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Honda GX160UT2 Manual

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62Z4H000.book 1 ページ 2011年5月20日 金曜日 午前10時5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 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
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 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 GX160UT2

  • 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 62Z4H000.book 2 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead How to use this manual SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING COVER FUEL SYSTEM GOVERNOR SYSTEM CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL MUFFLER CYLINDER HEAD CRANKCASE REDUCTION UNIT 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 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 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 62Z4H000.book 5 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead 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...
  • Page 6: Table Of Contents

    62Z4H000.book 1 ページ 2011年5月20日 金曜日 午前10時5分 dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ·····················1-2 ENGINE SPECIFICATIONS ························ 1-11 P.T.O. TYPE VARIATION······························1-2 PERFORMANCE CURVES························· 1-12 DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS······················· 1-15 SPECIFICATIONS ·······································1-10 P.T.O. DIMENSIONAL DRAWINGS ··········· 1-21...
  • Page 7: Serial Number Location

    62Z4H000.book 2 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead 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 GX120UT2 P.T.O.
  • Page 8: Specifications

    62Z4H000.book 3 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS P.T.O. type Type SX4 TX2 Air cleaner Dual Dual silent Cyclone Low profile Oil bath Semi dry Muffler Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal Cyclone Fixed throttle operation...
  • Page 9 62Z4H000.book 4 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS GX160UT2 P.T.O. type Type HX2 HX4 LX2 LX4 PXU QA2 Air cleaner Dual Dual silent Cyclone Low profile Oil bath Semi dry Muffler Standard Silent Low profile Spark arrester Fuel gauge Control base...
  • Page 10 62Z4H000.book 5 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS P.T.O. type Type QX2 QX4 QX9 Air cleaner Dual Dual silent Cyclone Low profile Oil bath Semi dry Muffler Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal Cyclone...
  • Page 11 62Z4H000.book 6 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS P.T.O. type Type SX4 SX9 SXU TX2 TX4 Air cleaner Dual Dual silent Cyclone Low profile Oil bath Semi dry Muffler Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote...
  • Page 12 62Z4H000.book 7 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS P.T.O. type Type Air cleaner Dual Dual silent Cyclone Low profile Oil bath Semi dry Muffler Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal Cyclone Fixed throttle operation Charge coil Lamp coil...
  • Page 13 62Z4H000.book 8 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS GX200UT2 P.T.O. type Type HX2 LX4 PXU QX2 QX4 QX9 Air cleaner Dual Dual silent Cyclone Low profile Oil bath Semi dry Muffler Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone...
  • Page 14 62Z4H000.book 9 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS P.T.O. type Type SX4 SX9 SXU TX2 Air cleaner Dual Dual silent Cyclone Low profile Oil bath Semi dry Muffler Standard Silent Low profile Spark arrester Fuel gauge Control base Manual Standard Cyclone standard Remote Internal...
  • Page 15 62Z4H000.book 10 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS DIMENSIONS AND WEIGHTS SPECIFICATIONS P.T.O. type GX120UT2/T2 GX160UT2/T2 GX200UT2/T2 Overall length 370 mm (14.6 in) 377 mm (14.8 in) 386 mm (15.2 in) 332 mm (13.1 in) 343 mm (13.5 in) 352 mm (13.9 in) P, Q, T * 305.5 mm (12.03 in)
  • Page 16: Engine Specifications

    62Z4H000.book 11 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS ENGINE SPECIFICATIONS Model GX120UT2/T2 GX160UT2/T2 GX200UT2/T2 Description code GCBMT/GCBNT GCBPT/GCBRT GCBTT/GCBUT Type 4 stroke, overhead valve, single cylinder, inclined by 25° Displacement 118 cm (7.2 cu–in) 163 cm (9.9 cu–in) 196 cm (12.0 cu–in) Bore x stroke 66.0 x 42.0 mm...
  • Page 17: Performance Curves

    62Z4H000.book 12 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS PERFORMANCE CURVES GX120 (N·m) (lbf·ft) (kgf·m) 0.75 NET TORQUE 0.70 (kW) (HP) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE 2000 3000 3600 ENGINE SPEED (rpm) 1-12...
  • Page 18 62Z4H000.book 13 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS GX160 (N·m) (lbf·ft) (kgf·m) NET TORQUE (kW) (HP) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE 2000 3000 3600 ENGINE SPEED (rpm) 1-13...
  • Page 19 62Z4H000.book 14 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS GX200 (N·m) (lbf·ft) (kgf·m) NET TORQUE (kW) (HP) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE 2000 3000 3600 ENGINE SPEED (rpm) 1-14...
  • Page 20: Dimensional Drawings

