Honda G 100 Manual

							MAINTENANCE  SAFETY 
Some  of  the  most  important  safety  precautions  follow.  However,  \
we  cannot 
warn  you  of  every  conceivable  hazard  that  can  arise  in performing 
maintenance.  Only  you  can  decide  whether  or  not  you  should  per\
form  a 
given  task. 
Failure 
to properly  follow  maintenance  instructions  and 
precautions  can  cause  you 
to be  seriously  hurt or killed. 
Always  follow  the  procedures  and  precautions  in this 
owner’s  manual. 
SAFETY  PRECAUTIONS 
Make  sure  the  engine  is off before  you  begin  any  maintenance  or 
repairs.  This  will eliminate  several  potential  hazards: 
- Carbon  monoxide  poisoning from  engine  exhaust. 
Be  sure  there  is adequate  ventilation  whenever  you  operate 
the  engine. 
Let  the  engine  and  exhaust  system  cool  before  touching. 
Do not  run  the  engine  unless  instructed to do so. 
- Burns  from  hot parts. 
- Injury  from  moving  parts. 
Read  the  instructions  before  you  begin,  and  make  sure  you  have\
  the 
To reduce.the  possibility  of  fire or  explosion,  be  careful  when 
tools and  skills  required. 
working  around  gasoline.  Use  only  a nonflammable  solvent,  not 
gasoline, 
to clean  parts.  Keep  cigarettes,  sparks  and  flames  away 
from  all fuel  related  parts. 
Remember  that  an  authorized  Honda  servicing  dealer  knows  your  e\
ngine 
best  and  is  fully  equipped 
to maintain  and  repair  it. 
To ensure  the  best  quality  and  reliability,  use  only  new  genuine  \
Honda 
parts  or  their  equivalents  for  repair  and  replacement. 
11  
						

							MAINTENANCE  SCHEDULE 
REGULAR  SERVICE  PERIOD (3) 
 Perform at every  indicated  month  or 
operating  hour  interval  whichever  Before 
each 
 comes  first. , I use ITEM U Engine  oil  Checklevel I 0 
Chanoe 
Air  cleaner  Check 
10 
Clean 
Spark  plug  Check-readjust 
I 
Replace 
Sediment  cup  Clean 
SDark  arrester  Clean 
I 
Idle  speed  Check-adiust I 
Combustion 
chamber  Clean 
Valve 
Clearance  Adjust 
Fuel  tank 
8 filter  Clean 
Fuel  line  Check  Every month  months 
20hrs 50 hrs loo hrs h rs 
(Every 
1 year 
year 
or 
I I O(2) years  (Replace  if necessary)  (2) 
14 
15 
16 
- 
17 
19 
20 - 
- 
0: Emission  related  items 
(1) Service  more  frequently  when  used  in  dusty  areas. 
(2) These  items  should  be  serviced  by  your  servicing  dealer, 
unless  you  have  the proper tools and  are  mechanically 
proficient.  Refer to Honda  shop  manual  for service  procedures. 
(3) For  commercial  use, log hours  of  operation to determine  proper 
maintenance  intervals. 
12  
						

							REFUELING 
Use unleaded  gasoline  with  a  pump  octane  rating  of 86 or  higher.  This 
engine  is certified 
to operate  on  unleaded  gasoline.  Unleaded  gasoline 
produces  fewer  engine  and  spark  plug  deposits  and  extends  exhau\
st 
system  life. 
flammable  and  explosive,  and  you  can 
be  burned  or  seriously  injured  when  refueling. 
0 Stop  engine  and  keep  heat,  sparks,  and  flame  away. 
Handle  fuel 
only outdoors. 
0 Wipe  up spills  immediately. 
pii5K-j 
Fuel  can  damage  paint  and some  types  of plastic.  Be  careful  not  to spill 
fuel  when filling your  fuel  tank.  Damage  caused by spilled  fuel  is not 
covered under  the  Distributor’s  Limited  Warranty. FUE~ TANK CAP 
Never  use  stale  or  contaminated 
gasoline  or  oillgasoline  mixture. 
Avoid  getting  dirt or  water  in the  fuel 
tank. 
Adding fuel 
1. Remove  the  fuel  tank  cap. 
2. Add  fuel  to  the  shoulder  of  the 
fuel  strainer. 
Do not  overfill.  Wip 
fuel  before  starting 
Fuel tank capacity: 1. (1.47 us qt)  
						

