User manual | Honda GC190 Engine Shop Manual

ANUAL
NAVIGATION TIPS
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A FEW WORDS ABOUT SAFETY
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It
could also damage the engine or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some
procedures require the use of special tools. Any person who intends to use a replacement part, service procedure, or a
tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the
engine.
If you need to replace a part, use genuine Honda parts with the correct part number, or an equivalent part. We strongly
recommend that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
WARNING
Proper service and maintenance are essential to the customer’s
safety and the reliability of the engine. Any error or oversight
while servicing an engine can result in faulty operation, damage
to the engine, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others
to be seriously hurt or killed.
For Your Safety
Follow the procedures and precautions in this
manual and other service materials carefully.
Because this manual is intended for the professional service
technician, we do not provide warnings about many basic shop
safety practices (eg, Hot parts – wear gloves). If you have not
received shop safety training or do not feel confident about your
knowledge of safe servicing practices, we recommend that you
do not attempt to perform the procedures described in this
manual.
Some of the most important general service safety precautions
are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and
repair procedures. Only you can decide whether or not you
should perform a given task.
WARNING
Failure to properly follow instructions and
precautions can cause you to be seriously hurt
or killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions
• Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate
clothing and using safety equipment. When performing any service task, be especially careful of the following:
! Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts,
and the skills required to perform the tasks safely and completely.
! Protect your eyes by using proper safety glasses, goggles, or face shields any time you hammer, drill, grind, or
work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put
on eye protection.
! Use other protective wear when necessary, for example, gloves or safety shoes. Handling hot or sharp parts can
cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Make sure the engine is off before you begin any servicing procedures, unless the instructions tell you to do
otherwise. This will help eliminate several potential hazards:
! Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the
engine.
! Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
! Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are
out of the way.
• Gasoline vapors are explosive. To reduce the possibility of a fire or explosion, be careful when working around
gasoline.
! Use only a nonflammable solvent, not gasoline, to clean parts.
! Never drain or store gasoline in an open container.
! Keep all cigarettes, sparks, and flames away from all fuel-related parts.
ANUAL
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ANUAL
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PTO DIMENSIONAL DRAWINGS
Unit: mm (in)
h
F
0
0 type
O
C Y 0
h
e
+?
0
a
e
5.2
00
+?
c-o
4.763
(0.187
+0.030
0
Y
I
62 (2.4)
5.2
(0.20)
V type
P type
5.2
(0.20)
62 (2.4)
ANUAL
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WIRING DIAGRAMS
With oil level switch
I
SPARK
PLUG
IGNITION
COIL
ENGINE STOP
SWITCH
(NORMAL OPEN
CONTACT)
1
STOP
I
I
CLOSE
I
OIL H ; ; :
CONTACT
LEVEL
NORMAL
CONTACT
I
OIL LEVEL
SWITCH
(NORMAL OPEN
CONTACT)
I
LOW LEVEL
I
CLOSE
-1
I
~
I
STOP
Without oil level switch
CONTACT
CLOSESTOP
SPARK
PLUG
IGNITION
COIL
ENGINE STOP
SWITCH
(NORMAL OPEN
CONTACT)
N
E
ANUAL
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THE IMPORTANCE OF PROPER SERVICING
Proper servicing is essential
to the safety of the operator and the reliability of the engine.
Any error or oversight made by
the technician while servicing can easily result in faulty operation, damage to the engine or injury to the operato
Follow the procedures and precautions
in this shop manual
carefully.
Some of the most important precautions are given below.
However, we cannot warnyou of every conceivable hazard that
can arise in performing maintenance or
repairs. Only you can decide whether or not you should perform a given
task.
you t o b eseriously hurl or killed.
Failure to follow maintenance instructions and precautions can cause
in this shop manual carefully.
Follow the procedures and precautions
IMPORTANT SAFETY PRECAUTIONS
Be sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clo
and safety equipment. When performing maintenance or repairs,
be especially careful of the following:
.
Read the instructions beforeyou begin, and be sure you have tools
the and skills required
to perform the tasks
safely.
Be sure the engine is
off before you begin any maintenance repairs.
or
This will reduce the possibility of several
hazards:
-
Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you run the engine.
