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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 GP160H

  • 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

    dummyhead dummyhead CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING FAN COVER FUEL SYSTEM GOVERNOR SYSTEM IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL MUFFLER CYLINDER HEAD 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 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 Battery...
  • Page 6: Specifications

    dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ················· 1-2 ENGINE SPECIFICATIONS ····················· 1-4 P.T.O. TYPE VARIATION ························ 1-2 PERFORMANCE CURVES ······················ 1-6 DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS ···················· 1-8 SPECIFICATIONS·································· 1-3 P.T.O. DIMENSIONAL DRAWINGS········· 1-10...
  • Page 7 SPECIFICATIONS SERIAL NUMBER LOCATION SPECIFICATIONS The model [1], type [2] and engine serial number [3] are stamped on the crankcase. Refer to them when ordering parts or making technical inquiries. P.T.O. TYPE VARIATION GP160H P.T.O. type Type QHB1 QHKR QMPB...
  • Page 8 SPECIFICATIONS DIMENSIONS AND WEIGHTS SPECIFICATIONS GP160H P.T.O. type DIMENSIONS AND WEIGHTS Overall length 314 mm (12.4 in) 324 mm (12.8 in) Overall width 363 mm (14.3 in) 363 mm (14.3 in) Overall height 335 mm (13.2 in) 335 mm (13.2 in) Dry weight 14.9 kg (32.8 lbs)
  • Page 9 SPECIFICATIONS ENGINE SPECIFICATIONS GP160H Model GP160H Description code GCASH Type 4 stroke, overhead valve, single cylinder, inclined by 25° Displacement 163 cm (9.9 cu-in) Bore x stroke 68.0 x 45.0 mm (2.68 x 1.77 in) Net power (SAE J1349) *1 3.6 kW (4.8 HP)/3,600 min...
  • Page 10 dummyhead dummyhead SPECIFICATIONS GP200H Model GP200H Description code GCATH Type 4 stroke, overhead valve, single cylinder, inclined by 25° Displacement 196 cm (12.0 cu-in) Bore x stroke 68.0 x 54.0 mm (2.68 x 2.13 in) Net power (SAE J1349) *1 4.1 kW (5.5 HP)/3,600 min (rpm) Continuous rated power...
  • Page 11 SPECIFICATIONS PERFORMANCE CURVES GP160H (N·m) (lbf·ft) (kgf·m) NET TORQUE (kW) (HP) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE 2,000 3,000 3,600 P.T.O. SPEED (min (rpm))
  • Page 12 dummyhead dummyhead SPECIFICATIONS GP200H (N·m) (lbf·ft) (kgf·m) NET TORQUE (kW) (HP) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE 2,000 3,000 3,600 P.T.O. SPEED (min (rpm))
  • Page 13 SPECIFICATIONS DIMENSIONAL DRAWINGS *: P.T.O. type. (page 1-2) GP160H Unit: mm (in) 124 (4.9) 239 (9.4) 93 (3.7) 157 (6.2) 363 (14.3) (13.1) (13.2) 106 (4.2) 75.5 (2.97) 162 (6.4) 5 (0.2) Q type*: 314 (12.4) 96 (3.8) 39.5 (1.56)
  • Page 14 dummyhead dummyhead SPECIFICATIONS GP200H Unit: mm (in) 124 (4.9) 254 (10.0) 106 (4.2) 157 (6.2) 378 (14.9) (13.2) (13.2) 106 (4.2) 75.5 (2.97) 162 (6.4) 5 (0.2) Q type*: 323 (12.7) 96 (3.8) 39.5 (1.56) V type*: 333 (13.1) 80 (3.1)
  • Page 15 SPECIFICATIONS P.T.O. DIMENSIONAL DRAWINGS *: P.T.O. type. (page 1-2) GP160H Unit: mm (in) 5/16-24UNF-2B (4 PLACES) 65.1 (2.56) 5/16-24UNF-2B 30 (1.18) 65.1 (2.56) 88 (3.46) CRANKSHAFT (P.T.O.) Q type* Unit: mm (in) 5/16-24UNF-2B 61.4 (2.42) 58.5 (2.30) 4.730 – 4.780 (0.1862 –...
