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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 engine 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
engine.
If you need to replace a part, use genuine Honda 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 engine. Any error or oversight
while servicing an engine can result in faulty operation, damage
to the engine, 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 (eg, 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 any time 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.
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A FEW WORDS ABOUT SAFETY
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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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Summarization of Contents

A FEW WORDS ABOUT SAFETY
Service Safety Introduction
Information for qualified technicians on safe service and repair procedures.
Customer Safety Importance
Importance of proper service for customer safety and engine reliability.
Technician Safety Guidelines
Manual for professional technicians, advising confidence and training.
Key Service Safety Precautions
Key safety practices for performing service and repairs.
OUTLINE OF CHANGES
Fuel Tank Design Change
Redesigned fuel filler neck.
Fuel Tank Cap Features
Features charcoal filter, tether, and ratchet mechanism.
Piston Design Updates
Changed identification markings, ring landings for thinner rings.
Piston Ring Material and Thickness
Thickness changed, material changed from cast iron to steel.
Engine Specifications
General Engine Specifications
Key technical data including displacement, power, torque, and cooling systems.
Dimensions and Weights
Engine Overall Dimensions
Length, width, and height of the engine models.
Engine Weight Specifications
Dry weight and operating weight of the engine.
Performance Curves
Engine Performance Curves
Graphical representation of engine performance over RPM range.
Dimensional Drawings
Overall Engine Dimensional Drawings
Detailed diagrams showing engine dimensions and mounting points.
PTO Dimensional Drawings
PTO Shaft Dimensional Diagrams
Diagrams illustrating PTO shaft dimensions for different types.
Wiring Diagram
Engine Electrical Wiring Schematic
Schematic showing ignition coil, switches, and oil alert unit connections.
Importance of Proper Servicing
Proper Servicing Safety Warnings
Warnings and precautions for safe maintenance and repair procedures.
Serial Number Location
Engine Serial Number Identification
Information on where to find the engine serial number.
Service Rules
General Service Guidelines
Guidelines for using parts, tools, and performing assembly.
MAINTENANCE STANDARDS
Engine and Carburetor Maintenance Specs
Standard specifications and service limits for engine and carburetor parts.
MAINTENANCE STANDARDS (Ignition System)
Ignition Component Standards
Standard resistance and gap specifications for ignition components.
MAINTENANCE STANDARDS (Valves)
Valve Component Maintenance Specs
Specifications for valve clearance, stem O.D., and head diameter.
MAINTENANCE STANDARDS (Mechanical Components)
Mechanical Component Maintenance Specs
Specifications for connecting rod, crankshaft, and rocker arm parts.
MAINTENANCE STANDARDS (Cylinder, Piston, Rings)
Cylinder, Piston, Ring Maintenance Specs
Specifications for cylinder bore, piston O.D., and piston ring dimensions.
Cam Pulley, Crankshaft, Piston, Cylinder Block
Piston Ring Inspection Standards
Standards and service limits for piston ring width, side clearance, and end gap.
Torque Values
Fastener Torque Specifications
Torque values for various fasteners and components.
Special Tools
List of Special Tools and Uses
List of special tools with their specific uses for maintenance.
Troubleshooting Guide
Troubleshooting: Engine Hard Starting
Common causes and solutions for engine hard starting issues.
TROUBLESHOOTING (Performance Issues)
Troubleshooting: Engine Performance Issues
Diagnosing and resolving issues with engine speed and performance.
Hard Starting Diagnosis
Diagnosing Hard Starting Issues
Step-by-step guide to diagnose and fix hard starting problems.
Cylinder Compression Check Procedure
Procedure for measuring cylinder compression.
Service Information
Troubleshooting: Engine Not Starting
Diagnosing why the engine does not start with the switch ON.
Ignition System
Ignition System Troubleshooting Guide
Steps for diagnosing and resolving ignition system problems.
Spark Plug Test Method
How to perform a spark plug test for engine diagnosis.
Engine Stalls Troubleshooting
Troubleshooting: Engine Stalling Causes
Diagnosing and fixing issues where the engine starts but then stalls.
Engine Lacks Power Troubleshooting
Troubleshooting: Low Engine Power
Diagnosing and resolving issues causing the engine to lack power.
Engine Speed Troubleshooting
Troubleshooting: Engine Speed Not Increasing
Diagnosing and fixing problems where engine speed does not increase.
Harness Routing
Electrical Harness Routing Diagrams
Diagrams showing the correct routing of electrical harnesses.
Maintenance Schedule
Regular Service Interval Schedule
Table detailing maintenance intervals for engine components.
