HONDA IGX440 User Manual [en, es, fr]

INTRODUCTION

Thank you for purchasing a Honda engine. We want to help you to get the best results from your new engine and to operate it safely. This manual contains information on how to do that; please read it carefully before operating the engine. If a problem should arise, or if you have any questions about your engine, consult an authorized Honda servicing dealer.

All information in this publication is based on the latest product information available at the time of printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission.

This manual should be considered a permanent part of the engine and should remain with the engine if resold.

Review the instructions provided with the equipment powered by this engine for any additional information regarding engine startup, shutdown, operation, adjustments or any special maintenance instructions.

United States, Puerto Rico, and U.S. Virgin Islands:

We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership. The warranty policy is a separate document that should have been given to you by your dealer.

SAFETY MESSAGES

Your safety and the safety of others are very important. We have provided important safety messages in this manual and on the engine. Please read these messages carefully.

A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol and one of three 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.

You CAN be HURT if you don’t follow instructions.

Each message tells you what the hazard is, what can happen, and what you can do to avoid or reduce injury.

DAMAGE PREVENTION MESSAGES

You will also see other important messages that are preceded by the word NOTICE.

This word means:

Your engine or other property can be damaged if you don’t follow instructions.

The purpose of these messages is to help prevent damage to your engine, other property, or the environment.

2005 - 2006 Honda Motor Co., Ltd. All Rights Reserved

37Z3S603	GX440IU
00X37-Z3S-6030

OWNER’S MANUAL	ENGLISH
MANUEL DE L’UTILISATEUR
MANUAL DEL PROPIETARIO

iGX440 FRANÇAIS

The engine exhaust from this product	ESPAÑOL
contains chemicals known to the State of
California to cause cancer, birth defects
or other reproductive harm.

CONTENTS
INTRODUCTION.......................	.1
SAFETY MESSAGES................	.1
SAFETY INFORMATION ..........	.2
SAFETY LABEL LOCATION .....	.2
COMPONENT & CONTROL
LOCATION ................................	.2
FEATURES................................	.3
BEFORE OPERATION
CHECKS ....................................	.3
OPERATION..............................	.4
SAFE OPERATING
PRECAUTIONS .....................	.4
STARTING THE ENGINE ......	.4
STOPPING THE ENGINE ......	.6
SETTING ENGINE SPEED.....	.6
SERVICING YOUR ENGINE .....	.6
THE IMPORTANCE OF
MAINTENANCE ....................	.6
MAINTENANCE SAFETY......	.6
SAFETY PRECAUTIONS.......	.6
MAINTENANCE
SCHEDULE............................	.7
REFUELING...........................	.7
ENGINE OIL...........................	.8
Recommended Oil ............	.8
Oil Level Check..................	.8
Oil Change.........................	.9
AIR CLEANER........................	.9
Inspection..........................	.9
Cleaning ............................	.9
SEDIMENT CUP ...................	10
Cleaning ...........................	10

SPARK PLUG .......................	11
SPARK ARRESTER ..............	11
FUSE.....................................	12
HELPFUL TIPS &
SUGGESTIONS .......................	13
STORING YOUR ENGINE....	13
TRANSPORTING .................	14
TAKING CARE OF
UNEXPECTED PROBLEMS .....	14
TECHNICAL INFORMATION...	15
Serial Number Location ......	15
Battery Connections for
Electric Starter .....................	16
Carburetor Modifications for
High Altitude Operation ......	16
Emission Control System
Information ..........................	17
Air Index...............................	17
Specifications ......................	18
Tuneup Specifications.........	18
Quick Reference
Information ..........................	19
Muffler Deflector Kit
Installation ...........................	19
Wiring Diagrams .................	19
CONSUMER INFORMATION..23
Distributor/Dealer Locator
Information ..........................	23
Customer Service
Information ..........................	23

ENGLISH

1

SAFETY INFORMATION

Understand the operation of all controls and learn how to stop the engine quickly in case of emergency. Make sure the operator receives adequate instruction before operating the equipment.

Do not allow children to operate the engine. Keep children and pets away from the area of operation.

Your engine’s exhaust contains poisonous carbon monoxide. Do not run the engine without adequate ventilation, and never run the engine indoors.

The engine and exhaust become very hot during operation. Keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Keep flammable materials away, and do not place anything on the engine while it is running.

SAFETY LABEL LOCATION

(STANDARD TYPES)

This label warns you of potential hazards that can cause serious injury. Read it carefully.

If the label comes off or becomes hard to read, contact your Honda dealer for replacement.

For Canadian types only: French label comes with the engine.

(LOW PROFILE TYPES)

These labels are packed in the box.

Gasoline is highly flammable and explosive.

Turn engine off and let cool before refueling.

The engine emits toxic poisonous carbon monoxide gas. Do not run in an enclosed area.

Read Owner’s Manual before operation.