  • Page 16 dummyhead dummyhead SPECIFICATIONS V type* Unit: mm (in) 5/16-24UNF-2B TAPER 2-1/4 71.4 (2.81) 33.5 (1.32) Φ 18.927 – 19.177 (0.7452 – 0.7550) Φ 19.830 – 19.843 (0.7807 – 0.7812) 1-11...
  • Page 17 dummyhead dummyhead SPECIFICATIONS GP200H Unit: mm (in) 5/16-24UNF-2B (4 PLACES) 65.1 (2.56) 5/16-24UNF-2B 30 (1.18) 65.1 (2.56) 88 (3.46) CRANKSHAFT (P.T.O.) Q type* Unit: mm (in) 5/16-24UNF-2B 61.4 (2.42) 58.5 (2.30) 4.730 – 4.780 (0.1862 – 0.1882) 17.0 (0.67) 16.260 – 16.360 (0.6402 –...
  • Page 18 dummyhead dummyhead SPECIFICATIONS V type* Unit: mm (in) 5/16-24UNF-2B TAPER 2-1/4 71.4 (2.81) 33.5 (1.32) Φ 18.927 – 19.177 (0.7452 – 0.7550) Φ 19.830 – 19.843 (0.7807 – 0.7812) 1-13...
  • Page 19 dummyhead dummyhead MEMO...
  • Page 20: 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 21 SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION GP160H 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 22 dummyhead dummyhead SERVICE INFORMATION GP200H Unit: mm (in) Part Item Standard Service limit Engine Maximum speed (at no load) – 3,850 ± 150 min (rpm) Idle speed + 200 1,400 – (rpm) – 150 Cylinder compression 0.35 MPa (3.6 kgf/cm , 51 psi)/600 min –...
  • Page 23 dummyhead dummyhead SERVICE INFORMATION TORQUE VALUES Torque values Item Thread Dia. (mm) Remark N·m kgf·m lbf·ft Crankcase cover bolt M8 x 1.25 Cylinder head bolt M8 x 1.25 Apply engine oil to the threads and seating surface. Engine oil drain plug bolt M10 x 1.25 Connecting rod bolt M7 x 1.0...
  • Page 24 dummyhead dummyhead SERVICE INFORMATION LUBRICATION & SEAL POINTS Material Location Remarks Engine oil Crankshaft pin and gear teeth Piston outer surface, ring groove and piston pin hole Piston pin outer surface Piston ring entire surface Cylinder inner surface Connecting rod big and small end bearing Connecting rod bolt threads and seating surface Camshaft cam profile and journal Valve lifter pivot, pivot end and slipper surface...
  • Page 25 dummyhead dummyhead SERVICE INFORMATION TOOLS Float level gauge Bearing driver attachment, Bearing driver attachment, 07401-0010000 37 x 40 mm 52 x 55 mm 07746-0010200 07746-0010400 Pilot, 25 mm Driver handle Seat cutter, 24.5 mm (45° EX) 07746-0040600 07749-0010000 07780-0010100 Seat cutter, 27.5 mm (45° IN) Flat cutter, 28 mm (32°...
  • Page 26 dummyhead dummyhead SERVICE INFORMATION Valve guide reamer, 5.510 mm 07984-2000001...
  • Page 27 dummyhead dummyhead SERVICE INFORMATION HARNESS AND TUBE ROUTING CYLINDER BARREL RIBS ENGINE WIRE HARNESS CYLINDER BARREL RIBS CARBURETOR INSULATOR HIGH-TENSION CORD ENGINE WIRE HARNESS CORD HOOK IGNITION COIL CONNECTOR...
  • Page 28 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE BREATHER TUBE HIGH-TENSION CORD...
  • Page 29 dummyhead dummyhead SERVICE INFORMATION WITH ENGINE STOP SWITCH: CLAMP ENGINE WIRE HARNESS ENGINE WIRE HARNESS ENGINE STOP SWITCH WIRE CONNECTOR WITH ENGINE STOP SWITCH AND OIL ALERT UNIT: HARNESS CLIP ENGINE WIRE HARNESS CLAMP OIL ALERT UNIT CONNECTOR ENGINE STOP To oil alert unit To ignition coil SWITCH WIRES...
  • Page 30: Maintenance

    dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE ··················· 3-2 IDLE SPEED CHECK/ADJUSTMENT ········ 3-6 ENGINE OIL LEVEL CHECK/CHANGE······ 3-3 VALVE CLEARANCE CHECK/ADJUSTMENT··························· 3-7 AIR CLEANER CHECK/CLEANING/REPLACEMENT ········ 3-4 COMBUSTION CHAMBER CLEANING······ 3-8 SPARK PLUG CHECK/ADJUSTMENT ······ 3-5 FUEL TANK AND FILTER CLEANING······· 3-9 SPARK PLUG REPLACEMENT ···············...
  • Page 31: Maintenance Schedule

    dummyhead dummyhead MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE ITEM Perform at every indicated month REGULAR SERVICE PERIOD (2) or operating hour interval, Every Every Every Refer First whichever comes first. Each 3 months 6 months year month or page 20 hrs. 50 hrs. 100 hrs.
  • Page 32: Engine Oil Level Check/Change

    Other ENGINE OIL CAPACITY: viscosities shown in GP160H: 0.58 liter (0.61 US qt, 0.51 Imp qt) the chart may be GP200H: 0.60 liter (0.63 US qt, 0.53 Imp qt) used when the AMBIENT TEMPERATURE average...
  • Page 33: Air Cleaner

    dummyhead dummyhead MAINTENANCE AIR CLEANER CHECK/CLEANING/REPLACEMENT 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 34: Spark Plug Check/Adjustment

    dummyhead dummyhead MAINTENANCE PAPER Tap the inner filter [1] lightly several times on a hard surface to remove excess dirt, or blow compressed air lightly (206 kPa (2.11 kgf/cm , 30 psi) or less) through the paper filter from the inside out. Never try to brush the dirt off;...
  • Page 35: Spark Plug Replacement

    dummyhead dummyhead MAINTENANCE SPARK PLUG REPLACEMENT REMOVAL 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 36: Valve Clearance Check/Adjustment

    dummyhead dummyhead 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] (4) –...
  • Page 37: Combustion Chamber Cleaning

    dummyhead dummyhead MAINTENANCE ADJUSTMENT Hold the rocker arm pivot [1] and loosen the pivot lock nut [2]. Insert a feeler gauge [3] between the valve rocker arm and the valve stem. Adjust by turning the rocker arm pivot until there is a slight drag on the feeler gauge.
  • Page 38: Fuel Tank And Filter Cleaning

    dummyhead dummyhead MAINTENANCE FUEL TANK AND FILTER 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. Remove the fuel tank (page 6-3).
  • Page 39 dummyhead dummyhead MEMO...
  • Page 40: Troubleshooting

    dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING ··············· 4-2 TROUBLESHOOTING ···························· 4-2...
  • Page 41 dummyhead dummyhead TROUBLESHOOTING 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. TROUBLESHOOTING ENGINE DOES NOT CRANK Disassemble the engine and replace the faulty Remove the recoil starter (page 9-2) and check Cannot be cranked...
  • Page 42 dummyhead dummyhead TROUBLESHOOTING ENGINE CRANKS BUT WON’T START • Check the oil level before troubleshooting (page 3-3). Turn the fuel valve lever to the ON position. Check for clogged fuel tank joint and fuel tube Loosen the carburetor drain screw and check the Does not flow (page 6-3).
  • Page 43 dummyhead dummyhead TROUBLESHOOTING ENGINE SPEED DOES NOT INCREASE OR STABILIZE Clogged Clean the air cleaner element (page 3-5). Check the air cleaner element (page 3-4, 3-5). Clean Abnormal Check the valve clearance (page 3-7). Adjust the valve clearance (page 3-8). Normal Abnormal Inspect the spark plug and adjust the spark plug...
  • Page 44 dummyhead dummyhead TROUBLESHOOTING ENGINE DOES NOT STOP WHEN ENGINE STOP SWITCH IS TURNED OFF Check the engine stop switch (page 10-3). Replace the engine stop switch (page 10-2). Abnormal Normal Check the wire harness connecting the engine Replace the engine wire harness. No continuity stop switch and the ignition coil for open circuit.
  • Page 45 dummyhead dummyhead MEMO...
  • Page 46: Fan Cover

    dummytext 5. FAN COVER FAN COVER REMOVAL/INSTALLATION ·· 5-2...
  • Page 47 dummyhead dummyhead FAN COVER FAN COVER REMOVAL/INSTALLATION FAN COVER When disassembling the fan cover, remove the following: – Recoil starter (page 9-2) – Engine stop switch (page 10-2) • Route the tube and wires properly (page 2-8). ENGINE WIRE HARNESS CONNECTOR (With oil level switch and oil alert unit) BOLT (6 x 12 mm) (4) ENGINE STOP SWITCH ONLY:...
  • Page 48: Fuel System

