iGX390 T2 | User manual | Honda iGX270 UT2, iGX390 UT2, T2 Engine Shop Manual

How to use this manual

How to use this manual

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 and/or others. It could also damage this Honda product or create an unsafe condition.

This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use a 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 this product.

If you need to replace a part, use Honda Genuine 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

Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight while servicing this product can result in faulty operation, damage to the product, 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.

Follow the procedures and precautions in this manual and other service materials carefully.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., 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.

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 anytime you hammer, drill, grind, or work around pressurized air, pressurized liquids, 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.

• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure that the hoist hook is securely attached to the product.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells 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 and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries.

• Use only a nonflammable solvent, not gasoline, to clean parts.

• Never store gasoline in an open container.

• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.

0-1

INTRODUCTION

This supplement covers the construction, function, and servicing procedures of the Honda iGX270UT2·iGX390T2/UT2 Engines.

For service information that is not covered in this supplement, please refer to the GX270T2/

UT2·GX390RT2/T2/UT2 base shop manuals (part number 62Z5F00Z·62Z5F00).

All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and tables.

As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to this Honda product, other property, or the environment.

SAFETY MESSAGES

Your safety and the safety of others are very important.

To help you make informed decisions, we have provided safety messages and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing these products. You must use your own good judgement.

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

· Safety Labels – on the product.

· Safety Messages – preceded by a safety alert symbol

and one of three signal words, DANGER,

WARNING, or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

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

· Instructions – how to service these products correctly and safely.

© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE

Date of Issue: September 2010

How to use this manual

OUTLINE OF CHANGES

SPECIFICATIONS

SERVICE INFORMATION

MAINTENANCE

TROUBLESHOOTING

COVER

FUEL SYSTEM

GOVERNOR SYSTEM

CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

OTHER ELECTRICAL

MUFFLER

CYLINDER HEAD/VALVES

CRANKCASE

WIRING DIAGRAMS

INDEX

The marked sections contain no changes.

They are not covered in this supplement.

13

14

15

9

10

11

12

7

8

5

6

3

4

1

2

0-2 i

How to use this manual

SYMBOLS

The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it will be explained specifically in the text without the use of the symbols.

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

( x ) ( ) page 1-1

Use automatic transmission fluid.

Indicates the diameter, length, and quantity of metric bolts used.

Indicates the reference page.

ITEM

Fan cover

GX270UT2·GX390UT2/T2

MODEL iGX270UT2·iGX390UT2/T2

Carburetor

ECM

Control base

Assy.

MANUAL OPERATION TYPE:

MANUAL OPERATION A TYPE:

EXCEPT MANUAL OPERATION TYPE:

UPPER SHROUD

INSULATOR (If equipped)

ITEM

Charge/lamp coil

MODEL

GX270UT2·GX390UT2/T2

10 A CHARGE COIL/12 V – 50 W LAMP COIL TYPE:

iGX270UT2·iGX390UT2/T2

18 A CHARGE COIL TYPE:

1 A/3 A CHARGE COIL TYPE:

12 V – 15 W/12 V – 25 W LAMP COIL TYPE:

Governor arm/ governor rod

GOVERNOR ROD

GOVERNOR ARM

0.9 A CHARGE COIL

POWER COIL

ITEM

Engine wire harness

GX270UT2·GX390UT2/T2

MODEL iGX270UT2·iGX390UT2/T2

Recoil starter

Starter motor

Control box

With circuit protector type

Without circuit protector type

ITEM

Auto throttle solenoid

GX270UT2·GX390UT2/T2

MODEL iGX270UT2·iGX390UT2/T2

Case cover packing

Crankcase/ oil level switch/ governor arm shaft

CRANKCASE

CRANKCASE

OIL LEVEL SWITCH

Crankcase cover

GOVERNOR

WEIGHT

HOLDER

GOVERNOR ARM SHAFT

GOVERNOR WEIGHT

CRANKCASE COVER

OIL LEVEL SWITCH

CRANKCASE COVER

1. SPECIFICATIONS

1

SERIAL NUMBER LOCATION ·····················1-2

TYPE CODE ··················································1-2

DIMENSIONS AND WEIGHTS

SPECIFICATIONS ·········································1-3

ENGINE SPECIFICATIONS·························· 1-3

DIMENSIONAL DRAWINGS························· 1-4

P.T.O. DIMENSIONAL DRAWINGS ············· 1-5

1-1

SPECIFICATIONS

SPECIFICATIONS

SERIAL NUMBER LOCATION

The engine serial number (1), description code (2) and type (3) are stamped on the crankcase.

