Honda GX120 Owner's Manual
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Honda GX120 Owner's Manual

Honda engine owner's manual
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Owner's Manual
GX120•GX160•GX200
o2002 Honda Motor Co., Ltd. -All Rights Reserved

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Summary of Contents for Honda GX120

  • Page 1 Owner’s Manual GX120•GX160•GX200 o2002 Honda Motor Co., Ltd. -All Rights Reserved...
  • Page 2 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Keep this owner’s manual handy, so you can refer to it at any time. This owner’s manual is considered a permanent part of the engine and should remain with the engine if resold.
  • Page 3 INTRODUCTION Congratulations on your selection of a Honda engine. We are certain you will be pleased with your purchase of one of the finest engines on the market. We want to help you get the best results from your new engine and to operate it safely.
  • Page 4 INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this engine safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.

  • Page 5: Table Of Contents

    CONTENTS ENGINE SAFETY IMPORTANT SAFETY INFORMATION CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS CONTROLS Fuel Valve Lever Engine Switch Choke Lever Throttle Lever Recoil Starter Grip FEATURES Oil Alert System (applicable engine types) Circuit Breaker (QXE2 type only) BEFORE OPERATION IS YOUR ENGINE READY TO GO? Check the General Condition of the Engine Check the Engine...
  • Page 6 CONTENTS SERVICING YOUR ENGINE (continued) SEDIMENT CUP CLEANING SPARK PLUG SERVICE IDLE SPEED ADJUSTMENT SPARK ARRESTER MAINTENANCE (optional part) HELPFUL TIPS & SUGGESTIONS STORING YOUR ENGINE Storage Preparation Storage Precautions Removal From Storage TRANSPORTING TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START ENGINE LACKS POWER FUSE REPLACEMENT (QXE2 type only) TECHNICAL &...

  • Page 7: Engine Safety

    ENGINE SAFETY IMPORTANT SAFETY INFORMATION Most accidents with engines can be prevented if you follow all instructions in this manual and on the engine. Some of the most common hazards are discussed below, along with the best way to protect yourself and others. Owner Responsibilities Honda engines are designed to give safe and dependable service if operated according to instructions.
  • Page 8 ENGINE SAFETY Carbon Monoxide Hazard Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run the engine in a closed garage or confined area. Other Equipment Review the instructions provided with the equipment powered by this engine for any additional safety precautions that should be observed in conjunction with engine startup, shutdown, operation, or protective apparel that may be needed to operate the equipment.

  • Page 9: Controls & Features

    CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS MUFFLER SPARK PLUG AIR CLEANER CHOKE LEVER FUEL VALVE LEVER FUEL FILLER CAP FUEL TANK OIL DRAIN PLUG STARTER GRIP ENGINE OIL FILLER CAP/DIPSTICK THROTTLE LEVER ENGINE SWITCH (QXE2 type) CIRCUIT BREAKER (QXE2 type) RECOIL STARTER ELECTRIC STARTER (QXE2 type)

  • Page 10: Controls

    CONTROLS & FEATURES CONTROLS Fuel Valve Lever The fuel valve opens and closes the passage between the fuel tank and the carburetor. The fuel valve lever must be in the ON position for the engine to run. When the engine is not in use, leave the fuel valve lever in the OFF position to prevent carburetor flooding and to reduce the possibility of fuel leakage.

  • Page 11: Engine Switch

    CONTROLS & FEATURES Engine Switch The engine switch enables and disables the ignition system. The engine switch must be in the ON position for the engine to run. Turning the engine switch to the OFF position stops the engine. ALL ENGINES EXCEPT QXE2 QXE2 TYPE ENGINE SWITCH CIRCUIT BREAKER...

  • Page 12: Choke Lever

    CONTROLS & FEATURES Choke Lever The choke lever opens and closes the choke valve in the carburetor. The CLOSED position enriches the fuel mixture for starting a cold engine. The OPEN position provides the correct fuel mixture for operation after starting, and for restarting a warm engine. Some engine applications use a remotely-mounted choke control rather than the engine-mounted choke lever shown here.

