Honda GX120 User's Manual
Contents
1.2. Running the engine with persistent spark knock or pinging is considered misuse and the Distributor s Limited Warranty does not cover parts damaged by misuse 2b SERVICING YOUR ENGINE ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position 1 Remove the filler cap dipstick and wipe it clean 2 Insert and remove the dipstick with out screwing it into the filler neck Check the oil level shown on the dipstick 3 f the oil level is low fill to the edge of the oil filler hole with the recommended oil see page 28 4 Screw in the filler cap dipstick securely FILLER CAP DIPSTICK UPPER LIMIT 9 LOWER LIMIT NOTICE Running the engine with a 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 limit However to avoid the inconvenience of an unexpected shutdown always check the engine oil level before startup 26 SERVICING YOUR ENGINE ENGINE OIL CHANGE Drain the used oil while the engine is warm Warm oil drains quickly and completely 1 Place a suitable container below the engine to catch the used oil then remove the filler cap dipstick and the drain plug 2 Allow the used oil to drain completely then reinstall the drain plug and tighten it securely Please dispose of used motor oil in a manner that is compatible with the environment
3. Always follow the procedures and precautions in the owner s manual Safety Precautions Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Remember that your servicing dealer knows your engine best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair and replacement 22 SERVICING YOUR ENGINE MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD 3 First E E E ITEM irs very very very Refer WT Each month months months year Perform at every indicated to use or or or or month or operating hour interval page 20 Hrs 50 Hrs 100 Hrs 300 Hrs whichever comes first Engine oil Check level O
4. BEFORE OPERATION Check the Engine e Check the engine oil level see 26 Running the engine with a 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 e Check the air filter see page 29 A dirty air filter will restrict air flow to the carburetor reducing engine performance e Check the fuel level see page 24 Starting with a full tank will help to eliminate or reduce operating interruptions for refueling Check the Equipment Powered by This Engine Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine startup 14 OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time please review the IMPORTANT SAFETY INFORMATION on page 5 f nd the chapter titled BEFORE OPERATION A WARNING 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 Review the instructions provided with the equipment powered by this engine for any safety precautions that should be observed in conjunction with engine startup shutdown or operation STARTING THE ENGINE 1 Move the f
5. A WARNING You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow CAUTION instructions e Safety Headings such as MPORTANT SAFETY INFORMATION Safety Section such as ENGINE SAFETY Instructions how to use this engine correctly and safely This entire book is filled with important safety information please read it carefully 2 ENGINE SAFETY IMPORTANT SAFETY INFORMATION Throttle Lever Recoil Starter Grip Cil Alert System applicable engine types Circuit Breaker OXE2 type only BEFORE OPERATION IS YOUR ENGINE READY TQ GO 13 Check the General Condition of the Engine heck the Engine Check the Equipment Powered by This Engine OPERATION SAFE OPERATING PRECAUTIONS STARTING THE ENGINE CONTENTS SERVICING YOUR ENGINE continued SEDIMENT CUP CLEANING 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 Read and understand this owner s manual before operating the engine Failure to do so could result in personal injury or equipment damage Know how to stop the engine
6. A short circuit or a battery connected with reverse polarity will trip the circuit breaker The green indicator inside the circuit breaker will pop out to show that the circuit breaker has switched off If this occurs determine the cause of the problem and correct it before resetting the circuit breaker Push the circuit breaker button to reset 12 BREAKER 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 A WARNING Improperly maintaining this engine or failing to correct a problem before operation could cause a malfunction in which you could be seriously injured Always perform a preoperation inspection before each operation and correct any problem Before beginning your preoperation checks be sure the engine is level and the engine switch is in the OFF position Check the General Condition of the Engine Look around and underneath the engine for signs of oil or gasoline leaks Remove any excessive dirt or debris especially around the muffler and recoil starter Look for signs of damage Check that all shields and covers are in place and all nuts bolts and screws are tightened 13
