62Z5F000.

book 1

How to use this manual

A Few Words About Safety
How to use this manual

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 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 Customers Safety
Proper service and maintenance are essential to the customers 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 man-
ual 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 practice, 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 precau-

tions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual 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 engine-power equipment up 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 battery 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
62Z5F000.book 2

CONTENTS
SPECIFICATIONS 1
SERVICE INFORMATION 2
MAINTENANCE 3
TROUBLESHOOTING 4
COVER 5
FUEL SYSTEM 6
GOVERNOR SYSTEM 7
CHARGING SYSTEM 8
IGNITION SYSTEM 9
STARTING SYSTEM 10
OTHER ELECTRICAL 11
MUFFLER 12
CYLINDER HEAD/VALVES 13
CRANKCASE 14
WIRING DIAGRAMS 15
INDEX
62Z5F000.book 3

How to use this manual

INTRODUCTION
This manual covers the service and repair procedures for Honda GX390RT2/T2/UT2.
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 dont follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you dont follow instructions.

You CAN be HURT if you dont follow instructions.

Instructions how to service these products correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Mo-
tor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING
ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PER-
MISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE
ON Honda products.

Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: March 2010

0-3
62Z5F000.book 4

How to use this manual

SERVICE RULES
Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Hondas design
specifications may damage the unit.
Use the special tools designed for the product.
Install new gaskets, O-rings, etc. when reassembling.
When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless
a particular sequence is specified.
Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
After reassembly, check all parts for proper installation and operation.
Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the
threads and ruin the hole.
Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. The
use of incorrect tools and fasteners will damage the unit.

SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would 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).

Use water resistant molybdenum disulfide grease (containing more than 3% molybdenum disulfide,
NLGI #2 or equivalent).
Example: UNILITE M No.2 manufactured by KYODO YUSHI, Japan

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

Apply sealant.

Use automatic transmission fluid.

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

page 1-1 Indicates the reference page.

0-4
62Z5F000.book 5

How to use this manual

ABBREVIATIONS
Throughout this manual, the following abbreviations are used to identify the respective parts or systems
Abbrev. term Full term
ACG Alternator
API American Petroleum institute
Approx. Approximately
Assy. Assembly
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
ATT Attachment
BAT Battery
BDC Bottom Dead Center
BTDC Before Top Dead Center
BARO Barometric Pressure
CKP Crankshaft Position
Comp. Complete
CMP Camshaft Position
CYL Cylinder
DLC Data Link Connector
EBT Engine Block Temperature
ECT Engine Coolant Temperature
ECM Engine Control Module
EMT Exhaust Manifold Temperature
EOP Engine Oil Pressure
EX Exhaust
F Front or Forward
GND Ground
HO2S Heated Oxygen sensor
IAC Idle Air Control
IAT Intake Air Temperature
I.D. Inside diameter
IG or IGN Ignition
IN Intake
INJ Injection
L. Left
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
O.D. Outside Diameter
OP Optional Part
PGM-FI Programmed-Fuel Injection
P/N Part Number
Qty Quantity
R. Right
SAE Society of Automotive Engineers
SCS Service Check Signal
STD Standard
SW Switch
TDC Top Dead Center
TP Throttle Position
VTEC Variable Valve Timing & Valve Lift Electronic Control

BI Black G Green Br Brown Lg Light green

Y Yellow R Red O Orange P Pink
BU Blue W White Lb Light blue Gr Gray

0-5
62Z5F000.book 1

1. SPECIFICATIONS

SERIAL NUMBER LOCATION 1-2 ENGINE SPECIFICATIONS 1-5

TYPE CODE 1-2 PERFORMANCE CURVES 1-6

DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS 1-7

SPECIFICATIONS 1-4
PTO DIMENSIONAL DRAWINGS 1-9

1-1
62Z5F000.book 2

SPECIFICATIONS
SERIAL NUMBER LOCATION
SPECIFICATIONS

The engine serial number (1), type (2) and model (3) is stamped on the
crankcase.
Refer to it when ordering parts or making technical inquiries.

(3)

(2)

(1)

