Honda GX120, Owner'S Manual

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Page 3: ...ain with the engine if resold The information and specifications included in this publication were in effect at the timeof approval for printing Illustrations are based on the GX160 Only the QXE2 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 ...

Page 4: ...mbol Thatinformationisintendedtohelpyouavoid damage to yourengine other property or the environment We suggest you read thewarrantypolicytofullyunderstandits 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 Hondaservicingdealerisspeciallytr...

Page 5: ...ou must use your own good judgment You will findimportant safety informationin a varietyofforms including Safety Labels on the engine Safety Messages preceded by a safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean YouWILL be KILLED or SERIOUSLYHURT if you don t follow instructions YouCANbe KILLED or SERIOUSLY HURT if you don t follow instructions...

Page 6: ... Check the Engine 14 Check the Equipment Poweredby This Engine 14 OPERATION 15 SAFE OPERATING PRECAUTIONS 15 STARTING THE ENGINE 15 STOPPING THE ENGINE 19 SETTING ENGINE SPEED 20 SERVICING YOUR ENGINE 21 THE IMPORTANCEOF MAINTENANCE 21 MAINTENANCE SAFETY 22 MAINTENANCE SCHEDULE 23 REFUELING 24 FUEL RECOMMENDATIONS 25 ENGINE OIL LEVEL CHECK 26 ENGINE OIL CHANGE 27 ENGINE OIL RECOMMENDATIONS 28 TRAN...

Page 7: ... ENGINE WILL NOTSTART 45 ENGINE LACKS POWER 45 FUSE REPLACEMENT QXE2 type only 46 TECHNICAL CONSUMER INFORMATION 47 TECHNICAL INFORMATION 47 Serial Number Location 47 Battery connections for Electric Starter QXE2 type only 48 Remote Control Linkage 49 Carburetor Modification for High Altitude 50 Oxygenated Fuels 51 Emission Control System Information 52 Air Index 54 Specifications 55 Wiring Diagra...

Page 8: ...dren to operate the engine Keep children and pets away from thearea of operation RefuelWith Care Gasolineisextremelyflammable andgasolinevaporcanexplode Refueloutdoors in awell ventilated area withtheenginestopped 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...

Page 9: ...un 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 or operation or protective apparel that may be neededto operate the equipment ...

Page 10: ...LOCATIONS MUFFLER THROlTLE LEVER ENGINE SWITCH QXEStype CIRCUIT BREAKER QXE2type AIR CLEANER RECOIL STARTER CHOKE LEVER FUELVALVE LEVER I Inner vent type STARTER GRIP BREATHERTUBE FUELTANK ELECTRIC STARTER OIL DRAIN PLUG FUEL FILLERCAP 7 ...

Page 11: ...ge 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 FUEL VALVE LEVER 8 ...

Page 12: ... the OFF position stops the engine ALL ENGINES EXCEPT QXE2 QXE2 TYPE ENGINE SWITCH CIRCUIT BREAKER QXE2 Type The engine switch on the QXE2 type includes a START position for operating the electric starter The key automatically returns to the ON position whenreleased from theSTART position The circuit breaker whichislocatedbelowthe key protectsthe battery charging circuit see page12 9 ...

Page 13: ...e CLOSED positionenrichesthefuelmixtureforstartingacold engine The OPEN positionprovidesthecorrectfuelmixtureforoperation after starting andfor restarting a warm engine Some engine applications use a remotely mounted choke control rather than the engine mounted choke lever shown here CHOKELEVER 1 10 ...

Page 14: ...in the directions shown makes the engine run faster or slower Someengineapplicationsuse a remotely mountedthrottlecontrol 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 engin STARTER GRIP 11 ...

Page 15: ... engine stops and will not restart check the engine oil level page 26 before troubleshootingin other areas Circuit Breaker QXEZ type only The circuit breaker protects the battery charging circuit 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 circuitbreaker has switched off If t...

Page 16: ...n could cause a malfunction in which you could be seriously injured Always performa preoperation inspection beforeeach operation i and correct any problem Before beginning your preoperation checks be surethe engine is level and the engine switch is in the OFF position Check the General Conditionof the Engine 0 Look around and underneaththe engine for signs of oil or gasoline leaks Remove any exces...

Page 17: ...mission oil level onapplicableenginetypes see page 29 Oil is essential to transmission operation and long life Check the air filter see page 31 A dirty air filter will restrict airflow to thecarburetor reducing engine performance 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 Poweredby This Engin...

Page 18: ...as is toxic Breathing it can cause unconsciousness and even kill you Avoid any areas or actionsthat 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 fuel valve lever to the ON position FUELVALVE LEVER 15 ...

