Honda GX120K1 Manual
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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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gx120k1_gx160k1_gx200

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Summary of Contents for Honda GX120K1

  • 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 dummyhead dummyhead gx120k1_gx160k1_gx200 How to use this manual SPECIFICATIONS SERVICE INFORMATION MAINTENANCE AIR CLEANER/MUFFLER RECOIL STARTER/FAN COVER CARBURETOR FUEL TANK/GOVERNOR ARM/CONTROL BASE FLYWHEEL/IGNITION COIL/ STARTER MOTOR CYLINDER HEAD/VALVES CRANKSHAFT COVER/ CRANKSHAFT/PISTON GOVERNOR/OIL LEVEL SWITCH REDUCTION UNIT OPTIONAL PARTS INDEX...
  • Page 3 How to use this manual INTRODUCTION This manual covers the service and repair procedures for the Honda GX120K1, GX160K1, and GX200 engines. 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 dummyhead dummyhead gx120k1_gx160k1_gx200 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 5. P.T.O. DIMENSIONAL DRAWINGS ..1-20 3. PERFORMANCE CURVES ... . 1-8 1. SPECIFICATIONS Model GX120K1 Type 4-stroke, overhead valve single cylinder, inclined by 25° Total displacement 118 cm (7.2 cu in)
  • Page 7 SPECIFICATIONS GX120K1•GX160K1•GX200 Model GX160K1 Type 4-stroke, overhead valve single cylinder, inclined by 25° Total displacement 163 cm (9.9 cu in) Bore and stroke 68 x 45 mm (2.7 x 1.8 in) 3.6 kW (4.8 HP)/3,600 min-1(rpm) Net power 10.3 N•m (7.61 ft•lb)/2,500 min-1(rpm)
  • Page 8 GX120K1•GX160K1•GX200 SPECIFICATIONS Model GX200 Type 4-stroke, overhead valve, single cylinder, inclined by 25° Total displacement 196 cm (12.0 cu in) Bore and stroke 68 x 45 mm (2.7 x 2.1 in) 4.1 kW (5.5 HP)/3,600 min-1(rpm) Net power 12.4 N•m (9.1 ft•lb)/2,500 min-1(rpm)
  • Page 9 SPECIFICATIONS GX120K1•GX160K1•GX200 Model GX120U1 GX120UT1 GX160U1 GX160UT1 GX200U GX200UT Description code GCAHK GCAGT GCACK GCAFT GCAJK GCAHT Type 4-stroke, overhead valve, single cylinder, inclined by 25° Displacement 119 cm (7.2 cu-in) 163 cm (9.9 cu-in) 196 cm (12.0 cu-in) 60.0 x 42.0 mm...
  • Page 10 GX120K1•GX160K1•GX200 SPECIFICATIONS 2. DIMENSIONS AND WEIGHTS GX120K1 *Type Cyclone Rammer Reduction Item Length (in) (11.7) (12.0) (12.0) (14.6) (12.2) (12.0) (12.0) (12.4) (15.1) (12.0) (12.3) Width (in) (13.4) (13.4) (13.4) (13.4) (13.4) (13.4) (13.4) (13.4) (13.4) (16.1) (13.0) Height (in) (12.5)
  • Page 11 SPECIFICATIONS GX120K1•GX160K1•GX200 GX160K1 *Type Cyclone Rammer Reduction Item Length (in) (12.0) (12.3) (13.5) (14.8) (12.5) (12.3) (12.3) (12.7) (15.4) (12.3) (12.6) Width (in) (14.3) (14.3) (14.3) (14.3) (14.3) (14.3) (14.3) (14.3) (14.3) (16.8) (13.5) Height (in) (13.2) (13.2) (13.2) (13.2)
  • Page 12 GX120K1•GX160K1•GX200 SPECIFICATIONS GX200 *Type Item Length (in) (12.3) (12.6) (15.2) (15.2) (15.7) (12.8) (12.6) (12.6) (13.0) (12.3) (12.6) (12.6) Width (in) (14.8) (14.8) (14.8) (14.8) (14.8) (14.8) (14.8) (14.8) (14.8) (14.8) (16.9) (15.6) Height (in) (13.2) (13.2) (13.2) (13.2) (13.2)
  • Page 13 SPECIFICATIONS GX120K1•GX160K1•GX200 3. PERFORMANCE CURVES GX120K1 GX120U1 GX120UT1...
  • Page 14 GX120K1•GX160K1•GX200 SPECIFICATIONS GX160K1 GX160U1 GX160UT1...
  • Page 15 SPECIFICATIONS GX120K1•GX160K1•GX200 GX200 GX200U GX200UT 1-10...
  • Page 16 GX120K1•GX160K1•GX200 SPECIFICATIONS 4. DIMENSIONAL DRAWINGS GX120K1 Unit: mm (in) 1-11...
  • Page 17 SPECIFICATIONS GX120K1•GX160K1•GX200 GX120K1 (1/2 REDUCTION) Unit: mm (in) GX120K1 1/2 REDUCTION (CENTRIFUGAL CLUTCH TYPE) (3.15) GX120K1 (1/6 REDUCTION) (3.4) (3.15) (1.4) 330 (14.6) 201.2 (7.92) 156 (6.1) (3.6) (2.6) (3.6) 2-9x14 (SLOT) 2-9 (HOLE) 5 (0.2) 39.5 (1.6) 35.7 (3.0)
  • Page 18 GX120K1•GX160K1•GX200 SPECIFICATIONS GX120K1 (RAMMER TYPE) Unit: mm (in) 1-13...
  • Page 19 SPECIFICATIONS GX120K1•GX160K1•GX200 GX160K1 Unit: mm (in) 1-14...
