Honda GX120 User manual

31Z0T600

00X31-Z0T-6000

31Z0T600

Owner’s Manual

GX120•GX160•GX200

Black

DIC 157

N

T1:GX120•GX160•GX200

2eY1

"

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.

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 engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

02/11/29 16:16:32 31Z0T600_001

1

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.

02/11/29 16:16:40 31Z0T600_002

2

INTRODUCTION

A FEW WORDS ABOUT SAFETY

Safety Labels

Safety Messages

Safety Headings

Safety Section

Instructions

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:

–– on the engine.

–– 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.

–– such as

IMPORTANT SAFETY INFORMATION.

–– such as

ENGINE SAFETY.

–– how to use this engine correctly and safely.

This entire book is filled with important safety information –– please

read it carefully.

02/11/29 16:16:51 31Z0T600_003

3

CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

System (applicable engine types) . 12

...................................................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

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

...................................................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

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4

CONTENTS

SERVICING YOUR ENGINE (continued)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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5

IMPORTANT SAFETY INFORMATION

Owner Responsibilities

Refuel With Care

Hot Exhaust

ENGINE SAFETY

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.

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.

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.

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.

02/11/29 16:17:09 31Z0T600_006

6

ENGINE SAFETY

Other Equipment

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.

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.

02/11/29 16:17:14 31Z0T600_007

7

COMPONENT & CONTROL LOCATIONS

CONTROLS & FEATURES

MUFFLER

SPARK PLUG

AIR CLEANER

CHOKE LEVER

STARTER GRIP

THROTTLE LEVER

CIRCUIT BREAKER

(QXE2 type)

RECOIL STARTER

FUEL FILLER CAP

FUEL TANK

OIL DRAIN PLUG

FUEL VALVE LEVER

ENGINE SWITCH

(QXE2 type)

ENGINE OIL FILLER CAP/DIPSTICK

ELECTRIC STARTER

(QXE2 type)

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8

CONTROLS & FEATURES

CONTROLS

Fuel Valve Lever

FUEL

VALVE

LEVER

OFF

OONN

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.

02/11/29 16:17:34 31Z0T600_009

9

CONTROLS & FEATURES

Engine Switch

QXE2 Type

ALL ENGINES EXCEPT QXE2 QXE2 TYPE

CIRCUIT BREAKER

ENGINE SWITCH

ON

OFF

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.

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).

02/11/29 16:17:43 31Z0T600_010

10

CONTROLS & FEATURES

Choke Lever

CLOSED

OPEN

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.

02/11/29 16:17:51 31Z0T600_011

11

CONTROLS & FEATURES

Throttle Lever

Recoil Starter Grip

THROTTLE LEVER

STARTER GRIP

FAST

SLOW

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.

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

02/11/29 16:18:00 31Z0T600_012

12

CONTROLS & FEATURES

FEATURES

Circuit Breaker

Oil Alert

System (applicable engine types)

(QXE2 type only)

CIRCUIT

BREAKER

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

) before troubleshooting in other areas.

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.

Push the circuit breaker button to

reset.

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

automatically stop the engine (the engine switch will remain in the ON

position).

26

02/11/29 16:18:09 31Z0T600_013

13

IS YOUR ENGINE READY TO GO?

Check the General Condition of the Engine

BEFORE OPERATION

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.

Before beginning your preoperation checks, be sure the engine is level

and the engine switch is in the OFF position.

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.

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.

02/11/29 16:18:18 31Z0T600_014

14

BEFORE OPERATION

Check the Engine

Check the Equipment Powered by This Engine

The Oil Alert

system (applicable engine types) will automatically

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 engine oil level (see page ). Running the engine with a

low oil level can cause engine damage.

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.

Review the instructions provided with the equipment powered by this

engine for any precautions and procedures that should be followed

before engine startup.

26

24

29

02/11/29 16:18:26 31Z0T600_015

15

SAFE OPERATING PRECAUTIONS

STARTING THE ENGINE

OPERATION

ON

FUEL VALVE

LEVER

Beforeoperatingtheengineforthefirsttime,pleasereviewthe

IMPORTANT SAFETY INFORMATION

on page and the chapter titled

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.

Move the fuel valve lever to the ON position.

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.

1.

5

02/11/29 16:18:36 31Z0T600_016

16

OPERATION

CHOKE LEVER

CLOSE

OPEN

SLOW

THROTTLE LEVER

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

the way toward the FAST position.

Some engine applications use a remotely-mounted throttle control

rather than the engine-mounted throttle lever shown here.

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.

2.

3.

02/11/29 16:18:44 31Z0T600_017

17

OPERATION

STARTER GRIP

ENGINE SWITCH

ON

QXE2 TYPE

ALL ENGINES EXCEPT QXE2

Turn the engine switch to the ON position.

Operate the starter.

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

Return the starter grip gently.

RECOIL STARTER (all engine types):

4.

5.

02/11/29 16:18:55 31Z0T600_018

18

OPERATION

CHOKE LEVER

OPEN

ENGINE SWITCH

(QXE2 type)

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

the engine, gradually move it to the OPEN position as the engine

warms up.

6.

02/11/29 16:19:07 31Z0T600_019

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