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How to use this manual
A ew 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 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 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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Table of Contents
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Summary of Contents for Honda WT20XK1

  • 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 PUMP ENGINE REMOVAL AIR CLEANER MUFFLER RECOIL STARTER / FAN COVER CARBURETOR FUEL TANK FLYWHEEL / IGNITION COIL CYLINDER HEAD / VALVES CRANKCASE / GOVERNOR CRANKSHAFT / PISTON INDEX...
  • Page 3 How to use this manual INTRODUCTION This manual covers the service and repair procedures for the Honda WT20XK1/K2/K3/K4, WT30XK1/K2/K3, and WT40XK0/K1/K2 water pumps. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice.
  • 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 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 Bottom Dead Center...
  • Page 6: Specifications

    1. SPECIFICATIONS 1. SERIAL NUMBER LOCATION ..1-2 3. PERFORMANCE CURVES ... . 1-6 2. SPECIFICATIONS ....1-2...
  • Page 7 1. SERIAL NUMBER LOCATION The engine serial number is stamped on the crankcase. Identify the engine by serial number when ordering parts or making technical inquiries. 2. SPECIFICATIONS DIMENSIONS AND WEIGHTS WT20XK1 WT20XK2 WT20XK3 WT20XK4 Overall length 620 mm (24.4 in) Overall width 435 mm (17.1 in)
  • Page 8 WT20X • WT30X • WT40X SPECIFICATIONS PUMP WT20XK1 WT20XK2 WT20XK3 WT20XK4 Type Self-priming centrifugal pump Drive Direct coupled Suction port diameter 50 mm (2 in) Discharge port diameter 50 mm (2 in) Maximum total head lift 26m (90 ft) 30m (100 ft)
  • Page 9 SPECIFICATIONS WT20X • WT30X • WT40X ENGINE GX140 GX160K1 GX160T2 Model (WT20XK1) (WT20XK2/K3) (WT20XK4) Type 4-stroke, overhead valve single cylinder inclined by 25° Total displacement 144 cm (8.8 cu.in) 163 cm (9.9 cu.in) Bore and stroke 64 x 45 mm (2.5 x 1.77 in) 68 x 45 mm (2.68 x 1.77 in)
  • Page 10 WT20X • WT30X • WT40X SPECIFICATIONS GX240 GX240K1 GX340 GX340K1 Model (WT30XK1) (WT30XK2/K3) (WT40XK0) (WT40XK1/K2) Type 4-stroke, overhead valve single cylinder inclined by 25° Total displacement 242 cm (14.8 cu.in) 337 cm (20.6 cu.in) Bore and stroke 73 x 58 mm (2.9 x 2.3 in) 82 x 64 mm (3.2 x 2.5 in) Maximum horsepower 5.88 Kw/4,000 min...
  • Page 11 SPECIFICATIONS WT20X • WT30X • WT40X 3. PERFORMANCE CURVES WT20XK1 WT20XK2 WT20XK3 WT20XK4...
  • Page 12 WT20X • WT30X • WT40X SPECIFICATIONS WT30XK1 WT30XK2 WT30XK3...
  • Page 13 SPECIFICATIONS WT20X • WT30X • WT40X WT40XK0 WT40XK1 WT40XK2...
  • Page 14: Service Information