Burns from hot parts.
it.
Let the engine cool before you touch
Injury from movingpa&.
Do not run the engine unless the instruction tells you to
so.do
Even then, keep yourhands, fingers, and clothingaway.
To reduce the possibility of a fire or explosion, be careful when working around gasoline. Use only a nonflammable
solvent, not gasoline, to clean parts. Keepall cigarettes, sparks, and flames away from all fuel-related parts.
ANUAL
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SERIAL NUMBER LOCATION
The engine serial number is stampedon the cylinder barrel. Refer to this
when ordering parts or making technical inquiries.
ENGINE SERIAL
ANUAL
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SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents.
Parts that do not meetHonda's
design specifications may damage the engine.
2. Use the special tools designed for the product.
3. Install new gaskets, O-rings, etc. when reassembling.
or inner bolts first and tighten
to thespecified torque diagonally,
nuts, begin with larger-diameter
4. When torquing bolts or
unless a particular sequence is specified.
5. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
6. After reassembly, check all parts for proper installation and operation.
Be aware that cross-threading or overtightening these screws will
7. Many screws used in this machine are self-tapping.
strip the threads and ruin the hole.
8. Use only metric tools when servicing engine.
this
Metric bolts, nuts and screws
are not interchangeable with nonmetric
fasteners. The useof incorrect tools and fasteners will damage the engine.
are used:
9. Follow the instructions represented by these symbols when they
[TOOL) :Use special tool
0x 0( 0): Indicates
3
the diameter, length, and number of the flange bolt
used.
:Apply oil
ANUAL
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MAINTENANCE STANDARDS
Item
Part
Spark plug
Ignition coil
Gap
Resistance
flywheel)
(at
Air gap
Primary coil
Secondary coil
Standard
0.7 - 0.8 m m (0.028- 0.031 in)
1.0- 1.2 a
10.6 - 12.8 k 0
0.2 - 0.6 m m (0.008 - 0.024 in)
Service limit
-
-
ANUAL
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MAINTENANCE STANDARDS
Part
Valves
clearance
Valve
Item
(cold)
Stem 0. D.
Guide 1. D.
Seat width
Spring free length
Valve head diameter
IN
EX
IN
EX
IN/EX
IN/EX
IN/EX
IN
EX
Standard
0.15 rt 0.04 mm
0.20 rt 0.04 mm
5.48 mm (0.216 in)
5.44 mm (0.214 in)
5.50 mm (0.217 in)
0.7 mm (0.028in)
34.0 mm (1.34 in)
25 mm (0.98 in)
24 mm (0.94 in)
Service limit
-
5.318 mm (0.2094 in)
5.275 mm (0.2077 in)
5.572 mm (0.2194 in)
1.8 mm (0.07 in)
32.5 mm (1.28 in)
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SPECIAL TOOLS
Tool name
2. Valve adjusting wrench B
3. Attachment, 32 x 35 m m
Tool number
0770 1-0010000
07708-0030400
07746-0010 100
4. Attachment, 52 x 55 m m
07746-0010400
5. Pilot, 28 m m
07746-004 1100
1. Float level gauge
6. Driver
7. Valve seat cutter, 45"1527.2
8. Cutter holder
9. Cleaning brush
m
07749-00 10000
07780-0010200
07981-VA20100 or
0798 1-VA20101
07998-VA20100
@\@I
Application
Carburetor float level inspection
Valve clearance adjustment
62/28 radial ball bearing removal (V and P
types only)
62/28 radial ball bearing installation (V and P
types only)
62/28 radial ball bearing removaI/installation
(V and P types only)
Driver for tools3,4 and 5
Valve seat reconditioning (IN/EX)
Valve seat reconditioning
Combustion chamber cleaning
0
W
n
@
ANUAL
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GENERAL SYMPTOMS AND POSSIBLE CAUSES
+
*
CARBURETORFLOATCHAMBER
contains stale gasoline.
~
-
TUBE
DIAPHRAGM
Inspect
-
d
I
I
Inspect
SPARKPLUG disconnected or no
spark at plug.
FUEL TANK TUBE and FUEL
TUBE
clogged.