    62Z4H000.book 15 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS DIMENSIONAL DRAWINGS *: P.T.O. type. (page 1-2) GX120 (WITHOUT REDUCTION) Unit: mm (in) Dual/dual silent: 160 (6.3) Cyclone: 166 (6.5) Oil bath: 157 (6.2) Semi dry: 156 (6.1) Dual/dual silent: 317 (12.5) 115 (4.5) 231 (9.1) Cyclone/Oil bath: 330 (13.0) Semi dry: 314 (12.4)
  • Page 21 62Z4H000.book 16 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS GX120 (WITH REDUCTION) Unit: mm (in) 115 (4.5) H type*: 45.1 (1.78) L type*: 66.1 (2.60) R type*: 89.7 (3.53) H type*: 185.9 (7.32) L type*: 164.9 (6.49) R type*: 141.3 (5.56) 91 (3.6) 160 (6.3) 346 (13.6) (12.5)
  • Page 22 62Z4H000.book 17 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS GX160 (WITHOUT REDUCTION) Unit: mm (in) 121 (4.8) 70 (2.8) Dual/dual silent: 160 (6.3) Cyclone: 168 (6.6) Oil bath: 159 (6.3) Semi dry: 156 (6.1) 123 (4.8) 239 (9.4) Dual/dual silent: 337 (13.3) Cyclone/Oil bath/Semi dry: 333 (13.1) Standard: 93 (3.7)
  • Page 23 62Z4H000.book 18 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS GX160 (WITH REDUCTION) Unit: mm (in) 121 (4.8) 70 (2.8) 123 (4.8) H type*: 45.1 (1.78) L type*: 66.1 (2.60) R type*: 89.7 (3.53) H type*: 193.9 (7.63) L type*: 172.9 (6.81) R type*: 149.3 (5.88) 419 (16.5) 93 (3.7) 160 (6.3)
  • Page 24 62Z4H000.book 19 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS GX200 (WITHOUT REDUCTION) Unit: mm (in) 121 (4.8) 70 (2.8) Dual/dual silent: 160 (6.3) Cyclone: 168 (6.6) Oil bath: 159 (6.3) Semi dry: 156 (6.1) Dual/dual silent: 339 (13.3) 253 (10.0) 123 (4.8) Cyclone/Oil bath/Semi dry: 335 (13.2) 433 (17.0)
  • Page 25 62Z4H000.book 20 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS GX200 (WITH REDUCTION) Unit: mm (in) 121 (4.8) 70 (2.8) 123 (4.8) H type*: 45.1 (1.78) L type*: 66.1 (2.60) R type*: 89.7 (3.53) H type*: 207.9 (8.19) L type*: 186.9 (7.36) R type*: 163.3 (6.43) 433 (17.0) 376 (14.8) 106 (4.2)
  • Page 26: P.t.o. Dimensional Drawings

    62Z4H000.book 21 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS P.T.O. DIMENSIONAL DRAWINGS *: P.T.O. type. (page 1-2) WITHOUT REDUCTION Unit: mm (in) 45° 45° M8 x 1.25 65.1 (2.56) M8 x 1.25 (4 PLACES) 88 (3.5) CRANKSHAFT (P.T.O.) P type* Unit: mm (in) Q type* Unit: mm (in) 5/16-24UNF-2B...
  • Page 27 62Z4H000.book 22 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS S type* Unit: mm (in) T type* Unit: mm (in) 53.2 (2.09) M8 X 1.25 5.00 – 5.03 50 (2.0) 61.7 (2.43) 5/8-18UNF-2ARH (0.197 – 0.198) 58.5 (2.30) GX120: Φ 78 (3.1) GX160/GX200: Φ...
  • Page 28 62Z4H000.book 23 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS WITH REDUCTION H type* Unit: mm (in) 45.1 (1.78) P.T.O. SHAFT 4.724 – 4.774 (0.1860 – 0.1880) 50 (2.0) Φ 41.25 (1.624) 48 (1.9) 16.23 – 16.36 (0.639 – 0.644) Φ 19.037 – 19.050 (0.7495 –...
  • Page 29 62Z4H000.book 24 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SPECIFICATIONS R type* Unit: mm (in) 45° M8 x 1.25 45° 52.7 (2.07) 7.000 – 7.036 (0.2756 – 0.2770) (2.8) Φ 50 (2.0) 50 (2.0) 17.90 – 18.00 25 (1.0) (2.8) (0.705 – 0.709) P.T.O.
  • Page 30 62Z4H000.book 1 ページ 2011年5月20日 金曜日 午前10時5分 dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-8 TORQUE VALUES ········································2-6 HARNESS AND TUBE ROUTING ·············· 2-11 LUBRICATION & SEAL POINTS··················2-7...
  • Page 31: Cover