  • Page 20 GX120K1•GX160K1•GX200 SPECIFICATIONS GX160K1 (1/2 REDUCTION) Unit: mm (in) GX160K1 1/2 REDUCTION (CENTRIFUGAL CLUTCH TYPE) 1-15...
  • Page 21 SPECIFICATIONS GX120K1•GX160K1•GX200 GX160K1 (1/6 REDUCTION) Unit: mm (in) GX160K1 (RAMMER TYPE) 1-16...
  • Page 22 GX120K1•GX160K1•GX200 SPECIFICATIONS GX200 Unit: mm (in) CRANKSHAFT P.T.O. (S, Q, U, P, T, and V-TYPES) 1-17...
  • Page 23 SPECIFICATIONS GX120K1•GX160K1•GX200 GX200 CAMSHAFT P.T.O. 1/2 REDUCTION (N-TYPE) Unit: mm (in) GX200 1/2 REDUCTION (L-TYPE) 1-18...
  • Page 24 GX120K1•GX160K1•GX200 SPECIFICATIONS GX200 1/2 REDUCTION WITH CENTRIFUGAL CLUTCH (R-TYPE) Unit: mm (in) GX200 1/6 REDUCTION (H-TYPE) 1-19...
  • Page 25 SPECIFICATIONS GX120K1•GX160K1•GX200 5. P.T.O. DIMENSIONAL DRAWINGS 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 61.7 (2.43) 3/4-16UNF-2ARH 4.73 –...
  • Page 26 GX120K1•GX160K1•GX200 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: 78 (3.1) GX160/GX200: 74 (2.9) GX120: 14.90 – 15.00 23 (0.9)
  • Page 27 SPECIFICATIONS GX120K1•GX160K1•GX200 WITH REDUCTION Unit: mm (in) H type* 45.1 (1.78) P.T.O. SHAFT 4.724 – 4.774 (0.1860 – 0.1880) 50 (2.0) 41.25 (1.624) 48 (1.9) 16.23 – 16.36 (0.639 – 0.644) 19.037 – 19.050 (0.7495 – 0.7500) REDUCTION UNIT...
  • Page 28 GX120K1•GX160K1•GX200 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) (2.0) 50 (2.0) 17.90 – 18.00 25 (1.0) (2.8) (0.705 – 0.709) P.T.O. SHAFT 21.947 – 21.980 (0.8641 – 0.8654) 89.7 (3.53)
  • Page 29 SPECIFICATIONS GX120K1•GX160K1•GX200 6. WIRING DIAGRAMS WITHOUT ELECTRIC STARTER AND OIL ALERT® WITHOUT ELECTRIC STARTER/WITH OIL ALERT GX120K1 2000001 - 2187466 GX160K1 2000001 - 2468253 GX200 1-24...
  • Page 30 GX120K1•GX160K1•GX200 SPECIFICATIONS WITH ELECTRIC STARTER/WITHOUT OIL ALERT GX120K1 2000001 - 2187466 GX160K1 2000001 - 2468253 GX200 WITH ELECTRIC STARTER AND OIL ALERT GX120K1 2000001 - 2187466 GX160K1 2000001 - 2468253 GX200 BLACK BROWN COMBINATION SWITCH CONTINUITY YELLOW ORANGE Bu BLUE...
  • Page 31 SPECIFICATIONS GX120K1•GX160K1•GX200 WITHOUT ELECTRIC START/WITH OIL ALERT GX120K1 2187467 - subsequent GX160K1 2468254 - subsequent GX200 WITH ELECTRIC START/WITH OIL ALERT GX120K1 2187467 - subsequent GX160K1 2468254 - subsequent GX200 1-26...
  • Page 32 GX120K1•GX160K1•GX200 SPECIFICATIONS 7 AMP CHARGING SYSTEM/WITHOUT ELECTRIC START/WITH OIL ALERT Charging System A 0.75 mm diameter wire (18 gauge AWG wire) or larger diameter/gauge wire must be used between the battery and sub wire harness. This same size wire must also be used between the regulator/rectifier and the frame ground.
  • Page 33 gx120k1_gx160k1_gx200 2. SERVICE INFORMATION 1. SERIAL NUMBER LOCATION ..2-2 4. TOOLS ......2-10 2.
  • Page 34 SERVICE INFORMATION GX120K1•GX160K1•GX200 1. SERIAL NUMBER LOCATION The engine serial number, the type, and the variation are stamped on the crankcase. Refer to these when ordering parts or making technical inquiries.
  • Page 35 GX120K1•GX160K1•GX200 SERVICE INFORMATION 2. MAINTENANCE STANDARDS PART ITEM GX120K1 STANDARD SERVICE LIMIT Engine Maximum speed 3,850± 150 rpm ----- ----- 3,500± 100 rpm ----- 3,750± 150 rpm (DS type) Idle speed 1,400± 150 rpm ----- ----- 1,500± 150 rpm...
  • Page 36 SERVICE INFORMATION GX120K1•GX160K1•GX200 PART ITEM GX120K1 STANDARD SERVICE LIMIT Valves Valve 0.15±0.02 mm (0.006±0.001 in) ----- clearance 0.20±0.02 mm (0.008±0.001 in) ----- Stem O.D. 5.48 mm (0.216 in) 5.318 mm (0.2094 in) 5.44 mm (0.214 in) 5.275 mm (0.2077 in) Guide I.D.
  • Page 37 GX120K1•GX160K1•GX200 SERVICE INFORMATION PART ITEM GX160K1 STANDARD SERVICE LIMIT Engine Maximum speed 3,850± 150 rpm ----- 3,800± 100 rpm 3,750± 150 rpm (DS type) Idle speed 1,400± 150 rpm ----- 1,500± 150 rpm Cylinder compression 6.0-8.5 kg/cm2 (85-121 psi) at 600 rpm...
  • Page 38 SERVICE INFORMATION GX120K1•GX160K1•GX200 PART ITEM GX160K1 STANDARD SERVICE LIMIT Valves Valve 0.15±0.02 mm (0.006±0.001 in) ----- clearance 0.20±0.02 mm (0.008±0.001 in) ----- Stem O.D. 5.48 mm (0.216 in) 5.318 mm (0.2094 in) 5.44 mm (0.214 in) 5.275 mm (0.2077 in) Guide I.D.
