Honda Automobiles GX200, GX120, GX160 User Manual

Owner’s Manual

Black

DIC 157

GX120•GX160•GX200

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

Keep this owner’s manual handy, so you can refer to it at any time. This owner’s manual is 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 the time of approval for printing. Illustrations are based on the GX160. Only the QXE2 type is equipped for both electric and manual starting. Honda Motor 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 this publication may be reproduced without written permission.

INTRODUCTION

Congratulations on your selection of a Honda engine. We are certain you will be pleased with your purchase of one of the finest engines on the market.

We want to help you get the best results from your new engine and to operate it safely. This manual contains the information on how to do that; please read it carefully.

As you read this manual, you will find information preceded by a

symbol. That information is intended to help you avoid

damage to your engine, other property, or the environment.

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.

When your engine needs scheduled maintenance, keep in mind that your Honda servicing dealer is specially trained in servicing Honda engines. Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns.

Best Wishes, Honda Motor Co., Ltd.

INTRODUCTION

A FEW WORDS ABOUT SAFETY

Your safety and the safety of others are very important. And using this engine safely is an important responsibility.

To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

Of course, it is not practical or possible to warn you about all the hazards associated with operating or maintaining an engine. You must use your own good judgment.

You will find important safety information in a variety of forms, including:

Safety Labels

Safety Messages

of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

Safety Headings

Safety Section

Instructions

This entire book is filled with important safety information –– please read it carefully.

–– on the engine.

–– preceded by a safety alert symbol and one

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.

–– such as

–– how to use this engine correctly and safely.

IMPORTANT SAFETY INFORMATION.

ENGINE SAFETY.

.......................................................................................ENGINE SAFETY . 5

............................................................................................CONTROLS . 8

.....................................................................................Choke Lever . 10

...........................................................................................FEATURES . 12

System (applicable engine types) . 12

............................................................................................OPERATION . 15

................................................IMPORTANT SAFETY INFORMATION . 5

........................................................................CONTROLS & FEATURES . 7

............................................COMPONENT & CONTROL LOCATIONS . 7

................................................................................Fuel Valve Lever . 8

....................................................................................Engine Switch . 9

..................................................................................Throttle Lever . 11

...........................................................................Recoil Starter Grip . 11

.................................Oil Alert

...................................................Circuit Breaker (QXE2 type only) . 12

.............................................................................BEFORE OPERATION . 13

.....................................................IS YOUR ENGINE READY TO GO? . 13

..................................Check the General Condition of the Engine . 13

.............................................................................Check the Engine . 14

............................Check the Equipment Powered by This Engine . 14

...................................................SAFE OPERATING PRECAUTIONS . 15

....................................................................STARTING THE ENGINE . 15

....................................................................STOPPING THE ENGINE . 19

...................................................................SETTING ENGINE SPEED . 20

....................................................................SERVICING YOUR ENGINE . 21

............................................THE IMPORTANCE OF MAINTENANCE . 21

....................................................................MAINTENANCE SAFETY . 22

..............................................................MAINTENANCE SCHEDULE . 23

..........................................................................................REFUELING . 24

.............................................................FUEL RECOMMENDATIONS . 25

................................................................ENGINE OIL LEVEL CHECK . 26

.........................................................................ENGINE OIL CHANGE . 27

..................................................ENGINE OIL RECOMMENDATIONS . 28

....................................................................AIR FILTER INSPECTION . 29

......................................................................AIR CLEANER SERVICE . 30

..............................................................Dual-Filter-Element Types . 30

...................................................................................Oil-Bath Type . 32

CONTENTS

SERVICING YOUR ENGINE (continued)

...............................................................SEDIMENT CUP CLEANING . 33

.......................................................................SPARK PLUG SERVICE . 34

...............................................................IDLE SPEED ADJUSTMENT . 35

.........................................................HELPFUL TIPS & SUGGESTIONS . 37

...................................................................STORING YOUR ENGINE . 37

........................................................................Storage Preparation . 37

........................................................................Storage Precautions . 40

...................................................................Removal From Storage . 41

.................................................................................TRANSPORTING . 42

.................................................................ENGINE WILL NOT START . 43

.....................................................................ENGINE LACKS POWER . 43

...............................................................TECHNICAL INFORMATION . 45

..................................................................Serial Number Location . 45

.................................................................Remote Control Linkage . 47

...........................................................................Oxygenated Fuels . 49

...........................................................................................Air Index . 52

..................................................................................Specifications . 53

.............................................................................Wiring Diagrams . 55

..............................................................CONSUMER INFORMATION . 57

.........................................................................Honda Publications . 57

........................................................Warranty Service Information . 58

........................SPARK ARRESTER MAINTENANCE (optional part) . 36

.....................................TAKING CARE OF UNEXPECTED PROBLEMS . 43

...........................................FUSE REPLACEMENT (QXE2 type only) . 44

........................................TECHNICAL & CONSUMER INFORMATION . 45

...........Battery connections for Electric Starter (QXE2 type only) . 46

....................................Carburetor Modification for High Altitude . 48

..........................................Emission Control System Information . 50

............................QUICK REFERENCE INFORMATION . Inside back cover

ENGINE SAFETY

IMPORTANT SAFETY INFORMATION

Most accidents with engines can be prevented if you follow all instructions in this manual and on the engine. Some of the most common hazards are discussed below, along with the best way to protect yourself and others.