    2. SERVICE INFORMATION 1. MAINTENANCE STANDARDS ..2-2 3. TOOLS ......2-13 2.
  • Page 15 SERVICE INFORMATION WT20X • WT30X • WT40X 1. MAINTENANCE STANDARDS WT20XK1 WT20XK2 (with Honda GX140 engine) (with Honda GX160K1 engine) PART ITEM STANDARD SERVICE LIMIT STANDARD SERVICE LIMIT Engine Idle speed 1,400 +200 rpm ----- 1,400 rpm ----- -150 rpm ±...
  • Page 16 WT20X • WT30X • WT40X SERVICE INFORMATION WT20XK1 WT20XK2 (with Honda GX140 engine) (with Honda GX160K1 engine) PART ITEM STANDARD SERVICE LIMIT STANDARD SERVICE LIMIT Piston Ring side Top/ 0.015-0.045 mm 0.15 mm 0.015-0.045 mm 0.15 mm clearance Second/ (0.0006-0.0018 in) (0.006 in)
  • Page 17 SERVICE INFORMATION WT20X • WT30X • WT40X WT20XK3 WT20XK4 (with Honda GX160K1 engine) (with Honda GX160T2 engine) PART ITEM STANDARD SERVICE LIMIT STANDARD SERVICE LIMIT Engine Idle speed 1,400 rpm 1,400 rpm ± 150 rpm ----- +200 rpm ----- -150 rpm Cylinder compression 6.0-8.5 kg/cm...
  • Page 18 WT20X • WT30X • WT40X SERVICE INFORMATION WT20XK3 WT20XK4 (with Honda GX160K1 engine) (with Honda GX160T2 engine) PART ITEM STANDARD SERVICE LIMIT STANDARD SERVICE LIMIT Piston Ring side Top/ 0.015-0.045 mm 0.15 mm 0.060-0.095 mm 0.15 mm clearance Second/ (0.0006-0.0018 in) (0.006 in)
  • Page 19 SERVICE INFORMATION WT20X • WT30X • WT40X WT30XK1 WT30XK2 - W30XK3 (with Honda GX240 engine) (with Honda GX240K1 engine) PART ITEM STANDARD SERVICE LIMIT STANDARD SERVICE LIMIT Engine Idle speed 1,400 rpm 1,400 rpm ----- ----- ± 150 rpm ± 150 rpm Cylinder compression 6.0-8.5 kg/cm...
  • Page 20 WT20X • WT30X • WT40X SERVICE INFORMATION WT30XK1 WT30XK2 - WT30XK3 (with Honda GX240 engine) (with Honda GX240K1 engine) PART ITEM STANDARD SERVICE LIMIT STANDARD SERVICE LIMIT Piston Ring side Top/ 0.015-0.045 mm 0.15 mm 0.015-0.045 mm 0.15 mm clearance Second/ (0.0006-0.0018 in)
  • Page 21 SERVICE INFORMATION WT20X • WT30X • WT40X WT40XK0 WT40XK1/K2 (with Honda GX340 engine) (with Honda GX340K1 engine) PART ITEM STANDARD SERVICE LIMIT STANDARD SERVICE LIMIT Engine Idle speed 1,400 ± 150 rpm ----- 1,400 ± 150 rpm ----- Cylinder compression 6.0-8.5 kg/cm...
  • Page 22 WT20X • WT30X • WT40X SERVICE INFORMATION WT40XK0 WT40XK1/K2 (with Honda GX340 engine) (with Honda GX340K1 engine) PART ITEM STANDARD SERVICE LIMIT STANDARD SERVICE LIMIT Connecting Small end I.D. 20.005 mm 20.07 mm 20.005 mm 20.07 mm (0.7876 in) (0.7902 in) (0.7876 in)
  • Page 23 2. TORQUE VALUES WT20X Note: Use standard torque values for items that are not listed in this table. Torque Item Thread dia. (mm) N•m ft•lb (WT20XK1) (WT20XK2) M7 x 1.0 (Special bolt) 10.8-13.2 7.8-9.5 Connecting rod bolt (WT20XK3) (WT20XK4) M6 x 1.0 Cylinder head bolt M8 X 1.25 X 60...
  • Page 24 WT20X • WT30X • WT40X SERVICE INFORMATION WT30X Note: Use standard torque values for items that are not listed in this table. Torque Item Thread dia. (mm) N•m ft•lb Cylinder head bolt M10 x 1.25 x 80 32-38 23.1-27.5 Pivot lock nut M6 x 0.5 8-12 5.8-8.7...
  • Page 25 SERVICE INFORMATION WT20X • WT30X • WT40X WT40X Note: Use standard torque values for items that are not listed in this table. Torque Item Thread dia. (mm) N•m ft•lb Cylinder head bolt M10 x 1.25 25.3 Pivot lock nut M6 x 0.5 (Special nut) Pivot bolt M8 x 1.25 (Special bolt) 17.4...
  • Page 26 WT20X • WT30X • WT40X SERVICE INFORMATION 3. TOOLS SPECIAL TOOLS Special tools used in this manual can be ordered using normal American Honda parts ordering procedures. Float level gauge Bearing driver attachment, Bearing driver attachment 07401-0010000 32 x 35 mm...
  • Page 27 SERVICE INFORMATION WT20X • WT30X • WT40X Pilot, 30 mm Pilot, 35 mm Bearing remover, 15 mm 07746-0040700 07746-0040800 07936-KC10500 Valve guide driver Valve guide driver Weight 07942-8920000 07942-6570100 07936-371020A Valve guide driver Valve guide reamer Valve guide reamer, 5.5 mm 07742-0010200 07984-ZE2000D 07984-200000D...
  • Page 28 WT20X • WT30X • WT40X SERVICE INFORMATION COMMERCIALLY AVAILABLE TOOLS Tool name Tool number Application Digital multimeter FLU87A Electrical testing Valve seat cutter, 30 x 45 degree NWYCU128 Valve seat cutter, 60 degree NWYCU114 Solid pilot bar, 6.60 mm NWY100-6.60 Solid pilot bar, 6.62 mm NWY100-6.62 Valve seat reconditioning...
  • Page 29: Maintenance