  • Page 39 GX120K1•GX160K1•GX200 SERVICE INFORMATION PART ITEM GX200 STANDARD SERVICE LIMIT Engine Maximum speed 3,850 ± 150 rpm ----- Idle speed 1,400 +200/-150 rpm ----- Cylinder compression ----- 353 kPa (3.6 kgf/cm , 51 psi) at 600 rpm Cylinder Sleeve I.D.
  • Page 40 SERVICE INFORMATION GX120K1•GX160K1•GX200 PART ITEM GX200 STANDARD SERVICE LIMIT Camshaft Cam height 27.7 mm (1.09 in) 27.45 mm (1.081 in) 27.75 mm (1.093 in) 27.50 mm (1.083 in) Camshaft O.D. 13.984 mm (0.5506 in) 13. 916 mm (0.5479 in) Crankcase Camshaft holder I.D.
  • Page 41 GX120K1•GX160K1•GX200 SERVICE INFORMATION 3. TORQUE VALUES Item Thread dia Torque (mm) N•m ft•lb Connecting rod bolt M7 x 1.0 Cylinder head bolt M8 x 1.25 Flywheel nut M14 x 1.5 Rocker arm pivot lock nut M6 x 0.5 Rocker arm pivot bolt M8 x 1.25...
  • Page 42 COMMERCIALLY AVAILABLE TOOLS ORDERING INFORMATION These tools are distinguished by the words (commercially available). They are not available through the 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.
  • Page 43 GX120K1•GX160K1•GX200 SERVICE INFORMATION SPECIAL TOOLS Special tools used in this manual are available through the American Honda Parts Department and can be ordered using normal American Honda Parts ordering procedures. Ref. No. Tool name Tool number Application Float level gauge...
  • Page 44 SERVICE INFORMATION GX120K1•GX160K1•GX200 5. TROUBLESHOOTING ENGINE DOES NOT CRANK • Perform the STARTER MOTOR DOES NOT OPERATE Remove the recoil starter (P. 5-1) Cannot be cranked TROUBLESHOOTING (P. 2-16) check whether the engine cranks. • Disassemble the engine and replace the faulty part(s) (P.
  • Page 45 GX120K1•GX160K1•GX200 SERVICE INFORMATION ENGINE CRANKS BUT WON’T START • Check the oil level before troubleshooting 3-3). Loosen the carburetor drain screw and No fuel Check for clogged fuel filter, fuel tank check the fuel flow from the fuel tank joint, fuel tube, or cup filter 7-1).
  • Page 46 SERVICE INFORMATION GX120K1•GX160K1•GX200 ENGINE SPEED DOES NOT INCREASE OR STABILIZE Clogged Clean or replace the air cleaner Check the air cleaner elements 4-1). elements 3-6). Clean Abnormal Adjust the spark plug gap or replace if Check the spark plug 3-9).
  • Page 47 GX120K1•GX160K1•GX200 SERVICE INFORMATION ENGINE DOES NOT STOP WHEN COMBINATION/ ENGINE STOP SWITCH IS TURNED OFF Check the engine stop switch Abnormal Replace the engine stop switch (P. 5-6) (if equipped)/combination switch /combination switch 5-7). equipped)(P. 5-8). Normal Check the wire harness connecting the...
  • Page 48 SERVICE INFORMATION GX120K1•GX160K1•GX200 STARTER MOTOR DOES NOT OPERATE Replace with a known-good battery. Abnormal If the battery runs down again, perform Check the battery condition. the CHARGING SYSTEM TROUBLESHOOTING 2-17). Normal Abnormal Check the fuse. Replace the fuse. Normal...
  • Page 49 GX120K1•GX160K1•GX200 SERVICE INFORMATION CHARGING SYSTEM Check the following before troubleshooting: - Faulty battery - Loose terminal connectors. 3 A charge coil type: Abnormal Replace the main fuse (5 A) 5-7). Check the main fuse (5 A)(P. 5-7) Normal Abnormal Check the charge/lamp coil 8-5).
  • Page 50 SERVICE INFORMATION GX120K1•GX160K1•GX200 NO OR WEAK SPARK AT SPARK PLUG Check the following before troubleshooting: - Loose connectors - Spark plug - Engine oil level Replace the oil level switch 11-2). Check the oil level switch (if equipped) Abnormal Replace the Oil Alert unit.
  • Page 51 GX120K1•GX160K1•GX200 SERVICE INFORMATION COMPRESSION TEST (mechanical decompressor engaged) 1. Remove the spark plug and install a compression gauge (commercially available) in the spark plug hole. 2. Crank the engine several times with the recoil starter, and measure the compression.
  • Page 52: Table Of Contents

