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Honda GX240RT2 User Manual

Honda GX240RT2
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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 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.
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.
Improper service or repairs can create an un-
safe 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 pre-
cautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
gx240ut2_gx270ut2_gx340ut2_gx390ut2

Table of Contents

Questions and Answers:

Honda GX240RT2 Specifications

General IconGeneral
Compression Ratio8.5:1
Fuel SystemCarburetor
Starting SystemRecoil Starter
Lubrication SystemSplash
Engine Type4-Stroke, OHV, Single Cylinder
Net/Max Power Output7.5 HP (5.5 kW) @ 3600 RPM
Fuel Tank Capacity5.3 L (1.4 US gal)
Ignition SystemTransistorized Magneto
Weight25 kg (55 lbs)
Displacement242 cm³ (14.8 cu-in)

Summary

How to Use This Manual

A Few Words About Safety

General safety information and warnings for users.

SERVICE INFORMATION

Information related to service and repair procedures.

For Your Customer’s Safety

Importance of proper service for customer safety and product reliability.

For Your Safety

Precautions for safe servicing practices.

Important Safety Precautions

Essential safety measures to follow before performing any task.

Introduction and Safety Messages

INTRODUCTION

Manual covers service and repair for specific Honda engines.

SAFETY MESSAGES

Importance of safety messages and signal words (DANGER, WARNING, CAUTION).

Manual Usage and Service Rules

SERVICE RULES

Rules for using genuine parts, special tools, and proper procedures.

SYMBOLS

Explanation of symbols used throughout the manual for service procedures.

Specifications Overview

SERIAL NUMBER LOCATION

Location of serial number, type code, and model identification.

TYPE CODE

Model and P.T.O. type variations for different engines.

DIMENSIONS AND WEIGHTS

Physical dimensions and weight specifications for different engine models.

ENGINE SPECIFICATIONS

Detailed engine specifications for each model.

PERFORMANCE CURVES

Graphs showing engine performance curves for different models.

DIMENSIONAL DRAWINGS

Visual representations of engine dimensions for each model.

P.T.O. DIMENSIONAL DRAWINGS

Dimensional drawings specific to Power Take-Off (P.T.O.) variations.

Service Information and Maintenance Standards

MAINTENANCE STANDARDS

Maintenance standards and specifications for GX240 engine.

TORQUE VALUES

Engine torque values for various parts and fasteners.

LUBRICATION & SEAL POINT

Lubrication points and material recommendations.

TOOLS

Special tools required for service procedures.

HARNESS ROUTING

Diagrams showing engine wire harness routing.

Maintenance Procedures

MAINTENANCE SCHEDULE

Schedule of periodic maintenance tasks and intervals.

ENGINE OIL LEVEL CHECK

Step-by-step guide to checking the engine oil level.

ENGINE OIL CHANGE

Procedure for draining and refilling engine oil.

AIR CLEANER CHECK/CLEANING/ REPLACEMENT

Procedures for air cleaner maintenance for dual and cyclone types.

SEDIMENT CUP CLEANING

Procedure for cleaning the fuel sediment cup.

SPARK PLUG CHECK/ADJUSTMENT

Steps for checking and adjusting spark plug gap.

SPARK PLUG REPLACEMENT

Procedure for replacing the spark plug.

SPARK ARRESTER CLEANING (if equipped)

Spark arrester cleaning for solid protector type mufflers.

IDLE SPEED CHECK/ADJUSTMENT

Procedure for checking and adjusting engine idle speed.

VALVE CLEARANCE CHECK/ ADJUSTMENT

Procedure for checking and adjusting valve clearance.

COMBUSTION CHAMBER CLEANING

Procedure for cleaning carbon deposits from the combustion chamber.

FUEL TANK AND FILTER CLEANING

Procedure for cleaning the fuel tank and filter.

FUEL TUBE CHECK

Inspection procedure for the fuel tube.

Troubleshooting Engine Issues

BEFORE TROUBLESHOOTING

Essential checks and precautions before troubleshooting.

TROUBLESHOOTING

Troubleshooting guide for hard starting issues.

