Honda GX360, Owner'S Manual

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Page 3: ... 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 thetimeofapprovalforprinting HondaMotor 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 thispublicationmay be r...

Page 4: ...bol Thatinformationis intendedtohelpyouavoid damage to your engine other property orthe environment Wesuggest 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 Hondaservicingdealer isspeciallytr...

Page 5: ...ust use your own good judgment You will findimportant safetyinformationinavarietyofforms 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 You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions Yo...

Page 6: ...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 HONDA ENGINE 21 THE IMPORTANCEOF MAINTENANCE 21 MAINTENANCE SAFETY 22 MAINTENANCE SCHEDULE 23 FUEL RECOMMENDATIONS 24 ENGINE OIL LEVEL CHECK 25 ENGINE OIL CHANGE 26 OIL FILTER CHANGE 27 ENGINE OIL RECOMMENDATIONS 28 AIRFILTER INSPECTION ...

Page 7: ...INE WILL NOTSTART 48 ENGINE LACKS POWER 49 ENGINE PROTECTION SYSTEM ACTIVATED 50 FUSE REPLACEMENT 51 TECHNICAL CONSUMER INFORMATION 53 TECHNICAL INFORMATION 53 Serial Number Location 53 Battery Connectionsfor Electric Starter 54 Oxygenated Fuels 56 Emission Control System Information 57 Air index 59 Specifications 60 Wiring Diagrams 61 CONSUMER INFORMATION 63 Honda Publications 63 Warranty Service...

Page 8: ...hildren to operate the engine Keep children and pets away from the area 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 en...

Page 9: ...n 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 needed to operate the equipment 6 ...

Page 10: ...se labels are considered permanent parts of your engine If a label comes off or becomes hard to read contact an authorized Honda servicing dealer for a replacement CAUTION APPLY A THIN FILM OF OIL TO THE GASKET BEFORESCREWING ON AND TIGHTEN THE CARTRIDGE TIGHTENING TORQUE 1 5 2 0 k9 m START ENGINE AND CHECK FOR OIL LEAKAGE 7 ...

Page 11: ...CONTROLS FEATURES COMPONENT CONTROL LOCATIONS RADIATOR RESERVETANK VENT TUBE FILLER CAP OIL DRAINPLUG CARBURETOR DRAINTUBE RADIATOR CAP RADIATOR DRAIN PLUG 8 ...

Page 12: ...in the ON position for the engine to run Turning the engine switch to the OFF position stops the engine Turning the engine switch to the START position operates the electric starter to crank the engine The key automatically returns to the ON position whenreleased from theSTART position 10A CHARGECOIL TYPE 3A CHARGECOIL TYPE 9 ...

Page 13: ... and for running the engine at maximum speed START Enriches the fuel mixture for starting a cold engine CHOKE Some engine applications use a remotely mounted control rather than the engine mounted control lever shown here Refer to the instructions provided with the equipment poweredby this engine for remote control information START FAST CHOKE CONTROLLEVER SLOW 10 ...

Page 14: ...m lack of lubrication or overheating If there is a loss of oil pressure which may indicate lowoil level or if the coolant becomes too hot the engine will stop and the alert light will come on the engine switch will remain inthe ON position ALERT LIGHT ENGINE SWITCH a 10A CHARGECOILTYPE ALERT LIGHT SWITCH ENGINE 3A CHARGE COIL TYPE 11 ...

Page 15: ...attery connected with reverse polarity will trip the circuit breaker The green indicator inside the circuit breaker will pop out to show that the circuit breakerhas switched off If thisoccurs determine thecause of the problem and correct it before resetting the circuit breaker Push the circuitbreaker button toreset CIRCUIT BREAKER 12 ...

Page 16: ...ration could cause a malfunction in which you could be seriously injured Always performa preoperation inspection beforeeach 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 Checkthe General Conditionof the Engine Look around and underneath the engine for signs of oil gasoline or coolant leaks Remove...

Page 17: ...arkswhentheengineisatnormal operating temperature Check the radiator screen see page 32 and clean it if blocked with dirt and debris Check the air filter see page29 A dirty air filter will restrict airflow to the carburetor reducing engine performance Check thefuellevel Starting with a fullfueltank will help to eliminate or reduce operating interruptions for refueling Check the Equipment Poweredby...

Page 18: ...ed BEFORE OPERA TION Carbon monoxidegas is toxic Breathing it can cause unconsciousness and even kill you Avoid any areas or actions that expose you tocarbon 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 15 ...

Page 19: ...e 2 To start a cold engine move the control lever to theSTART CHOKE position To restart a warm engine leave thecontrollever in the FAST position Someengineapplicationsuse a remotely mountedcontrolrather thantheengine mountedcontrollevershown here Refer tothe instructions provided with the equipment powered by this engine for remote control information CONTROL 16 ...