    gx120k1_gx160k1_gx200 3. MAINTENANCE 1. MAINTENANCE SCHEDULE ..3-2 7. SPARK PLUG..... . . 3-9 2.
  • Page 53: Maintenance Schedule

    MAINTENANCE GX120K1•GX160K1•GX200 1. MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD Refer First Every 3 Every 6 Every Perform at every indicated month or Each month months months year operating hour interval, whichever page or 20 or 50 or 100 or 300 comes first.
  • Page 54 GX120K1•GX160K1•GX200 MAINTENANCE Schedule below applies to GX120K1: GC01-3993726 and subsequent. REGULAR SERVICE PERIOD Refer First Every 3 Every 6 Every Perform at every indicated month or Each month months months year operating hour interval, whichever page or 20 or 50...
  • Page 55: Engine Oil

    CC, CD. Motor oils classified SG, SF, CC, CD will show this designation on the container. GX120K1: GC01-3993726 and subsequent use SJ or higher. SAE 10W-30 is recommended for general, all-temperature use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range.
  • Page 56: Reduction Case Oil

    GX120K1•GX160K1•GX200 MAINTENANCE 3. REDUCTION CASE OIL 1/2 REDUCTION (Centrifugal Clutch Type): 1. Remove the oil filler cap/dipstick and drain bolt. Allow the oil to drain completely. 2. Reinstall the drain bolt, and tighten to the specified torque. TORQUE: 18 N•m (13 ft•lb) 1.
  • Page 57: Oil Alert

    MAINTENANCE GX120K1•GX160K1•GX200 4. OIL ALERT Note: For convenience, perform this test in conjunction with the engine oil change. 1. With the engine running, disconnect the yellow lead from the engine switch, and ground the lead against the engine. The Oil Alert lamp should flash, and the engine should stop.
  • Page 58 GX120K1•GX160K1•GX200 MAINTENANCE • If you are using a container filled with solvent, immerse the filter and agitate it. Do not use a brush to clean the filter. 5. Shake excess solvent out the filter, and use compressed air (30 PSI or less) to dry it further. Direct the compressed air at the inside of the filter.
  • Page 59: Valve Clearance

    MAINTENANCE GX120K1•GX160K1•GX200 Rammer type: 1. Move and release the retaining clip, and remove the air cleaner cover. Remove the air filter elements and separate them. Carefully check both elements for holes or tears and replace it if damaged. 2. Paper element: Tap the element lightly several times on a hard surface to remove excess dirt or blow compressed air lightly (30 PSI or less) through the filter from the inside out.
  • Page 60: Maintenance

    GX120K1•GX160K1•GX200 MAINTENANCE 3. Insert a feeler gauge between the rocker arm and valve to measure valve clearance. 0.15±0.02 mm (0.006±0.001 in) Standard valve clearance 0.20±0.02 mm (0.008±0.001 in) 4. If adjustment is necessary, proceed as follows: a. Hold the rocker arm pivot and loosen the rocker arm pivot lock nut.
  • Page 61: Carburetor

    Maximum speed 3,850± 150 rpm (GX160K1 Rammer type) 3,800± 100 rpm (DS type) 3,750± 150 rpm (GX120K1 Rammer type) 3,500± 100 rpm 3-10...
  • Page 62: Sediment Cup

    GX120K1•GX160K1•GX200 MAINTENANCE 10. SEDIMENT CUP 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 63: Fuel Filter