TYPE CODE
Model GX390RT2
Type QWA2 VAA1 VEP9 VKE4 VKX4
P. T. O. Q type V type

Model GX390RT2
Type VPE5 VPE9 VPX4 VPX9 VSD4
P. T. O. V type

Model GX390RT2 GX390T2

Type VTH4 VWC VWC9 VWT4 ES2
P. T. O. V type E type

Model GX390T2
Type LH LH2 LHB5 LHP1 LXE9
P. T. O. L type

Model GX390T2
Type PX QAPW QBE1 QH QHB1
P. T. O. P type Q type

Model GX390T2
Type QHB3 QHB5 QHP1 QMH QN
P. T. O. Q type

1-2
62Z5F000.book 3

SPECIFICATIONS
Model GX390T2
Type QP QTD QX QXE QXEK
P. T. O. Q type

Model GX390T2
Type QXK SH SWE2 SWX SWX2
P. T. O. Q type S type

Model GX390T2
Type SX SXC VMQ3 VMT VMT2
P. T. O. S type V type E type

Model GX390T2
Type VMT3 VS4 VS6 VSB3 VSB4
P. T. O. E type V type

Model GX390T2
Type VSP VTE5 VX VXE VXK
P. T. O. V type

Model GX390T2 GX390UT2

Type VXU1 HA2 LKE LX2 LXE4
P. T. O. V type H type L type

Model GX390UT2
Type LXE8 LXQ4 LXU PA2 PAE2
P. T. O. L type P type

Model GX390UT2
Type PXD8 PXE8 PXU QA26 QA4
P. T. O. P type Q type

Model GX390UT2
Type QAA6 QAE2 QAE4 QAE6 QC2
P. T. O. Q type

Model GX390UT2
Type QDW9 QE QHB4 QK4 QKA4
P. T. O. Q type

Model GX390UT2
Type QME0 QNE2 QNE6 QNE8 QNR2
P. T. O. Q type

Model GX390UT2
Type QNR6 QWC4 QXB7 QXB9 QXC4
P. T. O. Q type

Model GX390UT2
Type QXC6 QXC9 QXCU QXE4 QXE6
P. T. O. Q type

Model GX390UT2
Type QXE7 QXE8 QXE9 QXER QXQ4
P. T. O. Q type

Model GX390UT2
Type QXS4 QXU QXUZ SCK4 SHQ4
P. T. O. Q type S type

Model GX390UT2
Type SHQ5 SM32 SMC1 SMD3 SME0
P. T. O. S type

1-3
62Z5F000.book 4

SPECIFICATIONS
Model GX390UT2
Type SME6 SNC STC4 SWA4 SXB7
P. T. O. S type

Model GX390UT2
Type SXE4 SXE8 SXQ4 SXU VA2
P. T. O. S type V type

Model GX390UT2
Type VM2 VN27 VSD7 VSD9 VX8
P. T. O. V type

Model GX390UT2
Type VXB7 VXB9 VXE2 VXE6 VXE7
P. T. O. V type

Model GX390UT2
Type VXE8 VXE9 VXQ4
P. T. O. V type

DIMENSIONS AND WEIGHTS

SPECIFICATIONS
Model GX390RT2 GX390T2 GX390UT2
Overall length H type* - - 452 mm (17.8 in)
L type* - 440 mm (17.3 in) 440 mm (17.3 in)
P type* - 405 mm (15.9 in) 405 mm (15.9 in)
Q type* 405 mm (15.9 in)
S type* - 380 mm (15.0 in) 380 mm (15.0 in)
V type* 425 mm (16.7 in) 425 mm (16.7 in) 425 mm (16.7 in)
Overall width H type* - - 460 mm (18.1 in)
L type* - 460 mm (18.1 in) 460 mm (18.1 in)
P type* - 460 mm (18.1 in) 460 mm (18.1 in)
Q type* 458 mm (18.0 in) 460 mm (18.1 in) 460 mm (18.1 in)
S type* - 460 mm (18.1 in) 460 mm (18.1 in)
V type* 458 mm (18.0 in) 460 mm (18.1 in) 460 mm (18.1 in)
Overall height H type* - - 448 mm (17.6 in)
L type* - 448 mm (17.6 in) 448 mm (17.6 in)
P type* - 448 mm (17.6 in) 448 mm (17.6 in)
Q type* - 448 mm (17.6 in) 448 mm (17.6 in)
S type* - 448 mm (17.6 in) 448 mm (17.6 in)
V type* - 448 mm (17.6 in) 448 mm (17.6 in)
Dry weight H type* - - 35.2 kg (77.6 lbs)
L type* - 35.2 kg (77.6 lbs) 35.2 kg (77.6 lbs)
P type* - 31.7 kg (69.9 lbs) 31.7 kg (69.9 lbs)
Q type* 29.9 kg (65.9 lbs) 31.7 kg (69.9 lbs) 31.7 kg (69.9 lbs)
S type* - 31.7 kg (69.9 lbs) 31.7 kg (69.9 lbs)
V type* 29.9 kg (65.9 lbs) 31.7 kg (69.9 lbs) 31.7 kg (69.9 lbs)
Operating weight H type* - - 41.2 kg (90.8 lbs)
L type* - 41.2 kg (90.8 lbs) 41.2 kg (90.8 lbs)
P type* - 37.8 kg (83.3 lbs) 37.8 kg (83.3 lbs)
Q type* 31.4 kg (69.2 lbs) 37.8 kg (83.3 lbs) 37.8 kg (83.3 lbs)
S type* - 37.8 kg (83.3 lbs) 37.8 kg (83.3 lbs)
V type* 31.4 kg (69.2 lbs) 37.8 kg (83.3 lbs) 37.8 kg (83.3 lbs)
*: P. T. O. type. (page 1-2)

1-4
62Z5F000.book 5

SPECIFICATIONS
ENGINE SPECIFICATIONS
Model GX390RT2 GX390T2 GX390UT2
Description code GCBCT GCBDT GCBCT
Type 4 stroke, overhead valve, single cylinder, inclined by 25
Displacement 389 cm3 (23.7 cuin)
Bore x stroke 88.0 x 64.0 mm (3.5 x 2.5 in)
Net power (SAE J1349)*1 8.7 kW (11.7 HP) / 3,600 min-1 (rpm)
Continuous rated power 7.0 kW (9.4 HP) / 3,600 min-1 (rpm)
Maximum net torque (SAE J1349)*1 26.5 Nm (2.7 kgfm, 19.5 lbfft) / 2,500 min-1 (rpm)
Compression ratio 8.2 0.2: 1
Fuel consumption (at continuous rat-
3.5 Liters (0.92 US gal, 0.77 Imp gal) / h
ed power)
Ignition system C.D.I.(Capacitor Discharge Ignition) type magneto ignition
Ignition timing B.T.D.C. 10 / 1,400min-1 (rpm)
Spark advancer performance B.T.D.C. 10- 22
Spark plug BPR6ES (NGK) / W20EPR-U (DENSO)
Lubrication system Forced splash
Oil capacity 1.1 Liters (1.16 US qt, 0.97 Imp qt)
Recommended oil SAE 10W-30 API service classification SE or later
Cooling system Forced air
Starting system Recoil, Recoil and Starter motor
Stopping system Ignition exciter coil circuit open
Carburetor Horizontal type, butterfly valve
Air cleaner Dual element type, Cyclone type, Oil bath type, Low profile type
Governor Mechanical centrifugal
Breather system Reed valve type
Fuel used 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 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.