    dummytext 6. FUEL SYSTEM TOOL··················································· 6-2 CARBURETOR BODY CLEANING ··········· 6-7 FUEL TANK REMOVAL/INSTALLATION ··· 6-3 CARBURETOR INSPECTION ·················· 6-7 AIR CLEANER PILOT SCREW REPLACEMENT ·············· 6-8 REMOVAL/INSTALLATION ····················· 6-4 CHOKE REPLACEMENT ························ 6-9 CARBURETOR REMOVAL/INSTALLATION ····················· 6-5 CARBURETOR STUD BOLT REPLACEMENT ····································...
  • Page 49 dummyhead dummyhead FUEL SYSTEM TOOL FUEL SYSTEM Float level gauge 07401-0010000...
  • Page 50 FUEL TUBE CHECK: NUT (6 mm) (2) Check for deterioration, cracks or clogs. 10 N·m (1.0 kgf·m, 7 lbf·ft) GP160H: BOLT (6 x 29 mm) GP200H: BOLT (6 x 34 mm) 10 N·m (1.0 kgf·m, 7 lbf·ft)
  • Page 51 dummyhead dummyhead FUEL SYSTEM AIR CLEANER REMOVAL/INSTALLATION • Route the breather tube properly (page 2-8). WING NUT AIR CLEANER COVER WING NUT GROMMET INNER FILTER (PAPER) OUTER FILTER (FOAM) BOLT (6 x 20 mm) AIR CLEANER ELBOW SEAL COLLAR AIR CLEANER ELBOW REMOVAL/INSTALLATION: Remove and install the air cleaner elbow with the fuel...
  • Page 52 dummyhead dummyhead FUEL SYSTEM 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. Remove the air cleaner (page 6-4). Set a commercially available tube clamp to the fuel tube.
  • Page 53 dummyhead dummyhead 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. To prevent serious eye injury, always wear safety goggles or other eye protection when using compressed air.
  • Page 54 Check the container for 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 55 Carburetor identification Pilot screw Model Number opening [3] + [4] GP160H BEA2F A 2-3/8 turns out GP200H BE69G A 2-1/2 turns out Refer to the table above for carburetor pilot screw initial opening setting.
  • Page 56 dummyhead dummyhead FUEL SYSTEM CHOKE REPLACEMENT Remove the carburetor (page 6-5). 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 57 dummyhead dummyhead MEMO...
  • Page 58: Governor System

    dummytext 7. GOVERNOR SYSTEM GOVERNOR MECHANISM ······················ 7-2 GOVERNOR ADJUSTMENT ···················· 7-5 GOVERNOR ARM/CONTROL BASE GOVERNOR REMOVAL/INSTALLATION ····················· 7-3 DISASSEMBLY/ASSEMBLY···················· 7-6 CONTROL BASE MAXIMUM SPEED ADJUSTMENT············ 7-7 DISASSEMBLY/ASSEMBLY···················· 7-4...
  • Page 59 dummyhead dummyhead GOVERNOR SYSTEM GOVERNOR MECHANISM GOVERNOR SYSTEM FUNCTION OF THE COMPONENTS STARTING While stopping the engine, the throttle valve [1] is remained in slightly returned position from full opening condition by the throttle return spring [2]. After starting the engine, the governor weights [3] are opened by centrifugal force according to the rising of the engine revolution, to close the throttle valve to the idling condition, through the governor slider [4], governor arm shaft [5], governor arm [6] and governor rod [7].
  • Page 60 [3]. GOVERNOR ARM BOLT NUT (6 mm) GP160H: GOVERNOR SCREW (5 x 16 mm) (Except VX3 type) CABLE HOLDER SCREW (4 x 6 mm)
  • Page 61 dummyhead dummyhead GOVERNOR SYSTEM CONTROL BASE DISASSEMBLY/ASSEMBLY REMOTE TYPE Remove the control base (page 7-3). LOCK NUT (6 mm) INSTALLATION: After installation the control base Assy., CONTROL LEVER WASHER measure force at 10 mm (0.4 in) from the tip of the control lever [1] by pulling. INSTALLATION: Adjust by turning the lock nut [2] so that Install the control lever washer by aligning the cutout of the control...
  • Page 62 dummyhead dummyhead GOVERNOR SYSTEM FIXED THROTTLE OPERATION TYPE Remove the control base.(page 7-3). CONTROL BASE SCREW (5 x 25 mm) CONTROL ADJUST SPRING 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].
  • Page 63 dummyhead dummyhead GOVERNOR SYSTEM GOVERNOR DISASSEMBLY/ASSEMBLY Remove the crankshaft (page 13-4). GOVERNOR WEIGHT CHECK: WASHER (6 mm) After installing the governor weights, check to be sure they move freely. GOVERNOR WEIGHT PIN GOVERNOR HOLDER CLIP INSTALLATION: Install firmly into the groove of the governor holder shaft.
  • Page 64 Make sure the carburetor throttle valve [2] is fully open. Turn the screw [3] of the control base to obtain the specified maximum speed. MAXIMUM SPEED: GP160H: 3,900 ± 100 min (rpm) GP200H: 3,850 ± 150 min (rpm)
  • Page 65 dummyhead dummyhead MEMO...
  • Page 66: Ignition System