ENGINE SPEED DOES NOT INCREASE OR STABILIZE

Troubleshooting steps for unstable or non-increasing engine speed.

ENGINE DOES NOT STOP WHEN COMBINATION SWITCH IS TURNED OFF

Troubleshooting for engine not stopping when switch is off.

ENGINE DOES NOT STOP WHEN ENGINE OIL LEVEL IS LOW

Troubleshooting for engine not stopping due to low oil level.

Engine Systems Service

TOOLS

Tools required for fuel system service.

FUEL TANK REMOVAL/INSTALLATION

Procedures for removing and installing the fuel tank.

AIR CLEANER REMOVAL/INSTALLATION

Procedures for air cleaner removal and installation.

CARBURETOR REMOVAL/INSTALLATION

Procedures for carburetor removal and installation.

CARBURETOR DISASSEMBLY/ASSEMBLY

Steps for disassembling and assembling the carburetor.

CHOKE DIAPHRAGM DISASSEMBLY/ ASSEMBLY

Procedures for choke diaphragm disassembly and assembly.

CARBURETOR BODY CLEANING

Cleaning procedures for the carburetor body.

CARBURETOR INSPECTION

Inspection steps for the carburetor.

CHOKE DIAPHRAGM INSPECTION

Inspection steps for the choke diaphragm.

PILOT SCREW REPLACEMENT

Procedure for replacing the pilot screw.

CHOKE SET REPLACEMENT

Procedure for replacing the choke set.

CYLINDER STUD BOLT REPLACEMENT

Procedure for replacing cylinder stud bolts.

Governor System Service

GOVERNOR ARM/CONTROL BASE ASSY. REMOVAL/INSTALLATION

Procedures for governor arm and control base assembly removal/installation.

MANUAL OPERATION TYPE

Governor arm/control baseassy removal/installation for manual operation.

FIXED THROTTLE OPERATION TYPE

Governor arm/control baseassy removal/installation for fixed throttle.

AUTO THROTTLE (IF EQUIPPED) REMOVAL/ INSTALLATION

Procedures for auto throttle removal and installation.

CONTROL BASE ASSY. DISASSEMBLY/ASSEMBLY

Control base assembly disassembly and assembly.

MAXIMUM SPEED ADJUSTMENT

Procedure for adjusting maximum engine speed.

SOLENOID (AUTO THROTTLE) INSPECTION

Inspection of the auto throttle solenoid.

Charging System Service

TOOLS

Tools for charging system service.

SYSTEM DIAGRAM

System diagram for the charging system.

BEFORE TROUBLESHOOTING

Preliminary checks before troubleshooting the charging system.

CHARGING SYSTEM TROUBLESHOOTING

Troubleshooting guide for charging system faults.

COOLING FAN/FLYWHEEL REMOVAL/ INSTALLATION

Procedures for cooling fan and flywheel removal/installation.

CHARGE / POWER COIL REMOVAL/ INSTALLATION

Procedures for charge/power coil removal and installation.

CHARGE/POWER COIL INSPECTION

Inspection procedures for charge and power coils.

Ignition System Service

SYSTEM DIAGRAM

System diagram for the ignition system.

IGNITION SYSTEM TROUBLESHOOTING

Troubleshooting guide for ignition system problems.

IGNITION COIL REMOVAL/ INSTALLATION

Procedures for ignition coil removal and installation.

IGNITION COIL INSTALLATION

Steps for installing the ignition coil.

SPARK TEST

Procedure for performing a spark test.

SPARK PLUG CAP INSPECTION

Inspection procedure for the spark plug cap.

IGNITION COIL INSPECTION

Inspection procedures for the ignition coil.

Starting System Service

SYSTEM DIAGRAM

System diagram for the starting system.

STARTING SYSTEM TROUBLESHOOTING

Troubleshooting guide for starting system issues.

RECOIL STARTER REMOVAL/ INSTALLATION

Procedures for recoil starter removal and installation.

RECOIL STARTER DISASSEMBLY

Steps for disassembling the recoil starter.

RECOIL STARTER ASSEMBLY

Steps for assembling the recoil starter.