COMPONENT & CONTROL LOCATION

STANDARD TYPES

MUFFLER

FUEL TANK

FUEL FILLER CAP

LED

AIR CLEANER

RECOIL STARTER (applicable types)

ECM
		STARTER GRIP
IGNITION COIL	SPARK PLUG	(applicable types)
	(Inside ignition coil)
	OIL FILLER CAP/DIPSTICK
		OIL EXTENSION
		(applicable types)
		ELECTRIC STARTER
		(applicable types)
		FUSE
		(applicable types)
		OIL DRAIN PLUG
ELECTRIC STARTER TYPES
MANUAL START LEVER		THROTTLE
		CONTROL

(applicable

types)

ENGINE

SWITCH (applicable types)

RECOIL STARTER TYPES

CHOKE LEVER

THROTTLE

CONTROL (applicable types)

ENGINE

SWITCH (applicable types)

FUEL VALVE LEVER (applicable types)

LOW PROFILE TYPES

OIL FILLER CAP/DIPSTICK

MUFFLER

(applicable types) ELECTRIC STARTER (applicable types)

RECOIL STARTER (applicable types)

STARTER GRIP (applicable types)

IGNITION COIL

AIR CLEANER

2

ENGLISH

ELECTRIC STARTER TYPES

RECOIL STARTER TYPES

MANUAL START LEVER

CHOKE LEVER

FEATURES

OIL ALERT SYSTEM

‘‘Oil Alert is a registered trademark in the United States’’

The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert system will either shut off the engine or issue a warning. Refer to the instructions provided by the equipment manufacturer.

If the ECM is set to stop the engine:

Engine type	Oil Alert action
Electric start	The LED on the ECM blinks twice.
	The engine stops.
	The engine will not restart.
Recoil start	The engine stops.
	The engine will not restart.

If the ECM is set to continue engine operation:

Engine type	Oil Alert action
Electric start	The LED on the ECM blinks twice.
	The engine continues to operate.
	The engine will not restart.
Recoil start	The engine continues to operate.
	The engine will not restart.

If the engine stops and/or will not restart, check the oil level (see page 8 ) before troubleshooting in other areas.

If you continue to operate the engine after the Oil Alert system has been activated, you can damage the engine.

BEFORE OPERATION CHECKS

IS YOUR ENGINE READY TO GO?

For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the engine to check its condition. Be sure to take care of any problem you find, or have your servicing dealer correct it, before you operate the engine.

Improperly maintaining this engine, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.

Always perform a pre-operation inspection before each operation, and correct any problem.

Before beginning your pre-operation checks, be sure the engine is level and the engine switch is in the OFF position.

Always check the following items before you start the engine:

Check the General Condition of the Engine

1.Look around and underneath the engine for signs of oil or gasoline leaks.

2.Remove any excessive dirt or debris, especially around the muffler and recoil starter.

3.Look for signs of damage.

4.Check that all shields and covers are in place, and all nuts, bolts, and screws are tightened.

Check the Engine

1.Check the fuel level (see page 7 ). Starting with a full tank will help to eliminate or reduce operating interruptions for refueling.

2.Check the engine oil level (see page 8 ). Running the engine with a low oil level can cause engine damage.

If the oil level in the crankcase falls below a safe limit, the Oil Alert system will either shut off the engine or issue a warning. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup.

3.Check the air filter element (see page 9, 10 ). A dirty air filter element will restrict air flow to the carburetor, reducing engine performance.

4.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.

ENGLISH

3

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the engine for the first time, please review the

SAFETY INFORMATION section on page 2 and the BEFORE OPERATION CHECKS on page 3 .

Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you.

Avoid any areas 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 with engine startup, shutdown or operation.

STARTING THE ENGINE

ELECTRIC STARTER TYPES:

1.Turn the engine switch to the START position, and hold it there until the engine starts.

The engine switch opens the fuel valve and operates the automatic choke.

Some engine applications do not include the enginemounted engine switch shown here. Refer to the instructions provided by the equipment manufacturer.

If the engine fails to start within 5 seconds, release the engine switch, and wait at least 10 seconds before operating the starter again.

Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.

When the engine starts, release the engine switch, allowing it to return to the ON position.

2.Warm up the engine for 2 or 3 minutes.

ON

START

ENGINE SWITCH

If the electric starter will not operate: (with recoil starter types)

1. Push the manual start lever.

STANDARD TYPES

MANUAL START LEVER

Push

LOW PROFILE TYPES

CLOSE	MANUAL START LEVER

Push

Do not move the manual start lever after the engine starts.

2. Turn the engine switch to the ON position.

ON

ENGINE SWITCH

3.Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown below. Return the starter grip gently.

STARTER GRIP

Direction to pull

Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.

4. Warm up the engine for 2 or 3 minutes.

4

ENGLISH

RECOIL STARTER TYPES:

1. Move the fuel valve lever (applicable types) to the ON position.

FUEL VALVE LEVER (applicable types)

ON

ON

2.To start a cold engine, move the choke lever to the CLOSED position.

Some engine types use a remote-mounted choke lever. Refer to the instructions provided by the equipment manufacturer.

STANDARD TYPES

CLOSE

CLOSE

CHOKE LEVER

LOW PROFILE TYPES

CLOSE

CLOSE

CHOKE LEVER

To restart a warm engine, leave the choke lever in the OPEN position.

3.Turn the engine switch to the ON position.

Some engine types use a remote-mounted engine switch. Refer to the instructions provided by the equipment manufacturer.

ON

ENGINE SWITCH

4.Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown below. Return the starter grip gently.

Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.

STARTER GRIP

Direction to pull

5.Warm up the engine for 2 or 3 minutes.

If the choke lever was moved to the CLOSED position to start the engine, gradually move it to the OPEN position as the engine warms up.

STANDARD TYPES

OPEN

CHOKE LEVER

LOW PROFILE TYPES

CHOKE LEVER

OPEN

ENGLISH

5

STOPPING THE ENGINE

To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure.

1.Move the throttle control to the MIN. position.

Some engine types use a remote-mounted throttle control. Refer to the instructions provided by the equipment manufacturer.

2.Turn the engine switch to the OFF position.

Some engine types use a remote-mounted engine switch. Refer to the instructions provided by the equipment manufacturer.

MIN

OFF

THROTTLE CONTROL

ENGINE SWITCH

3. Move the fuel valve lever (applicable types) to the OFF position.

FUEL VALVE LEVER (applicable types)

OFF

OFF

SETTING ENGINE SPEED

Adjust the throttle control for the desired engine speed.

Some engine types use a remote-mounted throttle control, rather than the engine-mounted throttle control shown here. Refer to the instructions provided by the equipment manufacturer.

For engine speed recommendations, refer to the instructions provided with the equipment powered by this engine.

MIN

MAX

THROTTLE CONTROL

SERVICING YOUR ENGINE

THE IMPORTANCE OF MAINTENANCE

Good maintenance is essential for safe, economical and troublefree operation. It will also help reduce pollution.

Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.

Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.

To help you properly care for your engine, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. Other service tasks that are more difficult, or require special tools, 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 severe conditions, such as sustained high-load or high-temperature operation, or use in unusually wet or dusty conditions, consult your servicing dealer for recommendations applicable to your individual needs and use.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are ‘‘certified’’ to EPA standards.

MAINTENANCE SAFETY

Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.

Always follow the procedures and precautions in this owner’s manual.

SAFETY PRECAUTIONS

Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:

Carbon monoxide poisoning from engine exhaust.

Be sure there is adequate ventilation whenever you operate the engine.

Burns from hot parts.

Let the engine and exhaust system cool before touching.

Injury from moving parts.

Do not run the engine unless instructed to do so.

Read the instructions before you begin, and make sure you have the tools and skills required.

To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a non-flammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and flames away from all fuel related parts.

Remember that an authorized Honda servicing dealer knows your engine best and is fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new genuine Honda parts or their equivalents for repair and replacement.

6

ENGLISH

MAINTENANCE SCHEDULE

STANDARD TYPES

REGULAR SERVICE PERIOD (3)				Each		First	Every 6	Every	Every	Refer
	Perform at every			Use		Month	Months	Year	2 Years	to
	indicated month or					or	or	or	or	Page
	operating hour interval,					20 Hrs	100 Hrs	300 Hrs	500 Hrs
	whichever comes first.
ITEM
Engine oil		Check level								8
		Change								9
Air cleaner		Check								9
		Clean					(1)			9
		Replace
Sediment cup		Clean								10
Spark plug		Check-adjust								11
		Replace
Spark arrester		Clean								11
Valve clearance		Check-adjust						(2)		Shop
										manual
Timing belt		Check			After every 500 Hrs. (2) (4)					Shop
										manual
Combustion		Clean				After every 500 Hrs. (2)				Shop
chamber										manual
Fuel tank &		Clean					(2)			Shop
filter										manual
Fuel tube		Check				Every 2 years				Shop
						(Replace if necessary) (2)				manual

LOW PROFILE TYPES

REGULAR SERVICE PERIOD (3)				Each		First	Every 3	Every 6		Every	Refer
	Perform at every			Use		Month	Months	Months		Year	to
	indicated month or					or	or	or		or	Page
	operating hour interval,					20 Hrs	50 Hrs	100 Hrs	300 Hrs
	whichever comes first.
ITEM
Engine oil		Check level									8
		Change									9
Air cleaner		Check									10
		Clean					(1)				10
		Replace
Sediment cup		Clean									10
Spark plug		Check-adjust									11
		Replace
Spark arrester		Check-Clean									11
Valve clearance		Check-adjust								(2)	Shop
											manual
Timing belt		Check			After every 500 Hrs. (2) (4)						Shop
											manual
Combustion		Clean				After every 500 Hrs. (2)					Shop
chamber											manual
Fuel tube		Check				Every 2 years					Shop
						(Replace if necessary) (2)					manual

(1)Service more frequently when used in dusty areas.

(2)These items should be serviced by your Honda servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures.

(3)For commercial use, log hours of operation to determine proper maintenance intervals.

(4)Check that there is no crack and abnormal wear-out in the belt, and replace if it is abnormal.

Failure to follow this maintenance schedule could result in nonwarrantable failures.

REFUELING (LOW PROFILE TYPES)

Follow the equipment manufacturers recommendation for refueling.

REFUELING (STANDARD TYPES)

Recommended Fuel

Unleaded gasoline

U.S.	Pump octane rating 86 or higher
Except U.S.	Research octane rating 91 or higher
	Pump octane rating 86 or higher

This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher (a research octane rating of 91 or higher).

Refuel in a well-ventilated area with the engine stopped. If the engine has been running, allow it to cool first. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks.