Refer to it when ordering parts or making technical inquiries.

(1)

(2)

(3)

TYPE CODE

Model

Type

P. T. O.

Model

Type

P. T. O.

Model

Type

P. T. O.

QZX4

Q type

VZX7

GX270UT2

GX390T2

VZX

V type

GX390UT2

V type

VZX7

V type

VZX8

1-2

SPECIFICATIONS

DIMENSIONS AND WEIGHTS SPECIFICATIONS

P.T.O. VARIATION

Model

Overall length

Overall width

Overall height

Dry weight

Operating weight

Q type*

V type*

Q type*

V type*

Q type*

V type*

Q type*

V type*

Q type*

V type*

*: P. T. O. type (page 1-2).

GX270UT2

380 mm (15.0 in)

400 mm (15.7 in)

462 mm (18.2 in)

462 mm (18.2 in)

422 mm (16.6 in)

422 mm (16.6 in)

29.4 kg (64.8 lbs)

29.4 kg (64.8 lbs)

34.2 kg (75.4 lbs)

34.2 kg (75.4 lbs)

GX390UT2·GX390T2

–

425 mm (16.7 in)

–

484 mm (19.1 in)

–

448 mm (17.6 in)

–

36.4 kg (80.2 lbs)

–

41.7 kg (91.9 lbs)

ENGINE SPECIFICATIONS

Model

Description code

Type

Displacement

Bore x stroke

Net power (SAE J1349)*1

Continuous rated power

Maximum net torque

(SAE J1349)*1

Compression ratio

Fuel consumption

(at continuous rated power)

Ignition system

Ignition timing

Spark advancer performance

Spark plug

Lubrication system

Oil capacity

Recommended oil

Cooling system

Starting system

Stopping system

Carburetor

Air cleaner

Governor

Breather system

Fuel used

GX270UT2

GCBGT

270 cm

4 stroke, overhead valve, single cylinder, inclined by 25°

3 (16.5 cu–in) 389 cm 3 (23.7 cu–in)

77.0 x 58.0 mm (3.0 x 2.3 in)

6.3 kW (8.4 HP) /

3,600 min -1 (rpm)

GX390UT2

GCBCT

88.0 x 64.0 mm (3.5 x 2.5 in)

8.7 kW (11.7 HP) / 3,600 min

GX390T2

GCBDT

-1

(rpm)

5.1 kW (6.8 HP) /

3,600 min

-1

(rpm)

19.1 N·m

(1.95 kgf·m, 14.1 lbf·ft) /

2,500 min -1 (rpm)

8.5 : 1

2.4 Liters

(0.63 US gal, 0.53 Imp gal)/h

7.0 kW (9.4 HP) / 3,600 min -1 (rpm)

26.5 N·m (2.7 kgf·m, 19.5 lbf·ft)/ 2,500 min

8.2 : 1

-1 (rpm)

3.5 Liters (0.92 US gal, 0.77 Imp gal) / h

C.D.I.(Capacitor Discharge Ignition) type magneto ignition

B.T.D.C. 10° – 20°

B.T.D.C. 10° / 1,400 min -1 (rpm)

B.T.D.C. 10° – 22°

BPR6ES (NGK) / W20EPR-U (DENSO)

Forced splash

1.1 Liters (1.16 US qt, 0.97 Imp qt)

SAE 10W-30 API service classification SE or later

Forced air

Recoil and Starter motor

Ignition primary circuit open

Horizontal type, butterfly valve

Dual element type

STR (Self Tuning Regulator) governor

Reed valve type

Unleaded gasoline with a pump octane rating 86 or higher

*1: 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 min

-1

(rpm) (net power) and at 2,500 min

-1

(rpm) (maximum 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.

1-3

SPECIFICATIONS

DIMENSIONAL DRAWINGS

*: P. T. O. type (page 1-2).

Unit: mm (in)

184 (7.2) GX270UT2: 278 (10.9)

GX390T2/UT2: 300 (11.8)

GX270UT2: 462 (18.2)

GX390T2/UT2: 484 (19.1)

CONTROL

BOX

GX270UT2: 116 (4.6)

GX390T2/UT2: 142 (5.6)

GX270UT2: 192 (7.6)

GX390T2/UT2: 201 (7.9)

CRANKSHAFT

(P. T. O.)

STARTER MOTOR

103 (4.1)

GX270UT2: 92.5 (3.64)

GX390T2/UT2: 100 (3.9)

GX270UT2:

*

Q: 380 (15.0)

*

V: 400 (15.7)

GX390T2/UT2:

*

V: 425 (16.7)

1-4

105 (4.1)

195.5 (7.70)

SPECIFICATIONS

P.T.O. DIMENSIONAL DRAWINGS

*: P. T. O. type (page 1-2).