Drainold fuel. Fill tank
with fresh gasoline.
Connect the tubeproperly
I
I
*
FUEL PUMP clogged.
Replace
FUEL STRAINERclogged.
Clean
CARBURETOR out ofadjustment.
_
+
I
Readjust
Disassemble and inspect
I
I
IGNITION COIL air gap incorrect.
IGNITION COIL faulty.
PLUG
SPARK
faulty.
-1
Inspect
Inspect
GOVERNOR out of adjustment.
Inspect
t'
t'
GOVERNOR out ofadjustment.
Clean
Readjust
1
ANUAL
VALVEORVALVE
damaged.
I
I
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SEAT worn or
Inspect and correct
~
I
1
CYLINDER, PISTON or PISTON
RING worn.
I
I
I
Engine will
sufficiently.
L
not
I
I
Clean or replace
SPARK ARRESTER restricted.
ct
1
Disassemble
inspect
and
rev
1
I
CARBURETOR out of adjustment.
Disassemble and inspect
I
I
t'
PLUG
L
SPARK
Inspect
I
faulty.
l GOVERNOR out of adjustment. 1
I
I
Readjust
Disassemble and inspect
t'
PLUG
SPARK
CLEANER
AIR
faulty..
Inspect
Clean restricted.
GOVERNOR
out
of adjustment.
Readjust
+A
C
Disassemble and inspect
CLEANER
AIR
-
1
I
I
Clean restricted.
GOVERNOR
Readjust
out of ad
Readjust
ANUAL
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HARD STARTING
1. First, check the fuel level in
the tank.
No fuel
t
-
2. Remove spark plug and
inspect forwet
orfouled
electrode.
Dry
Check for blockag of the fuel
tube, strainer or fuel pump.
Check for disconnection of the
diaphragm tube.
Check for blockage in the main
jet or nozzle of the carburetor.
D
Wet
Cleanelectrodeandrestart,
taking care that the choke is not
closed too much.
If flooding is severe, check the
carburetor float valve.
I
1
3. Check the ignition system
I
NO spark or weak spark ------+
Ignition system faulty
I
Good spark
4. Check the cylinder compres-
Abnormal compression
Normal compression
I
1
5. Install the spark plug and
restart the engine.
~
Check that the valve clearance
is correct.
Check to see whether excessive
carbon has accumulated in the
. combustion chamber.
Check for defective valves or
valve seats.
Check for worn piston rings,
piston or cylinder.
Check for cylinder leakage.
CYLINDER COMPRESSIONCHECK
1) Remove the spark plug and install a compression gauge in
the spark plug hole.
2) Pull the recoil starter several times with force and measure
the cylinder compression.
L
Compression
GAUGE
(Commercially
available)
ANUAL
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OIL ALERT SYSTEM (WITH OIL LEVEL SWITCH)
CAUTION:
I Never start the engine when the oil has been drained.
Engine does not start with the
ignition switch lever is moved
t o the ONposition.
* Check oil level
before
proceed-
+ Check for sparks usingnew
i
Spark
Fault other than oil alertsystem
Perform troubleshooting
Plug
No spark
mended
the ing. Add
engine oil if necessary.
v
Check continuity between oil
level switch yellow wire. and
ground.
.‘OntinuitL
Replace oil level switch
No continuity
v
ENGINE STOP SWITCHfaulty.
Replace engine stop switch
Disconnect theenginestop
,Spark
switch wire (Black) and recheck
plug orspark.
i
I
,
I
No spark
Enginedoesnotstopwhen
theignitionswitch
lever is
OFF position (Engine oilsufficient).
5c
*
Disconnect theenginestop
Replace engine
stop
switch Black wire.
Connect the Black wire of the moved to the
ignition coilside to the ground
and check spark at the spark
Plug.
Spark
*
I
1
’
Enginedoes notstopwhen
the engine oil isinsufficient.
k-
IGNITION COIL faulty.
Replace ignition coil
NO
Check continuity between oil continuity
level switch yellow wire and
ground.
Continuity
7
switch
IGNITION COIL faulty.
Replace ignition coil
1
ANUAL
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Continuity
v
Disconnect the engine
stop
spark
switch Black wire.