    dummytext 8. IGNITION SYSTEM IGNITION SYSTEM IGNITION COIL AIR GAP TROUBLESHOOTING ···························· 8-2 CHECK/ADJUSTMENT··························· 8-6 IGNITION COIL SPARK TEST········································ 8-6 REMOVAL/INSTALLATION ····················· 8-3 SPARK PLUG CAP INSPECTION············· 8-7 COOLING FAN/FLYWHEEL REMOVAL/INSTALLATION ····················· 8-4 IGNITION COIL INSPECTION ·················· 8-7...
  • Page 67 dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING IGNITION SYSTEM NO OR WEAK SPARK AT SPARK PLUG Check the following before troubleshooting: – Loose connectors – Spark plug (page 3-5) – Engine oil level (page 3-3) Replace the oil level switch (page 10-2). Check the oil level switch (If equipped) (page 10-3)/ Abnormal Replace the oil alert unit (page 10-3).
  • Page 68 dummyhead dummyhead IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Remove the following: – Fan cover (page 5-2) – Fuel tank (page 6-3) – Carburetor (page 6-5) • Route the engine wire harness and high-tension code properly (page 2-8). • After installation, check the ignition coil air gap (page 8-6). ENGINE WIRE HARNESS BOLT (6 x 25 mm) (2) HIGH-TENSION CORD...
  • Page 69 dummyhead dummyhead IGNITION SYSTEM COOLING FAN/FLYWHEEL REMOVAL/INSTALLATION REMOVAL Remove the ignition coil (page 8-3). SIDE PLATE WOODRUFF KEY MAGNET PART BOLT (6 x 22 mm) STARTER PULLEY COOLING FAN NUT (14 mm) (Threads and seating surface) 75 N·m (7.5 kgf·m, 55 lbf·ft) REMOVAL: Hold the flywheel [1] with a commercially available strap wrench [2], being careful not...
  • Page 70 dummyhead dummyhead 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. Set the woodruff key [3] in the key groove [4] of the crankshaft securely.
  • Page 71 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 72 dummyhead dummyhead IGNITION SYSTEM SPARK PLUG CAP INSPECTION Measure the resistance of the spark plug cap [1] by attaching one ohmmeter probe to the terminal in the spark plug cap and the other to the high-tension cord terminal. RESISTANCE: 7.5 – 12.5 kΩ (20°C/68°F) If measured resistance is out of specification, replace the spark plug cap.
  • Page 73 dummyhead dummyhead MEMO...
  • Page 74: Starting System

    dummytext 9. STARTING SYSTEM RECOIL STARTER RECOIL STARTER REMOVAL/INSTALLATION ····················· 9-2 DISASSEMBLY/ASSEMBLY···················· 9-3 RECOIL STARTER INSPECTION ············· 9-6...
  • Page 75 STARTING SYSTEM RECOIL STARTER STARTING SYSTEM REMOVAL/INSTALLATION RECOIL STARTER RECOIL STARTER COLLAR (3) (GP200H only) RECOIL MOUNT SPACER (GP200H only) GP160H: BOLT (6 x 16 mm) (3) GP200H: BOLT (6 x 25 mm) (3)
  • Page 76 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER 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 (page 9-2). SET SCREW 10 N·m (1.0 kgf·m, 7.0 lbf·ft) RATCHET GUIDE FRICTION SPRING STARTER RATCHET (2)
  • Page 77 dummyhead dummyhead STARTING SYSTEM ASSEMBLY • Wear gloves and eye protection. • During reassembly, take care not to allow the spring to come out. Pass the recoil starter rope [1] through the hole [2] of the recoil starter reel [3], and then tie the rope as shown.
  • Page 78 dummyhead dummyhead STARTING SYSTEM Apply grease to the two starter ratchets [1]. Install the two starter ratchets and the two return springs [2] to the recoil starter reel as shown. Apply grease to the inside of the ratchet guide [1]. Set the friction spring [2] and the ratchet guide to the recoil starter reel in the direction as shown.
  • Page 79 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER INSPECTION RECOIL STARTER OPERATION Remove the recoil starter (page 9-2). Pull the starter knob several times to inspect that the ratchets [1] are operated properly the ratchet ends come out from the ratchet guide [2]. STARTER PULLEY Remove the recoil starter (page 9-2).
  • Page 80: Other Electrical