You may use regular unleaded gasoline containing no more than 10% Ethanol (E10) or 5% Methanol by volume. In addition, Methanol must contain cosolvents and corrosion inhibitors. Use of fuels with content of Ethanol or Methanol greater than shown above may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system. Engine damage or performance problems that result from using a fuel with percentages of Ethanol or Methanol greater than shown above are not covered under warranty.

Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling.

Stop engine and keep heat, sparks, and flame away.

Refuel only outdoors. Wipe up spills immediately.

Fuel can damage paint and some types of plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under the Distributor’s Limited Warranty.

Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.

1.With the engine stopped and on a level surface, remove the fuel filler cap and check the fuel level. Refill the tank if the fuel level is low.

2.Add fuel to the bottom of the fuel level limit of the fuel tank. Do not overfill. Wipe up spilled fuel before starting the engine.

FUEL TANK TOP	MAXIMUM
	FUEL LEVEL

25 mm (1 inch)

ENGLISH

7

Refuel carefully to avoid spilling fuel. Do not fill the fuel tank completely. It may be necessary to lower the fuel level depending on operating conditions. After refueling, screw the fuel filler cap back on until it clicks.

Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc.

Spilled fuel is not only a fire hazard, it causes environmental damage. Wipe up spills immediately.

ENGINE OIL

Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil.

Recommended Oil

Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SJ or later (or equivalent). Always check the API service label on the oil container to be sure it includes the letters SJ or later (or equivalent).

AMBIENT TEMPERATURE

SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range.

Oil Level Check

Check the engine oil level with the engine stopped and in a level position.

1.Remove the oil filler cap/dipstick and wipe it clean.

2.Insert the oil filler cap/dipstick into the oil filler neck as shown, but do not push it in, then remove it to check the oil level.

3.If the oil level is below the upper limit mark on the dipstick, fill with the recommended oil (see page 9 ) to the upper limit mark. Do not overfill.

4.Reinstall and tighten the oil filler cap/dipstick.

DIPSTICK	OIL FILLER CAP

UPPER LIMIT

Running the engine with a low oil level can cause engine damage.

The Oil Alert system will stop the engine or issue a warning before the oil level falls below a safe limit. Refer to the instructions provided by the equipment manufacturer.

8

ENGLISH

Oil Change

Drain the used oil when the engine is warm. Warm oil drains quickly and completely.

1.Place a suitable container below the engine to catch the used oil, then remove the oil filler cap/dipstick, oil drain plug and washer.

2.Allow the used oil to drain completely, then reinstall the oil drain plug and new washer, and tighten the oil drain plug securely.

Please dispose 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 pour it 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 page 8 ).

Running the engine with a low oil level can cause engine damage.

4.Install the oil filler cap/dipstick and push it in securely.

OIL FILLER CAP

DIPSTICK

UPPER LIMIT

WASHER

DRAIN PLUG

AIR CLEANER

A dirty air cleaner will restrict air flow to the carburetor, reducing engine performance. If you operate the engine in very dusty areas, clean or replace the air filter more often than specified in the MAINTENANCE SCHEDULE.

Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered by the Distributor’s Limited Warranty.

Inspection (standard types)

Remove the air cleaner cover and inspect the filter elements. Clean or replace dirty filter elements. Always replace damaged filter elements.

Cleaning (standard types)

1.Remove the wing nut from the air cleaner cover, and remove the cover.

2.Remove the wing nut from the air filter, and remove the filter.

3.Remove the foam filter from the paper filter.

4.Inspect both air filter elements, and replace them if they are damaged. Always replace the paper air filter element at the scheduled interval (see page 7 ).

NUT

AIR CLEANER

COVER

WING NUT

PAPER FILTER ELEMENT

FOAM FILTER

ELEMENT

GASKET

5. Clean the filter elements if they are to be reused.

Paper filter element: Tap the filter element several times on a hard surface to remove dirt, or blow compressed air [not exceeding 207 kPa (2.1 kgf/cm, 30 psi)] through the filter element from the inside. Never try to brush off dirt; brushing will force dirt into the fibers.

Foam 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 all excess oil. The engine will smoke when started if too much oil is left in the foam.

Dry

Soak

Squeeze

Oil

Squeeze

ENGLISH

9

6.Wipe dirt from the inside of the air cleaner case and cover using a moist rag. Be careful to prevent dirt from entering the air duct that leads to the carburetor.

7.Place the foam filter element over the paper element, and reinstall the assembled air filter. Be sure the gasket is in place beneath the air filter. Tighten the air filter wing nut securely.

8.Install the air cleaner cover, and tighten the nut securely.

Inspection (low profile types)

Do not blow with compressed air or brush the paper filter element.

Remove the air cleaner cover and inspect the filter elements. Visually inspect the filter elements. Clean the foam filter element or replace the dirty paper filter element. Always replace damaged filter elements.

Cleaning (low profile types)

1.Loosen the cover screws and remove the air cleaner cover.

2.Remove the foam filter element from the air cleaner cover.

3.Remove the air cleaner grid and paper filter element.

4.Inspect both filter elements, and replace them if they are damaged. Always replace the paper filter element at the scheduled interval (see page 7 ).

