Honda Engine Gx25u Gx35u Owners Manual
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µµ µ µ µ ENGLISH COOLING FINS Inspection SPARK PLUG Recommended Spark Plug: SEALING WASHER SIDE ELECTRODE COOLING FINS SPARK PLUG CAP SPARK PLUG0.60 0.70 mm (0.024 0.028 in) SPARK PLUG CAP5mmHEXBOLT TOP COVER 11 Inspect the spark plug. Replace it if damaged or badly fouled, if the sealing washer is in poor condition, or if the electrode is worn. Measure the spark plug electrode gap with a wire- type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode. The gap should be: 0.60 0.70 mm (0.024 0.028 in) Install the spark plug carefully, by hand, to avoid cross- threading. After the spark plug is seated, tighten with a 5/8-inch spark plug wrench to compress the sealing washer. When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. When reinstalling the original spark plug, tighten 1/8 1/4 turn after the spark plug seats to compress the washer. A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head. Attach the spark plug cap to the spark plug. Reconnect the spark plug cap. Install the top cover, and tighten the 5 mm hex bolt securely. The recommended spark plug has the correct heat range for normal engine operating temperatures. An incorrect spark plug can cause engine damage. For good performance, the spark plug must be properly gapped and free of deposits. Remove the top cover. Loosen the 5 mm hex bolt with a hexagon wrench, then remove the top cover. You may be injured from the rotating parts or burned by the muffler. Do not pull the recoil starter handle when the top cover is removed. Do not operate the engine when the top cover is removed. Disconnect the spark plug cap, and remove any dirt from around the spark plug area. Remove the spark plug with a 5/8-inch spark plug wrench.CM5H (NGK) CMR5H (NGK) Disconnect the spark plug cap. Inspect the engine cooling fins, and clean out debris if necessary. Install the top cover, and tighten the 5 mm hex bolt securely with a hexagon wrench. Loosen the 5 mm hex bolt, then remove the top cover. 2.4. 3.5. 6. 7. 8. 9. 2. 3. 1. 4. 5. 10. 11. 1., 06/11/06 12:23:40 32Z6J600_011
ENGLISH Spark Arrester Cleaning & Inspection Spark Arrester Removal Standard/Pump type: SPARK ARRESTER (applicable types) FUEL FILTER AND FUEL TANK Fuel filter inspection and Fuel tank cleaning GX25 MUFFLER SPARK ARRESTER SPARK ARRESTER SCREEN FUEL FILTER4 mm SCREWSSPARK PLUG ENGINE OIL FILLER CAP FUEL FILLER NECK 12Install the top cover, and tighten the 5 mm hex bolt securely (see page ). When you install the spark arrester, the spark arrester’s outlet must point to the side opposite the spark plug. Install the spark arrester in the reverse order of disassembly. The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen. Remove the 4 mm screws from the spark arrester, and remove the spark arrester from the muffler. Loosen the 5 mm hex bolt, then remove the top cover (see page ). If the engine has been running, the muffler will be hot. Allow it to cool before servicing the spark arrester. The spark arrester must be serviced every 100 hours to keep it functioning as designed. The spark arrester may be standard or an optional part, depending on the engine type. In some areas, it is illegal to operate an engine without a spark arrester. Check local laws and regulations. A spark arrester is available from authorized Honda servicing dealers. Insert the fuel filter into the fuel tank and tighten the fuel filler cap securely. Inspect the fuel filter. If the fuel filter is dirty, wash it gently with non-flammable or high flash point solvent. If the fuel filter is excessively dirty, replace it. Pull the fuel filter out through the fuel filler neck byhooking the black fuel tube with a piece of wire, such as a partly straightened paper clip.Wipe up spills immediately. Handle fuel only outdoors. Stop engine and keep heat, sparks, and flame away. Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel. Check that the engine oil filler cap is tightened securely. Remove the fuel filler cap, and drain the fuel into an approved gasoline container by tipping the engine toward the fuel filler neck. Remove water and dirt from the fuel tank by rinsing the inside of the fuel tank with non-flammable or high flash point solvent.1. 2. 4. 3. 5. 6.1. 2. 3.11 1. 2. 11 06/11/06 12:24:05 32Z6J600_012