    dummytext 10. OTHER ELECTRICAL OIL LEVEL SWITCH OIL LEVEL SWITCH INSPECTION ········· 10-3 REMOVAL/INSTALLATION ··················· 10-2 ENGINE STOP SWITCH INSPECTION ···· 10-3 ENGINE STOP SWITCH REMOVAL/INSTALLATION ··················· 10-2 OIL ALERT UNIT INSPECTION ·············· 10-4 OIL ALERT UNIT REMOVAL/INSTALLATION ··················· 10-3 10-1...
  • Page 81: Oil Level Switch Removal/Installation

    dummyhead dummyhead OTHER ELECTRICAL OIL LEVEL SWITCH OTHER ELECTRICAL REMOVAL/INSTALLATION Disconnect the oil level switch connector. Remove the camshaft (page 13-4). • Take care not to drop the valve lifter. OIL LEVEL SWITCH OIL LEVEL SWITCH JOINT NUT (10 mm) 10 N·m (1.0 kgf·m, 7 lbf·ft) BOLT (6 x 12 mm) (2) O-RING...
  • Page 82: Oil Alert Unit Removal/Installation

    dummyhead dummyhead OTHER ELECTRICAL OIL ALERT UNIT REMOVAL/INSTALLATION Disconnect the oil alert unit connectors [1]. Remove the bolt (6 x 12 mm) [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 83: Oil Alert Unit Inspection

    dummyhead dummyhead OTHER ELECTRICAL OIL ALERT UNIT INSPECTION Remove the oil alert unit (page 10-3). Check the continuity between the terminals, and oil alert unit body. Unit: kΩ Bl [1] Y [2] Body [3] Bl [1] – 0.5 – 10 (–) Y [2] 0.5 –...
  • Page 84: Muffler

    dummytext 11. MUFFLER MUFFLER REMOVAL/INSTALLATION···· 11-2 EXHAUST PIPE STUD BOLT REPLACEMENT ·································· 11-3 11-1...
  • Page 85 dummyhead dummyhead MUFFLER 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. SCREW (5 x 8 mm) (4) MUFFLER PROTECTOR MUFFLER...
  • Page 86 dummyhead dummyhead MUFFLER EXHAUST PIPE STUD BOLT REPLACEMENT Remove the muffler (page 11-2). Thread two nuts onto the exhaust pipe stud bolts [1] SPECIFIED LENGTH and tighten them together, then use a wrench to turn the stud bolt out. Install and tighten new stud bolts until they are the specified length.
  • Page 87 dummyhead dummyhead MEMO...
  • Page 88: Cylinder Head

