Honda Engine GX120 GX160 GX200 Owners Manual

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21
Air cleaner service
Never use gasoline or low flash point solvents for cleaning the air
cleaner element. A fire or explosion could result.
Never run the engine wit hout the air cleaner. Rapid engine wear
will result.
Dual element type
2.
WING NUT
(GX120/160/200)
(GX120/160) PAPER
ELEMENT
FORM
ELEMENT
A dirty air cleaner will restrict air flow to the carburetor. To prevent
carburetor malfunction, service the air cleaner regularly. Service
more frequently when operating the engine in extremely...

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22
When reinstalling the cyclone, ensure that the tab on the air
intake fits properly into the groove in the pre-cleaner cap.
Be careful to install the air guide in the proper direction. Cyclone type
WING NUT
GROOVE PAPER
ELEMENT
FOAM
ELEMENT
AIR INTAKE TAB
CYCLONE
AIR GUIDE
Paper element: Tap the element lightly several times on a hard
surface to remove excess dirt, or blow compressed air through
the filter from the inside out. Never try to brush the dirt off;
brushing will force dirt into the...

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23
Semi-dry type
Oil bath typeWING NUT
WING NUT
AIR CLEANER
COVER
AIR CLEANER
COVER
ELEMENT
ELEMENTUnscrew the wing nut, remove the air
cleaner cover and remove the element.
Wash the element in a nonflammable
or high flash point solvent and dry it
thoroughly.
Soak the element in clean engine oil
and squeeze out the excess oil.
Unscrew the wing nut, remove the air
cleaner cover and remove the element.
Empty the oil from the air cleaner case
and wash out any accumulated dirt
with nonflammable or...

24
Sediment cup cleaning
Gasoline is extremely flammable and is explosive under certain
conditions. Do not smoke or allow flames or sparks in the area.
After installing the sediment cup, check for leaks, and make
sure the area is dry before starting the engine.
Spark plug service
Recommended spark plug:
Never use a spark plug of incorrect heat range.
If the engine has been running, the muffler will be very hot. Be
careful not to touch the muffler. 3.
4.
O-RING
SEDIMENT CUP
Turn the fuel valve to OFF....

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The spark plug must be securely tightened. An improperly
tightened spark plug can become very hot and may damage the
engine.
0.70 0.80 mm
(0.028 0.031 in)
0.70 0.80 mm (0.028 0.031 in)
Visually inspect the spark plug. Discard the spark plug if there is
apparent wear, or if the insulator is cracked or chipped. Clean
the spark plug with a wire brush if it is to be reused.
Measure the plug gap with a feeler gauge. Correct as necessary
by bending the side electrode.
The gap should be:
Check...

26
Spark arrester maintenance (optional part)
If the engine has been running, the muffler will be very hot. Allow
it to cool before proceeding.
The spark arrester must be serviced every 100 hours to maintain
its efficiency.
Be careful not to damage the spark arrester screen. 5.
MUFFLER PROTECTOR MUFFLER 4 mm SCREW
SCREEN EXHAUST DEFLECTOR
SPARK ARRESTER 4 mm SCREWS
5 mm SCREWS
Remove the two 4 mm screws from the exhaust deflector, and
remove the deflector.
Remove the four 5 mm screws from the muffler...

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27
Carburetor idle speed adjustment
6.
THROTTLE STOP SCREW
Standard idle speed:
Start the engine and allow it to warm up to normal operating
temperature.
With the engine idling, turn the throttle stop screw to obtain the
standard idle speed.
1.
2.
1,400 rpm.200
150 

28
THROTTLE AND CHOKE CONTROL CABLE
(optional part)
THROTTLE LEVER
FRICTION NUT
FLEXIBLE WIRE
CORE MOUNTING
SOLID WIRE
CORE MOUNTING RETURN SPRING
THROTTLE LEVER
WIRE HOLDER
5 mm CIRCLIP
5 mm CIRCLIP
WIRE
4 mm SCREW
WIRE HOLDER
The throttle and choke control levers are provided with holes for
optional cable attachment. The following illustrations show
installation examples for a solid wire cable and for a braided wire
cable. If using a braided wire cable, add a return spring as shown.
It is necessary to...

29
TRANSPORTING/STORAGE
When transporting the engine, turn the fuel valve OFF and keep
the engine level to prevent fuel spillage. Fuel vapor or spilled fuel
may ignite.
Gasoline is extremely flammable and is explosive under certain
conditions. Do not smoke or allow flames or sparks in the area.
DRAIN
SCREW
Align the mark on the starter
pulley with the hole at the top
of recoil starter. SEDIMENT CUP
Befor storing the unit for an extended period;
Be sure the storage area is free of excessive humidity and...

30
TROUBLESHOOTING
If any fuel is spilled, make sure the area is dry before testing the
spark plug or starting the engine. Fuel vapor or spilled fuel may
ignite.
DRAIN SCREW
Engine will not start using recoil starter:
Is the engine switch in the ON position?
Is there enough oil in the engine?
Is the fuel valve ON?
Is there fuel in the fuel tank?
Is gasoline reaching the carburetor?
To check,loosen the drain screw with the fuel valve ON?
Is there a spark at the spark plug?
If the engine still dose not...