1-5
62Z5F000.book 6

SPECIFICATIONS
PERFORMANCE CURVES

(Nm) (lbfft)
28 (kgfm)
21
2.8
20 2.7
26
NET TORQUE 19 2.6
TORQUE

18 2.5
24
17 2.4
16 2.3
22
2.2
15
20
(KW) (HP)
9 12

11
8
NET POWER
10

7
OUTPUT

6 8

7
5

6
RECOMMENDED OPERATING SPEED RANGE
4

2000 3000 3600 (min-1 [TRO])

ENGINE SPEED

1-6
62Z5F000.book 7

SPECIFICATIONS
DIMENSIONAL DRAWINGS
*: P. T. O. type. (page 1-2)
WITHOUT REDUCTION TYPE
Unit: mm (in)
121.8 (4.80)
98 (3.9)

158.7 (6.25) 301.3 (11.86)

With control box type: 498.6 (19.63)

CONTROL BOX CRANKSHAFT (P. T. O.)
(If equipped) Without control box type: 460 (18.1)

141.5 (5.57) 200.6 (7.90)

448 (17.6)
GX390RUT2: 447 (17.6)
GX390T2: 443 (17.4)

133.5 (5.26)

STARTER MOTOR 100 (3.9)

(If equipped) 195.5 (7.70)
* P/Q:405 (15.9)
105 (4.1) * S:380 (15.0)
* V:425 (16.7)
103 (4.1)
17 (0.7)

27 (1.1)

1-7
62Z5F000.book 8

SPECIFICATIONS
WITH REDUCTION UNIT TYPE
Unit: mm (in)
121.8 (4.80)
98 (3.9)

158.7 (6.25) 233.2 (9.18)

68.1 (2.68)

With control box type: 498.6 (19.63) P. T. O. SHAFT

Without control box type: 460 (18.1)

141.5 (5.57) 200.6 (7.9)
GX390RUT2: 447 (17.6)
GX390T2: 443 (17.4)

448 (17.6)
133.5 (5.26)

155 (6.1)
REDUCTION UNIT
* H:452 (17.8)
195.5 (7.70)
* L:440 (17.3)
105 (4.1)
103 (4.1)
17 (0.7)

27 (1.1)

1-8
62Z5F000.book 9

SPECIFICATIONS
PTO DIMENSIONAL DRAWINGS
*: P. T. O. type. (page 1-2)
E TYPE*
Unit: mm (in)

)
(8.1
1

7
84

.20
1 15 M6 x 1.0
(7

P.D
( 90.
7. 05
.24

48
2- - 19

(1.0235 - 1.0236)
7 .4 0 .
)

25.997 - 26.000
90 25
) 18
(0.71) 54 (2.13)

TAPER
1/5 35 (1.4)

(1.3759 - 1.3772)
34.947 - 34.980
15

15

28 (1.1)

M10 x 1.25

P. T. O. SHAFT

M6 x 1.0
15

H TYPE* (WITH REDUCTION)

Unit: mm (in)

45 45

7.15
(0.281) 85.7 (3.37)
(6PLACES)
6.31- 6.36
(0.248-0.250) 63 (2.5)
(0.9990 - 1.0000)
25.374 - 25.400
70 (2.8)

(0.854 - 0.859)

80 (3.20)
21.69 - 21.82
0)

P. T. O. SHAFT
5.0
7(

16 (0.6) 62.1 (2.45)

12

REDUCTION UNIT
D.
P.

103 (4.1)

1-9
62Z5F000.book 10

SPECIFICATIONS
L TYPE* (WITH REDUCTION)
Unit: mm (in)

45 45
64.8 (2.55)
M8 x 1.25
M8 x 1.25 (2PLACES)
(4PLACES) M8 x 1.25
7.00 - 7.05
(0.276 -0.278) 42 (1.7)

24.972-24.993
(0.9831-0.9840)
70 (2.8) 28 (1.1)

(0.82-0.83)
60.0 (2.36)

20.9-21.0

P. T. O. SHAFT
0)
5.0
7(

16 (0.6) 68.1 (2.68)

12

REDUCTION UNIT
D.
P.

103 (4.1)

P TYPE*
Unit: mm (in)

)
45 45 .50
30 30 (6
. 1
1 65
D.
P. 89 (3.5)
5/16-24UNF-2B 14NF2 Thread R. H.
(2 PLACES)
(4.3307 - 4.3327)
110.00 - 110.05
70 (2.8)

26-27
(1.0-1.1)
5/16-24UNF-2B
(0.9990 - 1.0000)
25.375 - 25.400

(4 PLACES)
72.5 (2.85)

3/8-16UNC-2B
(4 PLACES)
.00)

103 (4.1)
(5

CRANKSHAFT (P. T. O.)

127
P.D.

1-10
62Z5F000.book 11

SPECIFICATIONS
Q TYPE*
Unit: mm (in)

5 0)
45 45 6.
30 30 1(
6 5.
D .1
P. 88.5 (3.48)
3/8 - 24UNF - 2B TAP
5/16-24UNF-2B
(2 PLACES) 56 (2.2)

6.3 - 6.35
(0.2480 - 0.2500)

110.00 - 110.05
(4.331 - 4.333)
70 (2.8)

(0.8539 - 0.8591)
28 (1.1)

21.69 - 21.82

(0.9990 - 1.0000)
5/16-24UNF-2B

25.375 - 25.400
(4 PLACES) 72.2 (2.84)

3/8-16UNC-2B
(4 PLACES)
)
(5.00

103 (4.1)
CRANKSHAFT (P. T. O.)
127
P.D.