    dummytext 12. CYLINDER HEAD TOOLS ·············································· 12-2 CYLINDER HEAD/VALVES INSPECTION ······································ 12-5 CYLINDER HEAD REMOVAL/INSTALLATION ··················· 12-3 VALVE GUIDE REAMING ····················· 12-8 CYLINDER HEAD VALVE SEAT RECONDITIONING··········· 12-9 DISASSEMBLY/ASSEMBLY·················· 12-4 12-1...
  • Page 89 dummyhead dummyhead CYLINDER HEAD TOOLS CYLINDER HEAD Seat cutter, 24.5 mm (45° EX) Seat cutter, 27.5 mm (45° IN) Flat cutter, 28 mm (32° IN) 07780-0010100 07780-0010200 07780-0012100 Flat cutter, 24 mm (32° EX) Interior cutter, 22 mm (60° EX) Interior cutter, 26 mm (60°...
  • Page 90 dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD REMOVAL/INSTALLATION Set the piston at top dead center of the cylinder compression stroke (page 3-7). Remove the following: – Fan cover (page 5-2) – Carburetor (page 6-5) – Control base (page 7-3) – Muffler (page 11-2) After installation, inspect following: –...
  • Page 91 dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD DISASSEMBLY/ASSEMBLY Remove the cylinder head (page 12-3). VALVE SPRING RETAINER REMOVAL: Push down and slide the valve spring retainer [1] to the side so that the valve stem [2] slips through the hole at the side of the valve spring retainer.
  • Page 92 Attach a commercially available compression gauge [1] to the spark plug hole. Pull the recoil starter forcefully to measure stable cylinder compression. CYLINDER COMPRESSION: GP160H: 0.49 – 0.69 MPa (5.0 – 7.0 kgf/cm 71 – 100 psi)/600 min-1 (rpm) GP200H: 0.35 MPa (3.6 kgf/cm...
  • Page 93 dummyhead dummyhead CYLINDER HEAD VALVE SEAT WIDTH Remove the carbon deposits from the combustion VALVE LAPPER chamber (page 3-8). (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 94 dummyhead dummyhead CYLINDER HEAD VALVE FACE/VALVE STEM O.D. Inspect each valve face [1] for irregularities. If necessary, replace the valve. Inspect each valve [2] for bending or abnormal stem wear. If necessary, replace the valve. Measure and record each valve stem O.D. STANDARD: IN: 5.468 –...
  • Page 95 dummyhead dummyhead CYLINDER HEAD PUSH ROD RUNOUT Check both ends of the push rod for wear. Check the push rod for straightness. If necessary, replace the push rod. VALVE GUIDE REAMING For best results, be sure the cylinder head is at room HANDLE temperature before reaming valve guides.
  • Page 96 dummyhead dummyhead CYLINDER HEAD VALVE SEAT RECONDITIONING Inspect the valve seat contact area (page 12-6). Using a 45° seat cutter, remove any roughness or 45° irregularities from the seat. If the contact area is too low on the valve, the seat must TOO LOW be raised using a 60°...
  • Page 97 dummyhead dummyhead MEMO...
  • Page 98: Crankcase

    dummytext 13. CRANKCASE TOOLS ·············································· 13-2 PISTON DISASSEMBLY/ASSEMBLY······ 13-5 CRANKCASE COVER CRANKCASE COVER/CYLINDER BARREL/ REMOVAL/INSTALLATION ··················· 13-3 PISTON/CONNECTING ROD/CRANKSHAFT/ CAMSHAFT INSPECTION····················· 13-6 CRANKSHAFT/CAMSHAFT/PISTON REMOVAL/INSTALLATION ··················· 13-4 CRANKSHAFT BEARING/OIL SEAL REPLACEMENT ································· 13-12 13-1...
  • Page 99: Tools

    dummyhead dummyhead CRANKCASE TOOLS CRANKCASE Bearing driver attachment, 37 x 40 mm Bearing driver attachment, 52 x 55 mm Pilot, 25 mm 07746-0010200 07746-0010400 07746-0040600 Driver handle 07749-0010000 13-2...
  • Page 100: Crankcase Cover Removal/Installation

    Clean the mating surface and apply a bead (2.0 – 2.5 mm (0.08 – 0.10 in)) of liquid sealant (ThreeBon d® 1216E or equivalent) as shown. Install the cover within 3 minutes after application. Pouring the engine oil is performed after 30 minutes have elapsed from assembling. GP160H GP200H 13-3...
  • Page 101: Crankshaft/Camshaft/Piston

    dummyhead dummyhead CRANKCASE CRANKSHAFT/CAMSHAFT/PISTON REMOVAL/INSTALLATION Remove the following: – Fuel tank (page 6-3) – Flywheel (page 8-4) – Cylinder head (page 12-3) – Crankcase cover (page 13-3) PISTON (Outer surface and big end bearing) INSTALLATION: Install the piston to the cylinder barrel with the mark [1] on the piston head toward the push rod hole [2] of the cylinder head.
  • Page 102: Piston Disassembly/Assembly

    dummyhead dummyhead CRANKCASE PISTON DISASSEMBLY/ASSEMBLY Remove the piston (page 13-4). MAKER MARK PISTON RING SET (Entire surface) TOP RING INSPECTION: (page 13-8) 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 103: Crankcase Cover/Cylinder Barrel/Piston/Connecting Rod/ Crankshaft/Camshaft Inspection