Connect the wire of the ignition
coil sideto ground and pecform
spark test
Spark
ENGINE STOP
SWITCH
faulty.
switch
Replace
stop
engine
IGNITION COIL faulty.
Replace ignition coil
ANUAL
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IGNITION SYSTEM
Engine does not start with the
ignition switch lever moved to
the ON position.
+ Perform spark test (see below).
Plug gap:
0.7 - 0.8 m m (0.028 - 0.031 in)
No spark
1
Check after
replacing
with Sparks
new spark plug.
)I
Replace the spark plug.
No spark
from
the
engine
stop
switch
Replace engine stop
switch
No spark
Normal
1
Check resistance values of Abnormal
primary and seconrary coils of
transistorized ignitioncoil
1-
Primary coil:
Secondary coil:
SPARK PLUG TEST
1) Remove the spark plug, attach it to the spark plug cap, and
ground the sideelectrode against the cylinder head cover
bolt.
2) Move the ignition switchlever to the ON position, pull the
recoil starter and check t o see i f sparks jump across the
electrodes.
If ignited, gasoline canburn you severely.
Be surethere is no spilled fuel near the engine.
Place the spark plug away from the
spark plug hole.
Replace transistorized ignition
coil
ANUAL
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ENGINE STARTS BUT THEN STALLS
I
Check the fuel level in t h e t a n k . ,
No fuel
b
L
I
Add
fuel
and restart the engine.
I
Sufficient fuel
Check for blockage of the pump.
Replace
ifpump
fuel
the
necessary
Normal
t
Check for blockage o
Abnormal
the fueltube.
Clean the fuelstrainer
Normal
IC
Inspect the carburetor for loose installation
and secondary air sucked throughthe
carburetor insulator.
Abnormal
b
If thecarburetor is loose, tighten the bolts
securely.
Check the carburetor insulator for damage
and proper installation
Normal
Check the ignition system
No spark or weak spark
Replace the spark plug with a new one and
check for spark.
Check for leaking current causedby damaged
high tension cord insulation.
Check ignition coil
Good spark
Abnormal
Normal
Start the engine accordingto thestarting
*
Check that the valve clearance is correct
Check t o see whether excessive carbon
has accumulated in
the
combustion
chamber.
Check for defective valves or valve seat.
Check for worn piston rings, piston or
cylinder.
Check f o r cylinder leakage.
ANUAL
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ENGINE LACKS POWER
Contaminated
Inspect the air filter
Clean the air filter and replace if necessary
Not contaminated
t
Check for blockage in the mainjet or nozzle
of thecarburetor.
t
Abnormal
Clean and replace if necessary
7
Normal
Removethe
spark plugand
check the .
electrodes for carbonand spark plug gap
Abnormal
c
Clean the spark plug and adjust the spark
Plug gap
Replace the spark plug if necessary
I
1 Normal
t
Check the ignition
No spark or weak spark
Replace the spark plug with a new one
and check for spark.
*Checkforleakingcurrent
caused by
damaged high tension cord insulation.
Check ignition coil
I
Good spark
I Measure the
t
Abnormal
C
Normal
t
Start the engine according to the starting
procedure.
Check that the valve clearance is correct
Check to see whether excessive carbon
has accumulated
in
the
combustion
chamber.
Check for defective valves or valve seat.
Check for worn piston
rings, piston or
cylinder.
Check for cylinder leakage.
ANUAL
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ENGINE SPEED DOES NOT INCREASE
Check the governor out ofadjustment.
Adjust the governor
Correct
Contaminated
1
m
Clean the air filter and replace if necessary
I
I
Not contaminated
t
Check the valve clearance
Adjust the valve clearance
Correct
Incorrect
electrodes for carbon and spark plug gap
I,
Clean the spark plug and adjust the spark
Plug gap
Replace the spark plug if necessary
I
Normal
t
Check for blockage in the mainjet or nozzle
of thecarburetor.
I
Abnormal
*
Clean and replace if necessary
Normal
Abnormal
and for secondary air being drawn through
the carburetor insulator.
If thecarburetor is loose, tighten the bolts
securely.