Q TYPE* (GX270UT2)

45

°

30

°

30

°

45

°

P.D

. 16

5.1

(6.

50)

5/16 - 24UNF - 2B TAP

(2 PLACES)

6.3 – 6.35

(0.2480 – 0.2500)

Unit: mm (in)

88.5 (3.48)

56 (2.2)

28 (1.1)

72.2 (2.84)

Φ

1

(Φ

10

.0

0

–

4

.3

31

–

11

0.

05

4

.3

33

)

27

(

5.

00

)

P

.D

.1

V TYPE*

103 (4.1)

5/16 - 24UNF - 2B TAP

(4 PLACES)

3/8 - 16UNC - 2B TAP

(4 PLACES)

–

11

0.

05

Φ

1

10

.0

(Φ

4

0

.3

31

–

4

.3

33

)

P

.D

.1

27

(

5.

00

)

45

°

30

°

30

°

45

°

103 (4.1)

P.D

. 16

5.1

(6.

50)

5/16 - 24UNF - 2B TAP

(2 PLACES)

105.5 (4.15)

18 (0.7)

5/16 - 24UNF - 2B TAP

(4 PLACES)

46.5 (1.83)

GX270UT2: 76.5 (3.01)

GX390T2/UT2: 75.5 (2.97)

3/8 - 16UNC - 2B TAP

(4 PLACES)

Unit: mm (in)

1-5

MEMO

2. SERVICE INFORMATION

2

MAINTENANCE STANDARDS ·····················2-2

TORQUE VALUES ········································2-2

LUBRICATION & SEAL POINT···················· 2-2

HARNESS AND TUBE ROUTING ················ 2-3

2-1

SERVICE INFORMATION

SERVICE INFORMATION

MAINTENANCE STANDARDS

Part

Engine

Carburetor

Starter motor

Charge coil

Power coil

Item

Maximum speed (at no load)

Cylinder compression

GX270UT2

Main jet

Pilot screw opening

GX390T2/UT2

GX270UT2

GX390T2/UT2

GX270UT2

GX390T2/UT2

Brush length

Mica depth

Resistance

Resistance

0.9 A

3,600 min -1 (rpm)*

Standard

1.31 MPa (13.4 kgf/cm

2

, 190 psi) / 1,400 min

-1

(rpm)

1.29 MPa (13.2 kgf/cm

2

, 187 psi) / 1,400 min

-1

(rpm)

BE90A A: #85

BE92B A: #100

BE90A A: 1 - 1/2 turns out

BE92B A: 3 turns out

10 (0.4)

–

5.1 - 7.7 Ω

2.9 - 4.5 Ω

*: This figure is caused by basic program in the ECM. The engine speed is different depending on the program in the ECM.

Unit: mm (in)

Service limit

–

–

–

–

–

–

–

6 (0.2)

0.2 (0.01)

–

–

TORQUE VALUES

ENGINE TORQUE VALUES

Item

Starter motor stud bolt

Fan cover stud bolt

Combination switch nut

ECM screw/washer

Motor case set screw A/B

Starter motor nut

Jet set screw

Tread Dia. (mm)

M10 x 1.25

M8 x 1.25

M18 x 1.0

M4 x 0.7

M4 x 0.7

M8 x 1.25

M5 x 0.8

N·m

40

23

4.9

2.1

2.1

8.8

0.3

Torque values kgf·m

4.1

2.3

0.50

0.21

0.21

0.90

0.03

lbf·ft

30

17

3.6

1.5

1.5

6.5

0.22

LUBRICATION & SEAL POINT

Location

Crankcase cover mating surface

Material

Liquid sealant

(Threebond® 1207B or equivalent)

Remarks

2-2

HARNESS AND TUBE ROUTING

POWER COIL CORD

HARNESS CLIP

SERVICE INFORMATION

ENGINE WIRE HARNESS

ENGINE WIRE HARNESS

CARBURETOR INSULATOR

HIGH TENSION CORD

IGNITION COIL

BREATHER TUBE

HIGH TENSION CORD

ENGINE WIRE HARNESS

POWER COIL CORD

FUEL TUBE

2-3

SERVICE INFORMATION

2-4

CORD CLAMP

CORD GROMMET

POWER COIL CORD

CORD CLAMP

POWER COIL

CORD CLAMP

0.9 A CHARGE COIL

CORD GROMMET

CHARGE COIL CORD

SERVICE INFORMATION

Y/Bl Lg

TO ECM

(ENGINE CONTROL MODULE)

