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Honda WDP30X Instructions Manual
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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 or others. It could also damage the
water pump or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of 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 the pump.
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 the pump. Any error or oversight while servicing a pump can result
in faulty operation, damage to the pump, or injury to others.
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.
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 or liquids, and 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.
• Make sure the engine is off before you begin any servicing procedures, unless the instructions tell 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 are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline.
 Use only a nonflammable solvent, not gasoline, to clean parts.
 Never drain or store gasoline in an open container.
 Keep all cigarettes, sparks, and flames away from all fuel-related parts.
A FEW WORDS ABOUT SAFETY
WARNING
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.
WARNING
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.

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Summary of Contents for Honda WDP30X

  • Page 1 Honda, must determine the risks to their personal safety and the safe operation of the pump. 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 CONTENTS This manual covers service and repair procedures for the SPECIFICATIONS Honda WDP30X, K1, and K2 diaphragm pumps. All information contained in this manual is based on the latest SERVICE INFORMATION product information available at the time of printing. We reserve the right to make changes at any time without notice.
  • Page 3 WDP30X Revised: April 2012 (PSV61TDP00E2)
  • Page 4 1. SPECIFICATIONS WDP30X 1. SPECIFICATIONS ..... . . 1-1 3. DIMENSIONAL DRAWINGS ....1-4 2.
  • Page 5 WDP30X • ENGINE Engine model GX120K1QX2 GX120UT1QX2 GX120UT2QX2 Description code GCAAT GCAGT GCBMT Engine type 4-stroke, overhead-valve, single-cylinder inclined by 25° Displacement 118 cm³ (7.2 cu in) Bore x stroke 60 x 42 mm (2.4 x 1.7 in) Compression ratio 8.5: 1...
  • Page 6 WDP30X 2. PERFORMANCE CURVE (ft) 15.2 12.2 (US gal/min) (/min) DISCHARGE CAPACITY Pump Priming Pump priming is not required if the vertical distance from water to the pump (suction head) is less than 16 feet. The suction head can be increased to 24 feet if the pump is primed.
  • Page 7 WDP30X 3. DIMENSIONAL DRAWINGS WDP30X 594 mm (23.4 in) WDP30XK1, K2 755 mm (30.5 in) Dimensions are with the handlebar installed over the engine. Revised: April 2012 (PSV61TDP00E2) Date of Issue: April 2008...
  • Page 8 WDP30X 4. WIRING DIAGRAM IGNITION CONTROL MODULE IGNITION SWITCH SPARK PLUG OIL ALERT UNIT OIL LEVEL SWITCH BLACK YELLOW Date of Issue: April 2008...
  • Page 9 WDP30X Date of Issue: April 2008...
  • Page 10 4. MAINTENANCE STANDARDS ... . . 2-3 1. SERVICE RULES • Use Honda Genuine parts or their exact equivalent. Lower quality parts can damage the pump or reduce its performance.
  • Page 11 WDP30X 3. SERIAL NUMBER LOCATIONS There are two serial numbers, one for the engine and one for the frame. Always refer to these numbers when ordering parts and when making technical inquiries. FRAME SERIAL NUMBER ENGINE SERIAL NUMBER Date of Issue: April 2008...
  • Page 12 WDP30X 4. MAINTENANCE STANDARDS PART ITEM STANDARD SERVICE LIMIT 3,000 ~ 3,150 rpm Maximum governed speed ----------------------- 1,400 +200/-150 rpm Engine Idle speed ----------------------- Cylinder compression ----------------------- 6.0 ~ 8.5 kg/cm (85 ~ 121 psi) at 600 rpm Main jet...
  • Page 13 WDP30X 5. TORQUE VALUES TORQUE THREAD DIAMETER x SPECIAL FASTENERS PITCH mm N•m kg-m ft-lb Connecting rod bolt 7 x 1.0 Cylinder head bolt 8 x 1.25 Flywheel nut 14 x 1.5 (special) Rocker arm pivot lock nut 6 x 0.5 Rocker arm pivot stud 8 x 1.25 (special)
  • Page 14 WDP30X 6. TOOLS a. SPECIAL ITEM TOOL NAME TOOL NUMBER APPLICATION Carburetor float level gauge 07401-0010000 Carburetor float level inspection Attachment, 52 x 55 mm 07746-00010400 Crankshaft bearing 6205, 62/22 installation Driver, 40 mm ID 07746-0030100 Driver for attachments 4 and 5...
