Honda GXV120, Owner'S Manual

Page 1: ...HONDA E N G I N E S Owner sManual GXV120 2001 Honda Motor Co Ltd All Rights Reserved ...

Page 2: ...s 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 partofthispublicationmay be re...

Page 3: ...ol Thatinformationisintended to helpyouavoid 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 4: ...an engine You must use your own good judgment You will findimportant safety information in avarietyofforms including Safety Messages preceded by a safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILLbe KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HU...

Page 5: ...Check the Equipment Poweredby This Engine 13 OPERATION 14 SAFE OPERATING PRECAUTIONS 14 STARTING THE ENGINE 14 STOPPING THE ENGINE 17 SETTING ENGINE SPEED 18 SERVICING YOUR HONDA ENGINE 19 THE IMPORTANCEOF MAINTENANCE 19 MAINTENANCE SAFETY 20 MAINTENANCE SCHEDULE 21 REFUELING 22 FUEL RECOMMENDATIONS 23 ENGINE OIL LEVEL CHECK 24 ENGINE OIL CHANGE 25 ENGINE OIL RECOMMENDATIONS 26 AIRFILTER INSPECTIO...

Page 6: ...ACKS POWER 39 TECHNICAL I 3 CONSUMER INFORMATION 40 TECHNICAL INFORMATION 40 Serial Number Location 40 Battery Connections for Electric Starter 41 Carburetor Modification for High Altitude Operation 42 Oxygenated Fuels 43 Air Index 46 Specifications 47 CONSUMER INFORMATION 48 Honda Publications 48 Customer Service Information 49 Emission Control System Information 44 QUICK REFERENCE INFORMATION In...

Page 7: ...ldren to operate the engine Keep children and pets away from the area of operation Refuel With Care Gasolineisextremelyflammable andgasolinevaporcanexplode Refueloutdoors in a well 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 8: ...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 neededto operate the equipment 6 ...

Page 9: ...CONTROLS COMPONENT CONTROL LOCATIONS RECOIL STARTER STARTE I R GRIP SPARK PLUG NER I 1 CONTROLLEVER THROTTLE STOP SCREW FUEL FILLER CAP OIL FILLER CAP FUEL U OIL DRAIN PLUG 7 ...

Page 10: ...een 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 fuel leakage FUELVALVE LEVER 8 ...

Page 11: ...tem switched on SLOW For running the engine at idle speed FAST For restarting a warm engine and for running the engine at maximum speed CHOKE Enriches thefuelmixtureforstartingacoldengine The control lever shownhere will be connected to a remote control on theequipmentpoweredbythisengine Refer to the instructions provided with that equipment for remote control information SLOW STOP I FAST CONTROLL...

Page 12: ...CONTROLS RecoilStarter Grip Pulling the starter grip operates the recoil starter to crank the engin 10 ...

Page 13: ...or ElectricStarter applicable engine types Theelectricstarter will beconnected to a remotecontrolonthe equipment powered by this engine Refer to the instructions provided that equipment for remote control information 11 ...

Page 14: ...operation couldcause 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 Condition of the Engine Look around and underneath the engine for signs of oil or gasoline leaks Remove any ...

Page 15: ...erwill restrict airflow to thecarburetor reducing engine performance Check the fuel level Starting with a full tankwill 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 13 ...

Page 16: ...gas istoxic Breathing it can cause unconsciousness and even kill you Avoid anyareas 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 fuel valve lever to the ON position FUELVALVE LEVER 14 ...

Page 17: ...l lever shownhere will be connected to a remote control on the equipment powered by this engine Refer to the instructions provided with that equipment for remote control information CONTROL LEVER 3 Operate the starter RECOIL STARTER all engine types Pull the starter grip lightly until1you feel resistance then pull briskly Return the starter grip gently 15 ...