    MAINTENANCE GX120K1•GX160K1•GX200 12. 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 64 gx120k1_gx160k1_gx200 4. AIR CLEANER/MUFFLER 1. AIR CLEANER ..... . 4-1 2. MUFFLER......4-5 1.
  • Page 65 AIR CLEANER/MUFFLER GX120K1•GX160K1•GX200 SEMI-DRY TYPE:AAAAAAAAAAAAAAAAAAAAAAAADUAL ELEMENT TYPE: P. 3-6 P. 3-6 P. 3-6...
  • Page 66 GX120K1•GX160K1•GX200 AIR CLEANER/MUFFLER OIL BATH TYPE: AAAAAAAAAAAAAAAAAAAAAAACYCLONE TYPE: P. 3-6 P. 3-6 P. 3-6...
  • Page 67 AIR CLEANER/MUFFLER GX120K1•GX160K1•GX200 Rammer type P. 3-6 P. 3-6...
  • Page 68 GX120K1•GX160K1•GX200 AIR CLEANER/MUFFLER 2. MUFFLER DISASSEMBLY/REASSEMBLY P. 3-11...
  • Page 69 AIR CLEANER/MUFFLER GX120K1•GX160K1•GX200 Rammer type:...
  • Page 70 EQUIPPED TYPE) ....5-7 1. RECOIL STARTER WARNING • Wear gloves and eye protection. • During assembly, take care not to allow return spring to come out. DISASSEMBLY/REASSEMBLY GX120K1 • GX160K1...
  • Page 71 RECOIL STARTER/FAN COVER GX120K1•GX160K1•GX200 GX200...
  • Page 72 GX120K1•GX160K1•GX200 RECOIL STARTER/FAN COVER RECOIL STARTER DISASSEMBLY/REASSEMBLY (CONTINUED) RECOIL STARTER ASSEMBLY 1. Insert the hook on the outer side of the spring into the groove inside the reel. WARNING • Wear gloves and eye protection. • During assembly, take care not to allow return spring to...
  • Page 73 RECOIL STARTER/FAN COVER GX120K1•GX160K1•GX200 2. Pass the starter rope through the starter reel and tie it as shown. Wind the starter rope around the starter reel in direction of arrow. Leave approximately 30 cm (11.8 in) of the starter rope outside of the starter reel.
  • Page 74 GX120K1•GX160K1•GX200 RECOIL STARTER/FAN COVER 6. Install the ratchet with the spring and reel cover. Tighten the reel cover bolt. 7. Check the operation of the ratchet by pulling the starter rope several times.
  • Page 75 RECOIL STARTER/FAN COVER GX120K1•GX160K1•GX200 2. FAN COVER DISASSEMBLY/REASSEMBLY P. 5-7 P. 5-8 P. 5-8 P. 5-8...
  • Page 76 GX120K1•GX160K1•GX200 RECOIL STARTER/FAN COVER 3. CONTROL BOX (STARTER MOTOR EQUIPPED TYPE) DISASSEMBLY/REASSEMBLY P. 5-9 P. 5-8 P. 5-8 P. 5-9...
  • Page 77 RECOIL STARTER/FAN COVER GX120K1•GX160K1•GX200 INSPECTION ENGINE SWITCH (Without Oil Alert) Turn the switch, and check the continuity between the wire and the fan cover with an ohmmeter. Switch position Continuity Replace the switch if the correct continuity is not obtained.
  • Page 78 GX120K1•GX160K1•GX200 RECOIL STARTER/FAN COVER 2. OIL ALERT UNIT Connect a battery (1.5 to 6V) to the Oil Alert unit leads, as shown.The Oil Alert lamp should light.Replace the alert unit if the lamp does not light. Black/Red lead to battery (+)
  • Page 79 RECOIL STARTER/FAN COVER GX120K1•GX160K1•GX200 REGULATOR/RECTIFIER (7 A charging system) Using a digital multimeter in the CDI R x 1 range, or an analog multimeter, measure the resistance between the terminals as shown. Values are given as K 1 - 200 1 - 200 0.5 - 100...
  • Page 80 gx120k1_gx160k1_gx200 6. CARBURETOR 1. CARBURETOR ..............6-2...
  • Page 81 CARBURETOR GX120K1•GX160K1•GX200 1. CARBURETOR REMOVAL/INSTALLATION...
  • Page 82 GX120K1•GX160K1•GX200 CARBURETOR Rammer type...
  • Page 83 CARBURETOR GX120K1•GX160K1•GX200 DISASSEMBLY/REASSEMBLY WARNING • Remove the drain bolt and drain the carburetor before disassembling. Fuel vapor or spilled fuel may ignite. NOTICE Tampering is violation of Federal and California Law. P. 3-10 P. 6-8 P. 3-10 P. 3-11...
  • Page 84 GX120K1•GX160K1•GX200 CARBURETOR Rammer type NOTICE Tampering is violation of Federal and California Law. P. 3-10 P. 3-1...
  • Page 85 CARBURETOR GX120K1•GX160K1•GX200 LIMITER CAP MODELS ONLY NOTICE Tampering is violation of Federal and California Law. DISASSEMBLY/ASSEMBLY WARNING • Remove the drain bolt and drain the carburetor before disassembling. Fuel vapor or spilled fuel may ignite. P. 6-8 P. 3-10 P.
  • Page 86 GX120K1•GX160K1•GX200 CARBURETOR PILOT SCREW AND LIMITER CAP 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. A new pilot screw and limiter cap must be installed.
  • Page 87 O-rings, floats and float valve seats. Check the container for instructions. If you are in doubt, do not use these prod- ucts to clean Honda carburetors. • High air pressure may damage the carburetor. Use low pressure settings when cleaning passages and ports.
  • Page 88 gx120k1_gx160k1_gx200 7. FUEL TANK/GOVERNOR ARM/CONTROL BASE 1. FUEL TANK, CONTROL BASE ..7-1 4. EVAPORATIVE EMISSION CONTROL 2. GOVERNOR ARM ....7-3 SYSTEM .
  • Page 89: Fuel Tank/Governor Arm/Control Base