  • Page 15 American Honda Parts Department. Most commercially available tools shown in this shop manual can be ordered through the Honda Power Equipment (P/E) Tool and Equipment program by calling (888) 424-6857. Refer to the Tool and Equipment program catalog for a complete tool listing.
  • Page 16 WDP30X 7. TROUBLESHOOTING a. HARD STARTING 1. Check fuel level. NO FUEL IN TANK Refuel. SUFFICIENT FUEL IN TANK 2. Remove spark plug and inspect • Clean and install plug, then 3-5). restart engine. • Check carburetor for flooding. 3. Check spark plug operation WEAK OR NO SPARK •...
  • Page 17 WDP30X b. IGNITION SYSTEM Engine does not start with the ignition switch in the ON position. 1. Test the spark plug (see below). NO SPARK 2. Check again with a new spark SPARKS • Faulty spark plug. plug. • Install new spark plug 3-5).
  • Page 18 WDP30X c. PUMP Not self priming 1. Strainer CLOGGED/DAMAGED Clean or replace strainer. 2. Suction head TOO GREAT Move pump closer to the water 1-3). 3. Suction hose CLOGGED/DAMAGED Clean or replace hose. 4. Couplings AIR LEAKS Tighten couplings. 5. Clappet valve...
  • Page 19 WDP30X 2-10 Date of Issue: April 2008...
  • Page 20 (1) Log hours of operation to determine proper maintenance intervals. (2) Service more frequently when used in dusty areas. (3) These items should be serviced by an authorized Honda servicing dealer, unless you have the proper tools and are mechanically proficient.
  • Page 21 WDP30X 2. ENGINE OIL a. INSPECTION 1. Remove the oil filler cap, and wipe the dipstick clean. 2. Insert the dipstick in the oil filler neck, but do not screw it in. Remove the dipstick and check the oil level.
  • Page 22 WDP30X 3. PUMP GEARBOX SERVICE BULLETIN #7 PLASTIC ACCESS COVER a. CONNECTING ROD GREASE Remove the plastic access plug. Disconnect the spark plug cap and pull the starter grip until the grease nipple is visible in the access opening. Wipe the grease nipple to prevent dirt from getting into the bearing and using a manual grease gun, pump one or two strokes of general purpose grease into the bearing.
  • Page 23 WDP30X 4. AIR CLEANER CLEANING AIR CLEANER A dirty air filter will restrict air flow to the carburetor, reducing COVER NUT engine performance. If the engine is operated in dusty areas, clean the air filter more often than specified in the...
  • Page 24 WDP30X 5. SPARK PLUG INSPECTION Recommended spark plug BPR6ES NOTICE An incorrect spark plug can cause engine damage. Use the recommended spark plug or an exact equivalent. 1. Visually inspect the spark plug. Discard the plug if the insulator is cracked or chipped.
  • Page 25 WDP30X 6. SPARK ARRESTER (OPTIONAL PART) If the engine has been running, the muffler will be very hot. Allow the muffler to cool before servicing the spark arrester. MUFFLER 5 mm SCREW (4) PROTECTOR CLEANING 4 mm The spark arrester must be serviced every 100 hours to keep SCREW it functioning as designed.
  • Page 26 WDP30X 7. VALVE CLEARANCE CYLINDER HEAD COVER CYLINDER HEAD INSPECTION/ADJUSTMENT COVER GASKET Valve clearance inspection and adjustment must be performed with the engine cold. 1. Remove the four cylinder head cover bolts, cylinder head cover gasket, and cover. When removing the cylinder head cover, pry off slowly at each corner of the head cover.
  • Page 27 WDP30X 8. IDLE SPEED a. PILOT SCREW THROTTLE STOP SCREW The pilot screw is fitted with a limiter cap that prevents excessive enrichment of the air-fuel mixture in order to comply with emissions regulations. Do not attempt to remove the limiter cap for pilot screw adjustment.
  • Page 28 WDP30X 10. FUEL TANK & FUEL FILTER  WARNING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately.
  • Page 29 WDP30X 11. GOVERNOR ADJUSTMENT 1. Remove the fuel tank. THROTTLE CONTROL SCREW 2. Loosen the pinch bolt and nut, and then move the governor arm so that the throttle is completely open. PINCH BOLT/NUT 3. Rotate the governor arm shaft as far as it will go in the direction that it was just turned by the governor arm, and retighten the pinch bolt and nut.