							ENGINE OIL 
Recommended Oil 
Use  4-stroke  motor oil that  meets  or 
exceeds  the  requirements  for  API 
check  the  API  SERVICE  label  on  the 
oil  container  to  be  sure  it includes  the 
-30 -O -lo letters SJ. AMBIENT  TEMPERATURE 
SAE IOW-30 is  recommended  for  general  use.  Other  viscosities  shown  in 
the  chart  may  be  used  when  the  average  temperature  in your  area  is 
within  the  indicated  range. 
Oil  Level  Check 
1. Check  the  oil  level  with  the  engine  stopped  and  level. 
2. Remove  the  oil  filler cap/dipstick  and  wipe  it clean. 
3. Insert  the  oil  filler cap/dipstick  into  the  oil  filler neck  as  shown, 
but  do not  screw  it in,  then  remove  it to  check  the  oil  level. 
4. If  the  level  is  low, fill to  the  top  of  the  oil filler neck  with  the 
recommended  oil. 
5. Reinstall  the  oil  filler cap/dipstick. 
service  classification 
SJ. Always 
lo 2o 30 
OIL  FILLER  CAP1 
DlPSTlGK  UPPER 
LIMIT 
14  
						

							Oil Change 
Drain  the  engine  oil when  the  engine  is warm.  Warm  oil drains  quickly  and 
completely. 
1. 
2. 
3. 
4. 
Place  a suitable  container  next to the  oil  drain  bolt  area. 
Wipe  the  oil filler area  clean,  then  remove  the  oil  filler cap/ 
dipstick. 
Remove  the  oil  drain 
bolt and 
sealing  washer,  and  allow  the 
oil 
to drain  into  a suitable 
container.  After  draining, 
install  the  drain  bolt  with  the 
sealing  washer  and  tighten  it 
securely. 
With  the  engine  in a level 
position, 
fill with  the  recom- 
mended  oil. Do not overfill. 
Measure  the  oil level  as  shown 
on  page 
14. DRAIN BOLT 
Engine  oil capacity: 0.45 J? (0.48 US qt) 
Please  dispose  of  used  motor  oil  and  the  oil  containers  in a  manner  that  is 
compatible  with  the  environment.  We suggest  you  take  used  oil in  a  sealed 
container 
to your  local  service  station  for  reclamation. Do not  throw  it in  the 
trash,  pour  it  on  the  ground,  or  down  a  drain. 
I NOTICE I 
Running  the  engine  with  a  low oil level  can  cause  engine  damage. 
5. Reinstall  the  oil filler capldipstick  securely. 
15  
						

							AIR CLEANER 
A dirty  air  cleaner  will  restrict  air  flow to the  carburetor  and  cause  poor 
engine  performance.  Inspect  the  filter  element  each  time  the  en\
gine  is 
operated.  You  will  need  to clean  the  filter  element  more  frequently  than 
usual  if  you  operate  the  engine  in  very  dusty  areas. 
pEiq 
Operating the  engine  without  a  filter,  or with  damaged  filter,  will allow  dirt 
to enter  the  engine, causing  rapid engine  wear.  This  type of damage  is not 
covered  under  the  Distributor’s  Limited  Warranty. 
Inspection 
1. Remove  the  wing  nut, then  remove  the  air  cleaner  cover.  Be 
careful to prevent  dirt and  debris  from  falling  into  the  air  cleaner 
base. 
2. Remove  the  foam  filter element  from  the  air  cleaner  base. 
3. Inspect  the  filter element.  Replace  a damaged  filter. Clean  or 
replace  a dirty  filter. 
ELEMENT 
CLEANING 
1. Clean  the  air  filter with  warm 
soapy  water,  rinse,  and  allow to dry  thoroughly. 
Or  clean  in nonflammable 
solvent  and  allow 
to dry. 
2. Dip  the  filter in clean  engine  oil, WING  NUT then  squeeze  out  all excess  oil. 
The  engine  will smoke  when 
started  if 
too much  oil is left in 
the  foam. 
Be  careful 
to prevent  dirt from  entering  the  carburetor. 
AIR  CLEANER 
COVER 
3. Wipe  dirt from  the  air  cleaner  body  and  cover,  using  a moist  rag. 
16  
						