Page 19: ...applications usea remotely mountedchokecontrol rather than the engine mounted choke lever shown here CHOKE LEVER I 3 Move the throttlelever 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 THROlTLE LEVER 16 ...

Page 20: ... the ON position ALL ENGINES EXCEPTQXE2 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 ...

Page 21: ...e operating the starter again p i E q Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it Whentheengine starts release the key allowing it to return to the ON ENGINE SWITCH position QXE2 type 6 If the choke lever has been moved to theCLOSED position to start the engine gradually move it to the OPEN position as the engine warms up CHOKELEVE...

Page 22: ...ormal conditions use the following procedure 1 Move the throttle lever to theSLOW position Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here THROlTLE LEVER 2 Turn the engine switch to the OFF position ALL ENGINES EXCEPT QXEZ QXEZ TYPE ENGINE SWITCH 19 ...

Page 23: ...sition the throttle lever for the desired engine speed Someengineapplicationsusearemotely mountedthrottlecontrol 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 ...

Page 24: ...s andsimple maintenance procedures using basic hand tools Other service tasks that are more difficult or require specialtools 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...

Page 25: ...on monoxide poisoningfrom engine exhaust Be sure there is adequate ventilation whenever you operate the engine Let the engine and exhaust system cool before touching Do not run the engine unless instructedto doso Burns from hotparts Injury from movingparts Read the instructions before youbegin and make sure you have the tools andskills required Toreduce thepossibilityoffireorexplosion becarefulwhe...

Page 26: ...lace paper element type only Cyclone type every 2 years or 600 hours 1 Service more frequently when usedin dusty areas 2 These itemsshouldbeservicedbyyourservicing 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 ...

Page 27: ...al 3 6 Q 0 79 Imp gal With the engine stopped remove the fuel tank cap and check the fuel level Refill the tankif the fuel level is low Gasoline ishighlyflammable 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 24 ...

Page 28: ...nty FUEL RECOMMENDATIONS Use unleaded gasoline with a pumpoctane rating of 86 or higher These enginesare 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 meta...

Page 29: ... If the oil level is low fill to the edge of the oil filler hole with the recommended oil see page28 4 Screw in the filler cap dipstick securely FILLER CAP DIPSTICK LOWER LIMIT NOTICE I Running the engine with a low oil level can causeengine damage The OilAlert system applicable engine types will automatically stop the engine before the oil level falls below safe limit However to avoid theinconven...

Page 30: ...o your local recycling center or service station for reclamation Do not throwit 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 holewith the recommended oil see page28 Engine oil capacity 0 63 US qt 0 60 0 0 53 Imp qt m Running the engine with a low oil level can cause engine damage TheOilAlert system applicableengin...

Page 31: ... is recommended for general use Other viscositiesshown in the chart may be used when the average temperature in your area is within the recommendedrange I I I I 1 I I I 30 20 10 0 10 20 30 40 C AMBIENT TEMPERATURE The SAE oil viscosity and service classification are in the API label on theoilcontainer Hondarecommendsthatyouuse API SERVICE category SJ oil 28 ...

Page 32: ...l to reach the upper limit mark on the dipstick Use the same oil that is recommended for the engine see page 28 4 Screw in the filler cap dipstick securely ILLERCAP DIPSTICK UPP LlMI f 1 6 ReductionTransmission DRAIN BOLT 1 Remove the oil level check bolt and see weathertheoillevelis at the edge of the bolt hole 2 If theoillevelisbelowthe check bolt hole remove the filler bolt and add oil until1 i...

Page 33: ...environment We suggest you take Lased oil in a sealed container to your local recyling center or service station for reclamation Do not throwit in the trash pour it on the ground or down a drain 3 With the enginein a level position fill to the upper limit mark on the dipstick with the same oil that is recommended for the engine see page 28 To check the oillevel insert and move the dipstick without...

Page 34: ...ace damaged filter elements If equipped withan oil bath aircleaner also check the oil level Refer to pages 32 34 for instructions that apply to the air cleaner and filter on your type of engine PAPER FILTER ELEMENT FOAM FILTER ELEMENT STANDERD CYCLONE DUAL OIL BATH TYPE ELEMENTTYPE TYPE see p 32 33 seep 32 33 DUAL FILTER FILTER ELEMENT seep 34 31 ...

Page 35: ...ine causing rapid enginewear This type of damage is not covered by the Distributor s Limited Warranty Dual Filter Element Types 1 Remove the wing nut from the aircleanercover andremove the cover STANDERD DUAL FILTER ELEMENT TYPE 2 Remove the wing nut from the air filter and remove the filter 3 Remove the foam filter from the paper filter ELEMENT 4 Inspect both air filter elements and replace themi...