7. 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 ta pages 30 32 for instructions that apply to the air cleaner and filter on your type of engine PAPER FILTER ELEMENT FOAM FILTER ELEMENT it E STANDERD OIL BATH TYPE DUAL FILTER see p 32 ELEMENT TYPE see p 30 31 29 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 NOTICE Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine causing rapid engine wear This type of damage is not covered by the Distributor s Limited Warranty Dual Filter Element Types STANDERD DUAL FILTER ELEMENT 1 Remove the wing nut from the TYPE air cleaner cover and remove the cover AIR CLEANER COVER 2 Remove the wing nut from the air filter and remove the filter 3 Remove the foam filter from the PAPER paper filter PRETI T 4 Inspect both air filter elements and replace them if they are damaged Always replace the paper air filter element at the eee scheduled interval see page ELEMENT 5 Clean the ai
8. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash pour it on the ground or down a drain 3 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 0 GX160 0 63 US qt 0 60 0 GX200 0 63 US qt 0 60 0 NOTICE Running the engine with a 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 the safe limit However to avoid the inconvenience of an unexpected shutdown fill to the upper limit and check the oil level regularly 4 Screw in the filler cap dipstick securely FILLER CAP DIPSTICK S OIL LEVEL DRAIN BOLT 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 A 30 20 10 0 10 20 30 40C The SAE oil viscosity and service classification the API label on the oil container Honda recommends that you use API SERVICE category SJ oil 28 SERVICING YOUR ENGINE
9. amp 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 It is necessary to loosen the throttle lever friction nut when operating the throttle with a remotely mounted control REMOTE THROTTLE LINKAGE THROTTLE LEVER 1 RETURN PIVOT NUT NO SPRING Flexible wire core mounting NS mm SCREW WIRE M e HOLDER gt OPTIONAL 22 THROTTLE LEVER Solid wire core CIRCLIP 04 mounting lt gt REMOTE CHOKE LINKAGE _ WIRE HOLDER BI CHOKE LEVER 47 TECHNICAL amp 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 High altitude performance can be improved by specific modifications to the carburetor If you always operate your engine at altitudes above 5 000 feet 1 500 meters have your servicing dealer perform this carburetor mod
10. settings and other systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons The U S and California Clean Air Acts EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters 50 TECHNICAL amp 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 Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your Honda engine were designed built and certified to conform with EPA and California emission regulations We recommend the use of genuine Honda parts whenever you have maintenance
11. your engine other property or the environment We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership The warranty policy is a separate document that should have been given to you by your dealer When your engine needs scheduled maintenance keep in mind that your Honda servicing dealer is specially trained in servicing Honda engines Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns Best Wishes Honda Motor Co Ltd 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 This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all the hazards associated with operating or maintaining an engine You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels on the engine Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if DANGER you don t follow instructions
12. Change O O el Airfilter Check O Clean 1 e Sediment cup Clean Spark plug Check adjust Spark arrester Clean optional parts e Idle speed Check adjust 2 e Valve clearance Check adjust 2 mE Combustion chamber Clean After every 500 Hrs 2 e Fueltank amp filter Clean 2 Fuel tube Check Every 2 years Replace if necessary 2 Emission related items Replace the paper element type only 1 Service more frequently when used in dusty areas 2 These items should be serviced by your servicing dealer unless you have the proper tools and are mechanically proficient Refer to Honda shop manual for service procedures 3 For commercial use log hours of operation to determine proper maintenance intervals 23 SERVICING YOUR ENGINE REFUELING Fuel tank capacities GX120 0 66 US gal 2 5 0 GX160 0 95 US gal 3 6 0 GX200 0 95 US gal 3 6 0 With the engine stopped remove the fuel tank cap and check the fuel level Refill the tank if the fuel level is low AWARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately MAXIMUM FUEL LEVEL 24 SERVICING YOUR ENGINE Refuel in a well ventilated area before starting the e
