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How to use this manual

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How to use this manual

A Few Words About Safety

SERVICE INFORMATION

The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting

service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage

this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures

require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not

recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend

that you do not use replacement parts of inferior quality.

For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight

while servicing this product can result in faulty operation, damage to the product, or injury to others.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety

practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge

of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every

conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should

perform a given task.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and

using safety equipment. When performing any service task, be especially careful of the following:
 • Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills

required to perform the tasks safely and completely.

 • Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around

pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.

 • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe

burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

 • Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure

that the hoist hook is securely attached to the product.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will

help eliminate several potential hazards:
 • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.

 • Burns from hot parts. Let the engine and exhaust system cool before working in those areas.

 • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when

working around gasoline or batteries.
 • Use only a nonflammable solvent, not gasoline, to clean parts.

 • Never store gasoline in an open container.

 • Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.

Improper service or repairs can create an unsafe

condition that can cause your customer or others to

be seriously hurt or killed.

Follow the procedures and precautions in this man-

ual and other service materials carefully.

Failure to properly follow instructions and precau-

tions can cause you to be seriously hurt or killed.

Follow the procedures and precautions in this man-

ual carefully.

62Z4H00X.book  1 ページ  2011年12月9日 金曜日 午後5時40分

Summary of Contents for GX120T2

Page 1: ...ng safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields anytime you hammer drill grind or work around pressurized...

Page 2: ...smitted in any form by any means electronic mechanical photocopying recording or otherwise without prior written permission of the publisher This includes text figures and tables As you read this manual you will find information that is preceded by a symbol The purpose of this message is to help prevent damage to this Honda product other property or the environment SAFETY MESSAGES Your safety and ...

Page 3: ...l unless otherwise specified Use molybdenum oil solution mixture of the engine oil and molybdenum grease in a ratio of 1 1 Use multi purpose grease lithium based multi purpose grease NLGI 2 or equivalent Use marine grease water resistant urea based grease Apply a locking agent Use a medium strength locking agent unless otherwise specified Apply sealant Use automatic transmission fluid x Indicates ...

Page 4: ...1 1 1 dummytext 1 SPECIFICATIONS P T O TYPE VARIATION 1 2 DIMENSIONS AND WEIGHTS SPECIFICATIONS 1 12 ENGINE SPECIFICATIONS 1 13 P T O DIMENSIONAL DRAWINGS 1 14 62Z4H00X book 1 ページ 2011年12月9日 金曜日 午後5時40分 ...

Page 5: ...le With protector Rammer Spark arrester Fuel gauge Remote choke lever Control base Manual Remote Internal Internal S EXP Norton Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Combination switch Starter motor Oil level switch Engine stop switch Oil alert unit Circuit protector Auto throttle Reduction Gear 1 6 Chain 1 2 Without clutch With clutch Camshaft P ...

Page 6: ...ector Rammer Spark arrester Fuel gauge Remote choke lever Control base Manual Remote Internal Internal S EXP Norton Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Combination switch Starter motor Oil level switch Engine stop switch Oil alert unit Circuit protector Auto throttle Reduction Gear 1 6 Chain 1 2 Without clutch With clutch Camshaft P T O Chain 1 ...

Page 7: ...ctor Rammer Spark arrester Fuel gauge Remote choke lever Control base Manual Remote Internal Internal S EXP Norton Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Combination switch Starter motor Oil level switch Engine stop switch Oil alert unit Circuit protector Auto throttle Reduction Gear 1 6 Chain 1 2 Without clutch With clutch Camshaft P T O Chain 1 1...

Page 8: ...With protector Rammer Spark arrester Fuel gauge Remote choke lever Control base Manual Remote Internal Internal S EXP Norton Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Combination switch Starter motor Oil level switch Engine stop switch Oil alert unit Circuit protector Auto throttle Reduction Gear 1 6 Chain 1 2 Without clutch With clutch Camshaft P T O...

Page 9: ...protector Rammer Spark arrester Fuel gauge Remote choke lever Control base Manual Remote Internal Internal S EXP Norton Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Combination switch Starter motor Oil level switch Engine stop switch Oil alert unit Circuit protector Auto throttle Reduction Gear 1 6 Chain 1 2 Without clutch With clutch Camshaft P T O Chai...

Page 10: ...tector Rammer Spark arrester Fuel gauge Remote choke lever Control base Manual Remote Internal Internal S EXP Norton Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Combination switch Starter motor Oil level switch Engine stop switch Oil alert unit Circuit protector Auto throttle Reduction Gear 1 6 Chain 1 2 Without clutch With clutch Camshaft P T O Chain 1...