    FUEL TANK/GOVERNOR ARM/CONTROL BASE GX120K1•GX160K1•GX200 FUEL TANK FUEL CAPACITY: GX120K1: (0.52 US gal, 0.43 Imp gal) GX160K1/ GX200: (0.81 US gal, 0.68 Imp gal) REASSEMBLY: Wash to remove the sediment and dry thoroughly before installing. FUEL FILTER 2.0 N•m (0.2 kg-m, 1.4 ft-lb) CLEANING: P.
  • Page 90: Governor Arm

    GX120K1•GX160K1•GX200 FUEL TANK/GOVERNOR ARM/CONTROL BASE 2. GOVERNOR ARM Adjust the governor 3-10.
  • Page 91: Fuel Tank Cap (U/Ut/U1/Ut1 Type)

    FUEL TANK/GOVERNOR ARM/CONTROL BASE GX120K1•GX160K1•GX200 3. FUEL TANK CAP (U/UT/U1/UT1 TYPE) a. DISASSEMBLY/REASSEMBLY REMOVAL: 1. Turn the fuel tank cap counterclockwise 180 degrees to unlock it and remove the cap from the fuel filler neck. 2. Turn the fuel level gauge to align the fuel tank cap tether hole with the cutout of the fuel filler neck 3.
  • Page 92: System

    GX120K1•GX160K1•GX200 FUEL TANK/GOVERNOR ARM/CONTROL BASE 4. EVAPORATIVE EMISSION CONTROL SYSTEM The U/UT/U1/UT1 engines have an EVAPORATIVE EMISSION CONTROL CANISTER built into the fuel tank cap to prevent the escape of gasoline vapors to the atmosphere. PRINCIPLE CHARGING: Gasoline vapor produced in the fuel tank at high...
  • Page 93: Fuel Filter (U/Ut/U1/Ut1 Type)