13. GINE TYPE 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 58 Engine serial number 45 TECHNICAL amp CONSUMER INFORMATION Battery Connections for Electric Starter OXE2 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 negative battery cable so your tools cannot cause a short circuit if they touch a grounded part while tightening the positive battery cable end A WARNING A battery can explode if you do not follow the correct procedure seriously injuring anyone nearby Keep all sparks open flames and smoking materials away from the battery 1 Connect the battery positive cable to the starter solenoid terminal as shown 2 Connect the battery negative cable to an engine mounting bolt frame bolt or other good engine ground connection 3 Connect the battery positive cable to the battery positive terminal as shown 4 Connect the battery negative cable to the battery negative terminal as shown 5 Coat the terminals and cable ends with grease NEGATIVE BATTERY CABLE STARTER SOLENOID 46 TECHNICAL
14. HANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE methyl tertiary butyl ether 15 by volume You may use gasoline containing up to 1596 MTBE by volume METHANOL methyl or wood alcohol 596 by volume You may use gasoline containing up to 596 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 596 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty 49 TECHNICAL amp 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 Honda utilizes lean carburetor
15. HONDA ENGINES Owner s Manual 120 160 200 Click here to save this manual to your computer c 2002 Honda Motor Co Ltd All Rights Reserved WARNING 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 The information and specifications included in this publication were in effect at the time of approval for printing Illustrations are based on the GX160 Only the OXE2 type is equipped for both electric and manual starting Honda Motor Co Ltd reserves the right however to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever No part of this publication may be reproduced without written permission 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 This manual contains the information on how to do that please read it carefully As you read this manual you will find information preceded by a NOTICE symbol That information is intended to help you avoid damage to
16. OLIMS 3NION3 ams ALIHM a moraa 0 19379 TIO HOLIMS 13441 9nd 1109 x uvdS DNIDHVHO gt RA A Way a 18 3 DC 225 LINDYID C v gw S Zap YA NOILINDI 9 93921404 al De isNvul PO 19 M 93134938 10H1NO2 HOLIMS 55 TECHNICAL amp CONSUMER INFORMATION Engine Type With Oil Alert and Without Electric Starter IL TRANSIS 7 TORIZED IGNITION x na x o ES a s 56 TECHNICAL amp 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 Parts Catalog This manual provides complete illustrated parts lists 57 TECHNICAL amp 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 Almost all problems are solved in this way I
17. OXE2 type 6 If the choke lever has been moved to the CLOSED position to start the engine gradually move it to the OPEN position as the engine warms up CHOKE LEVER 18 To stop the engine in emergency simply turn the engine switch to the OFF position Under normal conditions use the following procedure 1 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 THROTTLE LEVER 2 Turn the engine switch to the OFF position ALL ENGINES EXCEPT OXE2 2 TYPE ENGINE SWITCH 19 3 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 THROTTLE LEVER 20 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 AWARNING Improperly maintaining this engine or failure to correct a problem before operation can cause a m
18. alfunction in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual To help you properly care for your engine the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your engine under unusual conditions such as sustained high load or high temperature operation or use in unusually wet or dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use Maintenance replacement or repair of emission control devices and systems may be done by any engine repair establishment or individual using parts that are certified to EPA standards 21 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 A WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed
19. anual Fuel filter clogged carburetor malfunction ignition malfunction valves stuck etc Replace or repair faulty components as necessary 43 TAKING CARE OF UNEXPECTED PROBLEMS FUSE REPLACEMENT 2 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 1 Remove the 6 12 mm screw from the rear cover of the engine switch box 2 Remove the fuse cover and inspect the fuse If the fuse is burnt out remove the fuse cover then pull out and discard the burnt out fuse Install a new 5 fuse and reinstall the fuse cover NOTICE Never use a fuse with a rating greater than 5 amperes Serious damage to the electrical system or a fire could result 3 Reinstall the rear cover Install the 6 X 12 mm screw and tighten it securely ENGINE SWITCH P REAR COVER FUSE oU 6 X12 mm SPECIAL SCREW Frequent fuse failure usually indicates a short circuit or an overload in the electrical system If the fuse burns out frequently take the engine to a servicing Honda dealer for repair 44 TECHNICAL amp CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location ELECTRIC STARTER OXE2 type only SERIAL NUMBER amp EN