· · · · ENGLISH Standard Type: Tiller type Spark Arrester Removal Spark Arrester Removal Spark Arrester Cleaning & Inspection Exhaust Filter Cleaning & Inspection Spark Arrester Cleaning & Inspection GX35 SPARK ARRESTER SCREEN SPARK ARRESTER SCREENSPARK PLUG MUFFLER EXHAUST FILTER SPARK ARRESTER OUTLET 46mm SELF-TAPPING SCREWS SPARK ARRESTER MUFFLER SPARK ARRESTER3 6 mm SELF-TAPPING SCREW 13 Remove the 4 6 mm self-tapping screws from the spark arrester, and remove the spark arrester and exhaust filter from the muffler. Loosen the 5 mm hex bolt, then remove the top cover (see page ). Loosen the 5 mm hex bolt, then remove the top cover (see page ). Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen. The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged. Install the top cover, and tighten the 5 mm hex bolt securely (see page ). Install the spark arrester in the reverse order of disassembly. Remove the 3 6 mm self-tapping screws from the spark arrester, and remove the spark arrester from the muffler. Pinch the exhaust filter, and strike it lightly with a finger, to remove carbon deposits. Be careful not to strike it too hard. The exhaust filter must be free of breaks and holes. If it is damaged or fouled excessively, have it serviced by your Honda dealer. Install the top cover, and tighten the 5 mm hex bolt securely (see page ). When you install the spark arrester, the spark arrester’s outlet must point to the side opposite the spark plug. Install the exhaust filter and spark arrester in the reverse order of disassembly. The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen. 1. 2. 3. 2. 3.1. 2.11 1. 2. 1.11 11 11 06/11/06 12:24:32 32Z6J600_013
· · HELPFUL TIPS & SUGGESTIONS STORING YOUR ENGINE Storage Preparation Cleaning Fuel Adding a Gasoline Stabilizer to Extend Fuel Storage Life Tiller type: Spark Arrester Removal Exhaust Filter Cleaning & Inspection Spark Arrester Cleaning & Inspection ENGLISH SPARK ARRESTERMUFFLERSPARK PLUG SPARK ARRESTER SCREEN 46mm SELF-TAPPING SCREWSEXHAUST FILTER 14Proper storage preparation is essential for keeping your engine trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your engine’s function and appearance, and will make the engine easier to start when you use it again. If the engine has been running, allow it to cool for at least half an hour before cleaning. Clean all exterior surfaces, touch up any damaged paint, and coat other areas that may rust with a light film of oil. Using a garden hose or pressure washing equipment can force water into the air cleaner or muffler opening. Water in the air cleaner will soak the air filter, and water that passes through the air filter or muffler can enter the cylinder, causing damage. Gasoline will oxidize and deteriorate in storage. Deteriorated gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your engine deteriorates during storage, you may need to have the carburetor and other fuel system components serviced or replaced. The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled. The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel problems may occur within a few months, or even less if the gasoline was not fresh when you filled the fuel tank. Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under the Distributor’s Limited Warranty. You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor. When adding a gasoline stabilizer, fill the fuel tank with fresh gasoline. If only partially filled, air in the tank will promote fuel deterioration during storage. If you keep a container of gasoline for refueling, be sure that it contains only fresh gasoline. Add gasoline stabilizer following the manufacturer’s instructions. After adding a gasoline stabilizer, run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor. Stop the engine. Loosen the 5 mm hex bolt, then remove the top cover (see page ). Remove the 4 6 mm self-tapping screws from the spark arrester, and remove the spark arrester from the muffler. Pinch the exhaust filter, and strike it lightly with a finger, to remove carbon deposits. Be careful not to strike it too hard. The exhaust filter must be free of breaks and holes. If it is damaged or fouled excessively, have it serviced by your Honda dealer. Install the top cover, and tighten the 5 mm hex bolt securely (see page ). When you install the spark arrester, the spark arrester’s outlet must point to the side opposite the spark plug. Install the exhaust filter and spark arrester in the reverse order of disassembly. The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen. 1. 2. 3. 2. 3. 1. 11 1. 2. 11 06/11/06 12:25:00 32Z6J600_014