  • Page 13: Throttle Lever

    CONTROLS & FEATURES Throttle Lever The throttle lever controls engine speed. Moving the throttle lever in the directions shown makes the engine run faster or slower. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here. THROTTLE LEVER SLOW FAST...

  • Page 14: Features

    CONTROLS & FEATURES FEATURES Oil Alert System (applicable engine types) The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert system will automatically stop the engine (the engine switch will remain in the ON position).

  • Page 15: Before Operation

    BEFORE OPERATION IS YOUR ENGINE READY TO GO? For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the engine to check its condition. Be sure to take care of any problem you find, or have your servicing dealer correct it, before you operate the engine.

  • Page 16: Check The Engine

    BEFORE OPERATION Check the Engine Check the engine oil level (see page low oil level can cause engine damage. The Oil Alert system (applicable engine types) will automatically stop the engine before the oil level falls below safe limits. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup.

  • Page 17: Operation

    OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time, please review the IMPORTANT SAFETY INFORMATION on page and the chapter titled BEFORE OPERATION . Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you. Avoid any areas or actions that expose you to carbon monoxide.
  • Page 18 OPERATION To start a cold engine, move the choke lever to the CLOSED position. To restart a warm engine, leave the choke lever in the OPEN position. Some engine applications use a remotely-mounted choke control rather than the engine-mounted choke lever shown here. CHOKE LEVER CLOSE Move the throttle lever away from the SLOW position, about 1/3 of...
  • Page 19 Turn the engine switch to the ON position. ALL ENGINES EXCEPT QXE2 Operate the starter. RECOIL STARTER (all engine types): Pull the starter grip lightly until you feel resistance, then pull briskly. Return the starter grip gently. ENGINE SWITCH STARTER GRIP OPERATION QXE2 TYPE...
  • Page 20 OPERATION ELECTRIC STARTER (QXE2 type): Turn the key to the START position, and hold it there until the engine starts. If the engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again.

  • Page 21: Stopping The Engine

    STOPPING THE ENGINE To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. Move the throttle lever to the SLOW position. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here.

  • Page 22: Setting Engine Speed

    OPERATION Turn the fuel valve lever to the OFF position. FUEL VALVE LEVER SETTING ENGINE SPEED Position the throttle lever for the desired engine speed. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here. For engine speed recommendations, refer to the instructions provided with the equipment powered by this engine.

  • Page 23: Servicing Your Engine

    SERVICING YOUR ENGINE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. Improperly maintaining this engine, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.

  • Page 24: Maintenance Safety

    SERVICING YOUR ENGINE MAINTENANCE SAFETY Some of the most important safety precautions are as follows: However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. Failure to properly follow maintenance instructions and precautions can cause you to be...

  • Page 25: Maintenance Schedule

    MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (3) ITEM Perform at every indicated month or operating hour interval, whichever comes first. Engine oil Air filter Sediment cup Spark plug Spark arrester (optional parts) Idle speed Valve clearance Combustion chamber Fuel tank & filter Fuel tube Emission-related items.

  • Page 26: Refueling

    SERVICING YOUR ENGINE REFUELING Fuel tank capacities GX120: 0.66 US gal (2.5 ) GX160: 0.95 US gal (3.6 ) GX200: 0.95 US gal (3.6 ) With the engine stopped, remove the fuel tank cap and check the fuel level. Refill the tank if the fuel level is low.

  • Page 27: Fuel Recommendations

    Refuel in a well-ventilated area before starting the engine. If the engine has been running, allow it to cool. Refuel carefully to avoid spilling fuel. Do not fill above the fuel strainer shoulder. After refueling, tighten the fuel tank cap securely. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks.

  • Page 28: Engine Oil Level Check

    SERVICING YOUR ENGINE ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position. Remove the filler cap/dipstick and wipe it clean. Insert and remove the dipstick with out screwing it into the filler neck.

  • Page 29: Engine Oil Change

    With the engine in a level position, fill to the outer edge of the oil filler hole with the recommended oil (see page 28). Engine oil capacities GX120 : 0.59 US qt (0.56 ) GX160 : 0.63 US qt (0.60 ) GX200 : 0.63 US qt (0.60 )

  • Page 30: Engine Oil Recommendations

    SERVICING YOUR ENGINE ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range.

