Honda GX120T2, Supplement Manual

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 ...