    62Z4H000.book 2 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION GX120 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) – –...
  • Page 32 62Z4H000.book 3 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION Part Item Standard Service limit Lamp coil Resistance 12 V – 50 W 0.18 – 0.23 Ω – Reduction unit P.T.O. shaft journal O.D. 19.929 – 19.950 (0.7846 – 0.7854) – (Chain type: P.T.O.
  • Page 33 62Z4H000.book 4 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION Part Item Standard Service limit Carburetor Main jet BE54C A – BE54D A – BE66U A – BE54P A – BE54J B – Pilot screw opening BE54C A 2-1/4 turns out – BE54D A 1-7/8 turns out –...
  • Page 34 62Z4H000.book 5 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION Part Item Standard Service limit Valves Valve clearance 0.15 ± 0.02 (0.006 ± 0.001) – 0.20 ± 0.02 (0.008 ± 0.001) – Valve stem O.D. 5.468 – 5.480 (0.2153 – 0.2157) 5.318 (0.2094) 5.425 –...
  • Page 35: Muffler

    62Z4H000.book 6 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION TORQUE VALUES Torque values Item Tread Dia. (mm) N·m kgf·m lbf·ft Crankcase cover bolt (GX120) M6 x 1.0 Crankcase cover bolt (GX160/GX200) M8 x 1.25 Cylinder head bolt M8 x 1.25 Engine oil drain plug bolt M10 x 1.25 Connecting rod bolt (GX120/GX200) M7 x 1.0...
  • Page 36: Cylinder Head

    62Z4H000.book 7 ページ 2011年5月20日 金曜日 午前10時5分 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...
  • Page 37 62Z4H000.book 8 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead 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, 5.5 mm 07401-0010000 07741-0010201...
  • Page 38 62Z4H000.book 9 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION Driver handle Seat cutter, 27.5 mm (45° IN) Seat cutter, 24.5 mm (45° EX) 07749-0010000 07780-0010200 07780-0010100 Seat cutter, 22 mm (45° IN/EX) Flat cutter, 21.5 mm (32° EX) Flat cutter, 22 mm (32° IN) 07780-0010701 07780-0012800 07780-0012601...
  • Page 39 62Z4H000.book 10 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION Bearing remover shaft set, 20 mm Bearing remover shaft handle Bearing remover shaft set, 25 mm 07936-3710600 07936-3710100 07936-ZV10100 Valve guide reamer, 5.510 mm Bearing driver attachment, Bearing driver attachment, 07984-2000001 45 x 50 mm 62 x 64 mm 07946-6920100 07947-6340400...
  • Page 40 62Z4H000.book 11 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION HARNESS AND TUBE ROUTING Connection of regulator/rectifier, charge/lamp coil and sub wire harness are depending on the application of the engine, therefore, the routing of these parts is not indicated in this manual. ENGINE WIRE HARNESS CYLINDER BARREL RIBS CARBURETOR INSULATOR...
  • Page 41 62Z4H000.book 12 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION GX120: GX160/GX200: FUEL TUBE BREATHER TUBE HIGH-TENSION CORD 2-12...
  • Page 42 62Z4H000.book 13 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION ENGINE STOP SWITCH TYPE ENGINE STOP SWITCH ONLY: GX120: GX160/GX200: CLAMP ENGINE WIRE HARNESS ENGINE WIRE HARNESS ENGINE WIRE HARNESS CONNECTOR ENGINE WIRE HARNESS CONNECTOR ENGINE STOP SWITCH WIRE ENGINE STOP SWITCH WIRE WITH OIL LEVEL SWITCH: HARNESS CLIP ENGINE STOP SWITCH WIRES...
  • Page 43 62Z4H000.book 14 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION WITH OIL LEVEL SWITCH AND OIL ALERT UNIT: ENGINE WIRE HARNESS GX160/GX200: HARNESS CLIP CLAMP ENGINE WIRE HARNESS ENGINE STOP To oil alert unit OIL ALERT UNIT CONNECTOR To ignition coil SWITCH WIRES OIL ALERT UNIT WIRES To engine stop switch...
  • Page 44 62Z4H000.book 15 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION COMBINATION SWITCH (CONTROL BOX) TYPE ENGINE WIRE HARNESS CHARGE COIL CORD STARTER SOLENOID WIRE ENGINE WIRE HARNESS CONNECTOR OIL LEVEL SWITCH WIRE TERMINAL WIRE OIL ALERT UNIT WIRE 45 ± 5° CHARGE COIL CONNECTOR TERMINAL WIRE FASTENER TUBE...
  • Page 45 62Z4H000.book 16 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead SERVICE INFORMATION WITH CHARGE COIL / LAMP COIL 1 A/3 A CHARGE COIL, 12 V – 15 W/12 V – 25 W LAMP COIL TYPE: COIL CORD CORD GROMMET CORD CLAMPER 7 A CHARGE COIL TYPE: COIL CORD CORD GROMMET CORD CLAMPER...
  • Page 46 62Z4H000.book 1 ページ 2011年5月20日 金曜日 午前10時5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 47: Maintenance Schedule