    3. MAINTENANCE 1. MAINTENANCE SCHEDULE ..3-1 6. VALVE CLEARANCE....3-5 2. ENGINE OIL ......3-2 7.
  • Page 30 MAINTENANCE WT20X • WT30X • WT40X 2. ENGINE OIL Check the OIL ALERT® system on this page at the time the engine oil is changed. Draining can be performed rapidly and completely while the engine is still warm. 1. Remove the oil filler cap/dipstick and drain plug. Allow the oil to drain completely.
  • Page 31 WT20X • WT30X • WT40X MAINTENANCE 4. AIR CLEANER 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 3-1).
  • Page 32 4. Check the plug gap with a wire-type feeler gauge and correct the gap as necessary by bending the side electrode. WT20X 0.7-0.8 mm (0.028-0.031 in) WT30X Electrode gap WT40X 1.0-1.1 mm (0.039-0.043 in) WT20XK1 BP6ES, BPR6ES (NGK) WT30XK1 W20EP-U, W20EPR-U (ND) WT20XK2 BPR6ES (NGK) WT20XK3 W20EPR-U (ND)
  • Page 33 2. Insert a feeler gauge between the rocker arm and valve to measure valve clearance. WT20XK1 0.15 ± 0.02 mm WT20XK2 (0.006 ± 0.001 in) WT20XK3 0.20 ±...
  • Page 34 The correct setting LIMITER CAP MODELS will usually be obtained at approximately the following number of turns out from the fully closed (lightly seated) position. WT20XK1 1-5/8 turns out Pilot screw WT30XK1 2-1/2 turns out...
  • Page 35 WT20X • WT30X • WT40X MAINTENANCE 8. GOVERNOR 1. Loosen the nut on the governor arm pinch bolt, and move the governor arm to fully open the throttle. 2. Rotate the governor arm shaft as far as it will go in the same direction the governor arm moved to open the throttle.
  • Page 36 MAINTENANCE WT20X • WT30X • WT40X 10. FUEL FILTER WARNING • Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area. • After installing the fuel filter, check for leaks, and make sure the area is dry before starting the engine.
  • Page 37: Troubleshooting

    4. TROUBLESHOOTING 1. BEFORE TROUBLESHOOTING ..4-2 6. HARD STARTING OR POOR 2. PUMP DOES NOT SELF-PRIME ..4-2 PERFORMANCE ..... 4-5 7.
  • Page 38: Before Troubleshooting

    TROUBLESHOOTING WT20X • WT30X • WT40X 1. BEFORE TROUBLESHOOTING • Use a known-good battery for troubleshooting. • Check that the connectors are connected securely. PUMP VAC TESTER • Check for sufficient fresh fuel in the fuel tank. • Read the circuit tester’s operation instructions carefully, and observe the instructions during inspection. 2.
  • Page 39: Noise Or Vibration