S TYPE*
Unit: mm (in)
SNC TYPE:
5 0) 5/16-24UNF-2B
45 45 6.
30 30 1( TAP (2 PLACES)
5.
16 SM32 TYPE:
D.
P. M8 x 1.25 63 (2.5)
(2PLACES) M8-1.25
41 (1.6)

7.00 - 7.03
110.00 - 110.05

(0.276 - 0.277)
(4.331 - 4.333)
70 (2.8)

SNC TYPE: 28 (1.1)

(0.82 - 0.83)
20.9 - 21.0

5/16-24UNF-2B
(0.9822 - 0.9835)

TAP
24.947 - 24.980

60 (2.4)
(4 PLACES)
SM32 TYPE:
M8 x 1.25
(4 PLACES)

SNC TYPE:
)

103 (4.1) 3/8-16UNC-2B

(5.00

TAP (4 PLACES)
127

SM32 TYPE:
8.51 (0.34)
P.D.

CRANKSHAFT (P. T. O.)

(4 PLACES)

1-11
62Z5F000.book 12

SPECIFICATIONS
V TYPE*
Unit: mm (in)

45 5 0)
45 6.
30 30 1( 5/16 - 24UNF - 2B TAP
5.
16
D.
P. 105.5 (4.15)
5/16-24UNF-2B
(2 PLACES)

18 (0.7)

110.00 - 110.05
(4.331 - 4.333)
70 (2.8)

5/16-24UNF-2B

(0.8715 - 0.8724)
(4 PLACES)
22.136 - 22.161
75.5 (2.97)

46.5 (1.83)
3/8-16UNC-2B
(4 PLACES)
)
(5.00

103 (4.1) CRANKSHAFT (P. T. O.)

127
P.D.

1-12
62Z5F000.book 1

2. SERVICE INFORMATION

MAINTENANCE STANDARDS 2-2 TOOLS 2-6

TORQUE VALUES 2-4 HARNESS AND TUBE ROUTING 2-8

LUBRICATION & SEAL POINT 2-5

2-1
62Z5F000.book 2

SERVICE INFORMATION
MAINTENANCE STANDARDS
SERVICE INFORMATION

Unit: mm (in)

Service
Part Item Standard
limit
Engine Maximum speed (at no load) 3,850 150 min-1 (rpm)
Idle speed 1,400 150 min-1 (rpm)
0.51-0.69 MPa (5.2-7.0 kgf/cm2, 74-100
Cylinder compression
psi) / 600 min-1 (rpm)
Cylinder head Warpage 0.10 (0.004)
Cylinder Sleeve I.D. 88.000 88.017 (3.4646 3.4652) 88.170
(3.4710)
Piston Skirt O.D. 87.975 87.985 (3.4635 3.4640) 87.85
(3.459)
Piston-to-cylinder clearance 0.015 0.042 (0.0006 0.0016) 0.12 (0.005)
Piston pin bore I.D. 20.002 20.008 (0.7875 0.7877) 20.042
(0.7891)
Piston pin Pin O.D. 19.994 20.000 (0.7872 0.7874) 19.950
(0.7854)
Piston pin-to-piston pin bore clearance 0.002 0.014 (0.0001 0.0006) 0.08 (0.003)
Piston rings Ring side clearance Top 0.015 0.060 (0.0006 0.0024) 0.15 (0.006)
Second 0.030 0.060 (0.0012 0.0024) 0.15 (0.006)
Ring end gap Top 0.200 0.350 (0.0079 0.0138) 1.0 (0.04)
Second 0.350 0.500 (0.0138 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 0.7 (0.01 0.03) 1.0 (0.04)
Ring width Top 1.160 1.190 (0.0457 0.047) 1.140
(0.0449)
Second 1.160 1.175 (0.0457 0.0463) 1.140
(0.0449)
Connecting rod Small end I.D. 20.005 20.020 (0.7876 0.7882) 20.07
(0.790)
Big end side clearance 0.1 0.4 (0.004 0.016) 1.0 (0.04)
Big end I.D. 36.025 36.039 (1.4183 1.4189) 36.07
(1.420)
Big end oil clearance 0.040 0.064 (0.0016 0.0025) 0.12 (0.005)
Crankshaft Crank pin O.D. 35.975 35.985 (1.4163 1.4167) 35.93
(1.415)
Crankshaft runout 0.1 (0.003)
Cylinder barrel Camshaft bearing I.D. 16.000 16.018 (0.6299 0.6306) 16.05
(Crankcase) (0.632)
Crankcase cover Camshaft bearing I.D. 16.000 16.018 (0.6299 0.6306) 16.05
(0.632)
Valves Valve clearance IN 0.15 0.02
EX 0.20 0.02
Valve stem O.D. IN 6.575 6.590 (0.2588 0.2594) 6.44 (0.254)
EX 6.535 6.550 (0.2572 0.2578) 6.40 (0.252)
Valve guide I.D. IN/EX 6.600 6.615 (0.2598 0.2604) 6.66 (0.262)
Guide-to-stem clear- IN 0.010 0.040 (0.0004 0.0016) 0.11 (0.004)
ance EX 0.050 0.080 (0.0020 0.0032) 0.13 (0.005)
Valve seat width 1.0 1.2 (0.04 0.05) 2.0 (0.08)
Valve spring free length 39.0 (1.54) 37.5 (1.48)
Valve spring perpendicularity 1.5 max.
Camshaft Cam height IN 32.498 32.698 (1.2794 1.2873) 32.198
(1.2676)
EX 31.985 32.185 (1.2592 1.2671) 29.886
(1.1766)
Camshaft O.D. 15.966 15.984 (0.6286 0.6293) 15.92
(0.627)