Storage Precautions Draining the Fuel Tank and Carburetor Engine OilRemoval from Storage TRANSPORTING ENGLISH ENGINE OIL FILLER CAP PRIMING BULB FUEL FILLER NECK FUEL RETURN TUBE 15 If your engine will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well-ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a spark- producing electric motor, or where power tools are operated. If possible, avoid storage areas with high humidity, because that promotes rust and corrosion. Keep the engine level in storage. Tilting can cause fuel or oil leakage. With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials. Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture around the engine, promoting rust and corrosion. Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel. Stop engine and keep heat, sparks, and flame away. Wipe up spills immediately. Handle fuel only outdoors. Make sure the engine oil filler cap is tightened securely. Remove the fuel filler cap and drain the fuel into an approved gasoline container by tipping the engine toward the fuel filler neck. Press the priming bulb several times until there is no more fuel in the fuel return tube. Tip the engine toward the fuel filler neck again to drain the fuel. After all fuel has drained, reinstall the fuel filler cap securely. Change the engine oil (see page ). Loosen the 5 mm hex bolt, then remove the top cover (see page ). Remove the spark plug (see page ). Apply a couple of drops of clean engine oil into the cylinder. Install the top cover temporarily. Pull the starter grip several times to distribute the oil in the cylinder. Remove the top cover, then reinstall the spark plug. Install the top cover, and tighten the 5 mm hex bolt securely (see page ). Pull the starter grip slowly until resistance is felt.Check your engine as described in the BEFORE OPERATION CHECKS section of this manual (see page ). If the fuel was drained during storage preparation, fill the tank with fresh gasoline. If you keep a container of gasoline for refueling, be sure it contains only fresh gasoline. Gasoline oxidizes and deteriorates over time, causing hard starting. If the cylinder was coated with oil during storage preparation, the engine will smoke briefly at startup. This is normal. If the engine has been running, allow it to cool for at least 15 minutes before loading the engine-powered equipment on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials. 2. 1. 3. 1. 2. 3. 4. 5. 6. 4. 5. 7. 8. 9.9 114 11 11 05/12/16 15:02:29 32Z6J600_015
µ TAKING CARE OF UNEXPECTED PROBLEMS TECHNICAL & CONSUMER INFORMATION ENGINE WILL NOT STARTPossible Cause Correction TECHNICAL INFORMATION Serial Number Location Remote Control Linkage Standard/Tiller type: Correction Possible Cause ENGINE LACKS POWER ENGLISH CABLE ATTACHMENT FITTING LOCK NUT THROTTLE CABLE ADJUST NUTSTAYENGINE TYPE ENGINE SERIAL NUMBER 16Date Purchased: ______ / ______ / ______Engine type: ___ ___ ___ ___ Engine serial number: __ __ __ __ __ __ __ __ __ __ __ The throttle control lever is provided with a fitting for cable attachment. Remove the air cleaner cover (see page ) for access to the throttle lever and cable fitting. Attach the throttle cable as shown in the illustration. To adjust the throttle cable, follow the equipment manufacturer’s instructions. Record the engine serial number, type and purchase date in the space below. You will need this information when ordering parts and when making technical or warranty inquiries. Choke open. Engine switch OFF.(on the equipment) Out of fuel. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline. Spark plug faulty, fouled, or improperly gapped. Spark plug wet with fuel (flooded engine). Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc. Check control positions. Check fuel. Remove and inspect spark plug. Take engine to an authorized Honda servicing dealer, or refer to shop manual. Filter element restricted. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline. Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc. Check air filter. Check fuel. Take engine to an authorized Honda servicing dealer, or refer to shop manual.Clean or replace filter element (p. 10). Drain fuel tank and carburetor (p. 15). Refuel with fresh gasoline (P. 8). Replace or repair faulty components as necessary. Move lever to CLOSED position unless the engine is warm. Turn engine switch to ON position. Refuel (p. 8). Drain fuel tank and carburetor (p. 15). Refuel with fresh gasoline(p. 8). Gap or replace spark plug (p. 11). Allow the spark plug to dry. After drying, install the spark plug and start the engine (p. 4). Replace or repair faulty components as necessary. 1. 2. 3. 4. 1. 2. 3.10 05/12/16 15:02:48 32Z6J600_016
ENGLISH Carburetor Modifications for High Altitude Operation Emission Control System Information Source of Emissions The U.S., California Clean Air Acts and Environment Canada Tampering and Altering Problems That May Affect Emissions Replacement Parts 17 When the carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use. Operation at altitudes below 1,500 meters (5,000 feet) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have your servicing dealer return the carburetor to original factory specifications. Even with carburetor modification, engine horsepower will decrease about 3.5% for each300-meter (1,000-foot) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made. High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above 1,500 meters (5,000 feet), have your servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life. At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons. EPA, California and Canadian regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems. The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards. Tampering with or altering the emission control system may increase emissions beyond the legal limit. Among those acts that constitute tampering are: Removal or alteration of any part of the intake, fuel, or exhaust systems. Altering or defeating the governor linkage or speed-adjusting mechanism to cause the engine to operate outside its design parameters. If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption. The emission control systems on your Honda engine were designed, built, and certified to conform with EPA, California and Canadian emission regulations. We recommend the use of genuine Honda parts whenever you have maintenancedone. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system. A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations. 06/11/07 17:37:03 32Z6J600_017
·· · ·· · µµ µµ µµ ENGLISH Air Index Specifications Maintenance Applicable to Emissions Durability Period Descriptive Term GX25 (Basic types) GX35 (Basic types) 18 Follow the maintenance schedule on page . Remember that this schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load or high- temperature operation, or use in unusually wet or dusty conditions, will require more frequent service. The durability description is intended to provide you with information relating to the engine’s emission durability period. The descriptive term indicates the useful life period for the engine’s emission control system. See your Emission Control System Warranty for additional information. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution. An Air Index Information hang tag/label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. Type S3 (Standard) (Without tank guard) 192 mm (7.6 in) 221 mm (8.7 in) 230 mm (9.1 in) 2.78 kg (6.13 lbs) 25 cm (1.5 cu-in) [3526mm(1.41.0in)] 0.72 kW (1.0 PS, 1.0 bhp) at 7,000 rpm 4-stroke, overhead camshaft, single cylinder GCART W3 (Pump) T3 (Tiller) 247 mm (9.7 in) 192 mm (7.6 in) 221 mm (8.7 in) 210 mm (8.3 in) 230 mm (9.1 in) 236 mm (9.3 in) 3.10 kg (6.83 lbs) 2.96 kg (6.53 lbs) Power equipment description code Length Width Height Dry weight (Without clutch) Engine type Displacement [Bore Stroke] Max. output Max. torque Engine oil capacity Fuel tank capacity Fuel consumption Cooling system Ignition system PTO shaft rotation 1.0 N·m (0.10 kgf·m, 0.74 lbf·ft) at 5,000 rpm 0.08 (0.08 US qt , 0.07 Imp qt) 0.58 (0.153 US gal , 0.128 Imp gal) 0.54 /h at 7,000 rpm Forced air Transistorized magneto Counterclockwise Type S3 (Standard) (Without tank guard) TR3 (Tiller) T3 (Tiller) GCAST 198 mm (7.8 in) 234 mm (9.2 in) 240 mm (9.4 in) 198 mm (7.8 