  • Page 30 4. AIR CLEANER/CARBURETOR WDP30X 1. AIR CLEANER ......4-1 2. CARBURETOR ......4-3 1.
  • Page 31 WDP30X AIR CLEANER COVER INSTALLATION: Install the air cleaner cover with the long skirt portion facing toward the front. WING NUT INNER FILTER (PAPER) GROMMET BOLT (6 x 20 mm) OUTER FILTER (FOAM) COLLAR AIR CLEANER ELBOW SEAL AIR CLEANER ELBOW...
  • Page 32 WDP30X 2. CARBURETOR a. REMOVAL/INSTALLATION THROTTLE RETURN SPRING GOVERNOR ROD FUEL TUBE ASSEMBLY: SPARK PLUG WIRE INSULATOR GASKET CARBURETOR GASKET Date of Issue: April 2008...
  • Page 33 WDP30X b. DISASSEMBLY/ASSEMBLY P. 4-5 CLEANING: P. 4-5 REPLACEMENT: P. 4-4 P. 4-4 REPLACEMENT: P. 4-5 P. 4-5 ASSEMBLY: ASSEMBLY: CLEANING: P. 3-8 P. 3-8 ASSEMBLY: ASSEMBLY: ASSEMBLY: Date of Issue: April 2008...
  • Page 34 WDP30X c. INSPECTION FLOAT LEVEL HEIGHT FLOAT LEVEL GAUGE Place the carburetor in the position as shown and measure 07401-0010000 the distance between the float top and carburetor body when the float just contacts the seat without compressing the valve spring.
  • Page 35 O-rings, floats, and float seats. 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. Use low air pressure (30 psi or less) when cleaning passages and ports.
  • Page 36 5. RECOIL STARTER/FUEL TANK WDP30X 1. RECOIL STARTER ..... . 5-1 3. FUEL TANK ......5-5 2.
  • Page 37 WDP30X c. ASSEMBLY 1. Insert the starter rope into the recoil starter reel and tie the rope as shown. STARTER REEL 2. Wind the rope onto the reel counterclockwise. STARTER ROPE 3. Wind the spring and install it to the recoil starter reel by aligning the outer end to the groove of the reel.
  • Page 38 WDP30X 8. Turn the reel three full turns counterclockwise to preload the return spring. 9. Pass the rope through the starter case hole and starter grip, and knot the end of the rope as shown. STARTER GRIP CASE HOLE 10.Check the operation of the ratchet by pulling the starter rope out several times.
  • Page 39 WDP30X 2. FAN COVER REMOVAL/INSTALLATION From ignition coil BLACK ENGINE ALERT SWITCH UNIT YELLOW YELLOW From oil level Retaining clip switch Date of Issue: April 2008...
  • Page 40 WDP30X 3. FUEL TANK REMOVAL/INSTALLATION FUEL TANK CAP Gasoline is highly flammable and explosive. ASSEMBLY: Make sure that the air vent hole is You can be burned or seriously injured when handling clean and unclogged. Blow with fuel. compressed air if necessary.
  • Page 41 WDP30X FUEL FILLER CAP FUEL FILLER CAP PACKING CHECK: Check for deterioration or cracks. FUEL TANK O-RING FUEL TANK JOINT 2 N·m (0.2 kgf·m, 18 lin·lb) CHECK: Check the screen of the fuel tank joint for clogs or damage. FUEL TANK NUT (6 mm) (2) 10 N·m (1.0 kgf·m, 89 in·lb)
  • Page 42 6. MUFFLER WDP30X 1. MUFFLER......6-1 1. MUFFLER DISASSEMBLY/ASSEMBLY  CAUTION...
  • Page 43 WDP30X Date of Issue: April 2008...
  • Page 44 7. FLYWHEEL/IGNITION COIL WDP30X 1. FLYWHEEL/IGNITION COIL ....7-1 1. FLYWHEEL/IGNITION COIL a. DISASSEMBLY/ASSEMBLY BLACK LEAD WOODRUFF KEY FLYWHEEL ASSEMBLY: ASSEMBLY: DISASSEMBLY: Insert securely into the two After installing the flywheel, •...
  • Page 45 WDP30X b. ADJUSTMENT IGNITION COIL Adjustment is required only when the ignition coil or the flywheel has been removed. 1. Loosen the ignition coil bolt. 2. Insert the feeler gauge between the ignition coil and flywheel. 3. Push the ignition coil firmly against the flywheel and tighten the ignition coil bolt.