Engine Oil
Oil Alert System Operation
Testing and understanding the oil alert system operation.
Checking Engine Oil Level
Procedure for checking the engine oil level.
Oil Change
Engine Oil Change Procedure
Step-by-step guide for draining and refilling engine oil.
Air Cleaner
Air Cleaner Cleaning and Inspection
Procedure for cleaning and inspecting the air filter.
Spark Plug
Spark Plug Inspection and Cleaning
Steps for inspecting, cleaning, and replacing spark plugs.
Valve Clearance
Valve Clearance Inspection and Adjustment
Procedure for checking and adjusting valve clearance.
VALVE CLEARANCE ADJUSTMENT
Valve Clearance Adjustment Procedures
Detailed steps for adjusting valve clearance using special tools.
Carburetor
Pilot Screw and Throttle Stop Screw
Information on pilot screw limiter caps and throttle stop screw adjustment.
Governor
Governor Adjustment Procedure
Steps for adjusting the engine governor for optimal speed.
Fuel Tank and Strainer
Fuel Tank and Strainer Cleaning
Procedure for draining and cleaning the fuel tank and strainer.
Fuel Line
Fuel Line and Pump Inspection
Inspection of fuel lines and fuel pump for damage or leaks.
Spark Arrester
Spark Arrester Cleaning and Replacement
Procedure for cleaning and replacing the spark arrester.
Muffler
Muffler Removal and Installation
Steps for removing and installing the engine muffler assembly.
Recoil Starter and Fan Cover
Recoil Starter/Fan Cover R&I
Procedures for removing and installing the recoil starter and fan cover.
Starter Rope Replacement Procedure
Guide for replacing the recoil starter rope.
Starter Rope Winding and Alignment
Starter Rope Winding and Alignment
Steps for winding the starter rope and aligning the reel.
Starter Rope Knotting and Ratchet Check
Starter Rope Knotting and Ratchet Check
Procedure for knotting the starter rope and checking ratchets.
Fuel Tank
Fuel Tank R&I
Steps for removing and installing the fuel tank assembly.
FUEL SYSTEM COMPONENTS INSTALLATION
Fuel Tank Tube and Pump Connections
Connecting fuel tank tube to pump and diaphragm tube to crankcase.
Air Cleaner and Carburetor
Air Cleaner/Carburetor R&I
Procedures for removing and installing air cleaner and carburetor.
Carburetor Disassembly/Reassembly
Carburetor Body Disassembly and Reassembly
Steps for disassembling and reassembling the carburetor body.
Carburetor Inspection
Float Level Height Inspection
Measuring carburetor float level height.
Pilot Screw and Limiter Cap Replacement
Procedure for replacing pilot screw and limiter cap.
Air Cleaner Disassembly/Reassembly
Air Cleaner Case and Breather Tube Install
Installing air cleaner case and connecting breather tube.
GOVERNOR ROD, THROTTLE SPRING, CHOKE ROD
Governor Rod, Throttle Spring, Choke Rod Removal
Steps for removing governor rod, throttle return spring, and choke rod.
Governor Rod, Throttle Spring, Choke Rod Installation
Steps for installing governor rod, throttle return spring, and choke rod.
AIR CLEANER INSTALLATION
Air Cleaner Install with Wire Routing
Installing air cleaner ensuring correct stop switch wire passage.
Control Base and Governor Arm
Control Base and Governor Arm Assembly
Procedures for assembling control base and governor arm.
REMOTE THROTTLE TYPE [Q type]
Remote Throttle Control Assembly
Assembly of control lever rod and stop switch for remote throttle.
MANUAL THROTTLE ASSEMBLY
Manual Throttle Control Assembly
Assembly of control lever and stop switch for manual throttle.
Governor Spring
Governor Spring Reassembly
Steps for reassembling the governor spring.
ENGINE STOP SWITCH INSPECTION
Engine Stop Switch Inspection
Testing continuity of the engine stop switch.
Flywheel and Ignition Coil
Flywheel/Ignition Coil R&I
Procedures for removing and installing flywheel and ignition coil.
FLYWHEEL NUT REMOVAL
Flywheel Nut Removal Procedure
Procedure for removing the 14 mm special nut securing the flywheel.
Flywheel Installation Procedure
Flywheel Installation Procedure
Steps for installing the flywheel onto the crankshaft.
Ignition Coil Inspection
Ignition Coil Resistance Inspection
Measuring primary and secondary coil resistance.
IGNITION COIL AIR GAP ADJUSTMENT
Ignition Coil Air Gap Adjustment
Adjusting the air gap between ignition coil and flywheel.
Breather Valve
Breather Valve R&I
Steps for removing and installing the breather valve cover.