If the paper filter element is dirty, replace it with a new one. Do not clean the paper filter element.

AIR CLEANER GRID

PAPER FILTER	COVER SCREW
ELEMENT

FOAM FILTER

ELEMENT

AIR CLEANER COVER

5. Clean the foam element if it is to be reused.

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 all excess oil. The engine will smoke when started if too much oil is left in the foam.

Squeeze

Squeeze

Soak

Oil

6.Wipe dirt from the inside of the air cleaner case and cover, using a moist rag. Be careful to prevent dirt from entering the air duct that leads to the carburetor.

7.Put the air cleaner grid on the paper filter element and install them to the air cleaner case.

8.Install the foam filter element to the air cleaner cover.

9.Install the air cleaner cover and tighten the cover screw.

SEDIMENT CUP (applicable types)

Cleaning

Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel.

Stop engine and keep heat, sparks, and flame away.

Handle fuel only outdoors. Wipe up spills immediately.

1.Remove the fuel sediment cup, O-ring and filter.

2.Wash the sediment cup in non-flammable solvent, and dry it thoroughly.

FILTER

O-RING

SEDIMENT

CUP

3. Reinstall the sediment cup. Tighten the sediment cup securely.

10

ENGLISH

NUT

SPARK PLUG WRENCH

SIDE ELECTRODE

SPARK PLUG

Recommended Spark Plugs: BKR7E-E (NGK)

K22PR-UR (DENSO)

The recommended spark plug has the correct heat range for normal engine operating temperatures.

An incorrect spark plug can cause engine damage.

For good performance, the spark plug must be properly gapped and free of deposits.

1.Remove the nut from the ignition coil, and remove the ignition coil/spark plug cap. Remove any dirt from around the spark plug

area.	IGNITION COIL/	SPARK PLUG
	SPARK PLUG CAP
	CLAMP

2.Remove the spark plug with a 5/8-inch spark plug wrench.

3.Inspect the spark plug. Replace it if damaged or badly fouled, if the sealing washer is in poor condition, or if the electrode is worn.

4.Measure the spark plug electrode gap with a wiretype feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode. The gap should be:

0.70 0.80 mm (0.028 0.031 in)

5.Install the spark plug carefully, by hand, to avoid crossthreading.

0.70 0.80 mm

(0.028 0.031 in)

SEALING

WASHER

6.After the spark plug is seated, tighten with a 5/8-inch spark plug wrench to compress the sealing washer.

7.When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer.

8.When reinstalling the original spark plug, tighten 1/8 1/4 turn after the spark plug seats to compress the washer.

A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head.

9.Set the harness in the clamp portion of the ignition coil/spark plug cap. Then, attach the ignition coil to the spark plug and tighten the nut securely.

SPARK ARRESTER

The spark arrester must be serviced every 6 months or 100 hours to keep it functioning as designed.

If the engine has been running, the muffler will be hot. Allow it to cool before servicing the spark arrester.

Spark Arrester Removal (standard types)

1.Remove the three 6 mm nuts and breather tube from the air cleaner, remove the air cleaner, and remove the 6 × 20 mm stud bolt.

BREATHER TUBE

AIR CLEANER

6 × 20 mm

STUD BOLT 6 mm NUTS

2.Remove the three 6 mm bolts from the muffler protector, and remove the muffler protector.

3.Remove the 5 × 8 mm screw from the spark arrester, and remove the spark arrester from the muffler.

6 mm BOLTS

SPARK ARRESTER

5 × 8 mm SCREW

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11

Spark Arrester Removal (low profile types)

1.Remove the three 6 mm bolts from the exhaust pipe protector and remove the exhaust pipe protector.

2.Remove the two 6 mm bolts from the lower shroud and remove the lower shroud.

3.To make the clearance for 6 mm bolts removing, loosen the 6 × 16 mm bolts, 10 × 35 mm flange bolt and slide the muffler stay as shown.

4.Remove the six 6 mm bolts from the lower muffler protector and remove the lower muffler protector.

5.Remove the three 6 mm bolts from the muffler protector and slide the muffler protector to upside.

6.Remove the 5 × 8 mm screw from the spark arrester and remove the spark arrester from the muffler.

6 mm BOLTS

EXHAUST PIPE PROTECTOR

LOWER SHROUD

6 mm BOLTS

SPARK ARRESTER

5 × 8 mm SCREW

LOWER MUFFLER PROTECTOR

6 mm BOLTS	10 × 35 mm
	FLANGE BOLT

MUFFLER STAY

6 × 16 mm

BOLT WASHER

Spark Arrester Cleaning & Inspection
1. Use a brush to remove carbon
deposits from the spark arrester
screen. Be careful not to damage
the screen. Replace the spark
arrester if it has breaks or holes.
2. Install the spark arrester to the	SCREEN
muffler.

3.STANDARD TYPES

Install the muffler protector and air cleaner in the reverse order of disassembly.

LOW PROFILE TYPES

Install the exhaust pipe protector, lower shroud, lower muffler protector and muffler in the reverse order of disassembly.

FUSE (applicable types)

If the fuse is blown, the battery cannot be charged.

Fuse change

1.Remove the fuse cover and pull the fuse out.

