Honda GX390RT2 Shop Manual

Honda GX390RT2 Shop Manual

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62Z5F000.book 1 ページ 2010年3月23日 火曜日 午後3時31分
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 man-
ual 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 practice, 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 precau-
tions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual 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 engine-power equipment 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 battery 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 GX390RT2

  • 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

    62Z5F000.book 2 ページ 2010年3月23日 火曜日 午後3時31分 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: Specifications

    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 Mo- tor 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 genuine Honda 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 62Z5F000.book 5 ページ 2010年3月23日 火曜日 午後3時31分 How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems Abbrev. term Full term Alternator American Petroleum institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Battery...
  • Page 6 62Z5F000.book 1 ページ 2010年3月23日 火曜日 午後3時31分 1. SPECIFICATIONS SERIAL NUMBER LOCATION ·····················1-2 ENGINE SPECIFICATIONS ·························· 1-5 TYPE CODE ··················································1-2 PERFORMANCE CURVES··························· 1-6 DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS························· 1-7 SPECIFICATIONS ·········································1-4 PTO DIMENSIONAL DRAWINGS ················ 1-9...
  • Page 7: Serial Number Location

    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. TYPE CODE Model GX390RT2 Type QWA2 VAA1 VEP9 VKE4 VKX4 P. T. O.
  • Page 8 62Z5F000.book 3 ページ 2010年3月23日 火曜日 午後3時31分 SPECIFICATIONS Model GX390T2 Type QXEK P. T. O. Q type Model GX390T2 Type SWE2 SWX2 P. T. O. Q type S type Model GX390T2 Type VMQ3 VMT2 P. T. O. S type V type E type Model GX390T2 Type...
  • Page 9 GX390UT2 Type VXE8 VXE9 VXQ4 P. T. O. V type DIMENSIONS AND WEIGHTS SPECIFICATIONS Model GX390RT2 GX390T2 GX390UT2 Overall length H type* 452 mm (17.8 in) L type* 440 mm (17.3 in) 440 mm (17.3 in) P type* 405 mm (15.9 in) 405 mm (15.9 in)
  • Page 10: Maintenance

    62Z5F000.book 5 ページ 2010年3月23日 火曜日 午後3時31分 SPECIFICATIONS ENGINE SPECIFICATIONS Model GX390RT2 GX390T2 GX390UT2 Description code GCBCT GCBDT GCBCT 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)*1 8.7 kW (11.7 HP) / 3,600 min...
  • Page 11: Performance Curves

    62Z5F000.book 6 ページ 2010年3月23日 火曜日 午後3時31分 SPECIFICATIONS PERFORMANCE CURVES (N·m) (lbf·ft) (kgf·m) NET TORQUE (KW) (HP) NET POWER RECOMMENDED OPERATING SPEED RANGE (min 2000 3000 3600 ENGINE SPEED...
  • Page 12: Dimensional Drawings

    62Z5F000.book 7 ページ 2010年3月23日 火曜日 午後3時31分 SPECIFICATIONS DIMENSIONAL DRAWINGS *: P. T. O. type. (page 1-2) WITHOUT REDUCTION TYPE Unit: mm (in) 158.7 (6.25) 301.3 (11.86) With control box type: 498.6 (19.63) CONTROL BOX CRANKSHAFT (P. T. O.) Without control box type: 460 (18.1) (If equipped) 141.5 (5.57) 200.6 (7.90)
  • Page 13 62Z5F000.book 8 ページ 2010年3月23日 火曜日 午後3時31分 SPECIFICATIONS WITH REDUCTION UNIT TYPE Unit: mm (in) 233.2 (9.18) 158.7 (6.25) 68.1 (2.68) P. T. O. SHAFT With control box type: 498.6 (19.63) Without control box type: 460 (18.1) 141.5 (5.57) 200.6 (7.9) 155 (6.1) REDUCTION UNIT * H:452 (17.8) 195.5 (7.70)
  • Page 14: Pto Dimensional Drawings