    FUEL TANK/GOVERNOR ARM/CONTROL BASE GX120K1•GX160K1•GX200 5. FUEL FILTER (U/UT/U1/UT1 TYPE) REMOVAL/INSTALLATION Remove or install the fuel filter by aligning the cutout of the fuel filter with the fuel tank cap tether, as shown. The fuel tank cap and fuel level gauge can be removed or installed...
  • Page 94 gx120k1_gx160k1_gx200 8. FLYWHEEL/IGNITION COIL/ STARTER MOTOR 1. FLYWHEEL, IGNITION COIL ... 8-1 2. STARTER MOTOR ....8-3 1.
  • Page 95 FLYWHEEL/IGNITION COIL/ STARTER MOTOR GX120K1•GX160K1•GX200 DISASSEMBLY/REASSEMBLY page 8-3. P. 8-5 P. 8-5 P. 8-4...
  • Page 96 GX120K1•GX160K1•GX200 FLYWHEEL/IGNITION COIL/ STARTER MOTOR 2. STARTER MOTOR 8-6, P. 8-7 P. 8-6 P. 8-7 P. 8-5...
  • Page 97 FLYWHEEL/IGNITION COIL/ STARTER MOTOR GX120K1•GX160K1•GX200 ADJUSTMENT IGNITION COIL AIR GAP Adjustment is required only when the ignition coil or the flywheel has been removed. 1. Loosen the ignition coil bolts. 2. Insert a long thickness gauge or a piece of paper of the proper thickness between the ignition coil and the flywheel.
  • Page 98 GX120K1•GX160K1•GX200 FLYWHEEL/IGNITION COIL/ STARTER MOTOR 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 Replace the spark plug cap if the resistance is not within the range specified.
  • Page 99 FLYWHEEL/IGNITION COIL/ STARTER MOTOR GX120K1•GX160K1•GX200 BRUSH LENGTH Measure the brush length. If brush length is less than service limit, replace the brush and brush holder plate. Standard Service limit 11.0 mm (0. 43 in) 6.0 mm (0.24 in) ARMATURE •...
  • Page 100 GX120K1•GX160K1•GX200 FLYWHEEL/IGNITION COIL/ STARTER MOTOR CONTINUITY CHECK - BRUSHES Remove the armature and check for continuity between the brushes. There should be no continuity. (One of the brush holders is insulated.) OVERRUNNING CLUTCH 1. Check the overrunning clutch for smooth axial movement.
  • Page 101 gx120k1_gx160k1_gx200 9. CYLINDER HEAD/VALVES 1. CYLINDER HEAD, VALVES ............9-2...
  • Page 102 CYLINDER HEAD/VALVES GX120K1•GX160K1•GX200 1. CYLINDER HEAD, VALVES REMOVAL/INSTALLATION 8 x 55 (4) (GX120K1) 8 x 60 (4) (GX160K1 / GX200) P. 3-9 P. 9-3...
  • Page 103 INTAKE: 22 mm (0.87 in) EXHAUST: 19 mm (0.75 in) GX160K1 / GX200 INTAKE: 25 mm (0.98 in) P. 9-4 EXHAUST: 24 mm (0.94 in) INSPECTION: P. 9-4 P. 9-6 INTAKE VALVE STEM SEAL GX120K1 (GC01-3993726 and subsequent) and GX200 engines: P. 9-4...
  • Page 104 CYLINDER HEAD/VALVES GX120K1•GX160K1•GX200 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 (1.161n) Replace the springs if they are shorter than the service limit. VALVE SEAT WIDTH Measure the valve seat width.
  • Page 105 GX120K1•GX160K1•GX200 CYLINDER HEAD/VALVES 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) 5.44 mm (0.214 in)
  • Page 106 CYLINDER HEAD/VALVES GX120K1•GX160K1•GX200 VALVE GUIDE REPLACEMENT 1. Chill the replacement valve guides in the freezer for about an hour. 2. Use a hot plate or oven to heat the cylinder head evenly to 150° C (300° F). Check the temperature with a temperature indicating stick (available at welding supply stores) or equivalent.
  • Page 107 GX120K1•GX160K1•GX200 CYLINDER HEAD/VALVES 4. Thoroughly clean the cylinder head to remove any cutting residue. 5. Check the valve guide bore; it should be straight, round and centered in the valve guide. Insert the valve and check operation. If the valve does not operate smoothly, the guide may have been bent during installation.
  • Page 108 CYLINDER HEAD/VALVES GX120K1•GX160K1•GX200 4. Use the 30°-32° and 60° cutters to narrow and adjust the valve seat so that it contacts the middle of the valve face. The 30°-32° cutter removes material from the top edge (contact too high).
  • Page 109 gx120k1_gx160k1_gx200 10. CRANKSHAFT COVER/ CRANKSHAFT/PISTON 1. CRANKCASE COVER, CRANKSHAFT, PISTON ........10-2 10-1...
  • Page 110 CRANKSHAFT COVER/ CRANKSHAFT/PISTON GX120K1•GX160K1•GX200 1. CRANKCASE COVER, CRANKSHAFT, PISTON DISASSEMBLY/REASSEMBLY P. 10-5 P. 10-2 OIL SEAL P. 10-6 GX120K1: 22 x 35 x 6 GX160K1 / GX200: P. 10-10 25 x 41 x 6 GX160K1 GX200 P. 10-4 (GX160K1 GX200) P.
  • Page 111 GX120K1•GX160K1•GX200 CRANKSHAFT COVER/ CRANKSHAFT/PISTON RAMMER TYPE 8 x 32 (6) GX160K1 / GX200 10-3...
  • Page 112 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 (GX120K1) 07746-0040100 Pilot, 25 mm (GX160K1 / GX200) 07746-0040600 TIMING GEAR/GOVERNOR DRIVE GEAR DISASSEMBLY: Mark a line on the crankshaft and a timing gear.
  • Page 113 GX120K1•GX160K1•GX200 CRANKSHAFT COVER/ CRANKSHAFT/PISTON GOVERNOR DRIVE GEAR Use a hydraulic press and the common tools shown below to press in a new governor drive gear. GX120K1 Driver, 40 mm I.D. 07746-0030100 Attachment, 30 mm I.D. 07746-0030300 GX160K1 / GX200 Driver, 40 mm I.D.
  • Page 114 CRANKSHAFT COVER/ CRANKSHAFT/PISTON GX120K1•GX160K1•GX200 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 115 GX120K1•GX160K1•GX200 CRANKSHAFT COVER/ CRANKSHAFT/PISTON PISTON SKIRT O.D. Measure and record the piston O.D. at a point 10 mm (0.4 in) from the bottom of the skirt and 90° to the piston pin bore. Standard Service limit GX120K1 59.985 mm (2.3616 in) 59.845 mm (2.3561 in)
  • Page 116 CRANKSHAFT COVER/ CRANKSHAFT/PISTON GX120K1•GX160K1•GX200 PISTON RING END GAP Standard Service limit 0.2-0.4 mm (0.008-0.016 in) 0.2-0.35 mm (0.008-0.014 in) 0.2-0.4 mm 1.0 mm (0.008-0.016 in) (0.04 in) Second 0.35-0.50 mm (0.014-0.020 in) 0.15-0.35 mm (0.006-0.014 in) Note: Use the top of the piston to position the ring horizontally in the cylinder.
  • Page 117 GX120K1•GX160K1•GX200 CRANKSHAFT COVER/ CRANKSHAFT/PISTON CONNECTING ROD SMALL END I.D. Standard Service limit GX120K1 13.005 mm (0.5120 in) 13.07 mm (0.515 in) GX160K1 18.002 mm (0.7087 in) 18.07 mm (0.711 in) GX200 CONNECTING ROD BIG END I.D. ORIGINAL SIZE Standard Service limit 26.02 mm...
  • Page 118 CRANKSHAFT COVER/ CRANKSHAFT/PISTON GX120K1•GX160K1•GX200 CONNECTING ROD BIG END SIDE CLEARANCE Standard Service limit 0.1-0.7 mm 1.1 mm (0.004-0.028 in) (0.043 in) CONNECTING ROD BIG END OIL CLEARANCE 1. Clean all oil from the crankpin and connecting rod big end surfaces.
  • Page 119 GX120K1•GX160K1•GX200 CRANKSHAFT COVER/ CRANKSHAFT/PISTON CAMSHAFT O.D. Standard Service limit 13.984 mm (0.5506 in) 13.916 mm (0.5479 in) CRANKSHAFT BEARING FREE PLAY 1. Clean the bearing in solvent and dry it. 2. Spin the bearing by hand and check for play. Replace the bearing if it is noisy or has excessive play.
  • Page 120 gx120k1_gx160k1_gx200 11. GOVERNOR/OIL LEVEL SWITCH 1. GOVERNOR , OIL LEVEL SWITCH ..........11-2 11-1...
  • Page 121 GOVERNOR/OIL LEVEL SWITCH GX120K1•GX160K1•GX200 1. GOVERNOR, OIL LEVEL SWITCH DISASSEMBLY/REASSEMBLY P. 11-3 11-2...
  • Page 122 GX120K1•GX160K1•GX200 GOVERNOR/OIL LEVEL SWITCH INSPECTION OIL LEVEL SWITCH Check continuity between the yellow and green switch leads with an ohmmeter. 1. Hold the switch in its normal position. The ohmmeter should read zero resistance. 2. Hold the switch upside down. The ohmmeter should read infinite ( ) resistance.
  • Page 123 gx120k1_gx160k1_gx200 12. REDUCTION UNIT 1. L-TYPE REDUCTION............12-2 2.
  • Page 124: L-Type Reduction

