Honda GX120K1 User Manual

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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 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.
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. Ho
wever, 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.
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 begi
n, 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 glasse
s, 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 wo
rking 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.
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.
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.
gx120k1_gx160k1_gx200

Honda GX120K1 Specifications

General

Brand	Honda
Model	GX120K1
Category	Engine
Language	English

Summary

How to use this manual

A Few Words About Safety

General safety advice for technicians and users regarding manual procedures.

Service Information

Information regarding service and repair intended for qualified technicians.

For Your Customer’s Safety

Emphasizes the importance of proper service for customer safety and product reliability.

For Your Safety

Guidance for users not trained in shop safety practices, recommending caution.

Important Safety Precautions

Key safety practices and precautions for performing service tasks safely and effectively.

INTRODUCTION

SAFETY MESSAGES

Explains safety symbols and signal words used throughout the manual.

SERVICE RULES

SYMBOLS

ABBREVIATIONS

1. SPECIFICATIONS

2. DIMENSIONS AND WEIGHTS

3. PERFORMANCE CURVES

4. DIMENSIONAL DRAWINGS

5. P.T.O. DIMENSIONAL DRAWINGS

6. WIRING DIAGRAMS

2. SERVICE INFORMATION

SERIAL NUMBER LOCATION

Identifies where to find the engine serial number and type on the crankcase.

MAINTENANCE STANDARDS

Specifies standard and service limit values for engine parts measurements.

TORQUE VALUES

Lists torque specifications for various fasteners and bolts.

TOOLS

Lists required special and commercially available tools for service.

TROUBLESHOOTING

Guides for diagnosing and resolving common engine operational problems.

3. MAINTENANCE

MAINTENANCE SCHEDULE

Recommended maintenance intervals and tasks based on time or usage.

ENGINE OIL

Procedures and specifications for checking and changing engine oil.

REDUCTION CASE OIL

Procedures and specifications for checking and changing reduction case oil.

AIR CLEANER

Detailed procedures for cleaning and maintaining different air cleaner types.

VALVE CLEARANCE

Procedures for inspecting and adjusting valve clearance when the engine is cold.

SPARK PLUG

Procedures for inspecting, adjusting the gap, and installing the spark plug.

CARBURETOR

Procedures for adjusting carburetor settings and performing maintenance.

GOVERNOR

Procedures for adjusting the governor arm and engine speed settings.

SEDIMENT CUP

Procedure for cleaning the fuel sediment cup and strainer.

FUEL FILTER

Procedure for removing, cleaning, and installing the fuel filter.

4. AIR CLEANER/MUFFLER

AIR CLEANER

Detailed procedures for servicing various air cleaner types.

MUFFLER

Procedures for muffler disassembly, reassembly, and spark arrester maintenance.

5. RECOIL STARTER/FAN COVER

RECOIL STARTER

Procedures for recoil starter disassembly, reassembly, and inspection.

FAN COVER

Procedures for fan cover disassembly and reassembly.

CONTROL BOX (STARTER MOTOR EQUIPPED TYPE)

Disassembly, reassembly, and inspection of the control box components.

6. CARBURETOR

REMOVAL/INSTALLATION

Steps for removing and installing the carburetor assembly.

DISASSEMBLY/REASSEMBLY

Step-by-step guide for disassembling and reassembling the carburetor.

PILOT SCREW AND LIMITER CAP

Procedures for adjusting and replacing the pilot screw and limiter cap.

7. FUEL TANK/GOVERNOR ARM/CONTROL BASE

FUEL TANK, CONTROL BASE

Disassembly and reassembly of the fuel tank and control base assembly.

GOVERNOR ARM

Procedures for governor arm adjustment and reassembly.

FUEL TANK CAP (U/UT/U1/UT1 TYPE)

Disassembly and reassembly of the fuel tank cap and fuel level gauge.

EVAPORATIVE EMISSION CONTROL SYSTEM

Explanation of the evaporative emission control system principle.

8. FLYWHEEL/IGNITION COIL/ STARTER MOTOR

FLYWHEEL, IGNITION COIL

Disassembly, reassembly, and adjustment of flywheel and ignition coil.

STARTER MOTOR

Disassembly, reassembly, and inspection of the starter motor components.

ADJUSTMENT

Procedures for adjusting the ignition coil air gap.

INSPECTION

Procedures for inspecting ignition coil resistance.

9. CYLINDER HEAD/VALVES

CYLINDER HEAD, VALVES

Procedures for cylinder head and valve removal and installation.

DISASSEMBLY/REASSEMBLY

Detailed steps for disassembling and reassembling cylinder head components.

VALVE GUIDE REPLACEMENT

Procedures for replacing valve guides using specific tools.

VALVE GUIDE REAMING

Procedures for reaming valve guides to achieve proper fit.

VALVE SEAT RECONDITIONING

Procedures for resurfacing and reconditioning valve seats.

10. CRANKSHAFT COVER/ CRANKSHAFT/PISTON

CRANKCASE COVER, CRANKSHAFT, PISTON

Disassembly and reassembly of crankcase cover, crankshaft, and piston.

PISTON RING WIDTH

Measurement of piston ring width for wear assessment.

PISTON RING SIDE CLEARANCE

Measurement of piston ring side clearance.

PISTON RING END GAP

Measurement of piston ring end gap.

CONNECTING ROD BIG END SIDE CLEARANCE

Measurement of connecting rod big end side clearance.

CONNECTING ROD BIG END OIL CLEARANCE

Measurement of connecting rod big end oil clearance using Plastigauge.

11. GOVERNOR/OIL LEVEL SWITCH

GOVERNOR, OIL LEVEL SWITCH

Disassembly and reassembly of governor and oil level switch components.

OIL LEVEL SWITCH

Procedures for inspecting the oil level switch for proper operation.

12. REDUCTION UNIT

1/2 REDUCTION (CENTRIFUGAL CLUTCH TYPE)

Disassembly and reassembly of the 1/2 reduction unit with centrifugal clutch.

1/6 REDUCTION

Disassembly and reassembly procedures for the 1/6 reduction unit.

RAMMER TYPE

Service procedures for the reduction unit's rammer type assembly.

13. OPTIONAL PARTS

LAMP COIL KIT

Details on available lamp coil kits and their electrical configurations.

REMOTE CONTROL CHOKE KIT

Instructions for installing the remote control choke kit.

REMOTE CONTROL THROTTLE KIT

Instructions for installing the remote control throttle kit.