Owner Responsibilities

Honda engines are designed to give safe and dependable service if operated according to instructions. Read and understand this owner’s manual before operating the engine. Failure to do so could result in personal injury or equipment damage.

Know how to stop the engine quickly, and understand the operation of all controls. Never permit anyone to operate the engine without proper instructions.

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

Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode. Refuel outdoors, in a well-ventilated area, with the engine stopped. 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 engine.

Hot Exhaust

The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Let the engine cool before storing it indoors.

To prevent fire hazards and to provide adequate ventilation for stationary equipment applications, keep the engine at least 3 feet (1 meter) away from building walls and other equipment during operation. Do not place flammable objects close to the engine.

ENGINE SAFETY

Carbon Monoxide Hazard

Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run 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, operation, or protective apparel that may be needed to operate the equipment.

CONTROLS & FEATURES

COMPONENT & CONTROL LOCATIONS

MUFFLER

SPARK PLUG

AIR CLEANER

CHOKE LEVER

FUEL VALVE LEVER

FUEL TANK

THROTTLE LEVER

ENGINE SWITCH (QXE2 type)

CIRCUIT BREAKER (QXE2 type)

RECOIL STARTER

STARTER GRIP

FUEL FILLER CAP

OIL DRAIN PLUG

ELECTRIC STARTER (QXE2 type)

ENGINE OIL FILLER CAP/DIPSTICK

CONTROLS & FEATURES

CONTROLS

Fuel Valve Lever

The fuel valve opens and closes the passage between 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 of fuel leakage.

FUEL VALVE LEVER

OONN

OFF

CONTROLS & FEATURES

Engine Switch

The engine switch enables and disables the ignition system.

The engine switch must be in the ON position for the engine to run.

Turning the engine switch to the OFF position stops the engine.

ALL ENGINES EXCEPT QXE2 QXE2 TYPE

ENGINE SWITCH

OFF

CIRCUIT BREAKER

QXE2 Type

The engine switch on the QXE2 type includes a START position for operating the electric starter. The key automatically returns to the ON position when released from the START position.

The circuit breaker, which is located below the key, protects the battery charging circuit (see page 12).

CONTROLS & FEATURES

Choke Lever

The choke lever opens and closes the choke valve in the carburetor.

The CLOSED position enriches the fuel mixture for starting a cold engine.

The OPEN position provides the correct fuel mixture for operation after starting, and for restarting a warm engine.

Some engine applications use a remotely-mounted choke control rather than the engine-mounted choke lever shown here.

CHOKE LEVER

OPEN

CLOSED

CONTROLS & FEATURES

Throttle Lever

The throttle lever controls engine speed.

Moving the throttle lever in the directions shown makes the engine runfasterorslower.

Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here.

THROTTLE LEVER

SLOW

FAST

Recoil Starter Grip

Pulling the starter grip operates the recoil starter to crank the engine.

STARTER GRIP

CONTROLS & FEATURES

FEATURES

Oil Alert

The Oil Alert 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 automatically stop the engine (the engine switch will remain in the ON position).

If the engine stops and will not restart, check the engine oil level (page

) before troubleshooting in other areas.

Circuit Breaker

The circuit breaker protects the battery charging circuit. A short circuit, or a battery connected with reverse polarity, will trip the circuit breaker.

The green indicator inside the circuit breaker will pop out to show that the circuit breaker has switched off. If this occurs, determine the cause of the problem, and correct it before resetting the circuit breaker.

System (applicable engine types)

system is designed to prevent engine damage caused

system will

(QXE2 type only)

CIRCUIT BREAKER

Push the circuit breaker button to reset.

BEFORE OPERATION

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 failing to correct a problem before operation, could cause a malfunction in which you could be seriously injured.

Always perform a preoperation inspection before each 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.

Check the General Condition of the Engine

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

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

Look for signs of damage.

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

BEFORE OPERATION

Check the Engine

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

The Oil Alert stop the engine before the oil level falls below safe limits. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup.

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

Check the fuel level (see page ). Starting with a full tank will 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.

system (applicable engine types) will automatically

OPERATION

SAFE OPERATING PRECAUTIONS

Beforeoperatingtheengineforthefirsttime,pleasereviewthe

IMPORTANT SAFETY INFORMATION BEFORE OPERATION

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

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.

on page and the chapter titled

Move the fuel valve lever to the ON position.

FUEL VALVE LEVER

OPERATION

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

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

Some engine applications use a remotely-mounted choke control rather than the engine-mounted choke lever shown here.

CHOKE LEVER

Move the throttle lever away from the SLOW position, about 1/3 of

OPEN

the way toward the FAST position.

Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here.

SLOW

THROTTLE LEVER

Turn the engine switch to the ON position.

OPERATION

ALL ENGINES EXCEPT QXE2

ENGINE SWITCH

Operate the starter.

RECOIL STARTER (all engine types):

Pull the starter grip lightly until you feel resistance, then pull briskly. Return the starter grip gently.

QXE2 TYPE

STARTER GRIP

OPERATION

ELECTRIC STARTER (QXE2 type):

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

If the engine fails to start within 5 seconds, release the key, 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.

Whentheenginestarts,releasethe key, allowing it to return to the ON position.

If the choke lever has been moved to the CLOSED position to start

6. the engine, gradually move it to the OPEN position as the engine warms up.

ENGINE SWITCH (QXE2 type)

CHOKE LEVER

OPEN

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