2-2
62Z5F000.book 3

SERVICE INFORMATION
Service
Part Item Standard
limit
Carburetor Main jet BE85C B: #100
BE85L A: #95
BE85Q A: #92
BE85Q A: #102
BE89F B: #108
BE89R A: #102
BE89U A: #108
BE94B A: #100
BE94A A: #115
Pilot screw opening BE85C B: 1 - 3/4 turns out
BE85L A: 2 turns out
BE85Q A: 1 - 7/8 turns out
BE85Q A: 2 - 1/4 turns out
BE89F B: 2 - 1/4 turns out
BE89R A: 2 - 1/4 turns out
BE89U A: 2 - 1/4 turns out
BE94B A: 1 - 3/4 turns out
BE94A A: 2 - 1/4 turns out
Float height 13.2 (0.52)
Spark plug Gap 0.7 0.8 (0.028 0.031)
Ignition coil Air gap 0.2 0.6 (0.01 0.02)
Starter motor Brush length 7.0 (0.28) 3.5 (0.14)
Mica depth 1.0 (0.04) 0.2 (0.01)
Charge coil Resistance 1A 3.00 - 4.00
3A 0.62 - 0.93
10A 0.16 - 0.24
18A 0.10 - 0.30
Lamp coil Resistance 12V - 15 W 1.04 - 1.56
12V - 25 W 0.30 - 0.46
12V - 50 W 0.29 - 0.44

2-3
62Z5F000.book 4

SERVICE INFORMATION
TORQUE VALUES
ENGINE TORQUE VALUES
Torque values
Item Tread Dia. (mm)
Nm kgfm lbfft
Crankcase cover bolt M8 x 1.25 24 2.4 17
Cylinder head bolt M10 x 1.25 35 3.5 26
Oil drain plug bolt M12 x 1.5 22.5 2.25 17
Connecting rod bolt M8 x 1.25 (Special bolt) 14 1.4 10
Rocker arm pivot bolt M8 x 1.25 (Special bolt) 24 2.4 17
Rocker arm pivot adjusting nut M6 x 0.5 10 1.0 7
Oil level switch nut M10 x 1.25 10 1.0 7
Flywheel nut M16 x 1.5 (Special nut) 170 17.3 125
Fuel tank nut/bolt M8 x 1.25 24 2.4 17
Fuel tank joint M10 x 1.25 2 0.2 1.5
Air cleaner elbow nut M6 x 1.0 9 0.9 6.6
Muffler nut M8 x 1.25 24 2.4 17
Exhaust pipe nut M8 x 1.25 24 2.4 17
Gear case cover bolt (With reduction) M8 x 1.25 24 2.4 17
Primary drive gear bolt (With reduction) M8 x 1.25 24 2.4 17
Engine stop switch tapping screw M3 x 1.06 0.45 0.046 0.33
Recoil starter center screw M5 x 0.8 (Special bolt) 3.9 0.40 2.9
Fuel strainer cup M24 x 1.0 3.9 0.40 2.9

STANDARD TORQUE VALUES

Torque values
Item Tread Dia. (mm)
Nm kgfm lbfft
Screw 4 mm 2.1 0.21 1.5
5 mm 4.3 0.43 3.1
6 mm 9.0 0.90 6.6
Bolt and nut 5 mm 5.3 0.53 3.9
6 mm 10 1.0 7
8 mm 22 2.2 16
10 mm 34 3.5 25
12 mm 54 5.5 40
Flange bolt and nut 5 mm 5.4 0.55 3.9
6 mm 12 1.2 9
8 mm 23 2.3 17
10 mm 40 4.0 30
SH (Small head) flange bolt 6 mm 9.0 0.90 6.6
CT (Cutting threads) flange bolt (Retightening) 5 mm 5.4 0.55 4.0
6 mm 12 1.2 9

2-4
62Z5F000.book 5

SERVICE INFORMATION
LUBRICATION & SEAL POINT
Location Material Remarks
Crankshaft pin, journal and gear Engine oil
Crankcase bearing
Crankcase cover bearing
Piston outer surface and piston pin hole
Piston pin outer surface
Piston ring
Cylinder inner surface
Connecting rod big and small end bearing
Connecting rod bolt threads and seating surface
Camshaft cam profile, bearing, decompressor and
gear
Valve lifter shaft and slipper
Valve stem seal contact area of seal lip
Valve stem sliding surface and stem end
Valve spring
Push rod end
Tappet adjusting screw and nut threads and seating
surface
Rocker arm shaft
Flywheel nut threads and seating surface
Governor weight holder gear and journal
Governor holder shaft
Governor slider
Governor arm shaft
Cylinder head bolt threads and seating surface
Rocker arm pivot threads and pivot
Balancer shaft bearing and gear
P.T.O. shaft bearing and gear
Counter shaft bearing and gears
Oil seal lip Multi-purpose grease
O-ring
Recoil starter case cutout
Recoil starter ratchet sliding surface
Recoil starter spring retainer inside
Camshaft cam profile Use molybdenum solution When installing a new cam-
(mixture of the engine oil and shaft
molybdenum grease with the
ratio 100 g grease: 70 cc oil)
Recoil starter center screw threads Threebond 2430 or equiva-
lent

2-5
62Z5F000.book 6

SERVICE INFORMATION
TOOLS
SPECIAL TOOLS
Special tools used in this manual can be ordered using normal American
Honda parts ordering procedures.
Float level gauge Sliding hammer weight Valve guide driver, 6.4511
07401-0010000 07741-0010201 07742-0010200

Bearing driver attachment, 3235 [in Bearing driver attachment, 4247 [in Bearing driver attachment, 5255 [in
combination with 07749-0010000] combination with 07749-0010000] combination with 07749-0010000]
07746-0010100 07746-0010300 07746-0010400