    62Z5F000.book 9 ページ 2010年3月23日 火曜日 午後3時31分 SPECIFICATIONS PTO DIMENSIONAL DRAWINGS *: P. T. O. type. (page 1-2) E TYPE* Unit: mm (in) 15° M6 x 1.0 (0.71) 54 (2.13) TAPER 35 (1.4) 1 / 5 15° 15° 28 (1.1) M10 x 1.25 P.
  • Page 15 62Z5F000.book 10 ページ 2010年3月23日 火曜日 午後3時31分 SPECIFICATIONS L TYPE* (WITH REDUCTION) Unit: mm (in) 45° 45° 64.8 (2.55) M8 x 1.25 (2PLACES) M8 x 1.25 (4PLACES) M8 x 1.25 7.00 - 7.05 (0.276 -0.278) 42 (1.7) 28 (1.1) 60.0 (2.36) P. T. O. SHAFT 16 (0.6) 68.1 (2.68) REDUCTION UNIT...
  • Page 16 62Z5F000.book 11 ページ 2010年3月23日 火曜日 午後3時31分 SPECIFICATIONS Q TYPE* Unit: mm (in) 45° 45° 30° 30° 88.5 (3.48) 3/8 - 24UNF - 2B TAP 5/16-24UNF-2B 56 (2.2) (2 PLACES) 6.3 - 6.35 (0.2480 - 0.2500) 28 (1.1) 5/16-24UNF-2B 72.2 (2.84) (4 PLACES) 3/8-16UNC-2B (4 PLACES) 103 (4.1)
  • Page 17 62Z5F000.book 12 ページ 2010年3月23日 火曜日 午後3時31分 SPECIFICATIONS V TYPE* Unit: mm (in) 45° 45° 5/16 - 24UNF - 2B TAP 30° 30° 105.5 (4.15) 5/16-24UNF-2B (2 PLACES) 18 (0.7) 5/16-24UNF-2B (4 PLACES) 75.5 (2.97) 46.5 (1.83) 3/8-16UNC-2B (4 PLACES) 103 (4.1) CRANKSHAFT (P. T. O.) 1-12...
  • Page 18 62Z5F000.book 1 ページ 2010年3月23日 火曜日 午後3時31分 2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-6 TORQUE VALUES ········································2-4 HARNESS AND TUBE ROUTING ················ 2-8 LUBRICATION & SEAL POINT ····················2-5...
  • Page 19: Cover

    62Z5F000.book 2 ページ 2010年3月23日 火曜日 午後3時31分 SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION Unit: mm (in) Service Part Item Standard limit Engine Maximum speed (at no load) 3,850 ± 150 min (rpm) – Idle speed – 1,400 ± 150 min (rpm) 0.51-0.69 MPa (5.2-7.0 kgf/cm , 74-100 Cylinder compression –...
  • Page 20 62Z5F000.book 3 ページ 2010年3月23日 火曜日 午後3時31分 SERVICE INFORMATION Service Part Item Standard limit Carburetor Main jet BE85C B: #100 – BE85L A: #95 BE85Q A: #92 BE85Q A: #102 BE89F B: #108 BE89R A: #102 BE89U A: #108 BE94B A: #100 BE94A A: #115 Pilot screw opening BE85C B: 1 - 3/4 turns out –...
  • Page 21: Muffler

    62Z5F000.book 4 ページ 2010年3月23日 火曜日 午後3時31分 SERVICE INFORMATION TORQUE VALUES ENGINE TORQUE VALUES Torque values Item Tread Dia. (mm) N·m kgf·m lbf·ft Crankcase cover bolt M8 x 1.25 Cylinder head bolt M10 x 1.25 Oil drain plug bolt M12 x 1.5 22.5 2.25 Connecting rod bolt M8 x 1.25 (Special bolt)
  • Page 22: Crankcase

    62Z5F000.book 5 ページ 2010年3月23日 火曜日 午後3時31分 SERVICE INFORMATION LUBRICATION & SEAL POINT Location Material Remarks Crankshaft pin, journal and gear Engine oil Crankcase bearing Crankcase cover bearing Piston outer surface and piston pin hole Piston pin outer surface Piston ring Cylinder inner surface Connecting rod big and small end bearing Connecting rod bolt threads and seating surface Camshaft cam profile, bearing, decompressor and...
  • Page 23: Special Tools

    62Z5F000.book 6 ページ 2010年3月23日 火曜日 午後3時31分 SERVICE INFORMATION TOOLS SPECIAL TOOLS Special tools used in this manual can be ordered using normal American Honda parts ordering procedures. Float level gauge Sliding hammer weight Valve guide driver, 6.45×11 07401-0010000 07741-0010201 07742-0010200 Bearing driver attachment, 32×35 [in Bearing driver attachment, 42×47 [in...
  • Page 24 62Z5F000.book 7 ページ 2010年3月23日 火曜日 午後3時31分 SERVICE INFORMATION Pilot, 35 [in combination with 07749- Pilot, 14 [in combination with 07749- Driver handle, 15×135L 0010000] 0010000] 07749-0010000 07746-0040800 07746-0041200 Seat cutter, 35 Seat cutter, 40 Flat cutter, 35 07780-0010400 07780-0010500 07780-0012300 Flat cutter, 38.5 Interior cutter, 37.5 Cutter holder, 6.6 07780-0012400...
  • Page 25 62Z5F000.book 8 ページ 2010年3月23日 火曜日 午後3時31分 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. ENGINE STOP SWITCH TYPE ENGINE STOP SWITCH ENGINE WIRE...
  • Page 26 62Z5F000.book 9 ページ 2010年3月23日 火曜日 午後3時31分 SERVICE INFORMATION COMBINATION SWITCH (CONTROL BOX) TYPE PURSE LOCK CLIP PURSE LOCK CLIP To ignition coil To starter motor To starter motor (YELLOW) To ignition coil To ignition coil (BLACK) (RED) ENGINE WIRE HARNESS (To ignition coil) STOP SWITCH CORD HOLDER OIL LEVEL...
  • Page 27 62Z5F000.book 10 ページ 2010年3月23日 火曜日 午後3時31分 SERVICE INFORMATION ALL TYPE GOVERNOR ARM ENGINE WIRE HARNESS HIGH-TENSION CORD CARBURETOR CONTROL BASE INSULATOR ASSY. CYLINDER BARREL RIB CONTROL BASE ASSY. TUBE CLIP IGNITION COIL BREATHER TUBE HIGH-TENSION CORD FUEL TUBE 2-10...
  • Page 28 62Z5F000.book 11 ページ 2010年3月23日 火曜日 午後3時31分 SERVICE INFORMATION WITH CHARGE COIL / LAMP COIL 10A CHARGE COIL TYPE: 12 V-50 W LAMP COIL TYPE: 18A CHARGE COIL TYPE: CORD CORD CLAMPER CLAMPER CORD COIL GROMMET CORD COIL CORD CORD GROMMET 1 A / 3 A CHARGE COIL TYPE: 12 V - 15 W / 12 V-25 W LAMP COIL TYPE: CORD CLAMPER...
  • Page 29 62Z5F000.book 12 ページ 2010年3月23日 火曜日 午後3時31分 MEMO...
  • Page 30 62Z5F000.book 1 ページ 2010年3月23日 火曜日 午後3時31分 3. MAINTENANCE MAINTENANCE SCHEDULE························3-2 SPARK ARRESTER CLEANING·················· 3-8 ENGINE OIL LEVEL CHECK ························3-3 IDLE SPEED CHECK/ADJUSTMENT ········ 3-10 ENGINE OIL CHANGE··································3-3 VALVE CLEARANCE CHECK/ ADJUSTMENT ········································· 3-10 AIR CLEANER CHECK/CLEANING/ REPLACEMENT············································3-4 COMBUSTION CHAMBER CLEANING ····· 3-12 SEDIMENT CUP CLEANING ························3-6 FUEL TANK AND FILTER CLEANING ······...
  • Page 31: Maintenance Schedule

