Table of Contents

Advertisement

Quick Links

dummyhead
dummyhead
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.
0

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the GX160UH2 and is the answer not in the manual?

Questions and answers

Summarization of Contents

SPECIFICATIONS
SERIAL NUMBER LOCATION
Location of model, type, and engine serial number stamped on the crankcase.
P.T.O. TYPE VARIATION
Table detailing P.T.O. type variations for different engine models and configurations.
DIMENSIONS AND WEIGHTS SPECIFICATIONS
Table listing overall dimensions and weights for various P.T.O. types across different engine models.
ENGINE SPECIFICATIONS
Detailed specifications for GX120, GX160, and GX200 engines, including displacement, power, torque, and ignition.
PERFORMANCE CURVES
Graphs illustrating net power and net torque curves against engine speed for GX120, GX160, and GX200 engines.
DIMENSIONAL DRAWINGS
Diagrams showing overall dimensions of GX120, GX160, and GX200 engines in various configurations.
P.T.O. DIMENSIONAL DRAWINGS
Detailed drawings of P.T.O. shaft dimensions for different types and models, with measurements in mm and inches.
SERVICE INFORMATION
MAINTENANCE STANDARDS
Table listing standard and service limit measurements for engine parts like pistons, rings, valves, and camshafts.
TORQUE VALUES
Table detailing torque specifications for various screws, bolts, and nuts used in engine assembly and maintenance.
LUBRICATION & SEAL POINTS
Identifies specific locations requiring engine oil, multi-purpose grease, or other lubricants for proper operation.
TOOLS
Lists special tools required for service procedures, including part numbers for ordering.
COMMERCIALLY AVAILABLE TOOLS
Lists common tools available commercially for specific service tasks, with tool names and applications.
HARNESS AND TUBE ROUTING
Illustrates the routing of wiring harnesses and tubes for various engine components.
MAINTENANCE
MAINTENANCE SCHEDULE
Schedule outlining recommended maintenance intervals based on usage hours or time for engine oil, air cleaner, spark plug, etc.
ENGINE OIL LEVEL CHECK/CHANGE
Procedures for checking and changing the engine oil, including recommended oil type and capacity.
REDUCTION CASE OIL LEVEL CHECK/CHANGE
Procedures for checking and changing the oil in the reduction case for gear and chain types.
AIR CLEANER CHECK/CLEANING/REPLACEMENT
Instructions for inspecting, cleaning, and replacing air cleaner elements for dual, cyclone, and low profile types.
SEDIMENT CUP CLEANING
Steps for cleaning the sediment cup and filter, including safety precautions for handling fuel.
SPARK PLUG CHECK/ADJUSTMENT
Procedure for inspecting, checking the gap, and adjusting the spark plug.
SPARK PLUG REPLACEMENT
Steps for removing and installing the spark plug, including recommended types and torque.
SPARK ARRESTER CLEANING
Instructions for cleaning the spark arrester screen for standard, silent, and low profile muffler types.
IDLE SPEED CHECK/ADJUSTMENT
Procedure for checking and adjusting the engine's idle speed using a tachometer.
VALVE CLEARANCE CHECK/ADJUSTMENT
Steps for checking and adjusting valve clearance while the engine is cold.
COMBUSTION CHAMBER CLEANING
Instructions for cleaning carbon deposits from the combustion chamber after removing the cylinder head.
FUEL TANK AND FILTER CLEANING
Procedure for cleaning the fuel tank and filter, including safety warnings for handling gasoline.
FUEL TUBE CHECK
Instructions for checking the fuel tube for deterioration, cracks, or leakage.
TROUBLESHOOTING
BEFORE TROUBLESHOOTING
Initial checks and precautions before starting troubleshooting, such as battery condition and fuel level.
ENGINE DOES NOT CRANK
Troubleshooting steps for diagnosing why the engine fails to crank, involving recoil starter and starting system checks.
ENGINE CRANKS BUT WON’T START
Diagnostic flowcharts for issues when the engine cranks but won’t start, covering fuel, spark, and compression.
ENGINE SPEED DOES NOT INCREASE OR STABILIZE
Troubleshooting guide for engine speed issues, checking air cleaner, valve clearance, spark plug, and carburetor.
ENGINE DOES NOT STOP WHEN COMBINATION/ ENGINE STOP SWITCH IS TURNED OFF
Troubleshooting steps for when the engine fails to stop after turning off the switch, checking related components.
ENGINE DOES NOT STOP WHEN ENGINE OIL LEVEL IS LOW
Troubleshooting for engine stopping issues related to low oil level, checking oil level switch and oil alert unit.
COVER
FAN COVER REMOVAL/INSTALLATION
Procedures for removing and installing the fan cover, including related components like recoil starter and stop switches.
FUEL SYSTEM
TOOLS
Lists specialized tools for fuel system service, including float level gauge and jet cleaner set.
FUEL TANK REMOVAL/INSTALLATION
Steps for removing and installing the fuel tank, including checking fuel filter, joint, and fuel tube.