  • Page 31: Air Filter Inspection

    AIR FILTER INSPECTION Remove the air cleaner cover and inspect the filter. Clean or replace dirty filter elements. Always replace damaged filter elements. If equipped with an oil-bath air cleaner, also check the oil level. Refer to pages 30-32 filter on your type of engine. PAPER FILTER ELEMENT FOAM FILTER...

  • Page 32: Air Cleaner Service

    SERVICING YOUR ENGINE AIR CLEANER SERVICE A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If you operate the engine in very dusty areas, clean the air filter more often than specified in the MAINTENANCE SCHEDULE. Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear.
  • Page 33 Paper air filter element: Tap the filter element several times on a hard surface to remove dirt, or blow compressed air [not exceeding 30 psi (207 kPa, 2.1 kgf cm )] through the filter element from the inside. Never try to brush off dirt; brushing will force dirt into the fibers. Foam air filter element: Clean in warm soapy water, rinse, and allow to dry thoroughly.

  • Page 34: Oil-Bath Type

    SERVICING YOUR ENGINE Oil-Bath Type Remove the wing nut, and remove the air cleaner cap and cover. Remove the air filter from the cover, Wash the cover and filter in warm, soapy water, rinse, and allow to dry thoroughly. Or clean in nonflammable solvent and allow to dry.

  • Page 35: Sediment Cup Cleaning

    SEDIMENT CUP CLEANING Move the fuel valve to the OFF position, then remove the fuel sediment cup and O-ring. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Keep heat, sparks and flame away. Handle fuel only outdoors.

  • Page 36: Spark Plug Service

    SERVICING YOUR ENGINE SPARK PLUG SERVICE Recommended spark plugs: An incorrect spark plug can cause engine damage. Disconnect the spark plug cap, and remove any dirt from around the spark plug area. Remove the spark plug with a 13/16-inch spark plug wrench. Inspect the spark plug.

  • Page 37: Idle Speed Adjustment

    After the spark plug seats, tighten with a 13/16-inch spark plug wrench to compress the water. If reinstalling the used spark plug, tighten 1/8 1/4 turn after the spark plug seat. if installing a new spark plug, tighten 1/2 turn after the spark plug seats.

  • Page 38: Spark Arrester Maintenance (Optional Part)

    SERVICING YOUR ENGINE SPARK ARRESTER SERVICE (optional equipment) Your engine is not factory-equipped with a spark arrester. In some areas, it is illegal to operate an engine without a spark arrester. Check local laws and regulations. A spark arrester is available from authorized Honda servicing dealers.

  • Page 39: Helpful Tips & Suggestions

    HELPFUL TIPS & SUGGESTIONS STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine troublefree and looking good. The following steps will help to keep rust and corrosion from impairing your engine’s function and appearance, and will make the engine easier to start after storage. Cleaning If the engine has been running, allow it to cool for at least half an hour before cleaning.
  • Page 40 HELPFUL TIPS & SUGGESTIONS The Distributor’s Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation. You can extend fuel storage life by adding a fuel stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor.
  • Page 41 DRAINING THE FUEL TANK AND CARBURETOR Place an approved gasoline container below the carburetor, and use a funnel to avoid spilling fuel. Remove the carburetor drain bolt and sediment cup, then move the fuel valve lever to the ON position. Gasoline is highly flammable and explosive.

  • Page 42: Storage Precautions

    HELPFUL TIPS & SUGGESTIONS Engine Oil Change the engine oil (see page 27). Remove the spark plugs (see page 34). Pour a tablespoon (5 10 cc) of clean engine oil into the cylinder. Pull the starter rope several times to distribute the oil in the cylinder. Reinstall the spark plugs.

  • Page 43: Removal From Storage

    HELPFUL TIPS & SUGGESTIONS Position the equipment so the engine is level. Tilting can cause fuel or oil leakage. With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials.

  • Page 44: Transporting

    HELPFUL TIPS & SUGGESTIONS TRANSPORTING If the engine has been running, allow it to cool for at least 15 minutes before loading the engine-powered equipment on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials.