RECOIL STARTER INSPECTION

Inspection of the recoil starter.

STARTER MOTOR REMOVAL/ INSTALLATION

Procedures for starter motor removal and installation.

STARTER MOTOR DISASSEMBLY/ ASSEMBLY

Steps for starter motor disassembly and assembly.

INSPECTION

Inspection procedures for starter motor components.

BRUSH REPLACEMENT

Procedure for replacing starter motor brushes.

Other Electrical Systems Service

COMPONENT LOCATION

Location of electrical components on the engine.

CONTROL BOX REMOVAL/ INSTALLATION

Procedures for control box removal and installation.

CONTROL BOX DISASSEMBLY/ ASSEMBLY

Control box disassembly and assembly steps.

OIL LEVEL SWITCH INSPECTION

Inspection of the oil level switch.

ENGINE STOP SWITCH INSPECTION

Inspection of the engine stop switch.

COMBINATION SWITCH INSPECTION

Inspection of the combination switch.

SILICON RECTIFIER INSPECTION

Inspection of the silicon rectifier.

CIRCUIT PROTECTOR INSPECTION

Inspection of the circuit protector.

FUSE INSPECTION

Inspection of the main fuse.

REGULATOR/RECTIFIER INSPECTION

Inspection of the regulator/rectifier.

Cylinder Head and Valves Service

TOOLS

Tools for cylinder head and valve service.

CYLINDER HEAD REMOVAL/ INSTALLATION

Procedures for cylinder head removal and installation.

CYLINDER HEAD DISASSEMBLY/ ASSEMBLY

Steps for cylinder head disassembly and assembly.

CYLINDER HEAD/VALVES INSPECTION

Inspection of cylinder head and valves.

VALVE GUIDE REPLACEMENT

Procedures for replacing valve guides.

VALVE GUIDE REAMING

Procedure for reaming valve guides.

VALVE SEAT RECONDITIONING

Procedures for reconditioning valve seats.

Crankcase Service

TOOLS

Tools for crankcase service.

CRANKCASE COVER REMOVAL/ INSTALLATION

Procedures for crankcase cover removal and installation.

CRANKSHAFT/BALANCER WEIGHT/PISTON REMOVAL/INSTALLATION

Procedures for removing and installing crankshaft, balancer weight, and piston.

BALANCER WEIGHT/CAMSHAFT INSTALLATION

Procedures for installing balancer weight and camshaft.

1/2 OR 1/6 REDUCTION UNIT DISASSEMBLY/ ASSEMBLY

Procedures for 1/2 or 1/6 reduction unit disassembly and assembly.

1/2 REDUCTION UNIT (CHAIN TYPE) DISASSEMBLY/ASSEMBLY (GX240 ONLY)

Disassembly/assembly for GX240 chain type reduction unit.

1/2 REDUCTION UNIT WITH CLUTCH DISASSEMBLY/ASSEMBLY (GX270 ONLY)

Disassembly/assembly for GX270 reduction unit with clutch.

GOVERNOR DISASSEMBLY ASSEMBLY

Governor disassembly and assembly procedures.

PISTON DISASSEMBLY/ASSEMBLY

Piston disassembly and assembly procedures.

1/2 OR 1/6 REDUCTION UNIT INSPECTION

Inspection of 1/2 or 1/6 reduction unit.

GX240/GX270 CRANKSHAFT/BALANCER WEIGHT BEARING/ OIL SEAL REPLACEMENT (CRANKCASE COVER SIDE)

Replacement of crank/balancer bearings/oil seals on crankcase cover side.

GX340/GX390 CRANKSHAFT/BALANCER WEIGHT BEARING/ OIL SEAL REPLACEMENT (CRANKCASE COVER SIDE)

Replacement of crank/balancer bearings/oil seals on crankcase cover side.

GX240/GX270 CRANKSHAFT BEARING REPLACEMENT (FLYWHEEL SIDE)

Replacement of crankshaft bearings on flywheel side.

GX270 CRANKSHAFT/BALANCER WEIGHT BEARING/OIL SEAL REPLACEMENT (CYLINDER BARREL SIDE)

Replacement of crank/balancer bearings/oil seals on cylinder barrel side.