Bearing driver attachment, 7275 [in Inner driver handle, 40 Inner bearing driver attachment, 35 [in
combination with 07749-0010000] 07746-0030100 combination with 07746-0030100]
07746-0010600 07746-0030400

Pilot, 15 [in combination with 07749- Pilot, 20 [in combination with 07749- Pilot, 30 [in combination with 07749-
0010000] 0010000] 0010000]
07746-0040300 07746-0040500 07746-0040700

2-6
62Z5F000.book 7

SERVICE INFORMATION
Pilot, 35 [in combination with 07749- Pilot, 14 [in combination with 07749- Driver handle, 15135L
0010000] 0010000] 07749-0010000
07746-0040800 07746-0041200

Seat cutter, 35 Seat cutter, 40 Flat cutter, 35

07780-0010400 07780-0010500 07780-0012300

Flat cutter, 38.5 Interior cutter, 37.5 Cutter holder, 6.6

07780-0012400 07780-0014100 07781-0010202

Flywheel puller set Bearing remover shaft, 15 Valve guide reamer, 6.612
07935-8050004 07936-KC10500 07984-ZE20001

Bearing driver attachment, 4550 [in Bearing driver attachment, 6264 [in
combination with 07749-0010000] combination with 07749-0010000]
07946-6920100 07947-6340400

2-7
62Z5F000.book 8

SERVICE INFORMATION
HARNESS AND TUBE ROUTING
Connection of regulator/rectifier, charge/lamp coil, sub wire harness, and auto throttle solenoid are depending on the application of
the engine, therefore, it does not indicate those parts in this manual.
ENGINE STOP SWITCH TYPE

ENGINE STOP SWITCH

ENGINE WIRE
HARNESS

HARNESS CLIP

To engine stop To ignition coil

OIL LEVEL
switch
SWITCH HARNESS CLIP

INSIDE
YELLOW RED BLACK

YELLOW RED BLACK

ENGINE STOP
SWITCH CORD

To oil level switch

2-8
62Z5F000.book 9

SERVICE INFORMATION
COMBINATION SWITCH (CONTROL BOX) TYPE
PURSE LOCK CLIP PURSE LOCK CLIP
To starter motor To ignition coil To starter motor
(YELLOW)

To ignition coil To ignition coil

(BLACK) (RED)

ENGINE WIRE
HARNESS (To
ignition coil)

STOP SWITCH
CORD HOLDER

OIL LEVEL
SWITCH

COMBINATION
SWITCH WIRE
CABLE STRAP/ FASTENER TUBE
To charge coil To ignition coil

CABLE STRAP
YELLOW
RED FASTENER TUBE
CABLE GRAY BLACK
STRAP
FASTENE
R TUBE

INSIDE
WHITE
COMBINATION
YELLOW
SWITCH WIRE
RED

BLACK
To oil level switch
To control box

WHITE

To starter motor
BLACK / WHITE

2-9
62Z5F000.book 10

SERVICE INFORMATION
ALL TYPE

GOVERNOR ARM

ENGINE WIRE
HARNESS

HIGH-TENSION
CORD

CARBURETOR CONTROL BASE

INSULATOR ASSY.
CYLINDER BARREL RIB

CONTROL BASE
ASSY.

TUBE CLIP

IGNITION COIL

BREATHER TUBE

HIGH-TENSION
CORD
FUEL TUBE

2-10
62Z5F000.book 11

SERVICE INFORMATION
WITH CHARGE COIL / LAMP COIL

10A CHARGE COIL TYPE:

18A CHARGE COIL TYPE: 12 V-50 W LAMP COIL TYPE:

CORD CORD
CLAMPER CLAMPER

COIL CORD
CORD GROMMET

CORD COIL
GROMMET CORD

1 A / 3 A CHARGE COIL TYPE:

12 V - 15 W / 12 V-25 W LAMP COIL TYPE:
CORD
CLAMPER
CORD
GROMMET

COIL
CORD

2-11
62Z5F000.book 12

MEMO
62Z5F000.book 1

3. MAINTENANCE

MAINTENANCE SCHEDULE3-2 SPARK ARRESTER CLEANING 3-8

ENGINE OIL LEVEL CHECK 3-3 IDLE SPEED CHECK/ADJUSTMENT 3-10

ENGINE OIL CHANGE3-3 VALVE CLEARANCE CHECK/

ADJUSTMENT 3-10
AIR CLEANER CHECK/CLEANING/
REPLACEMENT3-4 COMBUSTION CHAMBER CLEANING 3-12

SEDIMENT CUP CLEANING 3-6 FUEL TANK AND FILTER CLEANING 3-12

SPARK PLUG CHECK/ADJUSTMENT 3-7 FUEL TUBE CHECK 3-13

SPARK PLUG REPLACEMENT 3-8

3-1
62Z5F000.book 2

MAINTENANCE
MAINTENANCE SCHEDULE
MAINTENANCE

REGULAR SERVICE PERIOD (2) First Every Every Every

ITEM Perform at every indicated month 3 6 year Refer
Each
month or operating hour inter- or months months or to
use
val, whichever comes first. 20 hrs. or or 300 hrs. page
50 hrs. 100 hrs.
Engine oil Check level 3-3
Change 3-3
Air cleaner Check 3-4
Clean (1) (*)(1) 3-4
(Cyclone type) Every 6 months or 150 hours 3-4
Replace (**) 3-4
(Cyclone type) Every 2 years or 600 hours 3-4
Sediment cup Clean 3-6
Spark plug Checkadjust 3-7
Replace 3-8
Spark arrester Clean
3-8
(If equipped)
Idle speed Checkadjust 3-10
Valve clearance Checkadjust 3-10
Combustion chamber Clean After every 500 hours 3-12
Fuel tank and filter Clean 3-12
Fuel tube Check Every 2 years (Replace if necessary) 3-13
(1) Service more frequently when used in dusty areas.
(2) For commercial use, log hours of operation to determine proper maintenance intervals.
(*) Internal vent carburetor with dual element type only.
(**) Replace paper element type only.