    62Z4H000.book 2 ページ 2011年5月20日 金曜日 午前10時5分 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.
  • Page 48: Engine Oil Level Check/Change

    62Z4H000.book 3 ページ 2011年5月20日 金曜日 午前10時5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 49: Reduction Case Oil Level Check

    62Z4H000.book 4 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead MAINTENANCE REDUCTION CASE OIL LEVEL CHECK/ CHANGE • For the chain type (without clutch), refer to the ENGINE OIL LEVEL CHECK/CHANGE because it shares the reduction oil with the engine oil (page 3- CHECK GEAR TYPE Place the engine on a level surface.
  • Page 50 62Z4H000.book 5 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead MAINTENANCE CHANGE GEAR TYPE Remove the breathing bolt [1]. [2]/[3] Remove the drain plug bolt [2] and drain plug washer [3], tilt the engine and drain the oil into a suitable container. Please dispose of used oil in a manner that is compatible with the environment.
  • Page 51 62Z4H000.book 6 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead MAINTENANCE CHAIN TYPE (with clutch) Place the engine on a level surface and place a suitable container under the drain plug bolt [1]. Remove the oil filler cap/oil level gauge [2], drain plug bolt and drain plug washer [3] and drain the oil into a suitable container.
  • Page 52: Air Cleaner Check/Cleaning

    62Z4H000.book 7 ページ 2011年5月20日 金曜日 午前10時5分 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.
  • Page 53 62Z4H000.book 8 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead MAINTENANCE CYCLONE TYPE Remove the following: – Bolt (4 x 6 mm) [1] (3) – Pre air cleaner case [2] – Air cleaner guide [3] – Wing nut [4] – Air cleaner cover Assy. [5] –...
  • Page 54 62Z4H000.book 9 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead MAINTENANCE OIL BATH TYPE Remove the following: – Wing nut [1] – Air cleaner cap [2] – Air cleaner cover [3] – Air cleaner element [4] Carefully check the element for holes or tears and replace if damaged.
  • Page 55: Sediment Cup Cleaning

    62Z4H000.book 10 ページ 2011年5月20日 金曜日 午前10時5分 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 56: Spark Plug Check/Adjustment

    62Z4H000.book 11 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead MAINTENANCE SPARK PLUG CHECK/ADJUSTMENT Remove the spark plug (page 3-11). Clean the spark plug [1] electrodes with a wire brush [2] or special plug cleaner. Check the following and replace if necessary. – Insulator [3] and sealing washer [4] for damage –...
  • Page 57: Spark Arrester Cleaning

    62Z4H000.book 12 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead MAINTENANCE SPARK ARRESTER CLEANING The engine and the muffler comes 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. STANDARD, SILENT TYPE Remove the air cleaner (page 6-5).
  • Page 58: Idle Speed Check/Adjustment

    62Z4H000.book 13 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead MAINTENANCE IDLE SPEED CHECK/ADJUSTMENT Ensure the governor arm and governor arm shaft are installed correctly (page 7-5). Use a tachometer with graduations of 50 min (rpm) or smaller that will accurately indicate 50 min (rpm) change.
  • Page 59 62Z4H000.book 14 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead MAINTENANCE Insert a thickness gauge [1] between the valve rocker arm [2] and valve stem [3] to measure the valve clearance. VALVE CLEARANCE: GX120/GX200: IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in) EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in) GX160: IN: 0.08 ±...
  • Page 60: Combustion Chamber Cleaning

    62Z4H000.book 15 ページ 2011年5月20日 金曜日 午前10時5分 dummyhead dummyhead MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the cylinder head (page 13-4). Clean any carbon deposits from the combustion chamber [1]. Installation is in the reverse order of removal. FUEL TANK AND FILTER CLEANING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
  • Page 61: Fuel Tube Check

    62Z4H000.book 16 ページ 2011年5月20日 金曜日 午前10時5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.

This manual is also suitable for:

Gx200ut2Gx120ut2