  • Page 46 WDP30X SPARK PLUG CAP Measure the resistance of the spark plug cap by touching one test lead at the wire end of the cap, and the other at the spark plug end.  Resistance 7.5 ~ 12.5 k SPARK PLUG CAP...
  • Page 47 WDP30X Date of Issue: April 2008...
  • Page 48 8. CYLINDER HEAD/VALVES WDP30X 1. CYLINDER HEAD/VALVES ....8-1 1. CYLINDER HEAD/VALVES a. REMOVAL/INSTALLATION 8 x 55 (4) TORQUE: 24 N•m (18 ft-lb) REMOVAL/INSTALLATION: SPARK PLUG Loosen and tighten the bolts in a P.
  • Page 49 WDP30X b. DISASSEMBLY/ASSEMBLY VALVE SPRING RETAINER (2) DISASSEMBLY: Push down and slide the retainer to the side, so the valve stem slips through the hole at the side of the retainer. ASSEMBLY: EXHAUST VALVE The exhaust valve retainer has a larger...
  • Page 50 WDP30X c. INSPECTION • VALVE SPRING FREE LENGTH Measure the free length of the valve springs. Standard Service limit 30.5 mm (1.20 in) 29.5 mm (1.16 in) Replace the springs if they are shorter than the service limit. • VALVE SEAT WIDTH Measure the valve seat width.
  • Page 51 WDP30X • VALVE STEM O.D. Inspect each valve for face irregularities, bending, or abnormal stem wear. Replace the valve if necessary. Measure and record each valve stem O.D. Standard Service limit 5.48 mm (0.216 in) 5.318 mm (0.2094 in) 5.45 mm (0.215 in) 5.275 mm (0.2077 in)
  • Page 52 WDP30X d. VALVE GUIDE REPLACEMENT 1. Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. 2. Use a hot plate or oven to heat the cylinder head evenly to 150°C (300°F).  CAUTION To avoid burns, use heavy gloves when handling the heated cylinder head.
  • Page 53 WDP30X • VALVE GUIDE REAMING For best results, be sure the cylinder head is at room temperature before reaming valve guides. 1. Coat the reamer and valve guide with cutting oil. 2. Rotate the reamer clockwise through the valve guide the full VALVE GUIDE length of the reamer.
  • Page 54 WDP30X Standard Service limit 0.8 mm (0.03 in) 2.0 mm (0.08 in) 5. Make a light pass with 45° cutter to remove any possible burrs at the edge of the seat. 6. After resurfacing the seats, inspect for even valve seating.
  • Page 55 WDP30X Date of Issue: April 2008...
  • Page 56 9. CRANKCASE COVER/CRANKSHAFT/PISTON WDP30X 1. CRANKCASE COVER/CRANKSHAFT ..9-1 2. GOVERNOR ......9-8 1.
  • Page 57 WDP30X • CRANKSHAFT BEARING ASSEMBLY: Oil the circumference of the bearing, and install the bearing with the following special tools. Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 Pilot, 22 mm 07746-0040100 • TIMING GEAR/GOVERNOR DRIVE GEAR DISASSEMBLY: Mark a line on the crankshaft and timing gear.
  • Page 58 WDP30X • PISTON PISTON RINGS ASSEMBLY: • Install all rings with the markings facing up. • Be sure that the top and second rings are not interchanged. • Check that rings rotate smoothly after installation. • Space the piston ring end gaps 120 degrees apart, and do not align any gap with the piston pin bore.
  • Page 59 WDP30X b. INSPECTION • CYLINDER I.D. 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.
  • Page 60 WDP30X • PISTON RING END GAP K1QX2 Standard Service limit 0.2 ~ 0.4 mm 1.0 mm (0.04 in) Second (0.008 ~ 0.016 in) PISTON RING 0.15 ~ 0.35 mm 1.0 mm (0.04 in) (0.008 ~ 0.014 in) UT1(2)QX2 Standard Service limit 0.20 ~ 0.35 mm...
  • Page 61 WDP30X • CONNECTING ROD BIG END I.D. Original size - Standard Service limit 26.02 mm (1.024 in) 26.066 mm (1.0262 in) Undersize - Standard Service limit 25.770 ~ 25.783 mm 25.816 mm (1.0164 in) (1.0146 ~ 1.0151 in) • CRANKPIN O.D.
