push down and slide the valve spring retainer [1] (Sliding surface and stem end) to the side so that the valve stem [2] slips ASSEMBLY: through the hole at the side of the valve spring retainer.
  • Page 136 62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CYLINDER HEAD/VALVES CYLINDER HEAD/VALVES INSPECTION CYLINDER COMPRESSION CHECK Start the engine and warm up to normal operating temperature. Turn the fuel valve lever to the OFF position, and then remove the drain screw to drain the carburetor. Remove the spark plug cap [1] from the spark plug.
  • Page 137 Continue to rotate the special tool while removing it from the valve guide. VALVE SPRING SIDE Measure and record each valve guide I.D. GX270H: STANDARD: 6.600 – 6.612 mm (0.2598 – 0.2603 in) SERVICE LIMIT: 6.66 mm (0.262 in) GX390H1: STANDARD: 6.600 –...
  • Page 138 (page 13-4). GUIDE-TO-STEM CLEARANCE Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the guide-to-stem clearance. GX270H: STANDARD: IN: 0.010 – 0.037 mm (0.0004 – 0.0015 in) EX: 0.050 – 0.077 mm (0.0020 – 0.0032 in) SERVICE LIMIT: IN: 0.11 mm (0.004 in)
  • Page 139 62Z7B000.book 8 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CYLINDER HEAD/VALVES VALVE SPRING PERPENDICULARITY Measure the valve spring perpendicularity. SERVICE LIMIT: 1.5° If the measured perpendicularity is more than the service limit, replace the valve spring (page 13-4). PUSH ROD RUNOUT Check both ends of the push rod for wear. Check the push rod for straightness.
  • Page 140 Drive the intake valve guide to the specified height (measured from the end of the valve guide to the cylinder head as shown). GX270H: 6 mm (0.2 in) GX390H1: 5 mm (0.2 in) IN VALVE INSTALLATION HEIGHT: GX270H: 6 mm (0.2 in) GX390H1: 5 mm (0.2 in)
  • Page 141 62Z7B000.book 10 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CYLINDER HEAD/VALVES 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 142 CYLINDER HEAD/VALVES The 32° cutter removes material from the top edge CONTACT TO STANDARD (contact too high). TOOLS (GX270H): Cutter holder, 6.6 mm 07781-0010202 Flat cutter, 28 mm (32° EX) 07780-0012100 Flat cutter, 30 mm (32° IN) 07780-0012200 TOOLS (GX390H1): Cutter holder, 6.6 mm...
  • Page 143 62Z7B000.book 12 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead MEMO...
  • Page 144: Crankcase

    (CRANKCASE COVER SIDE) ·················· 14-24 CRANKCASE COVER REMOVAL/ INSTALLATION···········································14-4 CRANKSHAFT BEARING REPLACEMENT (FLYWHEEL SIDE) ··································· 14-26 CRANKSHAFT/BALANCER/PISTON REMOVAL/INSTALLATION························14-6 GX270H CRANKSHAFT OIL SEAL REPLACEMENT (CYLINDER BARREL BALANCER WEIGHT/CAMSHAFT SIDE) ························································· 14-27 INSTALLATION (GX390H1 ONLY)·············14-7 GX390H1 BALANCER WEIGHT BEARING/ REDUCTION UNIT DISASSEMBLY/ GOVERNOR ARM SHAFT OIL SEAL/ ASSEMBLY ·················································14-8...
  • Page 145: Tools

    62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE TOOLS CRANKCASE Sliding hammer weight Bearing driver attachment, 32 x 35 mm Attachment, 42 x 47 mm 07741-0010201 07746-0010100 07746-0010300 Attachment, 52 x 55 mm Attachment, 72 x 75 mm Inner driver handle, 40 mm 07746-0010400 07746-0010600 07746-0030100...
  • Page 146 62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE Pilot, 14 mm Driver handle Bearing remover shaft set, 15 mm 07746-0041200 07749-0010000 07936-KC10500 Bearing remover shaft set, 25 mm Attachment, 45 x 50 mm Attachment, 62 x 64 mm 07936-ZV10100 07946-6920100 07947-6340400 14-3...
  • Page 147: Crankcase Cover Removal

    62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE CRANKCASE COVER REMOVAL/ INSTALLATION EXCEPT E TYPE Drain the engine oil (page 3-3). Remove the key (7 x 7 x 33 mm)/(6.3 x 6.3 x 43 mm) (If equipped). CRANKCASE COVER (Without reduction) KEY (7 x 7 x 33 mm)/ (6.3 x 6.3 x 43 mm) (If equipped)
  • Page 148 62Z7B000.book 5 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE E TYPE Drain the engine oil (page 3-3). DOWEL PIN (8 x 12 mm) (2) CASE COVER PACKING BOTTOM RUBBER (LARGE) (2) CRANKCASE COVER BOTTOM RUBBER (SMALL) OIL FILLER CAP OIL FILLER CAP PACKING DUCT COVER (If equipped)
  • Page 149: Crankshaft/Balancer/Piston Removal/Installation