20. ations A spark arrester is available from authorized Honda servicing dealers The spark arrester must be serviced every 100 hours to keep it functioning as designed If the engine has been running the muffler will be very hot Allow the muffler to cool before servicing the spark arrester 1 Remove the three 4 mm screws from the exhust deflector and remove the deflector 2 Remove the four 5 mm screws from the muffler protector and remove the muffler protector 3 Remove the 4 mm screw from the spark arrester and remove the spark arrester from the muffler 5 mm SCREWS MUFFLER PROTECTOR EXHAUST a DEFLECTOR oa 4 mm SCREWS 4 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the screen SCREEN The spark arrester must be free of breaks and holes Replace the spark arrester if it is damaged 5 Install the spark arrester muffler protector and exhaust deflector the reverse order of disassembly 36 HELPFUL TIPS amp 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 Clean all exterior s
21. bhp 4 0 kW 5 5 PS at 3 600 rpm Max torque 8 0 Ibf ft 10 8 N m 1 1 kgf m at 2 500 rpm Fuel consumption 0 51 Ib hph 313 g kWh 230 g PSh Cooling system Forced air Ignition system Transistorized magneto PTO shaft rotation Counterclockwise 53 TECHNICAL amp CONSUMER INFORMATION GX200 Length Width X Height 12 3 X 14 8 X 13 2 in 313 376 X 335 mm Dry weight 35 3 Ibs 16 0 kg Engine type 4 stroke overhead valve single cylinder Displacement Bore X Stroke 12 0 cu in 196 cm 2 7 X 2 1 68 X 54 mm Max output 6 5 bhp 4 8 kW 6 5 PS at 3 600 rpm Max torque 9 76 Ibf ft 13 2 N m 1 35 kgf m at 2 500 rpm Fuel consumption 0 51 Ib hph 313 g kWh 230 g PSh Cooling system Forced air Ignition system Transistorized magneto PTO shaft rotation Counterclockwise GX120 GX160 GX200 Tuneup 0 70 0 80 mm ITEM SPECIFICATION MAINTENANCE Spark plug gap 0 028 0 031 in Refer tolpage 34 Valve clearance IN 0 155 0 02 mm cold EX 0 20 0 02 mm cold See your authorized Honda dealer Other specifications 54 No other adjustments needed TECHNICAL amp CONSUMER INFORMATION Wiring Diagrams QXE2 Type with Oil Alert and Electric Starter Ay311vV8 M GION310S 1 15 rem ES t TI 5 H
22. d fuse Battery discharged Fuse burnt out Recharge batte Replace fus p 44 2 Check control Fuel valve OFF Move lever to ON Move lever to CLOSED unless engine is warm Turn engine switch to positions Choke OPEN Engine switch OFF ON 3 Check fuel Out of fuel Refue Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and ca rburetor p 39 Refuel with fresh gasoline p 24 4 Remove and inspect spark plugs Spark plugs faulty fouled or improperly gapped Gap or replace spark plugs p 34 Spark plugs wet with fuel flooded engine Dry and reinstall spark plugs Start engine with throttle lever in FAST position 5 Take engine to authorized Honda servicing dealer or refer to shop manual Fuel filter clogged carburetor malfunction ignition malfunction valves stuck etc Replace or repair faulty components as necessary ENGINE LACKS POWER Possible Cause Correction 1 Check air filter Filter element s clogged Clean or replace filter element s p 30 32 2 Check fuel Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carburetor 39 Refuel with fresh gasoling P 241 3 Take engine to an authorized Honda servicing dealer or refer to shop m
23. done These original design replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations Maintenance Follow the maintenance schedule on page 23 Remember that this schedule is based on the assumption that you achine will be used for its designed purpose Sustained high load or high temperature operation or use in unusually wet or dusty conditions will require more frequent service 51 TECHNICAL amp 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 The lower the Air Index the less pollution The durability description is intended to provide you with information relating to the engine s emission durability period The descriptive term indicates the useful life p