Page 36: ...started if too much oil is left in the foam 6 CYCLONE TYPEONLY Remove the three pan head screws from the precleaner cap thenremovethecyclonehousingandairguide Wash the parts with water drythemthoroughly andreassemble them Be sure to install the air guide as shown in the illustration Install the cyclone housing so the air intake tab fits into the groove in the precleanercap 1 7 Wipe dirt from the i...

Page 37: ...ip the filterin clean engine oil then squeeze out allexcess oil The engine will smoke if too much oil is left in the foam 4 Emptytheusedoilfromthe air cleaner case washoutany accumulated dirt with nonflammable solvent and dry the case 5 Fill the air cleaner case to theOIL LEVEL mark with the same oil that is recommended for the engine see page28 Oil capacity 2 0 US oz 60 cm3 2 1 Imp 02 6 Reassembl...

Page 38: ...jured when handling fuel Keep heat sparks and flameaway 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 theO ring in thefuel valve andinstallthesediment cup Tighten the sediment cup securely 4 Move the fuel valve to the ON position and check for 1eaks Replace the O ring if there is any leakage O RING 35...

Page 39: ...g wrench SPARK PLUG WRENCH 3 Inspect the spark plug Replace it 0 028 0 031 in if the electrodes are worn or if the 0 70 0 80 mm insulatoris cracked orchipped Clean the spark plug with a wire brush if you are going toreuse it 4 Measure the spark plug electrode gap with asuitablegauge The g a p s h o u l d b e 0 028 0 031 i n 0 70 0 80 mm Correct the gap if necessary by carefully bending the side el...

Page 40: ...park plug seats I NOTICE I A loose sparkplug can overheatand damage the engine Overtightening the spark plug can damage the threads in the cylinder head 7 Attach the spark plug cap IDLE SPEEDADJUSTMENT 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 Stande...

Page 41: ...e servicing the spark arrester 1 Removethethree 4 m m screws fromtheexhustdeflector and remove the deflector 2 Removethefour 5 mm screws fromthemufflerprotectorand remove the muffler protector 3 Remove the 4 mm screw from the spark arrester and remove the spark arresterfrom the muffler 7 5 mm SCREWS MUFFLER PROTECTOR EXHAUST DEFLECTOR SPARK ARRESTER 4 Usea brushtoremovecarbondeposits from the spar...

Page 42: ...an enterthe cylinder causing damage Water contacting a hotengine can cause damage If the engine has been running allow it to cool for at least half an hour before washing Fuel Gasoline will oxidizeanddeteriorate in storage Oldgasoline will cause hard starting and it leaves gum depositsthatclogthefuel system If the gasoline in your engine deteriorates during storage you may need to have the carbure...

Page 43: ...XTEND FUEL STORAGE LIFE When adding a fuel stabilizer fill the fuel tank with fresh gasoline If onlypartiallyfilled airinthe tank willpromotefueldeterioration during storage If you keep a container of gasoline for refueling be sure thatit contains only fresh gasoline 1 Add fuel stabilizer following the manufacturer s instructions 2 After addinga fuel stabilizer run the engine outdoors for 10 minut...

Page 44: ...in bolt and sedimentcup then move the fuel valve lever to the ON position 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 drain bolt and sediment cup Tighten them securely 41 ...

Page 45: ...ylinder Return the starter rope gently Align notch on pulley with hole at top of cover Storage Precautions If yourenginewillbestoredwithgasoline in thefueltankand carburetor it isimportantto reduce the hazard of gasolinevapor ignition Select awell ventilated storagearea away from any appliance that operates with a flame such as a furnace water heater or clothes dryer Also avoid any area with a spa...

Page 46: ... starter QXE2 type recharge This will help to extend the service life of the battery the battery once a month while the engine is in storage Removal From Storage Check your engineas described in theBEFOREOPERATIONchapter of this manual If the fuel was drained during storage preparation fill the tank with freshgasoline If you keepa containerofgasolineforrefueling be sure that it contains only fresh...

Page 47: ...t least 15 minutes before loading the engine powered equipment on the transport vehicle A hot engine and exhaust system can burn you andcan 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 44 ...

Page 48: ...uretor malfunction ignition malfunction valves stuck etc PossibleCause Filter element s clogged Badfuel engine stored without treating or draininggasoline or refueledwith bad gasoline Fuel filter clogged carburetor malfunction ignition malfunction valves stuck etc Correction Recharge battery Replacefuse p 46 Move lever to ON Move lever to CLOSED unless engineis warm Turn engine switch to ON Refuel...

