Honda Engine GX120 GX160 GX200 Owners Manual

							1
OWNER’S MANUAL
GX120 GX160 GX200
Serial number and
engine typeHONDA EUROPE N.V.(EEC)
32ZH7620
00X32-ZH7-6201 
						

							2
Indicates a strong possibility of severe personal
injury or death if instructions are not followed.
Indicates a possibility of personal injury or equipment
damage if instructions are not followed.
Indicates that equipment or property damage can
result if instructions are not followed.
The Honda engine is designed to give safe and dependable service
if operated according to instructions. Read and understand the
Owner’s Manual before operating the engine. Failure to do so
could result in personal injury or equipment damage. Thank you for purchasing a Honda engine.
This manual covers the operation and maintenance of your engine:
All information in this publication is based on the latest product
information available at the time of printing.
Honda Motor Co., Ltd. reserves the right to make changes at any
time without notice and without incurring any obligation.
No part of this publication may be reproduced without written
permission.
This manual should be considered a permanent part of the engine
and should remain with it if it is resold.
Pay special attention to statements preceded by the following
words:
Gives helpful information.
If a problem should arise, or if you have any questions about your
engine, consult an authorized Honda dealer. GX120 GX160 GX200 
						

							µ
3
SAFETY INSTRUCTIONS
Honda engine is designed to give safe and
dependable service if operated according to
instructions. Read and understand the
Owner’s Manual before operating the
engine. Failure to do so could result in
personal injury or equipment damage.
To ensure safe operation
Always make a pre-operation inspection (page ) before you
start the engine. You may prevent an accident or equipment
damage.
To prevent fire hazards and to provide adequate ventilation,
keep the engine at least 1 meter (3 feet) away from buildings
and other equipment during operation. Do not place flammable
objects close to the engine.
Children and pets must be kept away from the area of operation
due to a possibility of burns from hot engine com ponents or
injury from any equipment the engine may be used to operate.
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 place flammable objects such as gasoline, matches, etc.,
close to the engine while it is running.
Refuel in a well-ventilated area with the engine stopped.
Gasoline is highly flammable and explosive under certain
conditions.
Do not overfill the fuel tank. There should be no fuel in the f iller
neck.
Do not smoke or allow flames or sparks where the engine is
refueled or where gasoline is stored.
Place the engine on a stable surface. Do not tilt the engine more
than 20° from horizontal. Operating at excessive angles may
result in fuel spillage. Exhaust gas contains poisonous carbon monoxide. Avoid
inhalation of exhaust gases. Never run the engine in a closed
garage or confined area. If any fuel is spilled, clean it up completely and allow petroleum
vapours to dissipate before starting the engine. Make sure that the filler cap is closed securely. 6 
						

							µ
4
SAFETY INSTRUCTIONS
SAFETY LABEL LOCATION
To ensure safe operation
Do not place anything on the engine, as it may create a fire
hazard.
A spark arrester is available as an optional part for this engine. It
is illegal in some areas to operate an engine without a spark
arrester. Check local laws and regulations before operating.
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. To avoid severe burns or fire hazards, let
the engine cool before transporting it or storing it indoors.
READ OWNER’S MANUAL
This label warns you of potential hazards that can cause serious
injury. Read it carefully.
If the label comes off or becomes hard to read, contact your Honda
dealer for replacement. 
						

							´
µ
µ
µ
µ
´
µ
5
BATTERY CONNECTIONS (for electric starter)
The battery gives off explosive gases; keep sparks, flames and
cigarettes away. Provide adequate ventilation when charging
or using batteries in an enclosed space.
The battery contains sulfuric acid (electrolyte). Contact with
skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
If electrolyte gets on your skin, flush with water.
If electrolyte gets in your eyes, flush with water for at least 15
minutes and call a physician immediately.
If swallowed, drink large quantities of water or milk and
follow with milk of magnesia or vegetable oil and call a
physician immediately.
KEEP OUT OF REACH OF CHILDREN.
Be careful not to connect the battery in reverse polarity, as this
will short circuit the battery charging system and trip the circuit
breaker. Filling the battery above the U PPER LEVEL line may cause the
electrolyte to overflow, resulting in corrosion to engine or
nearby parts. Immediately wash off any spilled electrolyte. Use only distilled water in the battery. Tap water will shorten
the service life of the battery. Electrolyte is poisonous.
STARTER SOLENOID
POSITIVE( )
BATTERY CABLE
NEGATIVE ( )
BATTERY CABLE
(to engine body)
Use a 12 volt battery with an ampere-hour rating of at least 18 AH.
Connect the battery positive ( ) cable to the starter solenoid
terminal, as shown.
Connect the battery negative ( ) cable to an engine mounting bolt,
frame bolt, or other good engine ground connection.
Check the battery cable connections to be sure the cables are
tightened and free of corrosion. Remove any corrosion, and coat
the terminals and cable ends with grease. 
						