24. drain bolt and sediment cup Tighten them securely 39 HELPFUL TIPS amp SUGGESTIONS Engine Oil 1 Change the engine oil 2 Remove the spark plugs see page 34 3 Pour a tablespoon 5 10 cc of clean engine oil into the cylinder 4 Pull the starter rope several times to distribute the oil in the cylinder 5 Reinstall the spark plugs 6 Pull the starter rope slowly untill resistance is felt and the notch on the starter pulley aligns with the hole at the top of the recoil starter cover This will close the valves so moisture cannot enter the engine cylinder Return the starter rope gently Align notch on pulley with hole at top of cover Storage Precautions If your engine will be stored with gasoline in the fuel tank and carburetor it is important to reduce the hazard of gasoline vapor ignition Select a well ventilated storage area away from any appliance that operates with a flame such as a furnace water heater or clothes dryer Also avoid any area with a spark producing electric motor or where power tools are operated If possible avoid storage areas with high humidity because that promotes rust and corrosion Unless all fuel has been drained from the fuel tank leave the fuel valve lever in the OFF position to reduce the possibility of fuel leakage 40 HELPFUL TIPS amp SUGGESTIONS Position the equipment so the engine is level Tilting can cause fuel or oil leakage With the engine and exhaust
25. ems 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 ADDING A FUEL STABILIZER TO EXTEND FUEL STORAGE LIFE When adding a fuel stabilizer fill the fuel tank with fresh gasoline If only partially filled air in the tank will promote fuel deterioration during storage If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline 1 Add fuel stabilizer following the manufacturer s instructions 2 After adding a fuel stabilizer run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor 3 Stop the engine and move the fuel valve to the OFF position FUEL VALVE 38 HELPFUL TIPS amp SUGGESTIONS DRAINING THE FUEL TANK AND CARBURETOR 1 Place an approved gasoline container below the carburetor and use a funnel to avoid spilling fuel 2 Remove the carburetor drain bolt and sediment cup then move the fuel valve lever to the ON position A WARNING 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 Wipe up spills immediately SEDIMENT CUP 3 After all the fuel has drain into the container reinstall the
26. eriod for the engine s emission control system See your Emission Control Warranty for additional information Descriptive Term Applicable to Emissions Durability Period Moderate 50 hours 0 65 cc 125 hours greater than 65 cc Intermediate 125 hours 0 65 cc 250 hours greater than 65 cc Extended 300 hours 0 65 cc 500 hours greater than 65 cc The Air Index Information hang tag must remain on the engine until it is sold Remove the hang tag before operating the engine 52 TECHNICAL amp CONSUMER INFORMATION Specifications GX 120 Length X Width X Height 11 7 X 13 4 X 12 5 in 297 X 341 X 318 mm Dry weight 28 7 16 13 0 kg Engine type 4 stroke overhead valve single cylinder Displacement Bore X Stroke 7 2 cu in 118 cm 2 4 X 1 7 in 60 X 42 mm Max output 3 9 bhp 2 9 kW 4 0 PS at 3 600 rpm Max torque 5 4 Ibf ft 7 4 N m 0 75 kgf m at 2 500 rpm Fuel consumption 0 51 Ib hph 313 g kWh 230 g PSh Cooling system Forced air Ignition system Transistorized magneto PTO shaft rotation Counterclockwise GX 160 Length X Width X Height 12 0 X 14 3 X 13 2 in 304 x 362 x 335 mm Dry weight 33 1 Ibs 15 0 kg Engine type 4 stroke overhead valve single cylinder Displacement Bore X Stroke 9 9 cu in 163 cm 2 7 X 1 8 in 68 X 45 mm Max output 5 4
27. f you are dissatisfied with the decision made by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write to American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia 30005 8847 Or telephone 770 497 6400 When you write or call please give us this information e Model and serial number see page 45 Name of dealer who sold the engine to you Name and address of dealer who services your engine Date of purchase Your name address and telephone number A detailed description of the problem 58 59 60 QUICK REFERENCE INFORMATION Type Unleaded gasoline with a pump octane rating of 86 or higher Capacity GX120 0 66 US gal 2 5 0 GX160 amp GX200 0 95 US gal 3 6 9 Engine Oil Type SAE 10W 30 API SJ for general use Capacity GX120 0 59 US qt 0 56 0 GX160 amp GX200 0 63 US qt 0 60 0 Spark Plug Type DENSO W20EPR U Gap 0 028 0 031 in 0 70 0 80 mm page 34 Carburetor Idle speed 1 400 rom page 35 Maintenance Each use Check engine oil level Check air filter First 20 hours Change engine oil Subsequent Refer to the maintenance schedule on page 23 HON DA The Power of Dreams T1 GX120 GX160 GX200 EM3 no
28. g wrench SPARK PLUG WRENCH 3 Inspect the spark plug Replace it if the electrodes are worn or if the insulator is cracked or chipped 0 028 0 031 in 0 70 0 80 mm 4 Measure the spark plug electrode gap with a suitable gauge The gap should be 0 028 0 031 in 0 70 0 80 mm Correct the gap if necessary by carefully bending the side electrode 5 Install the spark plug carefully by hand to avoid cross threading 34 SERVICING YOUR ENGINE 6 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 NOTICE A loose spark plug can overheat and damage the engine Overtightening the spark plug can damage the threads in the cylinder head 7 Attach the spark plug cap IDLE SPEED ADJUSTMENT 1 Start the engine outdoors and allow it to warm up to operating temperature 2 Move the throttle lever to its slowest position 3 Turn the throttle stop screw to obtain the standerd idle speed Standard idle speed 1 400589 rpm THROTTLE STOP SCREW 35 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 regul