Cam Pulley and Rocker Arm
Cam Pulley/Rocker Arm R&I
Procedures for removing and installing cam pulley and rocker arms.
Cam Pulley
Cam Pulley Installation on Timing Belt
Installing the cam pulley onto the timing belt and crankshaft.
Rocker Arm Shaft
Rocker Arm Shaft Installation
Procedure for installing the rocker arm shaft.
CYLINDER HEAD COVER INSTALLATION
Cylinder Head Cover Installation Procedure
Steps for cleaning mating surfaces and installing the cylinder head cover.
Cam Pulley, Crankshaft, Piston, Cylinder Block
Crankcase Cover, Crankshaft, Cylinder Barrel R&I
Procedures for removing and installing crankcase, crankshaft, and cylinder barrel.
Crankcase Cover
Crankcase Cover Removal Procedure
Steps for removing the crankcase cover.
Thrust Washer
Thrust Washer and Timing Belt Installation
Installing the timing belt and noting its direction.
Piston
Piston Rings Inspection and Reassembly
Inspection and reassembly of piston rings, ensuring proper placement.
Piston Pin Clip Reassembly
Procedure for installing piston pin clips.
Piston and Connecting Rod
Piston and Connecting Rod Reassembly
Reassembling piston with connecting rod and installing into cylinder.
Valves
Valve Disassembly and Reassembly
Procedures for disassembling and reassembling engine valves.
Cylinder Barrel
Cylinder Barrel Combustion Chamber Cleaning
Cleaning the combustion chamber using a brush and paper.
Governor Assembly
Governor Assembly Disassembly and Reassembly
Steps for disassembling and reassembling the governor assembly.
Crankcase Cover Components
Crankcase Cover Component Installation
Installing oil level switch, filler extension, and bearing.
Radial Ball Bearing
Radial Ball Bearing R&I
Procedures for removing and installing the radial ball bearing.
Oil Level Switch
Oil Level Switch Inspection Procedure
Testing the oil level switch continuity with an ohmmeter.
Component Inspection
Cam Pulley and Rocker Arm Inspection
Inspection of cam pulley and rocker arm components.
Shaft and Clearance Measurements
Measuring rocker arm shaft O.D. and clearances.
Cylinder and Piston Measurements
Measuring cylinder I.D., piston O.D., and clearance.
Piston Ring Width Measurement
Measuring piston ring width.
Cam Pulley, Crankshaft, Piston, Cylinder Block
Piston Ring Inspection Standards
Standards and limits for piston ring width, side clearance, and end gap.
Piston Pin O.D.
Piston Pin O.D. Measurement
Measuring piston pin outside diameter.
Piston Pin Bore I.D.
Piston Pin Bore I.D. Measurement
Measuring piston pin bore inside diameter.
Connecting Rod Measurements
Connecting Rod Small End I.D. Measurement
Measuring connecting rod small end inside diameter.
Connecting Rod Big End I.D. Measurement
Measuring connecting rod big end inside diameter.
Crankshaft Measurements
Crankshaft Main Journal O.D. Measurement
Measuring crankshaft main journal outside diameter.
Crank Pin O.D. Measurement
Measuring crank pin outside diameter.
Connecting Rod Big End Clearances
Connecting Rod Big End Axial Clearance
Measuring axial clearance of the connecting rod big end.
Connecting Rod Big End Oil Clearance
Procedure for measuring connecting rod big end oil clearance.
Cylinder Barrel Main Journal I.D.
Cylinder Barrel Main Journal I.D. Measurement
Measuring cylinder barrel main journal inside diameter.
Crankshaft Axial Clearance
Crankshaft Axial Clearance Measurement
Measuring crankshaft axial runout and clearance.
Valve Spring Free Length
Valve Spring Free Length Measurement
Measuring the free length of valve springs.
Valve Face and Stem O.D.
Valve Face and Stem O.D. Inspection
Inspecting valve face and measuring valve stem O.D.
Valve Guide I.D.
Valve Guide I.D. Measurement
Measuring valve guide inside diameter.
Valve Seat Width
Valve Seat Width Measurement
Measuring the width of the valve seat.
Valve Seat Reconditioning
Valve Seat Reconditioning Procedure
Steps for reconditioning valve seats using a cutter.
Valve Seat Width Measurement After Reconditioning
Measuring valve seat width after reconditioning.
Built-in Timing Belt
Built-in Timing Belt Operation
Explanation of how the timing belt operates the valves and lubricates.
Fuel System
Fuel Tank Cap and Evaporative Emission Control
Function of the fuel tank cap's evaporative emission control canister.