    WT20X • WT30X • WT40X TROUBLESHOOTING 3. DISCHARGE VOLUME OR PRESSURE TOO LOW Check the engine RPM 3-7). Too low Adjust the throttle lever 3-7). Measure the length and I.D. of the Reduce the hose length and/or increase Too long or discharge hose 1-3).
  • Page 40: Self-Priming Time Too Long

    TROUBLESHOOTING WT20X • WT30X • WT40X 5. SELF-PRIMING TIME TOO LONG Check the priming water level in the Too low Add priming water to the pump 5-6). pump 5-6). Inspect the strainer for clogs or Clean or replace the strainer. Clogged or damaged damage.
  • Page 41: Hard Starting Or Poor Performance

    WT20X • WT30X • WT40X TROUBLESHOOTING 6. HARD STARTING OR POOR PERFORMANCE Make sure the fuel valve and choke lever are on. Check the fuel level. Refuel. No fuel in tank Sufficient fuel Confirm the fuel quality. If the gasoline Drain the fuel system, and refill with fresh is over 30 days old, the engine may be Stale fuel...
  • Page 42: Oil Alert System

    TROUBLESHOOTING WT20X • WT30X • WT40X 7. OIL ALERT SYSTEM SERVICE BULLETIN #3 SERVICE BULLETIN #4 Check and adjust oil level before proceeding. Check continuity between Engine does not start with the Replace the oil level oil level switch yellow and Continuity engine switch turned ON.
  • Page 43: Ignition System

    WT20X • WT30X • WT40X TROUBLESHOOTING 8. IGNITION SYSTEM SERVICE BULLETIN #1 TRANSISTORIZED IGNITION COIL Engine does not start with the engine switch Check for spark 4-8). turned ON. No spark (Oil Alert system is OK) Spark plug was faulty. Check again with a new spark Install a new spark plug Sparks...
  • Page 44: Cylinder Compression Check

    TROUBLESHOOTING WT20X • WT30X • WT40X 9. CYLINDER COMPRESSION CHECK (MECHANICAL DECOMPRESSOR ENGAGED) 1. Remove the spark plug and install a compression gauge in the spark plug hole. 2. Crank the engine several times with the recoil starter and measure compression. 6.0 - 8.5 kg/cm (85 - 121 psi) Cylinder compression...
  • Page 45: Pump

    5. PUMP 1. DISASSEMBLY/REASSEMBLY..5-2 3. IMPELLER CLEARANCE ADJUSTMENT. 5-9 2. PUMP REMOVAL....5-5 4.
  • Page 46 PUMP WT20X • WT30X • WT40X 1. DISASSEMBLY/REASSEMBLY WT20XK1/K2 WT30XK1/K2 WT40XK0/K1 1. Loosen the clamp knobs, pivot the clamps out as shown, then pull the drain cover out of the pump casing. 2. Remove the two socket bolts, and then remove the volute case from the drain cover.
  • Page 47 WT20X • WT30X • WT40X PUMP WT20XK3 SERVICE BULLETIN #6 WT20XK4...
  • Page 48 PUMP WT20X • WT30X • WT40X WT30XK2 WT30XK3 SERVICE BULLETIN #6 WT40XK2...
  • Page 49 WT20XK1/K2 • WT30XK1/K2: 8 x 50 mm SEALING BOLT (4) 20-28 N•m (14.5-20.2 ft-lb) WT40XK0/K1: WT20XK1/K2: 8 mm WASHER NUT (2) WT20XK1/K2: 8 x 20 mm (2) 3/8-16 UNC (INCH BOLT) (4) WT30XK1/K2: 10 mm WASHER NUT (2) WT30XK1/K2: 10 x 25 mm (2) 35 N•m (25.3 ft-lb)
  • Page 50 PUMP WT20X • WT30X • WT40X FILLER CAP Priming water capacity: WT20X: 6.0 L (1.58 US gal, 1.32 Imp. gal) WT30X: 10.0 L (2.64 US gal, 2.20 Imp. gal) WT40X: 14.0 L (3.70 US gal, 3.08 Imp. gal) WT20X: 8 x 25 mm (3) WT30X: 10 x 30 mm (3) WT40X: 10 x 30 mm (4) 6-8 N•m...
  • Page 51 WT20X • WT30X • WT40X PUMP WT20XK3/K4 WT30XK3 WT40XK2 (P. 5-2) DISASSEMBLY: DISASSEMBLY: • To remove, pry the edge of the mechanical seal with a small screwdriver taking care not to damage the pump case. • Do not reuse. (P. 5-9) REASSEMBLY: •...
  • Page 52 PUMP WT20X • WT30X • WT40X...
  • Page 53 WT20X • WT30X • WT40X PUMP 3. IMPELLER CLEARANCE ADJUSTMENT WT20XK1/K2 WT30XK1/K2 WT40XK0/K1 1. Remove the drain cover 5-2). 2. Put a piece of modeling clay on the impeller as shown. 3. Install the drain cover, and tighten the clamp knobs securely.
  • Page 54 PUMP WT20X • WT30X • WT40X 4. PUMP PLACEMENT For best pump performance, the pump must be as close to the water level as possible, and the suction and discharge hoses must not be longer than necessary. This will enable the pump to produce the greatest output with the least self-priming time. As head (pumping height) increases, pump output decreases.
  • Page 55: Engine Removal