29. gine will smoke if too much oil is left in the foam 4 Empty the used oil from the air cleaner case wash out any accumulated dirt with nonflammable solvent and dry the case 5 Fill the air cleaner case to the OIL LEVEL mark with the same oil that is recommended for the engine see page28 Oil capacity 2 0 US oz 60 cm 6 Reassemble the air cleaner and tighten the wing nut securely WING g NUT OIL LEVEL 32 SERVICING YOUR ENGINE SEDIMENT CUP CLEANING 1 Move the fuel valve to the OFF position then remove the fuel sediment cup and O ring A WARNING 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 Wipe up spills immediately 2 Wash the sediment cup and O ring in nonflammable solvent and dry them thoroughly 3 Place the O ring in the fuel valve and install the sediment cup Tighten the sediment cup securely 4 Move the fuel valve to the ON position and check for leaks Replace the O ring if there is any leakage O RING SEDIMENT CUP 33 SERVICING YOUR ENGINE SPARK PLUG SERVICE Recommended spark plugs BPR6ES W20EPR U DENSO NOTICE An incorrect spark plug can cause engine damage 1 Disconnect the spark plug cap and remove any dirt from around the spark plug area 2 Remove the spark plug with a 13 16 inch spark plu
30. ification This engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 596 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made NOTICE When the carburetor has been modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 5 000 feet 1 500 meters with a modified carburetor may cause the engine to overheat and result in serious engine damage For use at low altitudes have your servicing dealer return the carburetor to original factory specifications 48 TECHNICAL amp 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 Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ET
31. l that may be needed to operate the equipment CONTROLS amp FEATURES COMPONENT amp CONTROL LOCATIONS MUFFLER THROTTLE LEVER co aN WS t gt ENGINE SWITCH OXE2 type SPARK PLUG ISS K oI 9 AIR CLEANER gt SN a C RECOIL STARTER CIRCUIT BREAKER QXE2 type CHOKE LEVER FUEL VALVE LEVER STARTER GRIP FUEL FILLER CAP FUEL TANK ELECTRIC STARTER OXE2 type CONTROLS amp 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 CONTROLS amp 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 2 OXE2 TYPE Type The engine switch on the OXE2 type includes a START position for operating the electric starter The key automatically returns to the ON position when released from the START position The circuit breaker which is located below the key protects the battery charging circuit see page 12 CONTROLS amp FEATURES Ch
32. ngine 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 Keep gasoline away from appliance pilot lights barbecues electric appliances power tools etc Spilled fuel is not only a fire hazard it causes environmental damage Wipe up spills immediately NOTICE Fuel can damage paint and plastic Be careful not to spill fuel when filling your fuel tank Damage caused by spilled fuel is not covered under warranty FUEL RECOMMENDATIONS Use unleaded gasoline with a pump octane rating of 86 or higher These engines are certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in the fuel tank Occasionally you may hear a light spark knock or pinging metallic rapping noise while operating under heavy loads This is no cause for concern If spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline If spark knock or pinging persists see an authorized Honda servicing dealer NOTICE Running the engine with persistent spark knock or pinging can cause engine damage
33. oke 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 CHOKE LEVER 10 CONTROLS amp 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 Recoil Starter Grip Pulling the starter grip operates the recoil starter to crank the engine STARTER GRIP 11 CONTROLS amp 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 If the engine stops and will not restart check the engine oil level page 26 before troubleshooting in other areas Circuit Breaker OXE2 type only The circuit breaker protects the battery charging circuit