COUNTER SHAFT/P.T.O. SHAFT BEARING/ OIL SEAL REPLACEMENT (GEAR CASE COVER SIDE)

Replacement of counter/P.T.O. shaft bearings/oil seals on gear case cover side.

GX240/GX270 COUNTER SHAFT/P.T.O. SHAFT BEARING REPLACEMENT (CRANKCASE COVER SIDE)

Replacement of counter/P.T.O. shaft bearings on crankcase cover side.

GX340/GX390 COUNTER SHAFT/P.T.O. SHAFT BEARING REPLACEMENT (CRANKCASE COVER SIDE)

Replacement of counter/P.T.O. shaft bearings on crankcase cover side.

GX240/GX270 CRANKSHAFT/P.T.O. SHAFT OIL SEAL REPLACEMENT (1/2 REDUCTION WITH CLUTCH)

Replacement of crank/P.T.O. shaft oil seals with clutch.

Muffler Service

MUFFLER REMOVAL/INSTALLATION

Procedures for muffler removal and installation.

MUFFLER COVER REMOVAL/INSTALLATION (IF EQUIPPED)

Procedures for muffler cover removal and installation.

EXHAUST PIPE STUD BOLT REPLACEMENT

Procedure for replacing exhaust pipe stud bolts.

Wiring Diagrams

HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION

Guide on how to read wiring diagrams and related information.

HOW TO READ CONNECTOR DRAWINGS

How to interpret connector drawings and terminal numbering.

NO CHARGE COIL TYPE WIRING DIAGRAM

Wiring diagram for engines without a charge coil.

1A/3A CHARGE COIL TYPE WIRING DIAGRAM

Wiring diagram for 1A/3A charge coil type engines.

10A CHARGE COIL TYPE WIRING DIAGRAM

Wiring diagram for 10A charge coil type engines.

18A CHARGE COIL TYPE WIRING DIAGRAM

Wiring diagram for 18A charge coil type engines.

Troubleshooting and Maintenance Schedules

MAINTENANCE SCHEDULE

Schedule of periodic maintenance tasks and intervals.

VALVE CLEARANCE CHECK/ ADJUSTMENT

Procedure for valve clearance check and adjustment.

COMBUSTION CHAMBER CLEANING

Procedure for cleaning combustion chamber.

FUEL TUBE CHECK

Inspection of the fuel tube.

Troubleshooting Engine Speed and Stopping

BEFORE TROUBLESHOOTING

Preliminary checks before troubleshooting.

TROUBLESHOOTING

Troubleshooting guide for general symptoms.

HARD STARTING

Troubleshooting steps for hard starting issues.

ENGINE SPEED DOES NOT INCREASE OR STABILIZE

Troubleshooting steps for engine speed issues.

ENGINE DOES NOT STOP WHEN COMBINATION SWITCH IS TURNED OFF

Troubleshooting for engine not stopping when switch is off.

ENGINE DOES NOT STOP WHEN ENGINE OIL LEVEL IS LOW

Troubleshooting for engine not stopping due to low oil level.

Fuel System Components

FUEL TANK REMOVAL/INSTALLATION

Procedures for fuel tank removal and installation.

CARBURETOR REMOVAL/ INSTALLATION

Procedures for carburetor removal and installation.

CARBURETOR DISASSEMBLY/ ASSEMBLY

Steps for carburetor disassembly and assembly.

CHOKE SET REPLACEMENT

Procedure for replacing the choke set.

CONTROL MOTOR/WAX HEATER INSPECTION

Inspection of control motor and wax heater.

TECHNICAL FEATURES/STR (Self Tuning Regulator) GOVERNOR OUTLINE

Outline of the STR governor system's technical features.

Charging System Troubleshooting

CHARGING SYSTEM DIAGRAM

System diagram for the charging system.

BEFORE TROUBLESHOOTING

Preliminary checks before troubleshooting the charging system.

CHARGING SYSTEM TROUBLESHOOTING

Troubleshooting guide for charging system faults.

CHARGE/POWER COIL REMOVAL/ INSTALLATION

Procedures for charge/power coil removal and installation.