							SPARK PLUG 
Recommended Spark Plug: NGK BPMR4A 
The  recommended  spark  plug  is  the  correct  heat  range  for  norma\
l  engine operating  temperatures. 
[ NOTICE I 
Incorrect  spark  plug  can cause  engine  damage. 
For  good  performance,  the 
spark  plug  must  be  properly 
gapped  and  free  of  deposits. 
1. Disconnect  the  cap  from 
SPARK 
the  spark  plug,  and  remove  any  dirt from  the  spark  plug 
area. 
2. Use  the  proper  size  spark 
plug  wrench to remove  the 
spark  plug. 
3. Inspect  the  spark  plug.  Replace  it  if 
damaged,  badly  fouled,  if the  sealing SPARK  PLUG CAP washer  is in  poor  condition,  or if  the 
electrode  is  worn.  If  the  spark  plug  is 0.6 - 0.7 rnrn to be  reused,  clean  it with  a  wire (0.024 - 0.028 in) 
brush. 
4. Measure  the  electrode  gap  with  a 
suitable  gauge.  The  correct  gap is 0.6 - 0.7 mm (0.024 - 0.028 in).  If 
adjustment  is  needed,  correct  the 
gap  by carefully  bending  the  side 
electrode. 
17  
						

							Install the spark plug carefully,  by hand, to avoid cross-threading. 
After the  spark  plug  is  seated, tighten with the  proper size spark 
plug  wrench 
to compress  the  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 
118 - 114 turn  after 
the  spark  plug seats to compress  the washer. 
I NOTICE I 
A loose  spark  plug can  become  very  hot and  can  damage  the  engine. 
Overtightening  the spark  plug can  damage  the  threads  in the  cylinder 
head. 
9. Attach the  spark  plug  cap to the spark  plug.  
						

							SEDIMENT CUP CLEANING 
1. Move the fuel  valve to the OFF position,  then  remove  the  fuel 
sediment  cup  and  O-ring. 
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. 
Handle  fuel only outdoors. 
Wipe  up  spills  immediately. 
2. Wash  the  sediment  cup  and  O-ring  in  nonflammable solvent, 
3. Place the O-ring  in  the fuel  valve,  and  install  the sediment  cup. 
4. Move the fuel  valve to the ON position,  and  check  for leaks. 
and 
dry them  thoroughly. 
Tighten  the sediment  cup  securely. 
Replace  the O-ring  it  there  is  any  leakage. 
FUEL  VALVE 
O-RING 
SEDIMENT  CUP 
SPARK  ARRESTER  (optional equipment) 
In some  areas,  it is illegal to operate  an engine  without  a USDA  (United 
States  Department of Agriculture)-qualified  spark  arrester.  Check  local 
laws  and  regulations.  A USDA-qualified  spark  arrester  is available  from  an 
authorized  Honda  servicing  dealer. 
19  
						

							The  spark  arrester  must  be  serviced  every 100 hours to keep it functioning 
as  designed. 
If the  engine  has  been  running,  the  muffler  will  be  hot.  Allow  it to cool 
before  servicing  the  spark  arrester. 
Spark  Arrester  Removal 
1. Remove  the two 6 mm  nuts  and  the two screws  and  remove  the 
muffler  cover. 
2. Remove  the two tapping  screws  from  the  muffler  deflector,  and 
remove  the  muffler  deflector,  arrester  plate  and  spark  arrester.\
 
SPARK 
ARRESTER ARRESTER 
MUFFLER DEFLECTOR 
MUFFLER  COVER 0 
SCREWS 
6 rnrn NCTS 
Spark  Arrester  Cleaning 8 Inspection 
1. Use  a brush  to  remove  carbon  deposits 
from  the  spark  arrester  screen.  Be  careful 
not 
to damage  the  screen.  Replace  the 
spark  arrester if it has  breaks  or  holes. 
2. Install  the  spark  arrester  in  the  reverse 
order of removal. 
20