    62Z7B000.book 6 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE CRANKSHAFT/BALANCER/PISTON REMOVAL/INSTALLATION Remove the following: – Cylinder head (page 13-3) – Fuel tank (page 6-3) – Flywheel (page 8-5) PISTON LOCK PIN (10 mm) INSTALLATION: INSTALLATION: Install the piston to the cylinder Install the lock pin immediately after installing the governor arm barrel with the mark on the piston shaft in the direction as shown.
  • Page 150: Balancer Weight/Camshaft Installation (Gx390H1 Only)

    62Z7B000.book 7 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE BALANCER WEIGHT/CAMSHAFT INSTALLATION (GX390H1 ONLY) Install the balancer weight [1] to the cylinder barrel by aligning the punch marks [2] of the balancer weight and the crankshaft [3] (marked on the balancer drive gear [4]).
  • Page 151: Reduction Unit Disassembly

    CRANKCASE REDUCTION UNIT DISASSEMBLY/ ASSEMBLY Remove the recoil starter (page 10-3). Drain the oil (page 3-3). After installation, fill the oil (page 3-3). 1/2 REDUCTION CHAIN TYPE (GX270H ONLY) DRIVE SPROCKET (Gear teeth) INSPECTION: (page 14-21) P.T.O. DRIVE CHAIN INSPECTION: (page 14-21) ASSEMBLY: Attach the P.T.O.
  • Page 152 62Z7B000.book 9 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE 1/2 REDUCTION CLUTCH TYPE (GX270H ONLY) REDUCTION OIL CAP/ OIL LEVEL GAUGE REDUCTION CASE O-RING ASSEMBLY: Be careful not to damage the lip of the oil CRANKSHAFT OIL seal when installing it onto the crankshaft.
  • Page 153 62Z7B000.book 10 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE 1/6 REDUCTION GEAR TYPE (GX390H1 ONLY) BOLT (8 x 25 mm) 24 N·m (2.4 kgf·m, 18 lbf·ft) PRIMARY DRIVE GEAR DISASSEMBLY/ASSEMBLY: Hold the 16 mm special nut of the (7 x 7 x 33mm/ WASHER flywheel and remove/install the 8 x 25 mm 6.3 X 6.3 X 43mm)
  • Page 154: Clutch Weight Holder Assy

    62Z7B000.book 11 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE CLUTCH WEIGHT HOLDER Assy. DISASSEMBLY/ASSEMBLY Remove the clutch weight holder Assy. (page 14-9). CLUTCH WEIGHT (48) CLUTCH FREE SPRING (4) CLUTCH SPRING HOLDER (4) CLUTCH PRESSURE PLATE CLUTCH WEIGHT CENTER CLUTCH WEIGHT HOLDER 14-11...
  • Page 155: Governor Disassembly

    After installing the governor slider, the governor shaft. Spread the governor weight to check to be sure it moves smoothly. install the governor slider. GX270H: After installing the governor slider, check to be sure it moves smoothly. GOVERNOR HOLDER CLIP ASSEMBLY: Install firmly into the groove of the governor shaft.
  • Page 156: Piston Disassembly/Assembly

    62Z7B000.book 13 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE PISTON DISASSEMBLY/ASSEMBLY Remove the piston(page 14-6). MAKER MARK TOP RING PISTON RING SET (Chrome plated) ASSEMBLY: 120° Be sure that the top ring and second ring are SECOND RING 120° not interchanged. 120° Install the top ring and second ring on the piston with the maker mark side facing up.
  • Page 157: Crankcase Cover/Cylinder Barrel