G P

TO IGNITION COIL

3P

COUPLER

TO OIL LEVEL SWITCH

TO CONTROL BOX

COMBINATION

SWITCH HARNESS

OIL LEVEL SWITCH

STARTER MOTOR

/

Gr

Gr

TO CHARGE COIL

2-5

SERVICE INFORMATION

RECTIFIER

CUTOUT

INDICATOR

/

RECTIFIER CORD

GROUND WIRE

TO ENGINE WIRE HARNESS

CHARGE COIL WIRES

TO STARTER MOTOR

2-6

COMBINATION SWITCH HARNESS

COMBINATION SWITCH

SERVICE INFORMATION

FUSE BOX

RECTIFIER

TO STARTER MOTOR

TO ENGINE WIRE HARNESS

INDICATOR

COMBINATION

SWITCH

MAIN FUSE 30 A

TO CHARGE COIL

3P

COUPLER

TO STARTER MOTOR

TO IGNITION COIL

2-7

MEMO

3. MAINTENANCE

3

MAINTENANCE SCHEDULE························3-2

VALVE CLEARANCE CHECK/

ADJUSTMENT···············································3-3

COMBUSTION CHAMBER CLEANING ······· 3-4

FUEL TUBE CHECK····································· 3-5

3-1

MAINTENANCE

MAINTENANCE

MAINTENANCE SCHEDULE

ITEM

Perform at every indicated month or operating hour interval, whichever comes first.

Each use

REGULAR SERVICE PERIOD (2)

First month or

20 hrs.

Every 3 months or

50 hrs.

Every 6 months or

100 hrs.

Engine oil

Air cleaner

Sediment cup

Spark plug

Spark arrester

(Applicable types)

Valve clearance

Combustion chamber

Fuel tank and filter

Fuel tube

Check level

Change

Check

Clean

Replace

Clean

Check–adjust

Replace

Check–clean

Check–adjust

Clean

Clean

Check

(1)

After every 1,000 hours

Every 2 years (Replace if necessary)

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

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

(*) Refer to page of base shop manual (GX390RT2/T2/UT2: 62Z5F00)

Every year or

300 hrs.

Refer to page

3-3*

3-4*

3-6*

3-7*

3-8*

3-8*

3-3

3-4

3-12*

3-5

3-2

VALVE CLEARANCE CHECK/

ADJUSTMENT

Remove the head cover bolt (1), the head cover (2), and the head cover packing (3).

(3)

MAINTENANCE

(2)

Disconnect the spark plug cap from the spark plug.

Set the piston near top dead center of the cylinder compression stroke (both valves fully closed) by pulling the recoil starter slowly. When the piston is near top dead center of the compression stroke, the triangle mark (1) on the starter pulley (2) will align with the projection (3) on the fan cover (4).

If the exhaust valve is opened, use the recoil starter to turn the crankshaft one additional turn and align the triangle mark on the starter pulley with the projection on the fan cover again.

Pull slowly

(2)

Insert a thickness gauge (1) between the valve rocker arm (2) and valve stem (3) to measure the valve clearance.

VALVE CLEARANCE:

IN: 0.15 ± 0.02 mm

EX: 0.20 ± 0.02 mm

If adjustment is necessary, refer to page 3-4.

(1)

(2)

(1)

(3)

(1)

(3)

(4)

3-3

MAINTENANCE

Hold the rocker arm pivot (1) and loosen the pivot adjusting nut (2).

Turn the rocker arm pivot to obtain the specified clearance.

VALVE CLEARANCE:

IN: 0.15 ± 0.02 mm

EX: 0.20 ± 0.02 mm

Hold the rocker arm pivot and retighten the pivot adjusting nut to the specified torque.

TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

Recheck the valve clearance, and if necessary, readjust the clearance.

Check the head cover packing for damage or deterioration, and install it to the head cover.

Attach the cylinder head cover to the cylinder head, and tighten the head cover bolt securely.

VALVE STEM

(2)

(2)

COMBUSTION CHAMBER CLEANING

Remove the cylinder head (page 13-2).

Clean any carbon deposits from the combustion chamber (1).

(1)

To increase valve clearance: screw out.

To decrease valve clearance: screw in.

(1)

3-4

FUEL TUBE CHECK

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

• Keep heat, sparks, and flame away.

• Handle fuel only outdoors.

• Wipe up spills immediately.

Remove the harness cover (1) (page 6-2).

Check the fuel tube (2) for deterioration, cracks, or signs of leakage.

Install the harness cover (page 6-2).

(1)

(2)

MAINTENANCE

3-5