Check the carburetor insulator for damage
and proper installation
Normal
t
Inspect the valve springs
Replace the valve springs
I
ANUAL
HARNESS ROUTING
HIGH TENSION
CORD
SWITCH
IGNITION COIL-
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ANUAL
REGULAR SERVICE PERIOD
\
ITEM
Performat every indicated month or
operating hour interval, whichever
comes first (3).
0 Engine oil
Check
FIRST
EVERY EVERY
BEFORE MONTH SEASON SEASON EVERY
OR
USE
OR
OR
5 HRS 25 HRS 50 HRS
0
Check
Clean
Change
Clean
0 Fuel tank and
strainer
0 Spark plug
Spark arrester (Optional part)
0 Idle speed
0 Valve clearance
0 Fuel line
0
0(2)
Check-Clean
Replace
Clean
Check-Adjust
Check-Adjust
Check
(Replace if necessary)
EVERY
I100 HRS 1150 HRS
0
Change
0 Air cleaner
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Every 2 years
0 Emission related items.
(1) Change engine oil every 25 hours when used under heavy load or in highambient temperature.
(2) Service more frequently when used in dustyareas.
(3)For commercial use, log hours of operation to determine proper maintenance.
ANUAL
ENGINE OIL
<= INDEX
I
/,GROUND
Oil alert (with oil level switchonly):
NOTE:
For convenience, perform this test in conjunction with the
engine oil change.
1) With theengine running, disconnect the black wire from the
stop switch wire, and ground the wireagainst the engine.
The engine should stop.
I
2) With the enginestopped, the crankcase filled with oil, and
the oil level switch wires disconnected, check continuity
between the yellow oillevel switch wire andground. There
should be no continuity.
3) With the engine stopped, the oildrained from the crankcase,
and the oil
level switch wires disconnected, check continuity
between the yellow oillevel switch wire and ground. There
should be continuity.
I
//
GROUND
Oil level check:
Check the engine oil level with the engine stopped and engine
on a level surface.
1) Remove the oil fillercap, and wipe the dipstick clean.
OIL FILLER CAP/
DIPSTICK
I
OIL FILLERCAP/DIPSTICK
2) Insert the dipstick in the oilfiller neck, but do not screw it in.
Remove the dipstick and check the oil level.
3) If the oil level is low, fill to the top of the oil fillerneck with
the recommended oil. Do not overfill.
4) Tighten the oil fillercap securely.
UPPER LIMIT
LOWER LIMIT
ANUAL
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Oil change:
OIL FILLER CA
Drain theused oil while the engine is
warm. Warm oil drains
quickly and completely.
1) Place a suitable container under the oil drain plug bolt.
OIL DRAIN PLUG
WASHER
2) Remove the oil filtercap and drain plug bolt, and drain the
oil into thesuitable container.
Please dispose of used motor oil in
a manner that is
compatible with theenvironment. We suggest you take used
oil in a sealed container to your local recyclingcenter or
service station for reclamation. Do not throwit in the trash,
pour it on theground, or down a drain.
\I/
PLUG BOLT
SAE Viscosity Grades
CAUTION:
Used engine oil contains substances that have been
identified as carcinogenic.
If repeatedly leftin contact with the skin for prolonged
periods, it may cause skin cancer.
Wash your handsthoroughly with soap and wateras soon
as possible after contact with used engine oil.
-io
I
-20
I
-10
I
0
1
10
I
20
I
I
30 40°C
AMBIENT TEMPERATURE
3) Reinstall the drain plug bolt, and tighten it securely.
TORQUE
OIL FILLER CAP/DIPSTICK
4) W i t h t h e e n g i n e o n
a level surface, refill with the
rec0mmende.d oil to the top of the oil neck.
filter
Engine oil capacity
I
Recommended operating
ambient temperature
- UPPER LIMIT
LOWER LIMIT
Oil is a major factor affecting performance and service life.
Use 4-stroke automotive detergent oil.
SAE IOW-30 is recommended for general use. Other
viscosities shown in thechart may be usedwhen the average
temperature in yourarea is within the
recommended range.
The SAE oil viscosity and service classification are in the API
label on the oilcontainer. Honda recommends that you use
API SERVICE category SF or SG oil.