  • Page 62 WDP30X 3. Remove the connecting rod and measure the plastigauge. PLASTIGAUGE Standard Service limit 0.040 ~ 0.063 mm 0.12 mm (0.005 in) 0.0016 ~ 0.0025 in) 4. If the clearance exceeds the service limit, replace the connecting rod and recheck the clearance.
  • Page 63 WDP30X • CRANKSHAFT BALL BEARING FREE PLAY PLAY 1. Clean the bearing in solvent and dry it. 2. Spin the bearing by hand and check for play. Replace the PLAY bearing if it is noisy or has excessive play. AXIAL RADIAL 2.
  • Page 64 10. CASE/DIAPHRAGM WDP30X 1. CASE/DIAPHRAGM..... 10-1 1. CASE/DIAPHRAGM a. DISASSEMBLY/ASSEMBLY UPPER CASE 12 x 1.75 x 50 mm HEX BOLT (4)
  • Page 65 WDP30X  b. CONNECTING ROD DISASSEMBLY GREASE NIPPLE 1. Remove the roll pin and place the upper rod end lightly in a vise. 2. Remove the bolt securing the spring and lower rod UPPER ROD end assembly. ROLL PIN SPRING...
  • Page 66 WDP30X c. DIAPHRAGM CONNECTING ROD INSPECTION Inspect the diaphragm for cracks, tears, or damage and NYLON WASHER replace if necessary. INSTALLATION BUSHING COVER 1. Install the connecting rod hex bolt with lock washer, bushing cover, and nylon washer into the crank arm.
  • Page 67 WDP30X 10-4 Date of Issue: April 2008...
  • Page 68 1. GEARBOX ......11-1 1. GEARBOX SERVICE BULLETIN #7 DISASSEMBLY/ASSEMBLY WDP30X up to S/N WZCA-6099999 GEAR KEY (3) SHAFT...
  • Page 69 WDP30X WDP30X up to S/N WZCA-6099999 5/16 x 18 x 1.5 HEX BOLT (4) ENGINE MOUNTING BRACKET 5/16 in 6 x 1 x 25 mm WASHER (8) ALLEN SCREW (10) LIFTING BAIL PLUGS GASKET BEARING 10 x 1.5 STUD (4)
  • Page 70 WDP30X WDP30XK1, K2 S/N WZCA-6200001 ~ later GEAR (HELICAL) SHAFT KEY (3) Continued on next page BEARING GEARBOX CASE GEAR (HELICAL) SHAFT WASHER BEARING CAP/DIPSTICK SEAL PLUG GASKET PLUG WASHER To CASE/DIAPHRAGM P. 10-1 P. 10-1 11-3 Revised: April 2012 (PSV61TDP00E2)
  • Page 71 WDP30X WDP30XK1, K2 S/N WZCA-6200001 ~ later 5/16 x 18 x 1.5 HEX BOLT (4) ENGINE MOUNTING BRACKET 6 x 1 x 25 mm 5/16 in ALLEN SCREW (10) WASHER (8) LIFTING BAIL PLUG (2) PINION GASKET BEARING 5/16 in...
  • Page 72 WDP30X 1. FRAME/WHEELS..... . . 12-1 1. FRAME/WHEELS DISASSEMBLY/ASSEMBLY WDP30X S/N WZCA-6000001 ~ 6099999 To CASE/DIAPHRAGM P. 10-1 P. 10-1...
  • Page 73 WDP30X WDP30XK1, K2 S/N WZCA-6100001 ~ later 5/16-18 x 1.5 in HEX BOLT (4) 5/16-18 NYLOCK NUT (4) AXLE SHAFT  15 N•m (11 ft-lb) Grease both ends. FRAME ASSEMBLY WHEEL (2) QUICK RELEASE RING-PIN 20 mm PLAIN WASHER (4)
  • Page 74 13. INDEX WDP30X ..........i Air Cleaner Safety Messages Cleaning ............3-4 Serial Numbers Location ..........2-2 Installation/Removal .......... 4-1 Service Rules ............2-1 Carburetor Spark Arrester ............3-6 Installation/Removal .......... 4-3 Spark Plug Disassembly ............4-4 Inspection............3-5 Cleaning ............4-6 Testing ...............2-8 Clappet Valve............
  • Page 75 WDP30X Date of Issue: April 2008 13-2...

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