Page 20: ... within 5 seconds release the key and wait at least 10seconds before operating the starter again Using the electricstarter for more than 5 seconds at a time will overheat the starter motor and can damageit When the engine starts release the key allowing it to return to the ON position m 10A CHARGECOIL TYPE 3A CHARGE COILTYPE 17 ...

Page 21: ...ally move it to theFAST or SLOW position as the engine warms up Someengineapplicationsuse a remotely mountedcontrolrather than theengine mountedcontrollevershown here Refer tothe instructions provided with the equipment powered by this engine for remote control information CONTROLLEVER START CHOKE 18 ...

Page 22: ...n Someengineapplicationsuse a remotely mountedcontrolrather thantheengine mountedcontrollevershown here Refer tothe instructions provided with the equipment powered by this engine for remote control information SLOW 2 Turn the engine switch to the OFF position SWITCH 10A CHARGECOIL TYPE 3A CHARGECOIL TYPE SWITCH 3 If the fuel tank is equipped with a valve turn the fuel valve to the CLOSED or OFF p...

Page 23: ...e desired engine speed Some engine applicationsuse a remotely mounted control rather than the engine mounted control lever shown here For engine speed recommendations refer to the instructions provided with the equipment powered by this engine CONTROL LEVER FAST 20 ...

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

Page 25: ... monoxide poisoning from 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 instructed to do so Burns from hotparts Injury from movingparts Read the instructions before you begin and make sure you have the tools and skills required To reduce thepossibilityoffireorexplosion becarefu...

Page 26: ...essary 2 Emission related items Replace the paper filter element 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 maintenance intervals 3 For commercial use log hours of operation to determine proper 4 The fuel tank is n...

Page 27: ...ater 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 Ifsparkknock orpinging occursatasteadyengine speed under normal load changebrands of gasoline Ifsparkknock orpinging persists see an authorized Honda servicing dealer Running the engine with persistent spark knock or pinging can cause ...

Page 28: ...l level is near or below the lowerlimit mark on thedipstick fill with the recommended oil to the upper limit mark see page28 4 Screw in the filler cap dipstick securely FILLERCAP DIPSTICK UPPER LOWER LIMIT LIMIT 1 Running the engine with a low oil level can causeengine damage The engine protection system will automatically stop the engine beforethe oil levelfalls below safe limits However toavoidt...

Page 29: ...ur 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 upper limit mark on the dipstick with the recommended oil see page28 ENGINE OIL REFILL CAPACITIES Without oil filter replacement 1 16 US qt 1 10 Z 0 97 Imp qt With oil filterreplacement 1 48 US qt 1 40I2 1 23 Imp qt Theengi...

Page 30: ...ter or a non Honda filter whichis not of equivalent quality may cause engine damage 4 Screw on the new oil filter by hand until the gasket contacts the filter mountingbase then usean oil filter wrench to tighten the filte an additional7 8 turn OIL FILTER TIGHTENINGTORQUE 13 Ibfmft 1 7 N m 1 75 kgf m 5 Refill the crankcase with the specified amount of the recommended oil see page 26 28 Reinstall th...

Page 31: ... general use Other viscositiesshown in the chart may be used when the average temperature in yourarea is within the recommended range SAE VISCOSITY GRADES 20 0 20 40 60 80 100 F I I I I I 1 1 1 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: ...ng nuts and remove the air cleaner cover Check thefilterelementstobe sure they arecleanand in good condition If the filter elements are dirty clean or replace them as described on page 30 Damaged filter elements must be replaced WING NUTS Y AIR CLEANER PAPER FILTER 29 ...

Page 33: ...ilter orwith adamaged air filter will allow dirt to enter the engine causing rapid enginewear Thistype of damage is not covered by the Distributor s Limited Warranty 1 Remove the two wing nuts from the air cleaner cover and WINGNUTS remove the cover 2 Remove the filter elements and separate the foam filter element from thepaper filter element 3 Inspect both air filter elements and replace themifth...

Page 34: ...am 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 allexcess oil The engine will smoke when started if too much oil is left in the foam 5 Wipe dirt from the inside of the air cleaner base and cover using a moist rag Be careful to prevent dirt from entering the ai...

Page 35: ...nehas been running the radiatorwill be very hot Allow the radiator to cool before servicing Check the radiator screen to be sure it is clean and in good condition If the radiator screenis dirty or clogged clean it as described on page 33 RADIATOR RADIATOR SCREEN 32 ...