    Measure and record the cylinder I.D. at three levels in both the “X” axis (perpendicular to crankshaft) and the “Y” axis (parallel to crankshaft). Take the maximum reading to determine cylinder wear and taper. GX270H: STANDARD: 77.000 – 77.017 mm (3.0315 – 3.0322 in)
  • Page 158 PISTON SKIRT O.D. Measure and record the piston skirt O.D. at a point 10 mm (0.4 in) from the bottom of the skirt and 90 degrees to the piston pin bore. GX270H: 90° STANDARD: 76.975 – 76.985 mm (3.0305 – 3.0309 in) SERVICE LIMIT: 76.85 mm (3.026 in)
  • Page 159 CRANKCASE 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. GX270H: STANDARD: 17.994 – 18.000 mm (0.7084 – 0.7087 in) SERVICE LIMIT: 17.950 mm (0.7067 in)
  • Page 160 62Z7B000.book 17 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE PISTON RING WIDTH Measure each piston ring width. STANDARD: Top: 1.170 – 1.190 mm (0.0460 – 0.0469 in) Second: 1.155 – 1.175 mm (0.0455 – 0.0463 in) SERVICE LIMIT: Top: 1.140 mm (0.0449 in) Second: 1.140 mm (0.0449 in) If any of the measurements is less than the service...
  • Page 161 62Z7B000.book 18 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE CONNECTING ROD SMALL END I.D. Measure the connecting rod small end I.D. GX270H: STANDARD: 18.005 – 18.020 mm (0.7089 – 0.7094 in) SERVICE LIMIT: 18.07 mm (0.711 in) GX390H1: STANDARD: 20.005 – 20.020 mm (0.7876 –...
  • Page 162 [1] 16 mm (0.6 in) [2] GX270H: 16 mm (0.6 in) GX390H1: 17 mm (0.7 in) [3] GX270H L TYPE: 31 mm (1.2 in) GX270H P TYPE: 32 mm (1.3 in) GX390H1 L TYPE: 36 mm (1.4 in) GX390H1 P TYPE: 32 mm (1.3 in) SERVICE LIMIT: 0.10 mm (0.004 in)
  • Page 163 CRANKCASE CAMSHAFT CAM HEIGHT Measure the cam height of the camshaft. GX270H: STANDARD: IN: 31.945 – 32.145 mm (1.2577 – 1.2655 in) EX: 31.666 – 31.866 mm (1.2467 – 1.2546 in) SERVICE LIMIT: IN: 31.35 mm (1.234 in) EX: 31.35 mm (1.234 in)
  • Page 164: Reduction Unit Inspection

    62Z7B000.book 21 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE RADIAL BALL BEARING Clean the bearing with solvent and dry it thoroughly. Turn the inner race (outer race: cylinder barrel side crankshaft bearing only) of the radial ball bearing with your finger and check for play. Replace the radial ball bearing if it is noisy or has excessive play.
  • Page 165 62Z7B000.book 22 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE CLUTCH TYPE CLUTCH FRICTION DISC Measure the clutch friction disc thickness. STANDARD: 3.5 mm (0.14 in) SERVICE LIMIT: 3.0 mm (0.12 in) CLUTCH PLATE Check the clutch plate warpage on a flat plate using a feeler gauge.
  • Page 166 62Z7B000.book 23 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE GEAR TYPE PRIMARY DRIVE GEAR Check for worn and weakened primary drive gear. If necessary, replace the primary drive gear (page 14- 10). P.T.O. SHAFT Check for worn and weakened gear of the P.T.O. shaft. If necessary, replace the P.T.O.
  • Page 167: Crankshaft/Balancer Weight Bearing/Oil Seal Replacement (Crankcase Cover Side)

    Remove the oil seal from the crankcase cover. Drive a new oil seal [1] in the position as shown using the special tools. TOOLS: GX270H (30 x 46 x 8 mm): Attachment, 45 x 50 mm [2] 07946-6920100 Driver handle [3]...
  • Page 168 62Z7B000.book 25 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE BALANCER WEIGHT BEARING (6202) (GX390H1 ONLY) Pull out the radial ball bearing [1] using the special tools. TOOLS: Bearing remover shaft set, 15 mm [2] 07936-KC10500 Sliding hammer weight [3] 07741-0010201 Drive a new bearing [4] until it is fully seated on the end using the special tools.
  • Page 169: Crankshaft Bearing Replacement

    Pull out the radial ball bearing [2] using a commercially available bearing puller [3]. Drive a new bearing [4] until it is fully seated on the end using the special tools and hydraulic press. TOOLS: GX270H (6206): Attachment, 30 mm [5] 07746-0030300 Inner driver handle, 40 mm [6] 07746-0030100...
  • Page 170: Gx270H Crankshaft Oil Seal Replacement

    62Z7B000.book 27 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE GX270H CRANKSHAFT OIL SEAL REPLACEMENT (CYLINDER BARREL SIDE) CRANKSHAFT OIL SEAL (30 x 46 x 8 Remove the oil seal from the cylinder barrel. Drive a new oil seal [1] in the position as shown using the special tools.
  • Page 171: Gx270H Crankshaft/P.t.o.shaft Oil Seal Replacement