34. quickly and understand the operation of all controls Never permit anyone to operate the engine without proper instructions Do not allow children to operate the engine Keep children and pets away from the area of operation Refuel With Care Gasoline is extremely flammable and gasoline vapor can explode Refuel outdoors in a well ventilated area with the engine stopped Never smoke near gasoline and keep other flames and sparks away Always store gasoline in an approved container If any fuel is spilled make sure the area is dry before starting the engine Hot Exhaust The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful not to touch the muffler while it is hot Let the engine cool before storing it indoors To prevent fire hazards and to provide adequate ventilation for stationary equipment applications keep the engine at least 3 feet 1 meter away from building walls and other equipment during operation Do not place flammable objects close to the engine 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 appare
35. r filter elements if GASKET they are to be reused 30 SERVICING YOUR ENGINE 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 Or clean in nonflammable solvent and allow to dry Dip the filter element in clean engine oil then squeeze out all excess oil The engine will smoke when started if too much oil is left in the foam 6 Wipe dirt from the inside of the air cleaner base and cover using a moist rag Be careful to prevent dirt from entering the air duct that leads to the carburetor 7 Place the foam air filter element over the paper element and reinstall the assembled air filter Be sure the gasket is in place beneath the air filter Tighten the air filter wing nut securely 8 Install the air cleaner cover and tighten the cover wing nut securely 31 SERVICING YOUR ENGINE Oil Bath Type 1 Remove the wing nut and remove the air cleaner cap and cover 2 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 3 Dip the filter in clean engine oil then squeeze out all excess oil The en
36. system cool cover the engine to keep out dust A hot engine and exhaust system can ignite or melt some materials Do not use sheet plastic as a dust cover A nonporous cover will trap moisture around the engine promoting rust and corrosion If equipped with a battery for an electric starter OXE2 type recharge the battery once a month while the engine is in storage This will help to extend the service life of the battery Removal From Storage Check your engine as described in the BEFORE OPERATION chapter of this manual If the fuel was drained during storage preparation fill the tank with fresh gasoline If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline Gasoline oxidizes and deteriorates over time causing hard starting If the cylinders were coated with oil during storage preparation the engine may smoke briefly at startup This is normal 41 HELPFUL TIPS amp 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 Keep the engine level when transporting to reduce the possibility of fuel leakage Move the fuel valve lever to the OFF position 42 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction 1 OXE2 electric starting Check battery an
37. uel valve lever to the ON position FUEL VALVE LEVER 15 2 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 S 3 Move the throttle lever away from the SLOW position about 1 3 of the way toward the FAST position Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here THROTTLE LEVER 16 4 Turn the engine switch to the ON position ALL ENGINES EXCEPT OXE2 QXE2 TYPE ENGINE SWITCH 5 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 STARTER GRIP 17 ELECTRIC STARTER OXE2 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 NOTICE Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it When the engine starts release the key allowing it to return to the ON ENGINE SWITCH position
38. urfaces touch up any damaged paint and coat other areas that may rust with a light film of oil NOTICE Using a garden hose or pressure washing equipment can force water into the air cleaner or muffler opening Water in the air cleaner will soak the air filter and water that passes through the air filter or muffler can enter the cylinder causing damage Water contacting a hot engine can cause damage If the engine has been running allow it to cool for at least half an hour before washing Fuel Gasoline will oxidize and deteriorate in storage Old gasoline will cause hard starting and it leaves gum deposits that clog the fuel system If the gasoline in your engine deteriorates during storage you may need to have the carburetor and other fuel system components serviced or replaced The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend your storage temperatures and whether the fuel tank is partially or completely filled The air in a partially filled fuel tank promotes fuel deterioration Very warm storage temperatures accelerate fuel deterioration Fuel deterioration problems may occur within a few months or even less if the gasoline was not fresh when you filled the fuel tank 37 HELPFUL TIPS amp SUGGESTIONS The Distributor s Limited Warranty does not cover fuel system damage or engine performance probl
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