CHARGE/POWER COIL INSPECTION

Inspection procedures for charge and power coils.

Ignition System Service

SYSTEM DIAGRAM

System diagram for the ignition system.

IGNITION SYSTEM TROUBLESHOOTING

Troubleshooting guide for ignition system problems.

IGNITION COIL REMOVAL/ INSTALLATION

Procedures for ignition coil removal and installation.

Starting System Service

SYSTEM DIAGRAM

System diagram for the starting system.

STARTING SYSTEM TROUBLESHOOTING

Troubleshooting guide for starter motor not operating.

RECOIL STARTER REMOVAL/ INSTALLATION

Procedures for recoil starter removal and installation.

RECOIL STARTER DISASSEMBLY

Steps for disassembling the recoil starter.

RECOIL STARTER ASSEMBLY

Steps for assembling the recoil starter.

RECOIL STARTER INSPECTION

Inspection of the recoil starter.

STARTER MOTOR REMOVAL/ INSTALLATION

Procedures for starter motor removal and installation.

STARTER MOTOR DISASSEMBLY/ ASSEMBLY

Steps for starter motor disassembly and assembly.

INSPECTION

Inspection procedures for starter motor components.

BRUSH REPLACEMENT

Procedure for replacing starter motor brushes.

Other Electrical Systems Service

COMPONENT LOCATION

Location of control box and oil level switch.

CONTROL BOX REMOVAL/INSTALLATION

Procedures for control box removal and installation.

CONTROL BOX DISASSEMBLY/ASSEMBLY

Disassembly and assembly of the control box.

OIL LEVEL SWITCH REMOVAL/ INSTALLATION

Procedures for oil level switch removal and installation.

REGULATOR/RECTIFIER INSPECTION

Inspection of the regulator/rectifier.

Cylinder Head and Valves Service

CYLINDER HEAD REMOVAL/ INSTALLATION

Procedures for cylinder head removal and installation.

Crankcase Service

CRANKCASE COVER REMOVAL/ INSTALLATION

Procedures for crankcase cover removal and installation.

CRANKSHAFT/BALANCER/PISTON REMOVAL/INSTALLATION

Procedures for crankshaft, balancer weight, and piston removal/installation.

Specifications Overview

SERIAL NUMBER LOCATION

Location of serial number, type code, and model identification.

TYPE CODE

Type codes for GX270UT2 and GX390UT2/T2 models.

DIMENSIONS AND WEIGHT SPECIFICATIONS

Dimensions and weight specifications for GX270UT2 and GX390UT2 models.

ENGINE SPECIFICATIONS

Engine specifications for GX270UT2 and GX390UT2 models.

DIMENSIONAL DRAWINGS

Dimensional drawings for GX270UT2 and GX390UT2 engines.

P.T.O. DIMENSIONAL DRAWINGS

P.T.O. dimensional drawings for GX270UT2.

Service Information Details

MAINTENANCE STANDARDS

Maintenance standards and specifications for GX270UT2 engine.

TORQUE VALUES

Torque values for various engine parts.

LUBRICATION & SEAL POINTS

Lubrication points and seal recommendations.

HARNESS AND TUBE ROUTING

Harness and tube routing diagrams.

Troubleshooting Guide

BEFORE TROUBLESHOOTING

Preliminary checks before troubleshooting.

TROUBLESHOOTING

Troubleshooting guide for general symptoms.

ENGINE SPEED DOES NOT INCREASE OR STABILIZE (QZAV TYPE)

Troubleshooting steps for engine speed issues on QZAV type.

Charging System Diagrams and Troubleshooting

CHARGING SYSTEM DIAGRAM

System diagram for the charging system.

BEFORE TROUBLESHOOTING

Preliminary checks before troubleshooting the charging system.

CHARGING SYSTEM TROUBLESHOOTING

Troubleshooting guide for charging system faults.

CHARGE/POWER COIL REMOVAL/ INSTALLATION

Procedures for charge/power coil removal and installation.

CHARGE/POWER COIL INSPECTION

Inspection procedures for charge and power coils.

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