  • Page 45: Taking Care Of Unexpected Problems

    TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START QXE2 electric starting: Check battery and fuse. Check control positions. Check fuel. Remove and inspect spark plugs. Take engine to an authorized Honda servicing dealer, or refer to shop manual. ENGINE LACKS POWER Check air filter.

  • Page 46: Fuse Replacement (Qxe2 Type Only)

    TAKING CARE OF UNEXPECTED PROBLEMS FUSE REPLACEMENT (QXE2 type only) The electric starter relay circuit and battery charging circuit are protected by a 5-ampere fuse. If the fuse burns out, the electric starter will not operate. The engine can be started manually if the fuse burns out, but running the engine will not charge the battery.

  • Page 47: Technical & Consumer Information

    TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location Record the engine serial number in the space below. You will need this serial number when ordering parts, and when making technical or warranty inquires (see page Engine serial number: ELECTRIC STARTER (QXE2 type only)

  • Page 48: Battery Connections For Electric Starter (Qxe2 Type Only)

    TECHNICAL & CONSUMER INFORMATION Battery Connections for Electric Starter (QXE2 type only) Use a 12-volt battery with an ampere-hour rating of at least 18 Ah. Be careful not to connect the battery in reverse polarity, as this will short circuit the battery charging system. Always connect the positive ( ) battery cable to the battery terminal before connecting the ＋...

  • Page 49: Remote Control Linkage

    TECHNICAL & CONSUMER INFORMATION Remote Control Linkage The throttle and choke control levers are provided with holes for optional cable attachment. The following illustrations show installation examples for a solid wire cable and for a flexible, braided wire cable. If using a flexible, braided wire cable, add a return spring as shown.

  • Page 50: Carburetor Modification For High Altitude

    TECHNICAL & CONSUMER INFORMATION Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.

  • Page 51: Oxygenated Fuels

    TECHNICAL & CONSUMER INFORMATION Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.

  • Page 52: Emission Control System Information

    TECHNICAL & CONSUMER INFORMATION Emission Control System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
  • Page 53 TECHNICAL & CONSUMER INFORMATION Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring).

  • Page 54: Air Index

    TECHNICAL & CONSUMER INFORMATION Air Index An Air Index Information hang tag/label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines.

  • Page 55: Specifications

    TECHNICAL & CONSUMER INFORMATION Specifications GX 120 Length × Width × Height Dry weight Engine type Displacement [Bore × Stroke] Max. output Max. torque Fuel consumption Cooling system Ignition system PTO shaft rotation GX 160 Length × Width × Height Dry weight Engine type Displacement...
  • Page 56 Engine type Displacement [Bore × Stroke] Max. output Max. torque Fuel consumption Cooling system Ignition system PTO shaft rotation GX120/GX160/GX200 Tuneup ITEM Spark plug gap Valve clearance Other specifications 12.3 × 14.8 × 13.2 in (313 35.3 lbs (16.0 kg) 4-stroke, overhead valve, single cylinder 12.0 cu-in (196 cm )

  • Page 57: Wiring Diagrams

    TECHNICAL & CONSUMER INFORMATION Wiring Diagrams QXE2 Type with Oil Alert and Electric Starter...
  • Page 58 TECHNICAL & CONSUMER INFORMATION Engine Type With Oil Alert and Without Electric Starter...

  • Page 59: Consumer Information

    TECHNICAL & CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing your engine. You may order them from your Honda engine dealer. Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician.

  • Page 60: Warranty Service Information

    TECHNICAL & CONSUMER INFORMATION Warranty Service Information Servicing dealership personnel are trained professionals. They should be able to answer any questions you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management. The Service Manager or General Manager can help.
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  • Page 63: Quick Reference Information

    Carburetor Maintenance Type Unleaded gasoline with a pump octane rating of 86 or higher (page 25) Capacity GX120: 0.66 US gal (2.5 ) GX160 & GX200: 0.95 US gal (3.6 ) Type SAE 10W-30, API SJ, for general Capacity GX120: 0.59 US qt (0.56 )
  • Page 64 31Z0T600 00X31-Z0T-6000 T1:GX120•GX160•GX200 2eY1 " 70000.2002.12 PRINTED IN THAILAND...

This manual is also suitable for:

Gx160Gx200

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