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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 GXR120T

  • 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 COVER FUEL SYSTEM GOVERNOR SYSTEM FLYWHEEL IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL MUFFLER CAM PULLEY/ROCKER ARM/VALVE CRANKSHAFT/PISTON/CYLINDER BARREL WIRING DIAGRAM 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 TYPE VARIATIONS································ 1-2 PERFORMANCE CURVES ······················ 1-5 DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS ···················· 1-6 SPECIFICATIONS·································· 1-3 P.T.O. DIMENSIONAL DRAWINGS··········· 1-7...
  • Page 7 dummyhead dummyhead SPECIFICATIONS SERIAL NUMBER LOCATION SPECIFICATIONS The model [1] and engine serial number [2] are stamped on the crankcase. Refer to them when ordering parts or making technical inquiries. TYPE VARIATIONS TYPE KRH2 KRGA KRAA KRGF KRDF KRBF KRSB KRWF KRWB KRDP KRDY Crankshaft Tapered Straight...
  • Page 8 dummyhead dummyhead SPECIFICATIONS DIMENSIONS AND WEIGHTS SPECIFICATIONS TYPE DIMENSIONS AND WEIGHTS Overall length KRGA, KRGF, KRWF, KRWB, KREU, KRBF, 259 mm (10.2 in) KRAA, KRG, KRB5 KRDF, KRDP, KREE, KRM, KRE4, KRB4, KRDY 271 mm (10.7 in) KRH, KRH2, KRSB, KRMB, KRF2, KRA2, KRS2 273 mm (10.7 in) Overall width KRAA, KRG, KRDY...
  • Page 9 SPECIFICATIONS ENGINE SPECIFICATIONS Model GXR120T GXR120RT Description code GCCET GCCDT Type 4 stroke, overhead camshaft, single cylinder Displacement 121 cm (7.4 cu-in) Bore x stroke 60.0 x 43.0 mm (2.36 x 1.69 in) Net power (SAE J1349) *1 2.7 kW (3.6 HP)/3,600 min...
  • Page 10 dummyhead dummyhead SPECIFICATIONS PERFORMANCE CURVES (N·m) (kgf·m) (lbf·ft) NET TORQUE (kW) (HP) (PS) RECOMMENDED OPERATING SPEED RANGE 2000 2500 3000 3600 4000 ENGINE SPEED (rpm)
  • Page 11 dummyhead dummyhead SPECIFICATIONS DIMENSIONAL DRAWINGS Unit: mm (in) A type: 141 (5.6) B type: 145 (5.7) C type: 160 (6.3) D type: 171 (6.7) A type: 264 (10.4) E type: 259 (10.2) B type: 268 (10.6) C type: 283 (11.1) F type: 271 (10.7) G type: 273 (10.7) D type: 294 (11.6)
  • Page 12 dummyhead dummyhead SPECIFICATIONS P.T.O. DIMENSIONAL DRAWINGS P.T.O. FLANGE A Unit: mm (in) 117.5 (4.63) (From cylinder center) CRANKSHAFT (P.T.O.) M10 x 1.25 M10 x 1.25 18 (0.7) 17 (0.7) 15 (0.59) TAPER 1/5 51.3 (2.02) 51.3 (2.02) 94 (3.7) 94 (3.7) 117.5 (4.63) (From cylinder center) 15 (0.59)
  • Page 13 dummyhead dummyhead SPECIFICATIONS P.T.O. FLANGE B Unit: mm (in) 114.5 (4.51) (From cylinder center) CRANKSHAFT (P.T.O.) 23.7 (0.93) 18 (0.7) 17 (0.7) TAPER 1/5 96 (3.8) 114.5 (4.51) (From cylinder center) M12 x 1.25 4.00 – 4.03 (0.157 – 0.159) 9.6 (3.78)
  • Page 14: Service Information

    dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ················· 2-2 TOOLS ················································ 2-5 TORQUE VALUES ································· 2-3 HARNESS AND TUBE ROUTING ············· 2-6 LUBRICATION & SEAL POINTS ·············· 2-4...
  • Page 15 dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION Unit: mm (in) Part Item Standard Service limit Engine Maximum speed (at no load) – 4,100 ± 100 min (rpm) Idle speed – 1,850 ± 150 min (rpm) Cylinder compression 0.50 MPa (5.1 kgf/cm , 73 psi)/ –...
  • Page 16 dummyhead dummyhead SERVICE INFORMATION TORQUE VALUES Torque values Item Tread Dia. (mm) Remarks N·m kgf·m lbf·ft Spark plug M10 x 1.0 Connecting rod bolt M6 x 1.0 Apply engine oil to the threads and seating surface. Oil drain plug bolt M10 x 1.25 Valve adjusting lock nut M5 x 0.5 (Special nut)
  • Page 17 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 Cam pulley cam lobe, journal and decompressor area Cam pulley shaft sliding surface...
  • Page 18 dummyhead dummyhead SERVICE INFORMATION TOOLS SPECIAL TOOLS Float level gauge Valve adjuster wrench, 3 mm Cleaning brush 07401-0010000 07908-KE90200 07998-VA20100 Valve guide driver, 3.6 x 8.0 mm Valve guide reamer, 4.008 mm Driver 07JMD-KY20100 07MMH-MV90100 07749-0010000 Driver, 22 mm I.D. Attachment, 44 x 49.5 mm Attachment, 32 x 35 mm 07746-0020100...
  • Page 19 dummyhead dummyhead SERVICE INFORMATION HARNESS AND TUBE ROUTING ENGINE STOP SWITCH, OIL LEVEL SWITCH AND OIL LEVEL SWITCH AND ENGINE STOP ENGINE STOP OIL ALERT UNIT TYPE OIL ALERT UNIT TYPE SWITCHLESS TYPE SWITCH TYPE ENGINE STOP ENGINE STOP ENGINE STOP SWITCH SWITCH CORD ENGINE STOP SWITCH...
  • Page 20 dummyhead dummyhead SERVICE INFORMATION to IGNITION COIL OIL ALERT to OIL LEVEL SWITCH UNIT OIL LEVEL SWITCH CORD ENGINE STOP CORD 10 – 15 mm OIL LEVEL OIL ALERT SWITCH PLUG UNIT PLUG OIL ALERT UNIT CORD 0 – 20° OIL LEVEL SWITCH CORD OIL LEVEL...
  • Page 21 dummyhead dummyhead SERVICE INFORMATION 1.0 – 2.0 mm (0.04 – 0.08) 30° AIR VENT TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL FILTER DRAIN TUBE FUEL TUBE 1.0 – 2.0 mm (0.04 – 0.08) FUEL TUBE FUEL FILTER 30° 30° RETURN TUBE...
  • Page 22 dummyhead dummyhead SERVICE INFORMATION AIR VENT TUBE 1.0 – 2.0 mm AIR VENT TUBE (0.04 – 0.08) 30° FUEL TUBE FUEL TUBE DRAIN TUBE...
  • Page 23 dummyhead dummyhead MEMO...
  • Page 24: Maintenance

    dummytext 3. MAINTENANCE TOOLS ················································ 3-2 SPARK PLUG REPLACEMENT ··············· 3-5 MAINTENANCE SCHEDULE ··················· 3-2 TIMING BELT CHECK ···························· 3-6 ENGINE OIL LEVEL CHECK/CHANGE······ 3-3 IDLE SPEED CHECK/ADJUSTMENT ········ 3-6 AIR CLEANER CHECK/CLEANING/ COMBUSTION CHAMBER CLEANING······ 3-7 REPLACEMENT ···································· 3-4 VALVE CLEARANCE CHECK/ SPARK PLUG CHECK/ADJUSTMENT ······...
  • Page 25: Tools

    dummyhead dummyhead MAINTENANCE TOOLS MAINTENANCE Valve adjuster wrench, 3 mm Cleaning brush 07908-KE90200 07998-VA20100 MAINTENANCE SCHEDULE ITEM Perform at every indicated month REGULAR SERVICE PERIOD (1) or operating hour interval, Refer Every Every Every First whichever comes first. Each 3 months 6 months year month or...
  • Page 26: Engine Oil Level Check/Change

    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 in 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 27: Cover