2.Replace the fuse with a fuse of the same type and rating.

Never use a fuse with different rating from that specified. Serious damage to the electrical system or fire may result.

FUSE COVER

FUSE

(30 A)

FUSE

(3 A)

3. Install the fuse cover.

12

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HELPFUL TIPS & SUGGESTIONS

STORING YOUR ENGINE

Storage Preparation

Proper storage preparation is essential for keeping your engine trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your engine’s function and appearance, and will make the engine easier to start when you use it again.

Cleaning

If the engine has been running, allow it to cool for at least half an hour before cleaning. Clean all exterior surfaces, touch up any damaged paint, and coat other areas that may rust with a light film of oil.

Using a garden hose or pressure washing equipment can force water into the air cleaner or muffler opening. Water in the air cleaner will soak the air filter, and water that passes through the air filter or muffler can enter the cylinder, causing damage.

Fuel

Gasoline will oxidize and deteriorate in storage. Deteriorated gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your engine deteriorates during storage, you may need to have the carburetor and other fuel system components serviced or replaced.

The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled. The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel deterioration problems may occur within a few months, or even less if the gasoline was not fresh when you filled the fuel tank.

Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under the

Distributor’s Limited Warranty.

You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor.

Adding a Gasoline Stabilizer to Extend Fuel Storage Life

When adding a gasoline stabilizer, fill the fuel tank with fresh gasoline. If only partially filled, air in the tank will promote fuel deterioration during storage. If you keep a container of gasoline for refueling, be sure that it contains only fresh gasoline.

1.Add gasoline stabilizer following the manufacturer’s instructions.

2.After adding a gasoline stabilizer, run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor.

3.Stop the engine.

Engine Oil

1.Change the engine oil (see page 9 ).

2.Remove the spark plug (see page 11 ).

3.Pour a tablespoon 5 10 cm (5 10 cc) of clean engine oil into the cylinder.

4.With recoil starter types:

Pull the starter grip (applicable types) several times to distribute the oil in the cylinder.

Without recoil starter types:

Turn the engine switch to the START position to distribute the oil in the cylinder.

5.Reinstall the spark plug.

6.With recoil starter types:

Pull the starter rope slowly until resistance is felt and the notch on the starter pulley aligns with the projection at the top of the recoil starter cover. This will close the valves so moisture cannot enter the engine cylinder. Return the starter rope gently.

Align the notch on the pulley with the projection at the top of the cover.

Without recoil starter types:

Remove the nuts and remove the fan cover.

Rotate the fin until resistance is felt and the fin with a notch (standard types)/alignment mark (low profile types) aligns with the projection at the top of the cover. This will close the valves so moisture cannot enter the engine cylinder.

STANDARD TYPES

Align the fin with a notch with the projection at the top of the cover.

LOW PROFILE TYPES

NUTS

Align the fin with a alignment mark with the projection at the top of the cover.

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13

Draining the Carburetor

Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel.

Stop engine and keep heat, sparks, and flame away.

Handle fuel only outdoors. Wipe up spills immediately.

1.Place an approved gasoline container below the carburetor, and use a funnel to avoid spilling fuel.

2.Loosen the carburetor drain screw and drain the gasoline from the carburetor.

3.After all the fuel has drained into the container, tighten the drain screw securely.

Storage Precautions

If your engine will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well-ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a sparkproducing electric motor, or where power tools are operated.

If possible, avoid storage areas with high humidity, because that promotes rust and corrosion.

Keep the engine level in storage. Tilting can cause fuel or oil leakage.

With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials. Do not use sheet plastic as a dust cover.

A nonporous cover will trap moisture around the engine, promoting rust and corrosion.

If equipped with a battery for electric starter types, 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 engine as described in the BEFORE OPERATION CHECKS section of this manual (see page 3 ).

If the fuel was drained during storage preparation, fill the tank with fresh gasoline. If you keep a container of gasoline for refueling, be sure it contains only fresh gasoline. Gasoline oxidizes and deteriorates over time, causing hard starting.

If the cylinder was coated with oil during storage preparation, the engine will smoke briefly at startup. This is normal.

TRANSPORTING

If the engine has been running, allow it to cool for at least 15 minutes before 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.

TAKING CARE OF UNEXPECTED PROBLEMS

ELECTRIC STARTER TYPES:

Check the LED on the ECM

LED ECM

To perform the LED check, the engine must be connected to a battery and the engine switch must be in the ON position.

ENGINE WILL	Possible Cause	Correction
NOT START
1. LED is not lit.	Fuse burnt out.	Replace fuse
		(p. 12).
		after replacing fuse,
		turn the engine
		switch to the ON
		position once
		again.
2. LED is lit.	Fuel, engine oil,	Check the BEFORE
	spark plug, etc.	OPERATION
		CHECKS (p. 3).
3. LED blinks	Engine oil level	Fill with the
twice.	low.	recommended oil
		to the proper level
		(p. 8 9).
4. LED blinks 3 or	ECM,	Take engine to an
more times.	TE sensor,	authorized Honda
	power coil.	servicing dealer, or
		refer to shop
		manual.
5. Take engine to	ECM,	Replace or repair
an authorized	sensors, etc.	faulty components
Honda		as necessary.
servicing
dealer, or refer
to shop
manual.