FUEL FILLER CAP/FUEL FILTER HOLDER REMOVAL/INSTALLATION
Procedures for removing and installing the fuel filler cap and filter holder, including cleaning the air vent.
AIR CLEANER REMOVAL/INSTALLATION
Instructions for removing and installing air cleaner assemblies for dual, silent, cyclone, and low profile types.
CARBURETOR REMOVAL/INSTALLATION
Steps for removing and installing the carburetor, including handling fuel and routing tubes.
CARBURETOR DISASSEMBLY/ASSEMBLY
Detailed instructions for disassembling and assembling the carburetor, including cleaning and inspecting internal parts.
CARBURETOR BODY CLEANING
Procedures for cleaning carburetor passages and ports using special tools and compressed air.
CARBURETOR INSPECTION
Steps for inspecting carburetor components, including float level height and checking for wear.
PILOT SCREW REPLACEMENT
Guide for replacing the pilot screw and limiter cap, including initial opening settings and application of locking agent.
CHOKE REPLACEMENT
Procedure for replacing the choke valve plate and shaft, ensuring correct positioning.
GOVERNOR SYSTEM
GOVERNOR MECHANISM
Explanation of the governor system components and their function in regulating engine speed.
GOVERNOR ARM/CONTROL BASE Assy. REMOVAL/INSTALLATION
Steps for removing and installing the governor arm and control base assembly, including adjustment procedures.
CONTROL BASE Assy. DISASSEMBLY/ASSEMBLY
Instructions for disassembling and assembling the control base Assy for manual/remote types, including force adjustment.
GOVERNOR ADJUSTMENT
Procedure for adjusting the governor to ensure full throttle opening and stable engine speed.
GOVERNOR DISASSEMBLY/ASSEMBLY
Detailed steps for disassembling and assembling governor components, including weights, pins, and shafts.
MAXIMUM SPEED ADJUSTMENT
Procedure for adjusting the engine's maximum speed using a tachometer and control base screw.
CHARGING SYSTEM
TOOL
Lists the specific puller collar set tool required for flywheel removal.
SYSTEM DIAGRAM
Wiring diagrams for 1 A/3 A and 7 A charge coil types, illustrating connections to battery, fuse, and control box.
CHARGING SYSTEM TROUBLESHOOTING
Troubleshooting guide for charging system issues, checking fuses, coils, and harnesses.
COOLING FAN/FLYWHEEL REMOVAL/INSTALLATION
Procedures for removing and installing the cooling fan and flywheel, including using special tools and torque specifications.
CHARGE/LAMP COIL REMOVAL/INSTALLATION
Steps for removing and installing the charge/lamp coils for different types, noting wire harness routing.
CHARGE/LAMP COIL INSPECTION
Procedures for inspecting charge/lamp coils by measuring resistance and checking for continuity.
IGNITION SYSTEM
SYSTEM DIAGRAM
Wiring diagrams for engine stop switch and control box types, showing connections of ignition coil, spark plug, and switches.
IGNITION SYSTEM TROUBLESHOOTING
Troubleshooting guide for no or weak spark issues, checking connectors, spark plug, oil level, switches, and ignition coil.
IGNITION COIL REMOVAL/INSTALLATION
Steps for removing and installing the ignition coil, including fan cover, fuel tank, and carburetor removal.
IGNITION COIL AIR GAP CHECK/ADJUSTMENT
Procedure for checking and adjusting the air gap between the ignition coil and flywheel using a thickness gauge.
SPARK TEST
Instructions for performing a spark test to check ignition system functionality, including safety precautions.
SPARK PLUG CAP INSPECTION
Procedure for inspecting the spark plug cap by measuring its resistance.
IGNITION COIL INSPECTION
Methods for inspecting the ignition coil's primary and secondary sides by measuring resistance.
STARTING SYSTEM
SYSTEM DIAGRAM
Wiring diagram for the starter motor system, showing connections for battery, starter motor, solenoid, and combination switch.
STARTING SYSTEM TROUBLESHOOTING
Troubleshooting steps for when the starter motor does not operate, checking battery, fuse, solenoid, and wire harness.
RECOIL STARTER Assy. REMOVAL/INSTALLATION
Procedures for removing and installing the recoil starter assembly, including specific bolt sizes for different models.
RECOIL STARTER Assy. DISASSEMBLY/ASSEMBLY
Detailed steps for disassembling and assembling the recoil starter assembly, including parts like friction plate and ratchets.
RECOIL STARTER INSPECTION
Guide for inspecting the operation of the recoil starter, checking ratchet function and spring retainer.
STARTER MOTOR REMOVAL/INSTALLATION
Steps for removing and installing the starter motor, involving control box and flywheel removal.
STARTER MOTOR DISASSEMBLY/ASSEMBLY
Detailed procedure for disassembling and assembling the starter motor, including armature, brushes, and overrunning clutch.
STARTER MOTOR INSPECTION
Methods for inspecting the starter motor solenoid and brushes, checking continuity and length.
OTHER ELECTRICAL
COMPONENT LOCATION
Diagrams showing the location of electrical components like engine stop switch, oil alert unit, and control box.