    07749-0010000 Apply grease to the lip of a oil seal. 2.0 mm (0.08 in) (Lips) GX270H CRANKSHAFT/P.T.O.SHAFT OIL SEAL REPLACEMENT (1/2 REDUCTION CLUTCH TYPE) P.T.O.SHAFT OIL SEAL (30 x 50 x 7 Remove the oil seal from the reduction cover.
  • Page 172 62Z7B000.book 29 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE CRANKSHAFT OIL SEAL (30 x 46 x 8 Remove the oil seal from the reduction case. Drive a new oil seal [1] in the position as shown using the special tools. TOOLS: Attachment, 45 x 50 mm [2] 07946-6920100 Driver handle [3] 07749-0010000...
  • Page 173: Gx390H1 Countershaft/P.t.o. Shaft Bearing/Oil Seal Replacement

    62Z7B000.book 30 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE GX390H1 COUNTERSHAFT/P.T.O. SHAFT BEARING/OIL SEAL REPLACEMENT (1/6 REDUCTION GEAR TYPE) COUNTERSHAFT BEARING (6202) (6302) Pull out the radial ball bearing [1] using the special tools. TOOLS: Bearing remover shaft set, 15 mm [2] 07936-KC10500 Sliding hammer weight [3] 07741-0010201...
  • Page 174 62Z7B000.book 31 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE P.T.O. SHAFT BEARING (6206) Drive out the radial ball bearing [1]. Drive a new bearing [2] until it is fully seated on the end using the special tools. TOOLS: Attachment, 62 x 64 mm [3] 07947-6340400 Pilot, 30 mm [4] 07746-0040700...
  • Page 175: Gx270H Countershaft/P.t.o. Shaft Bearing Replacement

    62Z7B000.book 32 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE GX270H COUNTERSHAFT/P.T.O. SHAFT BEARING REPLACEMENT (CRANKCASE COVER SIDE) P.T.O. SHAFT BEARING (6204) Remove the crankcase cover (page 14-4). Drive out the radial ball bearing [1]. Drive a new bearing [2] until it is fully seated on the end using the special tools.
  • Page 176: Gx390H1 Countershaft/P.t.o. Shaft Bearing Replacement

    62Z7B000.book 33 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE GX390H1 COUNTERSHAFT/P.T.O. SHAFT BEARING REPLACEMENT (CRANKCASE COVER SIDE) COUNTERSHAFT BEARING (6202) Remove the crankcase cover (page 14-4). Drive out the radial ball bearing [1] using the special tools. Drive a new bearing [2] until it is fully seated on the end using the special tools.
  • Page 177 62Z7B000.book 34 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead CRANKCASE P.T.O. SHAFT BEARING (6204) Remove the crankcase cover (page 14-4). Drive out the radial ball bearing [1]. Drive a new bearing [2] until it is fully seated on the end using the special tools. TOOLS: Attachment, 42 x 47 mm [3] 07746-0010300...
  • Page 178: Wiring Diagrams

    62Z7B000.book 1 ページ 2012年9月27日 木曜日 午前10時21分 dummytext 15. WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & WIRING DIAGRAMS ··································· 15-4 RELATED INFORMATION··························15-2 15-1...
  • Page 179 62Z7B000.book 2 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead WIRING DIAGRAMS HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION WIRING DIAGRAMS The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ CONNECTOR DRAWINGS Connector drawings show the terminal arrangement, terminal No., number of pins, and the shape of terminal (male or female).
  • Page 180 62Z7B000.book 3 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead WIRING DIAGRAMS HOW TO READ WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a male or female terminal. TERMINAL No. INVERTER UNIT M A I N ( U ) M A I N ( V ) A C 1 M A I N ( W )
  • Page 181 62Z7B000.book 4 ページ 2012年9月27日 木曜日 午前10時21分 dummyhead dummyhead WIRING DIAGRAMS WIRING DIAGRAMS NO CHARGE COIL TYPE 1 A/3 A CHARGE COIL TYPE 15-4...
  • Page 182: Index

    CHARGING SYSTEM ················································ 8-4 GX270H COUNTERSHAFT/P.T.O. SHAFT BEARING IGNITION SYSTEM ··················································· 9-3 REPLACEMENT (CRANKCASE COVER SIDE) ········14-32 STARTING SYSTEM ··············································· 10-2 GX270H CRANKSHAFT OIL SEAL REPLACEMENT TROUBLESHOOTING ··············································· 4-2 (CYLINDER BARREL SIDE)·······································14-27 TYPE CODE ··································································· 1-3 GX270H CRANKSHAFT/P.T.O.SHAFT OIL SEAL VALVE CLEARANCE CHECK/ADJUSTMENT ············...

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