14

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ENGINE WILL	Possible Cause	Correction
NOT START
1. Electric	Battery	Recharge battery.
starting	discharged.
(applicable
types):	Fuse burnt out.	Replace fuse.
Check battery		(p. 12).
and fuse.
2. Check control	Choke open.	Move choke lever
positions.	(Recoil starter	to CLOSED
	types)	position unless the
		engine is warm.
	Engine switch	Turn engine switch
	OFF.	to ON position.
3. Check engine	Engine oil level	Fill with the
oil level.	low.	recommended oil
		to the proper level
		(p. 8 9).
4. Check fuel.	Out of fuel.	Refuel (p. 7).
	Bad fuel; engine	Drain fuel tank and
	stored without	carburetor (p. 14).
	treating or	Refuel with fresh
	draining	gasoline (p. 7).
	gasoline, or
	refueled with
	bad gasoline.
5. Remove and	Spark plug faulty,	Gap or replace
inspect spark	fouled, or	spark plug (p. 11).
plug.	improperly
	gapped.
	Spark plug wet	Dry and reinstall
	with fuel	spark plug. Start
	(flooded engine).	engine with
		throttle lever in
		MAX. position.
6. Take engine to	Fuel filter	Replace or repair
an authorized	restricted,	faulty components
Honda	carburetor	as necessary.
servicing	malfunction,
dealer, or refer	ignition
to shop	malfunction,
manual.	valves stuck, etc.

ENGINE LACKS	Possible Cause	Correction
POWER
1. Check air filter.	Filter element(s)	Clean or replace
	restricted.	filter element(s)
		(p. 9 10).
2. Check fuel.	Bad fuel; engine	Drain fuel tank and
	stored without	carburetor (p. 14).
	treating or	Refuel with fresh
	draining	gasoline (p. 7).
	gasoline, or
	refueled with
	bad gasoline.
3. Take engine to	Fuel filter	Replace or repair
an authorized	restricted,	faulty components
Honda	carburetor	as necessary.
servicing	malfunction,
dealer, or refer	ignition
to shop	malfunction,
manual.	valves stuck, etc.

TECHNICAL INFORMATION

TECHNICAL INFORMATION

STANDARD TYPES

Serial Number Location

Record the engine serial number, engine type, and date of purchase in the space below. You will need this information when ordering parts and when making technical or warranty inquiries.

SERIAL NUMBER &

ENGINE TYPE LOCATION

ELECTRIC STARTER (applicable types)

LOW PROFILE TYPES

ELECTRIC STARTER (applicable types)

SERIAL NUMBER &

ENGINE TYPE LOCATION

Engine serial number: __ __ __ __ __ __ __ __ __ __ __

Engine type: ___ ___ ___ ___

Date Purchased: ______ / ______ / ______

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15

Battery Connections for Electric Starter (applicable types)

Use a 12-volt battery with an ampere-hour rating of at least 18 Ah.

Be careful not to connect the battery in reverse polarity, as this will short circuit the battery charging system. Always connect the positive ( ) battery cable to the battery terminal before connecting the negative ( ) battery cable, so your tools cannot cause a short circuit if they touch a grounded part while tightening 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 the battery positive ( ) cable to the starter solenoid terminal as shown.

2.Connect the battery negative ( ) cable to an engine mounting bolt, frame bolt, or other good engine ground connection.

3.Connect the battery positive ( ) cable to the battery positive ( ) terminal as shown.

4.Connect the battery negative ( ) cable to the battery negative ( ) terminal as shown.

5.Coat the terminals and cable ends with grease.

POSITIVE ( )

BATTERY CABLE

NEGATIVE ( ) BATTERY CABLE

Carburetor Modifications for High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.

High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above 1,500 meters (5,000 feet), have your servicing dealer perform this 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 300-meter (1,000-foot) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.

When the carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use. Operation at altitudes below 1,500 meters (5,000 feet) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have your servicing dealer return the carburetor to original factory specifications.

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Emission Control System Information

Source of Emissions

The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.

The U.S., California Clean Air Acts and Environment Canada

EPA, California and Canadian regulations require all manufacturers to furnish 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 emission control system may increase emissions beyond the legal limit. Among those acts that constitute tampering are:

Removal or alteration of any part of the intake, fuel, or exhaust systems.

Altering or defeating the governor linkage or speed-adjusting mechanism to cause the engine to operate outside its design parameters.

Problems That May Affect Emissions

If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer.

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

Replacement Parts

The emission control systems on your Honda engine were designed, built, and certified to conform with EPA, California and Canadian emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards 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 of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.

Maintenance

Follow the maintenance schedule on page 7 . Remember that this schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load or hightemperature operation, or use in unusually wet or dusty conditions, will require more frequent service.

Air Index

An Air Index Information hang tag/label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board.

The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution.

The durability description is intended to provide you with information relating to the engine’s emission durability period. The descriptive term indicates the useful life period for the engine’s emission control system. See your Emission Control System Warranty for additional information.