    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 28: Spark Plug Check/Adjustment

    dummyhead dummyhead MAINTENANCE SPARK PLUG CHECK/ADJUSTMENT Remove the spark plug (page 3-5). 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 29: Timing Belt Check

    dummyhead dummyhead MAINTENANCE TIMING BELT CHECK Check the timing belt [1] for deterioration or cracks. Replace if necessary (page 14-4). IDLE SPEED CHECK/ADJUSTMENT Use a tachometer with graduations of 50 min (rpm) or FLOATLESS TYPE: smaller that will accurately indicate a 50 min (rpm) change.
  • Page 30: Combustion Chamber Cleaning

    dummyhead dummyhead MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the piston/connecting rod assembly (page 14- Prepare a cylinder of a thick paper or equivalent material [1], which diameter is as large as to fit against the inner wall of the cylinder, and insert the paper into the cylinder.
  • Page 31 dummyhead dummyhead MAINTENANCE Insert a feeler gauge [1] between the valve adjust screw [2] and valve stem [3] to measure the valve clearance. VALVE CLEARANCE: IN: 0.15 ± 0.04 mm (0.006 ± 0.002 in) EX: 0.20 ± 0.04 mm (0.008 ± 0.002 in) If adjustment is necessary, proceed as follows.
  • Page 32 dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING ··············· 4-2 TROUBLESHOOTING ···························· 4-2...
  • Page 33: Ignition System

    dummyhead dummyhead TROUBLESHOOTING BEFORE TROUBLESHOOTING TROUBLESHOOTING • Check that the electrical 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 Cannot be cranked Remove the recoil starter (page 10-2) and check...
  • Page 34 dummyhead dummyhead TROUBLESHOOTING ENGINE SPEED DOES NOT INCREASE OR STABILIZE Clogged Check the air cleaner element (page 3-5). Clean the air cleaner element (page 3-5). Clean Abnormal Check the spark plug (page 3-6). Inspect the spark plug and adjust the spark plug gap.
  • Page 35 dummyhead dummyhead TROUBLESHOOTING ENGINE DOES NOT STOP WHEN ENGINE STOP SWITCH IS TURNED OFF (Applicable types) Replace the engine stop switch (page 11-3). Check the engine stop switch (page 11-4). Abnormal Normal Check the wire harness connecting the engine Replace the engine wire harness. No continuity stop switch and the ignition coil for open or short circuit.
  • Page 36: Wiring Diagram

    dummytext 15. WIRING DIAGRAM HOW TO READ A WIRING DIAGRAM & WIRING DIAGRAMS ···························· 15-4 RELATED INFORMATION····················· 15-2 15-1...
  • Page 37 dummyhead dummyhead WIRING DIAGRAM HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION WIRING DIAGRAM The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained in this section. HOW TO READ CONNECTOR DRAWINGS Connector drawings show the terminal arrangement, terminal No., number of pins, and the shape of terminal (male or female).
  • Page 38 dummyhead dummyhead WIRING DIAGRAM HOW TO READ WIRING DIAGRAM SYMBOL OF TERMINAL It shows the shape of each terminal to identify whether it is a male or female terminal. TERMINAL No. INVERTER UNIT M A I N ( U ) M A I N ( V ) A C 1 A C 2...
  • Page 39 dummyhead dummyhead WIRING DIAGRAM WIRING DIAGRAMS ENGINE STOP SWITCH TYPE UNIT ENGINE STOP SPARK SWITCH PLUG IGNITION COIL Bl: Black OIL LEVEL SWITCH AND OIL ALERT UNIT TYPE UNIT OIL LEVEL SWITCH SPARK IGNITION PLUG OIL ALERT ENGINE STOP COIL UNIT SWITCH Bl: Black...
  • Page 40: Index

    INDEX dummytext INDEX AIR CLEANER CHECK/CLEANING/REPLACEMENT···3-4 IGNITION SYSTEM TROUBLESHOOTING ················9-2 AIR CLEANER REMOVAL/INSTALLATION ················6-3 LUBRICATION & SEAL POINTS ······························2-4 BEFORE TROUBLESHOOTING ······························4-2 MAINTENANCE SCHEDULE···································3-2 BREATHER COVER DISASSEMBLY/ASSEMBLY····· 6-10 MAINTENANCE STANDARDS ································2-2 CAM PULLEY REMOVAL/INSTALLATION ··············· 13-3 METERING LEVER ADJUSTMENT CAM PULLEY/CAM PULLEY SHAFT/ROCKER ARM/ (FLOATLESS TYPE)··············································6-8 ROCKER ARM SHAFT INSPECTION ·····················...

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