Page 11: ...ammer Spark arrester Fuel gauge Remote choke lever Control base Manual Remote Internal Internal S EXP Norton Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Combination switch Starter motor Oil level switch Engine stop switch Oil alert unit Circuit protector Auto throttle Reduction Gear 1 6 Chain 1 2 Without clutch With clutch Camshaft P T O Chain 1 1 62Z4H...

Page 12: ... With protector Rammer Spark arrester Fuel gauge Remote choke lever Control base Manual Remote Internal Internal S EXP Norton Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Combination switch Starter motor Oil level switch Engine stop switch Oil alert unit Circuit protector Auto throttle Reduction Gear 1 6 Chain 1 2 Without clutch With clutch Camshaft P T ...

Page 13: ...rotector Rammer Spark arrester Fuel gauge Remote choke lever Control base Manual Remote Internal Internal S EXP Norton Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Combination switch Starter motor Oil level switch Engine stop switch Oil alert unit Circuit protector Auto throttle Reduction Gear 1 6 Chain 1 2 Without clutch With clutch Camshaft P T O Chain...

Page 14: ...ark arrester Fuel gauge Remote choke lever Control base Manual Remote Internal Internal S EXP Norton Fixed throttle operation Charge coil 1 A 3 A 7 A Lamp coil 12 V 15 W 12 V 25 W 12 V 50 W Combination switch Starter motor Oil level switch Engine stop switch Oil alert unit Circuit protector Auto throttle Reduction Gear 1 6 Chain 1 2 Without clutch With clutch Camshaft P T O Chain 1 1 62Z4H00X book...

Page 15: ...3 2 in N 335 mm 13 2 in 335 mm 13 2 in Q 318 mm 12 5 in 335 mm 13 2 in 335 mm 13 2 in R 335 mm 13 2 in S 318 mm 12 5 in 335 mm 13 2 in 335 mm 13 2 in T 318 mm 12 5 in V 318 mm 12 5 in 335 mm 13 2 in 335 mm 13 2 in VE 335 mm 13 2 in W 318 mm 12 5 in 335 mm 13 2 in WB 318 mm 12 5 in 335 mm 13 2 in Dry weight KR 16 5 kg 36 4 lbs L 14 0 kg 30 9 lbs 16 1 kg 35 5 lbs 17 1 kg 37 7 lbs N 15 1 kg 33 3 lbs ...

Page 16: ...p gal h 1 7 Liters 0 45 US gal 0 37 Imp gal h Ignition system C D I Capacitor Discharge Ignition type magneto ignition Ignition timing B T D C 20 1 400 min 1 rpm B T D C 18 1 400 min 1 rpm B T D C 20 1 400 min 1 rpm Recommended spark plug Except rammer type BPR6ES NGK W20EPR U DENSO Rammer type BPR4ES NGK W14EPR U DENSO Lubrication system Forced splash Oil capacity Except rammer type 0 56 Liter 0 ...

Page 17: ...0 8 3 954 0 1557 5 9 6 0 0 23 0 24 M8 x 1 25 TAPER 1 5 30 3 1 19 65 1 2 56 M8 x 1 25 45 45 Unit mm in 36 5 1 44 Φ19 972 19 993 0 7863 0 7871 M8 x 1 25 50 2 0 52 5 2 07 23 0 9 Φ41 25 1 624 65 1 2 56 65 1 2 56 50 1 1 97 51 5 2 03 P T O SHAFT N type M8 x 1 25 6 PLACES 62 2 4 33 1 1 30 5 00 5 03 0 197 0 198 16 90 17 00 0 665 0 669 62Z4H00X book 14 ページ 2011年12月9日 金曜日 午後5時40分 ...

Page 18: ...2 1 2 dummytext 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 62Z4H00X book 1 ページ 2011年12月9日 金曜日 午後5時40分 ...

Page 19: ... BE60W A 13 7 mm 0 54 in BE60Y A 13 7 mm 0 54 in BE60Z A 13 7 mm 0 54 in BE61L A 13 7 mm 0 54 in BE61M A 13 7 mm 0 54 in BE61N A 13 7 mm 0 54 in BE62J A 18 7 mm 0 74 in BE99A A 13 7 mm 0 54 in BE99D A 13 7 mm 0 54 in Part Item Standard Service limit Carburetor Main jet BE54D A 68 BE54G A 70 BE54H A 68 BE54J A 68 BE54K A 68 BE54M A 70 BE54P A 70 BE54Q A 70 BE66U A 68 BE66V A 68 BE67V A 75 Pilot scr...