Descriptive Term	Applicable to Emissions Durability Period
Moderate	50 hours [0 80 cm (0 80 cc) inclusive]
	125 hours [greater than 80 cm	(80 cc)]
Intermediate	125 hours [0 80 cm (0 80 cc) inclusive]
	250 hours [greater than 80 cm	(80 cc)]
Extended	300 hours [0 80 cm (0 80 cc) inclusive]
	500 hours [greater than 80 cm	(80 cc)]

The Air Index Information hang tag/label must remain on the engine until it is sold. Remove the hang tag before operating the engine.

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17

Specifications (standard types)

PTO shaft type S

Length × Width ×	407 × 505 × 454 mm
Height	(16.0 × 19.9 × 17.9 in)
Dry mass [weight]	39.4 kg (86.9 lbs)
Engine type	4-stroke, overhead camshaft, single
	cylinder
Displacement	438 cm (26.7 cu-in)
[Bore × Stroke]	[88.0 × 72.1 mm (3.46 × 2.84 in)]
Net power	9.5 kW (12.9 PS, 12.7 bhp)
(in accordance with SAE J1349 )	at 3,600 rpm
Max. Net torque	29.8 N·m (3.04 kgf·m, 22.0 lbf·ft)
(in accordance with SAE J1349 )	at 2,500 rpm
Engine oil capacity	1.1 (1.2 US qt , 1.0 Imp qt)
Fuel tank capacity	5.9 (1.56 US gal , 1.30 Imp gal)
Cooling system	Forced air
Ignition system	CDI type magneto ignition
PTO shaft rotation	Counterclockwise
Specifications (low profile types)
PTO shaft type V
Length × Width ×	553 × 553 × 346 mm
Height	(21.8 × 21.8 × 13.6 in)
Dry mass [weight]	42.8 kg (94.4 lbs)
Engine type	4-stroke, overhead camshaft, single
	cylinder
Displacement	438 cm (26.7 cu-in)
[Bore × Stroke]	[88.0 × 72.1 mm (3.46 × 2.84 in)]
Net power	9.5 kW (12.9 PS, 12.7 bhp)
(in accordance with SAE J1349 )	at 3,600 rpm
Max. Net torque	29.8 N·m (3.04 kgf·m, 22.0 lbf·ft)
(in accordance with SAE J1349 )	at 2,500 rpm
Engine oil capacity	1.1 (1.2 US qt , 1.0 Imp qt)
Cooling system	Forced air
Ignition system	CDI type magneto ignition
PTO shaft rotation	Counterclockwise

The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine model and measured in accordance with SAE J1349 at 3,600 rpm (Net Power) and at 2,500 rpm (Max. Net Torque). Mass production engines may vary from this value.

Actual power output for the engine installed in the final machine will vary depending on numerous factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables.

Tuneup Specifications

ITEM	SPECIFICATION	MAINTENANCE
Spark plug gap	0.70 0.80 mm	Refer to page: 11
	(0.028 0.031 in)	See your
Valve clearance	IN: 0.12 ± 0.02 mm
(cold)	EX: 0.15 ± 0.02 mm	authorized
		Honda dealer
Other	No other adjustments needed.
specifications

18

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Quick Reference Information

Wiring Diagrams

1 FUSE 3 A

13 FUEL CUT SOLENOID

Fuel

Unleaded gasoline (Refer to page 7)

2 FUSE 30 A

14 IGINITION COIL

U.S.

Pump octane rating 86 or higher

3 FUEL CUT SOLENOID

15 SPARK PLUG

Except

Research octane rating 91 or higher

RECTIFIER

16 OIL LEVEL SWITCH

U.S.

Pump octane rating 86 or higher

4 REGULATOR RECTIFIER

17 ECM

Engine oil

SAE 10W-30, API SJ or later, for general use.

5 ENGINE GROUND

18 STEP MOTOR (GOV)

Refer to page 8.

6 BATTERY

19 STEP MOTOR (CHOKE)

Spark plug

BKR7E-E (NGK)

7 STARTER MOTOR

20 PC CONNECTOR

K22PR-UR (DENSO)

8 POWER COIL

21 ENGINE TEMPERATURE

Maintenance

Before each use:

9 FUEL CUT SOLENOID COIL

SENSOR

Check engine oil level. Refer to page 8.

10 CHARGE COIL 20 A

22 THROTTLE CONTROL

Check air filter. Refer to page 9 10.

11 CHARGE COIL 3 A

23 COMBINATION SWITCH

First 20 hours:

12 CRANKSHAFT POSITION

24 RECTIFIER

Change engine oil. Refer to page 9.

(CKP) SENSOR

25 ENGINE STOP SWITCH

Subsequent:

Refer to the maintenance schedule on page 7.

Bl

Black

Br

Brown

Y

Yellow

O

Orange

Muffler Deflector Kit Installation (standard types)

Bu

Blue

Lb

Light blue

G

Green

Lg

Light green

Muffler deflector (applicable types)

R

Red

P

Pink

W

White

Gr

Gray

Turn the outlet of the muffler deflector downward and tighten the three 4 × 6 mm screws securely.

ATTACHMENT POSITION

4 × 6 mm SCREWS MUFFLER DEFLECTOR

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19

ELECTRIC STARTER TYPES (20 A)

20

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ELECTRIC STARTER TYPES (3 A)

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21

RECOIL STARTER TYPES

22

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