    6. ENGINE REMOVAL 1. ENGINE REMOVAL ............6-2...
  • Page 56 ENGINE REMOVAL WT20X • WT30X • WT40X 1. ENGINE REMOVAL 1. Remove the pump 5-2). 2. Remove the two washer nuts, then remove the engine. WT20X: 8 x 35 mm (2) WT20X: 8 mm WASHER NUT (4) WT30X WT40X: WT30X 10 x 40 mm (2) WT40X: 10 mm WASHER NUT (4)
  • Page 57: Air Cleaner

    7. AIR CLEANER 1. DISASSEMBLY/REASSEMBLY........... 7-2...
  • Page 58 AIR CLEANER WT20X • WT30X • WT40X 1. DISASSEMBLY/REASSEMBLY WT30X WT40X WT20X (P. 3-3) CLEANING: (P. 3-3) CLEANING:...
  • Page 59: Muffler

    8. MUFFLER 1. DISASSEMBLY/REASSEMBLY...........8-2...
  • Page 60 MUFFLER WT20X • WT30X • WT40X 1. DISASSEMBLY/REASSEMBLY WT20X 1. Loosen the 8mm nuts (2) and detach the muffler. 2. Detach the 5 mm self-tapping screw and remove the muffler protector.
  • Page 61 WT20X • WT30X • WT40X MUFFLER WT30X WT40X...
  • Page 62: Recoil Starter / Fan Cover

    9. RECOIL STARTER / FAN COVER 1. RECOIL STARTER....9-2 3. ENGINE SWITCH ....9-8 2.
  • Page 63 RECOIL STARTER / FAN COVER WT20X • WT30X • WT40X 1. RECOIL STARTER DISASSEMBLY/REASSEMBLY WT20XK1...
  • Page 64 WT20X • WT30X • WT40X RECOIL STARTER / FAN COVER WT20XK2 WT20XK3 WT20XK4 RETURN SPRING:...
  • Page 65 RECOIL STARTER / FAN COVER WT20X • WT30X • WT40X WT30XK1 WT40XK0...
  • Page 66 WT20X • WT30X • WT40X RECOIL STARTER / FAN COVER WT30XK2 WT30XK3 WT40XK1 WT40XK2 RETURN SPRING:...
  • Page 67 RECOIL STARTER / FAN COVER WT20X • WT30X • WT40X RECOIL STARTER ASSEMBLY 1. Feed the end of the rope through the hole in the starter reel, and tie a knot in the rope end. Wind the rope onto the reel in the direction shown, and wedge the rope end in the notch on the edge of the reel.
  • Page 68 WT20X • WT30X • WT40X RECOIL STARTER / FAN COVER 5. Rotate the reel 3 full turns in the direction of the arrow. 6. Check the operation of the ratchet by pulling the starter rope out several times.
  • Page 69 RECOIL STARTER / FAN COVER WT20X • WT30X • WT40X 2. FAN COVER 3. ENGINE SWITCH (P. 9-9) INSPECTION: (P. 9-9) INSPECTION:...
  • Page 70 WT20X • WT30X • WT40X RECOIL STARTER / FAN COVER INSPECTION ENGINE SWITCH Check the continuity between the engine switch black wire and the switch body with an ohmmeter. Switch position Continuity Connect a 6V battery to the black and yellow wires of the engine switch, and check that the warning lamp lights up.
  • Page 71: Carburetor