3-2
62Z5F000.book 3

MAINTENANCE
ENGINE OIL LEVEL CHECK
Place the engine on a level surface.
Remove the oil filler cap (1), and wipe the oil level (1)
gauge (2) clean.
Insert the oil filler cap without screwing it into the oil filler
neck (3).
Remove the oil filler cap and check oil level shown on
the oil level gauge.
If the oil level is low, fill with recommended oil to the
upper level (4) of the oil filler neck.

(2) (3)

(1)
(4)

(3)

(2)

SAE 10W - 30 is recommended for general use. Other

viscosities shown in the chart may be used when the SAE VISCOSITY GRADES
average temperature in your area is within the
recommended range.
RECOMMENDED OIL:
SAE 10W-30 API service classification SE or later
Tighten the oil filler cap securely.

AMBIENT TEMPERATURE

ENGINE OIL CHANGE

Drain the oil in the engine while the engine is warm.
Warm oil drains quickly and completely. (1)
Place the engine on a level surface, and place a
suitable container under the drain plug bolt.
Remove the oil filler cap (1), drain plug bolt (2), and
drain plug washer (3) to drain the oil into the suitable
container.
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.
(2) (3)

3-3
62Z5F000.book 4

MAINTENANCE

Used engine oil contains substances that have

been identified as carcinogenic. If repeatedly left in
contact with the skin for prolonged periods, it may
cause skin cancer. Wash your hands thoroughly
with soap and water as soon as possible after con-
tact with used engine oil.

Install a new drain plug washer (3) and tighten the drain
plug bolt (2) to the specified torque.
TORQUE: 22.5 Nm (2.25 kgfm, 17 lbfft)
Fill with recommended oil to the upper level mark of the
oil level dipstick (page 3-3).
Engine oil capacity: 1.1 (1.16 US gal, 0.97 Imp gal)
Tighten the oil filler cap securely.

AIR CLEANER CHECK/CLEANING/

REPLACEMENT
DUAL ELEMENT TYPE:
A dirty air filter will restrict air flow to the carburetor,
reducing engine performance. If the engine is operated (1)
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE.
(2)

Operating the engine without the air filters or with the

filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely. (3)
Remove the nut (1) and the air cleaner cover (2).
Remove the wing nut (3) and air filter assembly (4)(5). (4)
Separate the inner filter (Paper) (4) from the outer filter
(Foam) (5). Carefully check both filters for holes or tears
and replace if damaged.
(5)
Clean the filters if they are to be reused.
Install the elements in the reverse order of removal
(page 3-5).

3-4
62Z5F000.book 5

MAINTENANCE
CYCLONE TYPE:
A dirty air filter will restrict air flow to the carburetor,
reducing engine performance. If the engine is operated (1)
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE.
(2)

Operating the engine without the air filters or with the

filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely.
(3)
Remove the wing nut (1) and the air cleaner cover (2).
Remove the wing nut (3) and air filter assembly (4)(5).
Separate the inner filter (Paper) (4) from the outer filter (4)
(Foam) (5). Carefully check both filters for holes or tears
and replace if damaged.
Clean the filters if they are to be reused.
Install the elements in the reverse order of removal. (5)

LOW PROFILE TYPE:

A dirty air filter will restrict air flow to the carburetor,
reducing engine performance. If the engine is operated (1)
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE.

(2)
Operating the engine without the air filters or with the
filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely.
Remove the air cleaner case lid spring (1) and air
cleaner cover (2).
Remove the air cleaner element (3).
Carefully check air cleaner element and replace if
damaged. (3)
Clean the filter if it is to be reused (page 3-5).
Install the element in the reverse order of removal.

FILTER (FOAM) TYPE:

Clean the filter (1) in warm soapy water (2), rinse, and
allow to dry thoroughly, or clean with a non-flammable (1)
solvent and allow to dry thoroughly. (3)
Squeeze
Dip the filter in clean engine oil (3), and squeeze out all and dry
the excess oil.
Excess oil will restrict air flow through the foam element
and may cause the engine to smoke at startup.
Check the air cleaner case packing for deterioration or (2)
damage. Make sure the air cleaner packing is installed
securely.
Install the cleaner in the reverse order of removal.
Squeeze thoroughly

3-5
62Z5F000.book 6

MAINTENANCE
INNER FILTER (PAPER) TYPE:
Tap the inner filter (1) lightly several times on a hard
surface to remove excess dirt, or blow compressed air (1)
lightly (207 kPa (2.11 kgf/cm2, 30 psi) or less) through
the paper filter from the inside out. Never try to brush
the dirt off; brushing will force dirt into the fibers.
Wipe dirt from the inside of the air cleaner case and the
air cleaner cover, using a rag.
Check the air cleaner case packing for deterioration or
damage. Make sure the air cleaner packing installed
securely.
Install the cleaner in the reverse order of removal.

SEDIMENT CUP CLEANING

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.

Turn the fuel cock lever (1) to the OFF position.

Remove the sediment cup (2) and the O-ring (3).
(1)
Remove the cup filter (4) while releasing the tabs (5).
Clean the sediment cup and the cup filter with non-
flammable solvent and allow them to dry thoroughly.
Install the cup filter as the direction shown in the
illustration.
Install a new O-ring and tighten the sediment cup to the
specified torque.
TORQUE: 3.9 Nm (0.40 kgfm, 2.9 lbfft) OFF ON
(5)
Check the installation part of the sediment cup for any
BOSS
sign of fuel leakage.