Page 18: ...least 10 seconds before operating the starter again Usingtheelectricstarterformorethan 5 seconds at a time will overheat the starter motor and can damage it 4 If the control lever has been moved to theCHOKE position to start the engine gradually move it to the FAST or SLOW position as the engine warms up The control lever shown here will be connected to a remote control on theequipmentpowered by t...

Page 19: ...The control lever shown herewill be connected toa remote control on the equipment powered by this engine Refer to the instructions provided with that equipment for remote control information STOP CONTROL LEVER 2 Turn the fuel valve lever to the OFF position FUELVALVE LEVER 17 ...

Page 20: ...r the desired engine speed The control lever shown here will be connectedto a remote control on theequipmentpowered by thisengine Refer totheinstructions provided with thatequipmentforremotecontrolinformationand engine speed recommendations l 2 CONTROLLEVER 18 ...

Page 21: ...e 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 suchas sustained high load or high temperature operation ...

Page 22: ...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 instructedto doso Burns from hotparts Injury from moving parts Read the instructions beforeyou begin and make sureyou have the tools and skills required To reduce thepossibilityoffireorexplosion becarefulwhe...

Page 23: ...ry Every Refer to 20Hrs page 200Hrs 100Hrs 50Hrs 0 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 ma...

Page 24: ...pped remove the fuel tank cap and check the fuel level Refillthe tankif the fuel level is low 1 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 22 ...

Page 25: ...NDATIONS 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 oiI gasoline mixture Avoid getting dirt or water in the fueltank Occasionally you may hear a light spark knock or pinging me...

Page 26: ...ve the dipstick without screwing it into the filler neck Check the oil level shown on the dipstick 3 If the oil level is near or below the lowerlimit mark on thedipstick and fill with the recommended oil to the upper limit mark see page 26 4 Screw in the filler cap dipstick securely OIL FILLER CAP DIPSTICK LIMIT Running the engine with a low oillevel can causeengine damage 24 ...

Page 27: ...se of used motor oil in a manner that is compatible with the environment 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 4 With the engine in a level position fill to the upper limit mark on the dipstick with the recommended oil see page 26 Engine oil capacity 0 6...

Page 28: ... for general use Other viscositiesshown in the chart may be used when the average temperature in your area is within the recommendedrange 20 0 20 40 60 80 100 F L I I I 1 I I I 4 0 20 10 0 10 20 30 40 C AMBIENT TEMPERATURE The SAE oil viscosity and service classification are in the API label on the oil container Honda recommends that you use API SERVICE category SJ oil 26 ...

Page 29: ... and remove the air cleaner cover Check the air filter to be sure it is clean and in good condition If the air filter elements are dirty clean or replace them as described on page 28 Damaged filter elements must be replaced WING BOLTS R FILTERELEMENT AIR CLEANER COVER 27 ...

Page 30: ...witha damaged air filter will allow dirt to enter the engine causing rapid enginewear This type of damage is not covered by the Distributor s LimitedWarranty 1 Remove the two wing bolts fromthe air cleaner cover and remove the cover 2 Remove the filter and remove the foam filter from the paper filter 3 I n s p e c t b o t h a i r f i l t e r elements and replace them if they are dameged Always rep...

Page 31: ...armsoapy 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 enginewill 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 air duct that leads to the carb...

Page 32: ...k plug witha 13 16 inch sparkplug wrench 3 Inspect the spark plug Replace it if the electrodes are worn or ifthe 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 e0 028 0 031 i n 0 70 0 80 mm Correct the gap if necessary by carefully bending the side electrode 5 Instal...

Page 33: ...er the spark plug seats 1 A loose sparkplug can overheatand damage the engine Overtightening the spark plug can damage the threads in the cylinder head 7 Attach thespark plug cap IDLE SPEEDADJUSTMENT 1 Starttheengineoutdoors andallow 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 idle speed Standerd idle...