    10. CARBURETOR 1. REMOVAL/INSTALLATION ... 10-2 3. FLOAT LEVEL HEIGHT ....10-7 2. DISASSEMBLY/REASSEMBLY..10-3 10-1...
  • Page 72 CARBURETOR WT20X • WT30X • WT40X 1. REMOVAL/INSTALLATION WARNING Remove the fuel drain bolt and drain the carburetor before removing it from the engine. Fuel vapor or spilled fuel may ignite. WT20X WT30X WT40X 10-2...
  • Page 73 WT20X • WT30X • WT40X CARBURETOR 2. DISASSEMBLY/REASSEMBLY WT20XK1 WT30XK1 WT40XK0 WARNING Remove the fuel drain bolt and drain the carburetor before removing it from the engine. Fuel vapor or spilled fuel may ignite. (P. 3-6) ADJUSTMENT: (P. 3-6) ADJUSTMENT: WARNING...
  • Page 74 CARBURETOR WT20X • WT30X • WT40X WT20XK2/K3/K4 WT30XK2/K3 WT40XK1/K2 (P. 3-6) ADJUSTMENT: (P. 10-6) REPLACEMENT: 10-4...
  • Page 75 WT20X • WT30X • WT40X CARBURETOR LIMITER CAP MODELS ONLY NOTICE Tampering is violation of Federal and California Law. (P. 3-6) ADJUSTMENT: (P. 3-6) ADJUSTMENT: (P. 10-6) REPLACEMENT: (P. 3-7) CLEANING: 10-5...
  • Page 76 CARBURETOR WT20X • WT30X • WT40X PILOT SCREW WITH LIMITER CAP The limiter cap is an emission-related part. Leave the pilot screw and limiter cap in place during carburetor cleaning. Remove only if necessary for carburetor repair. Removal of the limiter cap requires breaking the pilot screw.
  • Page 77 If the height is out of specification, replace the float. WT20XK1 12.2-15.2 mm (0.48-0.60 in) WT20XK2 WT20XK3 13.7 mm (0.54 in)
  • Page 78: Fuel Tank

    11. FUEL TANK 1. DISASSEMBLY/REASSEMBLY..........11-2 11-1...
  • Page 79 1. DISASSEMBLY/REASSEMBLY WT20X WARNING • Before disassembly, drain the tank and fuel line completely. • Fuel vapor or spilled fuel may ignite. FUEL TANK Fuel tank capacity: WT20XK1 3.6 L WT20XK2 (0.95 US gal) WT20XK3 3.1 L WT20XK4 (0.82 US gal)
  • Page 80 WT20X • WT30X • WT40X FUEL TANK WT30X WT40X WARNING • Before disassembly, drain the tank and fuel line completely. • Fuel vapor or spilled fuel may ignite. FUEL TANK Fuel tank capacity: WT30X 6.0 L (1.59 US gal) WT40X 6.5 L (1.72 US gal) REASSEMBLY: Wash the tank to remove...
  • Page 81: Flywheel / Ignition Coil

    12. FLYWHEEL / IGNITION COIL 1. DISASSEMBLY/REASSEMBLY..12-2 3. C.D.I. IGNITION COIL ....12-5 2. TRANSISTORIZED IGNITION COIL ..12-4 4.
  • Page 82: Disassembly/Reassembly