Page 36: ...g the radiatorwill be very hot Allow the radiator to cool before servicing 1 Remove the four 6 m m flange bolts from the radiator screen and remove thescreen 2 Clean debris from the screen andradiator core 3 Install the radiator screen in the reverse order of removal 6 mm FLANGE BOLT 4 RADIATOR 33 ...

Page 37: ...adiator the engine protectionsystem will not stop theengine and the temperature warninglight will notcome on Always check the coolant level before operation Check the coolant level in the reserve tank It should be between the MAX and MIN marks when the engine is at normal operating temperature If the coolant level is near the MIN mark adda 50 50 solution of antifreeze and water to bring it up to t...

Page 38: ...t counterclockwise untill it stops Afteranyremainingpressure has been relieved remove the cap by pressing down and again turning it counterclockwise Addenoughcoolanttofillthethe radiator and reinstall the cap Fill the reserve tankto theMAX mark afterthe engine I reaches normal operating temperature Removing the radiator cap while the engine is hot can cause the coolant to spray out seriously scald...

Page 39: ...re removing the radiator cap or drain plug 1 Remove the radiatorcap using the following procedure Without pressing down on the cap turn it counterclockwise until it stops After any remaining pressure has been relieved remove the cap by pressing down and again turning it counterclockwise 2 Place a suitablecontainerbelowtheenginetocatchtheused coolant then remove the coolant drain plug 3 Allow the u...

Page 40: ...filler opening without tightening the cap Start theengine and letit run until the upper radiator feels warm 8 Stop the engine and remove the radiator cap Check the coolant level and add more coolant to the radiator if necessary 9 Againf put the radiator cap o n t h e f i l l e r o p e n i n g withouttightening Restart the engine and run it for a few minutes Stop the engine check thecoolant level a...

Page 41: ...hylene glycol antifreeze and water is recommended for most temperatures andit provides good corrosion protection A higherconcentration of antifreezedecreasescooling efficiency and is recommended if additional protection against freezing is needed A concentration of less than 40 antifreeze will not provide enough corrosion protection 1 I NOTICE I The wrong type of antifreeze hard water orsalt water...

Page 42: ...rench SPARK PLUG CAP 3 Inspect the spark plugs Replace 0 024 0 028in them if the electrodes are worn 0 60 0 70mm orif the insulatoris cracked or chipped Clean the spark plugs with a wire brush if youare going to reuse them 4 Measure the spark plug electrode gapwith a suitable gauge The g a p s h o u l d b e0 024 0 028 i n 0 60 0 70 mm Correct the gap if necessary by carefully bending the side elec...

Page 43: ...n after each spark plug seats I A loose sparkplug can overheat and damage the engine Overtightening the spark plug can damage the threads in the cylinder head 7 Attach the spark plug caps IDLE SPEEDADJUSTMENT 1 Start the engine outdoors and allow it to warm up to operating temperature 2 Move the control lever to its slowest position 3 Turn the throttle stop screw to obtain the standard idlespeed S...

Page 44: ...erwillbeveryhot Allowthe muffler to cool before servicing the spark arrester 1 Loosen two 5 m m pan screwson the arrestercap 2 Remove the arrester cap then pull out spark arrester taking care not to damage the wire mesh 3 Check the muffler exhaust port for carbon deposits clean if necessary m ARRESTER CAP 5mm PAN SCREWS 4 Use a brushtoremovecarbondeposits from the spark ester en Be P careful to av...

Page 45: ...ffler can enterthe cylinder causing damage Water contacting a hotengine can cause damage If the engine has been running allowitto cool forat least half an hour before washing Fuel Gasoline will oxidizeanddeteriorateinstorage Oldgasoline will cause hardstarting and it leaves gum depositsthatclogthefuel system If the gasoline in your engine deteriorates during storage you may need to have the carbur...

Page 46: ...naddingafuel stabilizer fillthefueltank with freshgasoline If onlypartiallyfilled airinthe tank will promotefueldeterioration during storage If you keepa 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 gasol...

Page 47: ...or ON position to enable draining After draining is completed reconnect the fuel line 2 Loosen the carburetor drain screw and drain the carburetor into an approvedgasolinecontainer Afterdrainingiscompleted tighten the carburetor drain screw I Gasoline ishighly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors...

Page 48: ...ankand carburetor it isimportantto reduce the hazard ofgasolinevapor 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 spark producing electric motor or where power tools are operated Ifpossible avoidstorage areas with highhumidity because that promotes rust and corrosion Unless...

Page 49: ...acool dry place 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 engineas described in the BEFOREOPERATIONchapter of this manual If the fuel was drained during storage preparation fill the tank with freshgasoline If you keep a containerofgasolineforrefueling be sure that it contains only fresh ...