    62Z5F000.book 2 ページ 2010年3月23日 火曜日 午後3時31分 MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE REGULAR SERVICE PERIOD (2) First Every Every Every month year Refer ITEM Perform at every indicated Each months months month or operating hour inter- 20 hrs. 300 hrs. page val, whichever comes first. 50 hrs.
  • Page 32: Engine Oil Level Check

    62Z5F000.book 3 ページ 2010年3月23日 火曜日 午後3時31分 MAINTENANCE ENGINE OIL LEVEL CHECK Place the engine on a level surface. Remove the oil filler cap (1), and wipe the oil level gauge (2) clean. Insert the oil filler cap without screwing it into the oil filler neck (3).
  • Page 33 62Z5F000.book 4 ページ 2010年3月23日 火曜日 午後3時31分 MAINTENANCE Used engine oil contains substances that have been identified as carcinogenic. If repeatedly left in contact with the skin for prolonged periods, it may cause skin cancer. Wash your hands thoroughly with soap and water as soon as possible after con- tact with used engine oil.
  • Page 34 62Z5F000.book 5 ページ 2010年3月23日 火曜日 午後3時31分 MAINTENANCE CYCLONE 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 35: Sediment Cup Cleaning

    62Z5F000.book 6 ページ 2010年3月23日 火曜日 午後3時31分 MAINTENANCE INNER FILTER (PAPER) TYPE: Tap the inner filter (1) lightly several times on a hard surface to remove excess dirt, or blow compressed air lightly (207 kPa (2.11 kgf/cm , 30 psi) or less) through the paper filter from the inside out.
  • Page 36 62Z5F000.book 7 ページ 2010年3月23日 火曜日 午後3時31分 MAINTENANCE SPARK PLUG CHECK/ADJUSTMENT If the engine has been running, the engine will be very hot. Allow it to cool before proceeding. Remove the spark plug cap, and then remove the spark plug (1) using a spark plug wrench (2). Visually check the spark plug.
  • Page 37: Spark Plug Replacement

    62Z5F000.book 8 ページ 2010年3月23日 火曜日 午後3時31分 MAINTENANCE SPARK PLUG REPLACEMENT If the engine has been running, the engine will be very hot.Allow it to cool before proceeding. Remove the spark plug cap, and then remove the spark plug (1) using a spark plug wrench (2). Verify the new spark plug gap is correct (page 3-7).
  • Page 38 62Z5F000.book 9 ページ 2010年3月23日 火曜日 午後3時31分 MAINTENANCE SEPARATED PROTECTOR TYPE Remove the muffler cover (page 12-6), If equipped. Remove the 4 x 6 mm tapping screws (1), and muffler cap (2), If equipped. Remove the 5 x 8 mm tapping screws (3), R. muffler protector (4), and L.muffler protector (5).
  • Page 39 62Z5F000.book 10 ページ 2010年3月23日 火曜日 午後3時31分 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 40 62Z5F000.book 11 ページ 2010年3月23日 火曜日 午後3時31分 MAINTENANCE Disconnect the spark plug cap from the spark plug. 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 triangle mark (1) on the starter pulley (2) will align with the top Pull slowly.
  • Page 41 62Z5F000.book 12 ページ 2010年3月23日 火曜日 午後3時31分 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 42: Fuel Tube Check

    62Z5F000.book 13 ページ 2010年3月23日 火曜日 午後3時31分 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.

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