    FLYWHEEL / IGNITION COIL WT20X • WT30X • WT40X 1. DISASSEMBLY/REASSEMBLY WT20X IGNITION COIL Inspection and adjustment: (P. 12-4) Transistorized ignition: (P. 12-5) C.D.I. ignition: 12-2...
  • Page 83 WT20X • WT30X • WT40X FLYWHEEL / IGNITION COIL WT30X WT40X BLACK WIRE REASSEMBLY: WT40X: WT20X/ WT30X: Insert the ignition coil black wire onto the crankcase using the clamps. WT40X: Insert the ignition coil black wire securely into the ribs on the crankcase.
  • Page 84: Transistorized Ignition Coil

    PRIMARY SIDE Measure the resistance of the primary coil by attaching one ohm- meter lead to the ignition coil's primary (black) lead while touching the other test lead to the iron core. WT20XK1 0.7 - 0.9 Ω WT30XK1 WT20XK2 Primary side...
  • Page 85 WT20X • WT30X • WT40X FLYWHEEL / IGNITION COIL 3. C.D.I. IGNITION COIL PRIMARY SIDE Remove the fan cover. Disconnect the ignition coil connector. Measure the resistance of the primary coil by attaching one ohmmeter probe to the ignition coil wire terminal and the other at the iron core.
  • Page 86: Air Gap Adjustment

    FLYWHEEL / IGNITION COIL WT20X • WT30X • WT40X 4. AIR GAP ADJUSTMENT 1. Loosen the ignition coil mounting bolts. 2. Insert a thickness gauge or a piece of paper of the proper thickness between the transistorized ignition coil and the flywheel.
  • Page 87: Cylinder Head / Valves

    13. CYLINDER HEAD / VALVES 1. DISASSEMBLY/REASSEMBLY..13-2 3. VALVE GUIDE REPLACEMENT ..13-5 2. INSPECTION ..... . 13-4 4.
  • Page 88 CYLINDER HEAD / VALVES WT20X • WT30X • WT40X 1. DISASSEMBLY/REASSEMBLY SERVICE BULLETIN #1 WT20X: WT30X/WT40X: M8 x 1.25 mm M10 x 1.25 mm 22 - 26 N•m (15.9 - 18.8 ft-lb) 35 N•m (25.3 ft-lb) SPARK PLUG adjustment:(P. 3-4) Cleaning and WT30X/WT40X ONLY: (Exhaust valve only) INTAKE VALVE...
  • Page 89 WT20X • WT30X • WT40X CYLINDER HEAD / VALVES WT20XK4 WT30XK2/K3 WT40XK1/K2 VALVE ROTATOR (WT30X / WT40X only) INTAKE VALVE REASSEMBLY: Do not interchange with the exhaust valve. The intake valve is larger than the exhaust valve. 13-3...
  • Page 90 (0.039 in) WT30X 0.06-0.087 mm 0.12 mm WT40X (0.0024-0.0034 in) (0.047 in) VALVE SPRING FREE LENGTH Standard Service limit WT20XK1 34.0 mm (1.339 in) 32.5 mm (1.28 in) WT20XK2 30.5 mm 29.5 mm WT20XK3 (1.20 in) (1.16 in) WT20XK4 WT30X 39.0 mm...
  • Page 91 3. Remove the heated cylinder head from the hot plate and support it with wooden blocks. Drive the valve guides out of the head from the combustion chamber side. TOOLS: VALVE GUIDE DRIVER WT20XK1/K2/K3: 07942-8920000 WT30XK1, WT40XK0: 07942-6570100 WT20XK4,...
  • Page 92 CYLINDER HEAD / VALVES WT20X • WT30X • WT40X VALVE SEAT REAMING For best results, be sure the cylinder head is at room temperature before reaming the valve guides. 1. Coat the reamer and valve guide with cutting oil. 2. Rotate the reamer clockwise through the valve guide the full length of the reamer.
  • Page 93 WT20X • WT30X • WT40X CYLINDER HEAD / VALVES 4. VALVE SEAT RECONDITIONING 1. Thoroughly clean the combustion chamber and valve seats to remove carbon deposits Apply a light coat of Prussian Blue or erasable felt-tipped marker ink to the valve face. 2.
  • Page 94: Crankcase / Governor