Page 50: ...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 Ifthefueltankisequippedwith a fuelvalveand orvent valve turn them to thsCLOSED or OFF position 47 ...

Page 51: ... Spark plugs faulty fouled or improperly gapped Spark plugs wet with fuel flooded engine Carburetor malfunction ignition malfunction valves stuck etc Correction Recharge battery Replace fuse p 51 Move lever to ON Move leverto START position unless engine is warm Turn engine switchto ON Refuel Drain fuel tank and carburetor p 44 Refuel with fresh gasoline Clean gap or replace spark plugs p 39 Dry a...

Page 52: ...manual PossibleCause Filter elements clogged Bad fuel engine stored without treating or draininggasoline or refueled with bad gasoline Carburetor malfunction ignition malfunction valves stuck etc Correction Clean or replace filter elements p 30 Drain fuel tank and carburetor p 44 Refuel with fresh gasoline Replace or repair faulty componentsas necessary 49 ...

Page 53: ...el in the reserve tank and add coolant if needed see pages 34 35 Inspect the radiatorscreen see pages 32 33 Cleanit if blockedwith dirt and debris Allow anoverheatedengine tocoolforabouthalfanhourbefore restarting If restarted while overheated the engine protection system will immediately stop the engine again INOTICE I If the coolingsystem is empty orif the coolant level is lower than the tempera...

Page 54: ... box 2 Remove the6 X 12 m m special pan screwfrom the control box case 3 Remove the control box case and inspectthe fuse If the fuse is burnt out remove the fuse cover then pull out and discard the burnt out fuse Install a new specified fuse and reinstall the fuse cover pEiG l Neveruseafuse with a rating greater than specified Serious damage to the electrical system or a fire couldresult 4 Install...

Page 55: ...CTED PROBLEMS I FUSE BOX SPARE FUSE Frequent fuse failure usually indicatesa 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 52 ...

Page 56: ...INFORMATION Serial Number Location SERIAL NUMBER AND ENGINE TYPE Record the engine serial number in the space below Youwill need this serialnumberwhenordering parts andwhenmakingtechnicalor warranty inquires see page 64 Engine serial number 53 ...

Page 57: ...ounded part while tightening the positive battery cable end A batterycan explode if you do not follow the correct procedure seriously injuringanyone nearby Keep all sparks open flames and smoking materials away from the battery 1 Connect thebatterypositive cable tothe startersolenoid 2 Connect the battery negative cable to an engine monutingbolt 3 Connect the battery positive cable to the battery ...

Page 58: ...erformthis carburetor modification This engine when operated at high altitude with the carburetor modifications for high altitude use will meet each emission standard throughout itsuseful 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 59: ...aining 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 mayuse gasoline containing up to 15 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 also contains cosolvents and corrosion inhibitors to protect the fuel system Gaso...

Page 60: ...drocarbons The U S 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 Tampering and Altering Tampering with or altering the ...

Page 61: ...entparts are manufactured 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 reb...

Page 62: ...ption 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 2...

Page 63: ...pm Max torque 12 3 hp 1 2 5 PS 9 2 kW at 3 600 rpm Max output 2 3 X 2 7 in 58 X 68 mm Bore X Stroke 21 9 cu in 359 cm3 Displacement 4 stroke overhead camshaft twin cylinder Engine type 99 2 Ibs 45 0 kg Dry weight 20 3 X 19 3 X 20 9 in 515 X 490 X 530 mm Tuneup ITEM MAINTENANCE SPECIFICATION Spark plug gap 0 024 0 028 i n I Refer to page 39 0 60 0 70 mm Valve clearance No other adiustmentsneeded Ot...

Page 64: ...TECHNICAL CONSUMER INFORMATION Wiring Diagrams 1OA CHARGE COIL TYPE _ _ _ _ _ _ _ _ _ _ _ _ _ 0 0 0 0 N I N P 0 I c I 0 I I 1 1 J p 1 1 a T m m c 61 ...

Page 65: ...TECHNICAL CONSUMER INFORMATION 3A CHARGE COIL TYPE _ _ _ _ i _ N 0 I 00 0 0 62 L r 0 3 i 0 m 0 I ...

Page 66: ...u additional information for maintainingandrepairingyourengine Youmayorderthemfrom 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 63 ...

Page 67: ...ay If you are dissatisfiedwiththedecisionmade by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write to American Honda MotorCo 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 page53 Name...

Page 68: ...QUICK REFERENCE INFORMATION Fuel Engine Oil Spark Plug Carburetor Maintenance ...

Page 69: ...HONDA The Powerof Dreams 3 1 ZA07 53 E m 3KI HI Printed in Japan AH Hc 300 2001 05 00x31 ZAO 7530 ...