CONTROL BOX REMOVAL/INSTALLATION
Procedures for removing and installing the control box, including disconnecting wires and routing harnesses.
CONTROL BOX DISASSEMBLY/ASSEMBLY
Steps for disassembling and assembling the control box, including inspection of silicon rectifier, fuses, and circuit protector.
OIL LEVEL SWITCH REMOVAL/INSTALLATION
Procedures for removing and installing the oil level switch, including taking care not to drop the valve lifter.
ENGINE STOP SWITCH REMOVAL/INSTALLATION
Steps for removing and installing the engine stop switch, including aligning tabs and bending for secure fit.
OIL ALERT UNIT REMOVAL/INSTALLATION
Procedures for removing and installing the oil alert unit, including disconnecting connectors and bolting to the stay.
COMBINATION SWITCH INSPECTION
Method for inspecting the combination switch by checking continuity between terminals at different positions.
SILICON RECTIFIER INSPECTION
Procedure for inspecting the silicon rectifier by checking continuity in one direction only.
CIRCUIT PROTECTOR INSPECTION
Method for inspecting the circuit protector by checking continuity between its terminals.
MAIN FUSE INSPECTION
Instructions for visually inspecting the main fuse and checking continuity across its blades.
OIL LEVEL SWITCH INSPECTION
Procedure for inspecting the oil level switch by checking continuity under different oil level conditions.
ENGINE STOP SWITCH INSPECTION
Method for inspecting the engine stop switch by checking continuity at different switch positions.
OIL ALERT UNIT INSPECTION
Procedure for inspecting the oil alert unit by checking continuity between terminals and the unit body.
REGULATOR/RECTIFIER INSPECTION
Method for inspecting the regulator/rectifier by measuring resistance between terminals and comparing to specified ranges.
MUFFLER
MUFFLER REMOVAL/INSTALLATION
Steps for removing and installing the muffler for standard and silent types, including safety warnings about hot parts.
EXHAUST PIPE STUD BOLT REPLACEMENT
Procedure for replacing exhaust pipe stud bolts by threading nuts and turning the bolt out, then installing new ones.
CYLINDER HEAD
TOOLS
Lists specialized tools for cylinder head service, including valve guide driver and reamer.
CYLINDER HEAD REMOVAL/INSTALLATION
Procedures for removing and installing the cylinder head, including related component removal and post-installation checks.
CYLINDER HEAD DISASSEMBLY/ASSEMBLY
Detailed steps for disassembling and assembling the cylinder head, including valve components, rocker arms, and push rods.
CYLINDER HEAD/VALVES INSPECTION
Methods for inspecting cylinder head and valves, including cylinder compression check and checking for head warpage.
VALVE GUIDE REPLACEMENT
Procedure for replacing valve guides, involving chilling new guides and heating the cylinder head.
VALVE GUIDE REAMING
Steps for reaming valve guides to ensure proper fit, using cutting oil and a special tool.
VALVE SEAT RECONDITIONING
Instructions for reconditioning valve seats using seat cutters of different angles to correct contact areas.
CRANKCASE
TOOLS
Lists specialized tools for crankcase service, including various attachments, pilots, and drivers.
CRANKCASE COVER REMOVAL/INSTALLATION
Procedures for removing and installing the crankcase cover, including oil drain and reduction unit removal.
CRANKSHAFT/PISTON REMOVAL/INSTALLATION
Steps for removing and installing the crankshaft and piston assembly, including valve lifter installation.
PISTON Assy. DISASSEMBLY/ASSEMBLY
Detailed procedure for disassembling and assembling the piston, including rings, pin, clips, and connecting rod.
CRANKCASE COVER/CYLINDER BARREL/PISTON/CONNECTING ROD/CRANKSHAFT/CAMSHAFT INSPECTION
Inspection procedures for various crankcase components, including bore IDs, O.D.s, and clearances.
CRANKSHAFT BEARING/OIL SEAL REPLACEMENT
Procedures for replacing crankshaft bearings and oil seals on the crankcase and cylinder barrel sides.
REDUCTION UNIT
TOOLS
Lists specialized tools for reduction unit service, including remover weights and bearing removers.
REDUCTION UNIT DISASSEMBLY/ASSEMBLY
Procedures for disassembling and assembling reduction units for gear and chain types, including oil filling.
REDUCTION UNIT INSPECTION
Inspection of reduction unit components like P.T.O. shaft, drive sprocket, drive chain, and clutch parts for wear.
REDUCTION UNIT BEARING/OIL SEAL REPLACEMENT
Procedures for replacing reduction unit bearings and oil seals on different shaft and case sides.
WIRING DIAGRAMS
HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION
Explanation of wiring diagram symbols, connector drawings, and terminal numbering conventions.
1 A/3 A CHARGE COIL TYPE
Wiring diagram illustrating the connections for engines with 1 A or 3 A charge coil types.
7 A CHARGE COIL TYPE
Wiring diagram illustrating the connections for engines with a 7 A charge coil type.

Table of Contents