    REDUCTION UNIT GX120K1•GX160K1•GX200 1. L-TYPE REDUCTION DISASSEMBLY/REASSEMBLY 12-2...
  • Page 125: Reduction (Centrifugal Clutch Type)

    GX120K1•GX160K1•GX200 REDUCTION UNIT 2. 1/2 REDUCTION (CENTRIFUGAL CLUTCH TYPE) DISASSEMBLY/REASSEMBLY P. 12-7 P. 12-7 12-3...
  • Page 126: Camshaft P.t.o. 1/2 Reduction (N-Type)

    REDUCTION UNIT GX120K1•GX160K1•GX200 3. CAMSHAFT P.T.O. 1/2 REDUCTION (N-TYPE) 12-4...
  • Page 127: Reduction

    GX120K1•GX160K1•GX200 REDUCTION UNIT 4. 1/6 REDUCTION DISASSEMBLY/REASSEMBLY DRIVER 07746-0010500 12-5...
  • Page 128: Rammer Type

    REDUCTION UNIT GX120K1•GX160K1•GX200 5. RAMMER TYPE 6005 BALL BEARING 12-6...
  • Page 129 GX120K1•GX160K1•GX200 REDUCTION UNIT INSPECTION CLUTCH FRICTION DISC THICKNESS Standard Service limit 3.5 mm (0.14 in) 3.0 mm (0.12 in) CLUTCH PLATE WARPAGE Check clutch plate warpage on a flat plate using a feeler gauge. Service limit 0.10 mm (0.004 in)
  • Page 130 gx120k1_gx160k1_gx200 13. OPTIONAL PARTS 1. LAMP COIL KIT ....13-1 3. REMOTE CONTROL THROTTLE KIT. . . 13-2 2. REMOTE CONTROL CHOKE KIT ..13-2 1.
  • Page 131 OPTIONAL PARTS GX120K1•GX160K1•GX200 2. REMOTE CONTROL CHOKE KIT The metal plate attached to the air cleaner case (A) should be used for cable attachment. Stranded cable wire should be used, and cable ends should be used to attach the cable to the choke lever (commercially available stranded cable may be used).
  • Page 132 gx120k1_gx160k1_gx200 INDEX Cylinder I.D. inspection......10-6 Disassembly/reassembly ..... . . 9-3 Abbreviations .
  • Page 133 gx120k1_gx160k1_gx200 Reduction case ......3-5 Big end oil clearance ......10-10 Oil Alert .

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