Page 34: ...er will be very hot Allow the muffler to cool before servicing the spark arrester 8 1 Loosen thetwo 6 mm nutsandremovethemufflerprotector identification plate muffler andgasket from the cylinder 2 Removethesparkarrestorfromthemuffler take care notto demage the wire mesh MUFFLER PROTECTOR SPARK ARRESTER 6 mm NUT 3 Use a brush to remove carbon deposits from the spark arrester screen Be careful to av...

Page 35: ...uffler can enterthe cylinder causing damage Water contacting ahot engine can cause damage If the enginehas been running allow it to coolforat least half an hourbefore washing Fuel Gasoline will oxidize and deteriorate in storage Oldgasolinewill cause hardstarting and it leaves gumdepositsthatclogthefuel system Ifthe gasolinein your engine deteriorates during storage you may need to have the carbur...

Page 36: ...FUEL STORAGE LIFE When adding a fuel stabilizer fill the fuel tank with fresh gasoline If onlypartiallyfilled airinthetankwillpromotefueldeterioration 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 munufacturer s instructions 2 After addinga fuel stabilizer run the engine outdoors for 10 minutes to b...

Page 37: ...ve the carburetor drainbolt 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 3 After all the fuel has drained into the container reinstall the drain bolt and tighten it securely 35 ...

Page 38: ...e gently Storage Precautions If your engine will be stored with gasoline in the fuel tank and 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 Ifpossib...

Page 39: ...ectric starter recharge the battery This will help to extend theservice life or of the battery oncea monthwhiletheengineis in storage Removal From Storage Check your engineas described in theBEFOREOERATIONchapter of this manual If the fuel was drained during storage preparation fill the tank with freshgasoline If you keep a container ofgasolineforrefueling be sure that it contains only fresh gasol...

Page 40: ...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 Turn the fuel valve lever to theOFF position 38 ...

Page 41: ...eled with bad ENGINE LACKS POWER Possible Cause Filter elements 1 Check air filter 2 Check fuel Bad fuel engine clogged stored without treating or draininggasoline or refueled with bad gasoline 3 Take engine to an Fuel strainer clogged authorized Honda valves stuck etc refer to shop manual ignition malfunction servicing dealer or carburetormalfunction 1 Correction Clean or replace filter elements ...

Page 42: ...N TECHNICAL INFORMATION Serial Number Location Record the engine serial number in the space below Youwill need this serial number when ordering parts and when making technical or warranty inquires see page49 Engine serial number 40 ...

Page 43: ...htening the positive battery cable end A batterycan 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 Connectthebatterypositive 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...

Page 44: ...lerperformthis carburetor modification 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 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carbur...

Page 45: ...taining up to 10 ethanolbyvolume Gasolinecontainingethanol may be marketed underthe 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 methanolbyvolume as long as it also contains cosolvents and corrosion inhibitors to protect the fuelsystem Gasolinecon...

Page 46: ...drocarbons The U S and California Clean Air Acts EPA and Californiaregulationsrequire 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 TamperingandAltering Tampering with or altering the e...

Page 47: ...parts are manufactured to the 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 partassumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebuil...

Page 48: ...iption is intended to provide you with information relating tothe engine s emissiondurabilityperiod 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 49: ... overhead valve single cylinder I Fuel consumDtion 0 56 Ibs hDh 340 q kWh 250 n PSh Cooling system Counterclockwise PTO shaft rotation Transistorized magneto Ignition system Forced air Tuneup ITEM MAINTENANCE SPECIFICATION Spark plug gap See you authorized IN 0 15 t 0 02 mm cold Valve clearance Rerer to page 30 0 028 0 031 in 0 70 0 80 mm EX 0 20 f 0 02 mm cold I Honda dealer Other specifications ...

Page 50: ...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 by a skilled technician Parts Catalog This manual provides complete illustrated parts lists 48 ...

Page 51: ...ay If you aredissatisfied withthe decisionmade bythe 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 and serial number see page40 Nam...

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