Page 20: ... 75 BE74W A 78 BE74Y A 78 Pilot screw opening BE59L A 1 7 8 turns out BE59M A 1 7 8 turns out BE59N A 1 7 8 turns out BE59Q A 1 7 8 turns out BE59S A 2 1 4 turns out BE59U A 2 1 4 turns out BE59V A 2 1 4 turns out BE59W A 2 1 4 turns out BE69D A 2 1 4 turns out BE74W A 2 3 4 turns out BE74Y A 2 3 4 turns out Float height 13 7 mm 0 54 in 62Z4H00X book 3 ページ 2011年12月9日 金曜日 午後5時40分 ...

Page 21: ...MEMO 62Z4H00X book 4 ページ 2011年12月9日 金曜日 午後5時40分 ...

Page 22: ...6 1 6 6 FUEL SYSTEM FUEL TANK REMOVAL INSTALLATION 6 2 62Z4H00X book 1 ページ 2011年12月9日 金曜日 午後5時40分 ...

Page 23: ...dling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately Starter motor type 1 2 FUEL FILTER If equipped FUEL TANK JOINT FUEL TANK BOLT 6 x 29 mm FUEL FILLER CAP CHECK Check the fuel filter for clogs or damage O RING FUEL TANK FUEL TUBE CHECK Check for deterioration or cracks FUEL FILLER CAP PACKING CHECK Check for deterioration or cracks FUEL TANK NUT 6 mm 2 ...

Page 24: ...12 1 12 dummytext 12 MUFFLER MUFFLER REMOVAL INSTALLATION 12 2 62Z4H00X book 1 ページ 2011年12月9日 金曜日 午後5時40分 ...

Page 25: ...eful not to touch the muffler while it is hot Allow it to cool before proceeding MUFFLER PROTECTOR SCREW 5 x 8 mm 4 SCREW 4 x 6 mm BOLT 6 x 14 mm If equipped SPARK ARRESTER If equipped MUFFLER MUFFLER NUT 8 mm 2 EXHAUST PIPE GASKET 24 N m 2 4 kgf m 18 lbf ft If equipped If equipped SCREW 4 x 6 mm 3 LOWER PROTECTOR SCREW 4 x 8 mm 2 MUFFLER GUIDE DEFLECTOR 62Z4H00X book 2 ページ 2011年12月9日 金曜日 午後5時40分 ...

Page 26: ...15 1 15 dummytext 15 REDUCTION UNIT REDUCTION UNIT DISASSEMBLY ASSEMBLY 15 2 REDUCTION UNIT INSPECTION 15 3 REDUCTION UNIT BEARING OIL SEAL REPLACEMENT 15 3 62Z4H00X book 1 ページ 2011年12月9日 金曜日 午後5時40分 ...

Page 27: ...et the connecting rod lower with the oil dipper toward the camshaft Big end bearing DOWEL PIN CRANKSHAFT INSPECTION page 14 6 INSTALLATION Be careful not to damage the oil seal lips Pin and gear teeth REMOVAL Mark the valve lifters so that the intake and exhaust sides can be distinguished INSTALLATION Attach the valve lifters to the cylinder barrel immediately before installing the camshaft CAMSHA...

Page 28: ...SE COVER SIDE BEARING CRANKSHAFT BEARING 6304 Pull out the crankshaft bearing 1 using the special tools Drive a new crankshaft bearing 5 until it is fully seated on the end using the special tools 1 2 3 TOOLS Bearing remover shaft set 20 mm 2 07936 3710600 Bearing remover shaft handle 3 07936 3710100 Sliding hammer weight 4 07741 0010201 TOOLS Bearing driver attachment 52 x 55 mm 6 07746 0010400 P...

Page 29: ...FT OIL SEAL Remove the oil seal from the chain case cover Drive a new oil seal 1 in the position as shown using the special tools TOOLS Bearing driver attachment 52 x 55 mm 2 07746 0010400 Pilot 25 mm 3 07746 0040600 Driver handle 4 07749 0010000 4 2 3 1 INSTALLATION HEIGHT 1 5 mm 0 06 in TOOLS Bearing driver attachment 37 x 40 mm 2 07746 0010200 Driver handle 3 07749 0010000 2 1 3 62Z4H00X book 4...

Page 30: ...L INSTALLATION 6 2 M MAINTENANCE STANDARDS 2 2 MUFFLER REMOVAL INSTALLATION 12 2 P P T O DIMENSIONAL DRAWINGS 1 14 P T O TYPE VARIATION 1 2 R REDUCTION UNIT BEARING OIL SEAL REPLACEMENT 15 3 REDUCTION UNIT DISASSEMBLY ASSEMBLY 15 2 REDUCTION UNIT INSPECTION 15 3 62Z4H00X book 1 ページ 2011年12月9日 金曜日 午後5時40分 ...

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