    dummyhead dummyhead CRANKCASE CRANKCASE COVER/CYLINDER BARREL/PISTON/CONNECTING ROD/ CRANKSHAFT/CAMSHAFT INSPECTION CAMSHAFT JOURNAL I.D. CRANKCASE COVER SIDE Measure the camshaft journal I.D. of the crankcase cover. STANDARD: 14.000 – 14.027 mm (0.5512 – 0.5522 in) SERVICE LIMIT: 14.048 mm (0.5531 in) If the measurement is more than the service limit, replace the crankcase cover.
  • Page 104 dummyhead dummyhead CRANKCASE 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° to the piston pin bore. 90° STANDARD: GP160: 67.965 – 67.985 mm (2.6758 – 2.6766 in) GP200: 67.965 –...
  • Page 105 dummyhead dummyhead 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. STANDARD: 17.992 – 17.998 mm (0.7083 – 0.7086 in) SERVICE LIMIT: 17.954 mm (0.7068 in) If the measurement is less than the service limit, replace the piston pin.
  • Page 106 dummyhead dummyhead CRANKCASE PISTON RING WIDTH Measure each piston ring width. 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) If any of the measurements is less than the service limit, replace the piston rings (top, second, oil) as a set.
  • Page 107 dummyhead dummyhead CRANKCASE CONNECTING ROD SMALL END I.D. Measure the connecting rod small end I.D. STANDARD: 18.006 – 18.017 mm (0.7089 – 0.7093 in) SERVICE LIMIT: 18.07 mm (0.711 in) If the measurement is more than the service limit, replace the connecting rod. Inspect the piston pin O.D.
  • Page 108 dummyhead dummyhead CRANKCASE Remove the connecting rod and measure the plastigauge. STANDARD: 0.035 – 0.055 mm (0.0014 – 0.0022 in) SERVICE LIMIT: 0.12 mm (0.005 in) If the clearance is more than the service limit, inspect the connecting rod big end I.D. and the crankpin O.D. If necessary replace the part that is not within the service limit and recheck the clearance.
  • Page 109: Crankshaft Bearing/Oil Seal

    dummyhead dummyhead CRANKCASE DECOMPRESSOR WEIGHT Check for worn and weakened spring. If the weight return spring [1] is worn or weakened, replace it. Check that the decompressor weight moves smoothly. If the decompressor weight does not move correctly, replace the camshaft. CRANKSHAFT BEARING Turn the inner race of the bearing with your finger and check for play.
  • Page 110 dummyhead dummyhead CRANKCASE CRANKSHAFT OIL SEAL CRANKCASE COVER SIDE Remove the oil seal. Drive a new oil seal [1] in the position as shown using the special tools. INSTALLATION HEIGHT: 5.5 mm (0.22 in) TOOLS: Bearing driver attachment, 37 x 40 mm [2] 07746-0010200 Driver handle [3] 07749-0010000...
  • Page 111 dummyhead dummyhead MEMO...
  • Page 112: Wiring Diagrams

    dummytext 14. WIRING DIAGRAMS WIRING DIAGRAMS ···························· 14-2 14-1...
  • Page 113 dummyhead dummyhead WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WITHOUT OIL ALERT UNIT: ENGINE STOP SWITCH Black Brown Yellow Orange Blue Light blue SPARK PLUG IGNITION COIL ENGINE STOP SWITCH Green Light green Pink White Gray WITH OIL ALERT UNIT: ENGINE STOP SWITCH Black Brown Yellow...
  • Page 114: Index

    INDEX dummytext INDEX AIR CLEANER CHECK/CLEANING/REPLACEMENT···3-4 HARNESS AND TUBE ROUTING ····························2-8 AIR CLEANER REMOVAL/INSTALLATION ················6-4 IDLE SPEED CHECK/ADJUSTMENT························3-7 BEFORE TROUBLESHOOTING ······························4-2 IGNITION COIL AIR GAP CHECK/ADJUSTMENT ·······8-6 CARBURETOR BODY CLEANING ···························6-8 IGNITION COIL INSPESTION ·································8-7 CARBURETOR DISASSEMBLY/ASSEMBLY··············6-7 IGNITION COIL REMOVAL/INSTALLATION···············8-3 CARBURETOR INSPECTION ·································6-8 IGNITION SYSTEM TROUBLESHOOTING ················8-2 CARBURETOR REMOVAL/INSTALLATION ···············6-6...

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Gp200h

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