    14. CRANKCASE / GOVERNOR 1. DISASSEMBLY/REASSEMBLY..........14-2 14-1...
  • Page 95 CRANKCASE / GOVERNOR WT20X • WT30X • WT40X 1. DISASSEMBLY/REASSEMBLY 6205 BALL BEARING (WT20X) 6206 BALL BEARING (WT30X) 6207 BALL BEARING (WT40X) (P. 15-4) REMOVAL/INSTALLATION: OIL SEAL 24 x 41 x 6 (WT20X) 30 x 46 x 8 (WT30X) 35 x 52 x 8 (WT40X) REASSEMBLY When inserting the crankshaft, do not allow the lips to turn inside out.
  • Page 96: Crankshaft / Piston

    15. CRANKSHAFT / PISTON 1. DISASSEMBLY/REASSEMBLY..........15-2 15-1...
  • Page 97 6206 BALL BEARING WT40X: 6207 BALL BEARING (P. 15-4) REASSEMBLY: (P. 3-2) WT20XK1/K2/K3 10.8 - 13.2 N•m (7.8 - 9.5 ft-lb) WT20XK4 10 N•m (7 ft-lb) WT30X 12 - 16 N•m (8.7 - 11.5 ft-lb) WT40X 24 N•m (17.4 ft-lb) TIMING MARK ALIGNMENT Align the index marks on the camshaft and timing gear.
  • Page 98 WT20X • WT30X • WT40X CRANKSHAFT / PISTON CONNECTING ROD 15-3...
  • Page 99 CRANKSHAFT / PISTON WT20X • WT30X • WT40X CRANKCASE COVER BEARING (6205/6206/6207) REMOVAL: 1. Drive out the oil seal. 2. Support the crankcase cover with wood blocks. Drive out the bearing, using the following special tools: TOOLS: Driver 07749-0010000 Attachment, 37 x 40 mm 07746-0010200 Pilot, 25 mm (WT20X) 07746-0040600...
  • Page 100 WT20X • WT30X • WT40X CRANKSHAFT / PISTON CRANKSHAFT OIL SEALS (WT20X ONLY) CRANKCASE: Support the crankcase with wood blocks. Oil the circumference of the seal, and drive in the seal to the specified seating depth. Crankcase oil seal 1.5 mm (0.06 in) seating depth Use the following special tools: TOOLS:...
  • Page 101 CRANKSHAFT / PISTON WT20X • WT30X • WT40X CONNECTING ROD SMALL END I.D. Standard Service limit WT20XK1 18.002 mm 18.07 mm WT20XK2 (0.7087 in) (0.711 in) WT20XK3 18.005-18.020 mm 18.07 mm WT20XK4 (0.7089-07094 in) (0.711 in) 18.005 mm 18.07 mm WT30X (0.7089 in)
  • Page 102 Replacement connecting rods are available with standard and undersized bearing surfaces. CAMSHAFT CAM LOBE HEIGHT Standard Service limit 27.7 mm (1.091 in) 27.45 mm (1.081 in) WT20XK1 27.75 mm (1.093 in) 27.50 mm (1.083 in) 31.85-32.25 mm 31.10 mm (1.254-1.27 in) (1.224in)
  • Page 103 CRANKSHAFT / PISTON WT20X • WT30X • WT40X CAMSHAFT O.D. Standard Service limit WT20XK1 13.984 mm 13.916 mm WT20XK2 (0.551 in) (0.548 in) WT20XK3 13.966-13.984 mm 13.916 mm WT20XK4 (0.5498-0.5506 in) (0.548 in) WT30X 15.984 mm (0.6293 in) 15.92 mm (0.627 in) WT40X CAMSHAFT HOLDER I.D.
  • Page 104: Index

    INDEX Fuel filter Cleaning ........3-8 Abbreviations .
  • Page 105 Pulser coil (WT40XK0 only) ..... 12-5 Pump Valve Disassembly/reassembly ..... . . 5-2 Adjustment .

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