5) Reinstall the dipstick, and tighten the oil filter
cap securely.
OIL FILLER CAP/
DIPSTICK
ANUAL
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AIR CLEANER COVER
I
Cleaning:
LATCH
TABS
A dirty air filter will restrict air flow to thecarburetor, reducing
engine performance. If the filter operated
is
in dusty areas, clean
the air filter more often than specified in theMAINTENANCE
SCHEDULE.
CAUTION:
Operating theengine without an airfilter or with a damaged
air filter, will allow dirtt o enter the engine, causing rapied
engine wear. This type of damage is not covered by the
Distributor's Limited Warranty.
Press the latch tabs on the fueltank side of the aircleaner
cover, and remove the cover.
Inspect the air filter, and replace if damaged.
Tap the filterseveral times ona hardsurface to remove dirt,
or blowcompressed air [not exceeding 207 kPa (2.1 kgf/cm2,
30 psi)] through the filter from the
clean side that faces the
engine.
Never try to brushoff dirt; brushing will force dirt into the
fibers.
AIR CLEANER
CASE
L
Wipe dirt from the inside of the cleaner
air
cover and air
cleaner case, using a moist rag. Be careful to prevent dirt
from entering the air duct that leads to thecarburetor.
Reinstall the filterand air cleaner cover.
AIR FILTER
\
AIR DUCT
ANUAL
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SPARK PLUG
Inspection/Cleaning:
I
Standard spark plug
I
Clean any dirt from around the
spark plug.
Remove the plugcap, and use a spark plug wrench to remove
the plug.
Visually inspect the spark plug. Discard the plug if the
insulator is cracked or chipped.
Remove carbon or other deposits with a stiff wire brush.
Measure the pluggap with a wire-type feeler gauge.
1
Spark plug gap
I
If necessary, adjust the gap by bending theside electrode.
Make sure the sealing washer is in goodcondition; replace
the plug ifnecessary.
Install the plug fingertight to
seat the washer, then tighten
with a plug wrench (an additional1/2 turn ifa new plug)to
coppress the sealing washer. If you are reusing a plug,
tighten 1/8-1/4 turn after the plugseats.
CAUTION:
A loose sparkplug can become veryhot and can damage
the engine. Overtightening thespark plug can damage
the threads in thecylinder barrel.
GAP
SIDE ELECTRODE
/
0
WIRE
BRUSH
ANUAL
<= INDEX
VALVE CLE.ARANCE
CYLINDER HEAD
COVER
CORNER
lnspection/Adjustment:
/
NOTE:
CORNER
Valve clearanceinspection and adjustment must be performed
with theengine cold.
1) Remove the four 6 x 12 m m flange bolts.
2) When removing the cylinder head cover, pry off slowly at
each corner of thehead cover.
CAUTION:
6 x 12 (4)
\
Do not remove thecylinder head cover with force. It
can deform the cylinder head cover.
Replace the cylinder head cover if it is deformed.
I
3) Set the piston at top dead center of thecompression stroke
\
(both valves fully closed).
CYLINDER
HEAD COVER
Top dead center
of the compression. stroke is in the
position where the cylinder head cover mating surface is
in line with the cam pulley alignment marks.
ALIGNMENT MARKS
CAM
PULL
IIQ
-/
CYLINDER HEAD COVER MATING SURFACE
ANUAL
4) Insert a feeler gauge between the valve stem and the
adjusting screw on therocker arm.
Standard valve
clearance
I
<= INDEX
(S.TOOL)
VALVE ADJUSTING
WRENCH B
5) If adjustment is necessary, proceed as follows:
a. Hold the adjusting screw using the special tool, and loosen
the lock nut.
b. Turn the adjustingscrew t o obtain the specified intake
and exhaust valve clearance.
c. Hold the adjusting screw using the special tool, and
tighten the lock nut.
TORQUE
6 ) Recheck valve clearance after tightening the lock nut.
7) Apply a liquid packing (Three Bond 1207 Honda Bond #4 or
equivalent) to the cylinder
head cover installation surface,
and install thecylinder head cover
VALVE
ADJUSTING
LOCK NUT
VALVE STEM
To increase valve clearance, screw out.