(5)

(4)
(3)

(2)

CARBURETOR
(5)

(5)

BOSS
UNDER VIEW:

3-6
62Z5F000.book 7

MAINTENANCE
SPARK PLUG CHECK/ADJUSTMENT

If the engine has been running, the engine will be

very hot. Allow it to cool before proceeding.

Remove the spark plug cap, and then remove the spark
plug (1) using a spark plug wrench (2). (2)

(1)

Visually check the spark plug. Replace the plug if the

insulator (1) is cracked or chipped. (2)
Check the sealing washer (2) for damage.
Replace the spark plug if the sealing washer is
damaged (page 3-8).
SPARK PLUG: BPR6ES (NGK) W20EPR-U(DENSO)

(1)

Measure the plug gap with a wire-type feeler gauge. If

the measurement is out of the specification, adjust by
bending the side electrode. 0.7 0.8 mm
(0.028 0.031 in)
PLUG GAP: 0.7 0.8 mm (0.028 0.031 in)
Install the spark plug finger-tight to seat the washer,
and then tighten 1/8 1/4 turn with a spark plug
wrench.

A loose spark plug can become very hot and can

damage the engine. Overtightening can damage the
threads in the cylinder block.
Install the spark plug cap securely.

3-7
62Z5F000.book 8

MAINTENANCE
SPARK PLUG REPLACEMENT

If the engine has been running, the engine will be

very hot.Allow it to cool before proceeding.

Remove the spark plug cap, and then remove the spark
plug (1) using a spark plug wrench (2). (2)

Verify the new spark plug gap is correct (page 3-7).

(1)
Install a new spark plug finger-tight to seat the washer,
and then tighten 1/2 turn with a spark plug wrench.
SPARK PLUG: BPR6ES (NGK)W20EPR-U(DENSO)

A loose spark plug can become very hot and can

damage the engine. Overtightening can damage the
threads in the cylinder block.
Install the spark plug cap securely.

SPARK ARRESTER CLEANING

The engine and the muffler becomes very hot dur-

ing operation and remains hot for a while after stop-
ping the engine. Be careful not to touch the muffler
while it is hot. Allow it to cool before proceeding.

SOLID PROTECTOR TYPE

Remove the muffler cover (page 12-6), If equipped. (1)
Remove the 5 x 8 mm tapping screws (1), 6 x 10 mm
tapping screw (2), and muffler protector (3).
Remove the 5 x 8 mm tapping screws (4) and spark
arrester (5).
(3)
(5)

(2)
(4)

3-8
62Z5F000.book 9

MAINTENANCE
SEPARATED PROTECTOR TYPE
Remove the muffler cover (page 12-6), If equipped.
Remove the 4 x 6 mm tapping screws (1), and muffler
(3)
cap (2), If equipped.
(4)
Remove the 5 x 8 mm tapping screws (3), R. muffler
protector (4), and L.muffler protector (5). (3)
Remove the 5 x 8 mm tapping screws (6) and spark (2)
arrester (7).
(5)

(1)

(6)
(7)
(3)

INNER/OUTER PROTECTOR TYPE

Remove the 6 x 10 mm bolts (1), and outer muffler
protector (2).
Remove the 4 x 8 mm tapping screw (3), and spark
arrester (4).
(3)

(1)

(1) (1)

(4)

(2)

(1)

3-9
62Z5F000.book 10

MAINTENANCE
CLEANING

Be careful to avoid damaging the screen.

Clean the carbon deposits from the spark arrester
screen (1) with a wire brush (2). (2)
Check the spark arrester screen for damage. If the
screen is damaged, replace the spark arrester.
Install the spark arrester in the reverse order of
removal.

(1)

IDLE SPEED CHECK/ADJUSTMENT

Start the engine and allow it to warm up to normal
operating temperature.
Turn the throttle stop screw (1) to obtain the specified
idle speed.

IDLE SPEED: 1,400 150 min-1 (rpm)

(1)

VALVE CLEARANCE CHECK/

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

(1)

3-10
62Z5F000.book 11

MAINTENANCE
Disconnect the spark plug cap from the spark plug.
(1) (3)
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 top Pull slowly.
hole (3) on the recoil starter case (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 top hole on
the recoil starter case again.
(4) (2)

Insert a thickness gauge (1) between the valve rocker

arm (2) and valve stem (3) to measure the valve (1) (3)
clearance.

VALVE CLEARANCE:
IN: 0.15 0.02 mm
EX: 0.20 0.02 mm
If adjustment is necessary, proceed as follows.

(2)

Hold the rocker arm pivot (1) and loosen the pivot
adjusting nut (2). (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 Nm (1.0 kgfm, 7 lbfft)
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.
VALVE STEM
Attach the cylinder head cover to the cylinder head, and
tighten the head cover bolt securely.

(1)

(2)
To increase valve clearance: screw out.
To decrease valve clearance: screw in.

3-11
62Z5F000.book 12

MAINTENANCE
COMBUSTION CHAMBER CLEANING
Remove the cylinder head (page 13-3).
(1)
Clean any carbon deposits from the combustion
chamber (1).

FUEL TANK AND FILTER CLEANING

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.

Drain the fuel into a suitable container.

Remove the fuel tank (1) and fuel tank joint (2) (page 6- (1)
3).
Clean the fuel tank joint and fuel tank with non-
flammable solvent, and allow them to dry thoroughly.
Install the fuel tank (page 6-3).
Check the installation part of the fuel tank for any sign
of fuel leakage.

(2)

3-12
62Z5F000.book 13

MAINTENANCE
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.

Check the fuel tube (1) for deterioration, cracks or signs

of leakage.

(1)

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