Page 49: ...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 ampere fuse and reinstall the fuse cover Neveruse 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 REAR C...

Page 50: ...TION TECHNICAL INFORMATION Serial Number Location Record the engine serial number in the space below Youwill need this serialnumberwhenordering parts andwhenmakingtechnicalor warranty inquires see page 60 Engine serial number 47 ...

Page 51: ... the positive battery cable end 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 thebatterypositive cable tothe startersolenoid 2 Connect the battery negative 1 cable to an engine mounting bolt 3 Connect the battery positive cable to the battery positive 4 Connect the ...

Page 52: ...ible 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 REMOTETHROTTLE LINKAGE THROTTLE LEVER PIVOT NUT Flexiblewire core mouTg mounting RETURN SPRING W I R h WIRE HOLDER 4 mm SCREW 1 ClRCLlP mm eTHROTTLE J LEVER 6 REMOTECHOKE LINKAGE I I I OPTIO...

Page 53: ...erformthis carburetor modification This engine when operated at high altitude with the carburetor modifications for high altitudeuse will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor ...

Page 54: ...line containing up to 10 ethanol by volume Gasolinecontainingethanol may be marketed under the name Gasohol MTBE methyl tertiary butyl ether 15 by volume You may use gasoline containing up to15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it alsocontains cosolvents and corrosion inhibitors to protect the fuelsystem...

Page 55: ...hydrocarbons The US and California Clean Air Acts EPA andCaliforniaregulationsrequire all manufacturers tofurnish 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 Tamperingand Altering Tampering with or altering the ...

Page 56: ...artsaremanufactured tothe samestandards 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...

Page 57: ...iption is intended to provide you with information relating tothe engine semissiondurabilityperiod Thedescriptive term indicates the useful life period for the engine s emission control system See your Emission Control Warranty for additional information Descriptive Term 50 hours 0 65 cc Moderate Applicable to Emissions Durability Period 125 hours greater than 65 cc Intermediate 125 hours 0 65 cc ...

Page 58: ...ment 4 stroke overhead valve single cylinder Engine type 28 7 Ibs 13 0 kg Dry weight 11 7 X 13 4 X 12 5in 297 X 341 X 318 mm Length X Width X Height Counterclockwise PTO shaft rotation Transistorized magneto Ignition system Forced air Cooling system 0 51 Ib hph 313g kWh 230 g PSh Fuel consumption 8 0 Ibf ft 10 8N m 1 I kgf m at 2 500 rpm Max torque 5 4 bhp 4 0kW 5 5 PS at 3 600 rpm Max output 2 7 ...

Page 59: ...nsumption 9 76Ibf ft 13 2N m 1 35kgf m at 2 500rpm Max torque 6 4bhp 4 8 kW 6 5PS at3 600rpm Max output 2 7X 2 1 in 68X 54mm Bore X Stroke I lanition svstem I Transistorized maaneto I I PTO shaft rotation ounterclockwise GX120 GX160 GX200 Tuneup ITEM MAINTENANCE SPECIFICATION Spark plug gap No other adjustmentsneeded Other specifications See your authorized IN 0 15k0 02mm cold Valve clearance 0 70...

Page 60: ...ENGINE SWITCH CONTROL BOX CHARGING SPARK COIL PLUG FUSE I Iw IWHITE IIG IGREEN I OIL Bvw LEVEL SWITCH W BAlTERY 4 0 m I 2 D 5 r ...

Page 61: ...BI BLACK LEVEL SWITCH ...

Page 62: ...u additional information for maintainingandrepairingyourengine You mayorderthemfrom your Honda engine dealer Shop Manual This manual covers complete maintenance and overhaul procedures It is intended tobe used bya skilled technician Parts Catalog This manual provides complete illustrated parts lists 59 ...

Page 63: ...y If you are dissatisfiedwiththedecisionmade bythe 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 Model andserial number see page47 Name ...

Page 64: ...S gal 3 6 e 0 79 Imp gal Capacity GXI20 TY Pe SAE IOW 30 API SJ for general use page 28 Capacity NGK BPRGES Tvpe 0 63 US qt 0 60 0 0 53 Imp qt DENSO W20EPR U 0 028 0 031 in 0 70 0 80 mm Each use Check engine oil level First 20 hours Subsequent Check trakmission oillevel if applicable Check air filter Change engine oil Change transmission oilif applicable Refer to themaintenance schedule on page 23...

Page 65: ...HONIBA The Powerof Dreams K1 GX120 GXI60 31ZH7630 HC 32000 2001 06 00x31 ZH7 6300 Printed in Japan ...