in) 243 mm (9.6 in) 242 mm (9.5 in) 198 mm (7.8 in) 243 mm (9.6 in) 242 mm (9.5 in) 3.33 kg (7.34 lbs) 3.52 kg (7.76 lbs) 3.52 kg (7.76 lbs) 4-stroke, overhead camshaft, single cylinder 35.8 cm (2.18 cu-in) [3930mm(1.51.2in)] 0.10 (0.11 US qt , 0.09 Imp qt) 0.70 (0.185 US gal , 0.154 Imp gal) 0.71 /h at 7,000 rpm Forced air Transistorized magneto Counterclockwise Power equipment description code Length Width Height Dry weight (Without clutch) Engine type Displacement [Bore Stroke] Max. output Max. torque Engine oil capacity Fuel tank capacity Fuel consumption Cooling system Ignition system PTO shaft rotation 1.6 N·m (0.16 kgf·m, 1.2 lbf·ft) at 5,500 rpm 1.0 kW (1.4 PS, 1.3 bhp) at 7,000 rpm Moderate 50 hours [0 80 cm (0 80 cc) inclusive] 125 hours [greater than 80 cm (80 cc)] Intermediate 125 hours [0 80 cm (0 80 cc) inclusive] 250 hours [greater than 80 cm (80 cc)] Extended 300 hours [0 80 cm (0 80 cc) inclusive] 500 hours [greater than 80 cm (80 cc)] 1,000 hours [225 cm (225 cc) and greater] The Air Index Information hang tag/label must remain on the engine until it is sold. Remove the hang tag before operating the engine. 7 0.57(0.151 US gal , 0.125 Imp gal) 0.63 (0.166 US gal , 0.139 Imp gal) 06/11/06 12:26:52 32Z6J600_018
µ µ ¶ ¶ ¶ ENGLISH Tuneup Specifications Quick Reference InformationITEM SPECIFICATION MAINTENANCEWiring Diagrams Pump type: Standard/Tiller type: 19 Spark plug gap Idle speed Valve clearance (cold) Other specificationsNo other adjustments needed. 0.60 0.70 mm (0.024 0.028 in) 3,100 200 rpm IN: 0.08 0.02 mm EX: 0.11 0.02 mmRefer to page: 11 See your authorized Honda dealer U.S. Except U.S.Pump octane rating 86 or higher Research octane rating 91 or higher Pump octane rating 86 or higher Unleaded gasoline (Refer to page 8) Fuel Engine oil Spark plug MaintenanceCM5H (NGK) CMR5H (NGK) SAE 10W-30, API SJ or later, for general use. Refer to page 8. Before each use: Check engine oil level. Refer to page 9. Check air filter. Refer to page 10. First 10 hours: Change engine oil. Refer to page 9. Subsequent: Refer to the maintenance schedule on page 7. Bl BlackENGINE SWITCH SPARK PLUG IGNITION COIL Engine switch on the equipment powered by the engine. (1) (2) (3) (4) ON OFF 06/11/06 12:27:06 32Z6J600_019
¬ Canada: United States, Puerto Rico, and U.S. Virgin Islands: Distributor/Dealer Locator Information CONSUMER INFORMATION For European Area: Customer Service Information United States, Puerto Rico, and U.S. Virgin Islands: All Other Areas: Honda’s Office United States, Puerto Rico, and U.S. Virgin Islands: American Honda Motor Co., Inc.Canada: Honda Canada, Inc. For European Area: Honda Europe NV. All Other Areas: ENGLISH20 or visit our website: www.honda.ca Call (888) 9HONDA9 or visit our website: www.honda-engines.com Call (800) 426-7701 visit our website: http://www.honda-engines-eu.com Servicing dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management. The Service Manager, General Manager, or Owner can help. Almost all problems are solved in this way. If you are dissatisfied with the decision made by the dealership’s management, contact the Honda Regional Engine Distributor for your area. If you are still dissatisfied after speaking with the Regional Engine Distributor, you may contact the Honda Office as shown. If you are dissatisfied with the decision made by the dealership’s management, contact the Honda Office as shown. When you write or call, please provide this information: Equipment manufacturer’s name and model number that the engine is mounted on Name of dealer who sold the engine to you Name, address, and contact person of the dealer who services your engine Date of purchase Your name, address and telephone number A detailed description of the problem Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta, GA 30005-8847715 Milner Avenue Toronto, ON M1B 2K8 Telephone: (888) 9HONDA9 (888) 946-6329 (416) 299-3400 (416) 287-4776 (877) 939-0909 (416) 287-4776Toll free Local Toronto dialing area Local Toronto dialing area Toll free Local Toronto dialing area Facsimile:English: French: Or telephone: (770) 497-6400, 8:30 am - 8:00 pm ESTEuropean Engine Center http://www.honda-engines-eu.com Please contact the Honda distributor in your area for assistance. Engine model, serial number, and type (see page )16 05/12/16 15:04:22 32Z6J600_020