To decrease valve clearance, screw in.
ANUAL
CARBURETOR
<= INDEX
I
Pilot screw:
The pilot screw is fitted witha limiter cap that prevents excessive enrichment of theair-fuel mixture inorder to comply with
emissions regulations.
Do not attempt toremove the limitercap for pilotscrew adjustment. The limiter cap cannot be removedwithout breaking the
pilot screw.
Pilot screw adjustment must be performed only whenit is disassembled
Throttle stop screw:
1) Start the engine and allow it to warm up to normal
operating temperature.
2) With theengine idling, turn the throttle
stop screwto obtain
the standard idle speed.
I Standard idle speed I
I
THROTTLE
ANUAL
<= INDEX
GOVERNOR
GOVERNOR
VALVE
Adjustment:
ARM\
CARBURETOR
THROTTLE
CONTROL
LEVER
I
Remove the fueltank.
Move the controllever to the FAST position.
Loosen the governor arm nut on the
governor arm.
Pushing the governor arm toward thecarburetor side, open
the carburetor throttle valve fully.
Holding the carburetor throttle valve fullyopen, turn the
governor arm shaft clockwise fully, and tighten thegovernor
arm nut to the
specified torque.
TORQUE
Move the controllever to the SLOW position.
With the controllever in the SLOW position, check to see
whether the carburetor throttle valve is fullyclosed.
Check to see whether the governor arm and the carburetor
throttle valve operate smoothly.
Start the engine and warm it up to the normal operating
temperature. Move the control lever to the maximum
engine
speed position, and check the maximumengine speed.
I
Maximum speed (no load)
I
IO) Adjustment is made at the governor spring installation
position of the controllever.
GOV~RNOR
ARM NUT
\
GOVERNOR SPRING
INSTALLATION
POSITION
GOVERNOR ARM
SHAFT
ANUAL
<= INDEX
FUEL TANK/FUEL STRAINER
Cleaning:
FUElL 'rANK
Gasoline is highly flammable and explosive.
You can be burnedor seriously injured when handling fuel.
Keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.
1) Drain the fuel into a suitable container, and remove the fuel
tank.
/
FUEL TUBE
6 x 25 mm BOLT
WASHER (2)
6 mm FLANGE
NUT
ANUAL
<= INDEX
Disconnect the fuel line, and unscrew the fuel strainer from
the tank.
FUEL TANK
\
Clean the strainer with solvent, and check to be sure the
strainer screen is unda.maged.
lnser the fuelstrainer in the fuel
tank.
Connect the fuel tube to the fuel
tank.
Install the fueltank.
After assembly, check for fuel leaks.
FUEL LINE
STRAINER
Check:
1
I
FUEL TUBE
Gasoline is highly flammable and
explosive.
You can be burned or seriously injured when handling fuel.
Keep heat, sparks, and flameaway.
Handle fuelonly outdoors.
Wipe up spills immediately.
1) Check the fuel lines for deterioration, cracks or sings of
leakage.
2) Check the fuel pump for dirt
and other foreign material.
I
FUEL
PUMP-
3) Drain the fuel into a suitable container.
4) Replace the fuel lines and fuel pump as necessary.
FUEL TANK
TUBE
ANUAL
<= INDEX
SPARK ARRESTER (OPTIONAL PART)
Cleaning:
The muffler becomes veryhot during operation and remains
hot fora while after stopping theengine. Be carefuln o t t o
touch the muffler whileit is hot. Allow it t o cool before
proceeding.
MUFFLER
PROTECTOR
CAUTION:
The spark arrester must be serviced every100 hours to
maintain itsefficiency.
Remove the three 6 x 12 m m flange bolts from the muffler
protector, and remove the muffler protector.
6 X 12 (3)
Remove the 4 x 6 m m tapping screw from thespark arrester,
and remove thespark arrester from themuffler.
Check for carbon deposits around the exhaust port and spark
arrester. Clean, if necessary, with a wire brush.
Replace the spark arrester if there are any breaks or tears.
Install the spark arrester and muffler protector in thereverse
order of removal.
GENERAL INFO #6 =>
.
SPARKARRESTER