							6
PRE-OPERATION CHECK
Engine oil l
evel
Running the engine with insufficient oil can cause serious
engine damage.
Be sure to check the engine on a level surface with the engine
stopped.
Using nondetergent oil or 2-stroke engine oil could shorten the
engine’s service life. 1.
Ambient temperature SINGLE VISCOSITY
MULTI VISCOSITY
OIL FILLER CAP/
DIPSTICK LEVEL
If the level is low, fill to the top of the oil filler neck with the
recommended oil. Remove the oil filler cap and wipe the dipstick clean.
Insert the dipstick into the oil filler neck, but do not screw it in.
Use Honda 4-stroke, or an equivalent
high detergent, premium quality mo-
tor oil certified to meet or exceed U.S.
automobile manufacturer’s require-
ments for service classification SG, SF.
Motor oils classified SG, SF will show
this designation on the container.
SAE 10W-30 is recommended for gen-
eral, all temperature use. If single vis-
cosity oil is used, select the appropri-
ate viscosity for the average tempera-
ture in your area. 1.
2.
3. 
						

							ª«
ª«
7
Reduction gear oil
1/2 reduction with automatic centrifugal clutch
Oil capacity:
Oil capacity: 1/6 reduction
2.
OIL LEVEL BOLT
UPPER LEVEL
DIPSTICK/FILLER CAP
DRAIN BOLT
FILLER BOLT
Check reduction gear oil level.
Fill with SG, SF rated engine oil, if necessary. Remove the oil filler cap and wipe the dipstick clean.
Insert the dipstick into the filler neck but do not screw it in.
If the level is low, fill to the upper level mark with the same oil
recommended for the engine (see engine oil recommendations
on page ).
Install the oil level bolt and filler bolt. Tighten them securely. Check the oil level; it should reach the edge of the oil level bolt
hole. If the oil level is low, remove the filler bolt, and add oil until
it starts to flow out the oil level bolt hole. Use the same oil
recommended for the engine (see engine oil recommendations
on page ). Remove the oil level bolt.
1.
2.
3.
6
1.
2.
3. 6
0.50(0.53 US qt , 0.44 Imp qt)
0.15
(0.16 US qt , 0.13 Imp qt) 
						

							ª«
ª«
8
Air cleaner
Never run the engine wit hout the air
cleaner. Rapid engine wear will result.
Dual element type
Cyclone type
3.
ELEMENTS
ELEMENTS
CYCLONE
(GX120/160) (GX120/160/200)Check the air cleaner elements to be
sure they are clean and in good con-
dition.
Clean or replace the elements if
necessary (page ).
Check cleaner for dirt or obstruction
of elements.
Check the cyclone housing for any
dirt build-up, clean it, if necessary
(page ).
22
1.
2.
21
1.
2. 
						

							ª«
ª«
9
Semi-dry type
Oil bath type
Never run the engine wit hout the air cleaner. Rapid engine wear
will result.
OIL LEVEL ELEMENT
Check cleaner for dirt or obstruction of element (page ).
Check the air cleaner element to be sure it is clean and in good
condition. Clean or replace the element if necessary (page ).
Check oil level and c ondition.
1.
2. 23
23 
						

							10
Fuel
Gasoline is extremely flammable and is explosive under certain
conditions.
Refuel in a well-ventilated area with the engine stopped. Do not
smoke or allow flames or sparks in the area where the engine is
refueled or where gasoline is stored.
Do not overfill the fuel tank (there should be no fuel in the filler
neck). After refueling, make sure the tank cap is closed properly
and securely.
Be careful not to spill fuel when refueling. Spilled fuel or fuel
vapor may ignite. If any fuel is spilled, make sure the area is dry
before starting the engine.
Avoid repeated or prolonged contact with skin or breathing of
vapor.
KEEP OUT OF REACH OF CHILDREN.
4.
Fuel tank capacity: Use automotive gasoline (Unleaded or lowleaded is preferred to
minimize combustion chamber deposits).
FOR NEW SOUTH WALES ONLY:
Use unleaded fuel only.
Never use an oil/gasoline mixture or dirty gasoline. Avoid getting
dirt, dust or water in the fuel tank.
GX120…
GX160…
GX200…
2.5(0.66 US gal , 0.55 Imp gal)
3.6(0.95 US gal , 0.79 Imp gal)
3.6(0.95 US gal , 0.79 Imp gal)