Honda G400 Service Manual

							FOR SAFE OPERATION 
WARNING: 
* To prevent  fire  hazards  and to provide  adequate  ventilation,  keep  the  engine at  least 3 ft away  from 
buildings  and other  equipment,  during operation. 
* 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 flammable  and explosive  under certain 
conditions. 
* Do not  smoke  or allow  flames  or  sparks  where the engine is  refueled or where  gasoline is  stored. 
* Do not overfill  the  tank.  There should  be no  fuel  in  the  filler neck.  Make sure that  the  filler  cap  is closed 
* If any  fuel  is spilled,  make sure the area is dry  before  starting. 
* Operate the engine on a level  surface  to prevent  fuel spillage. 
* This  engine is not  equipped  with a spark 
arrester,  and  operation  may  be illegal in some 
areas.  Check  local laws and regulations  before 
operation. 
securely. 
WARNING: 
* Exhaust 
contains  poisonous  carbon  monoxide 
Avoid  inhalation 
of exhaust  gases.  Never 
engine  in a closed garage  or  confined area. gas. 
run  
						

							Check cleaner for dirt j Check  cleaner tor rut or obstruction of elc- i or obstruction of ele. Check oil level and  con- 
dition. 
~ ments. i ment. , 
f --I 
Check  battery condition 
+Be sure the nuid level of each dl is 
+Add  distilled  water if necessary. 
+Check  battery 
@ 2nd Q terminals for 
between  upper  and  lower levcl marks. 
proper connection. 
 Check reduction gear oil level Fill with SE rated SAE 1OW-40 engine oil,  if nccossary. 
< l/2 > 
Fuel tiller an 
Fuel  valve 
Air cleaner 
Throttle lever 
Engine switch  Spark  plug 
. ., .... ..  Fill sump %th SE rated SAE 1OW-40 engine oil.  
						

							\ 
  
						

							First 20 Hrs. operating  Every 50 Hrs. operating 
CHANGE  ENGINE  OIL  AND  REDUCTION  GEAR  OIL CLEAN  AIR  CLEANER  ELEMENT  ing  in  a  dusty  area. Clean more  frequently  if operat- 
ing  solvent.  After  drying,  soak  in  oil  and  squeeze  out  the  excess. 
After  hand  tightening  oil  filler  cap, tighten 
with 
a lever 
* Wash “B” and “C” in  cleaning 
solvent.  After  drying,  refill  with  clean  engine 
oil up to oil  level 
mark. * Tap “D” and  “E”  lightly  or  blow 
clean  by  applying  compressed  air 
from  the  inside  of  the  elements. 
~- , Every 100 Hrs. operating I WARNING 
CHANGE  ENGINE  OIL  CLEAN  FUEL  STRAINER  CLEAN  SPARKPLUG  ANDCHECK 
GAP , Do  not use gasoline  or low flash , point solvents  for cleaning.  They  are 
ilammable  and  explosive  under  cer- 0.6 - 0.7 mrn (.024 - ,027 in)  tain  conditions. 
Use  NGK B4H or  BR4HS  wash removed  parts 
m  solvent,  dry  them 
thoroughly  and  in- 
stall  securely.  Turn 
the  fuel  valve “ON” 
and  check  for leaks. 
CDI rype 
’ ’ Every 300 Hrs. operating 
0.9 - 1.0  mm LO35 - ,039  in) 
Use  NGK  BPJHS-IO  or 
BPR-4HS-iO 
, * Check  fuel  tube  for  cracks  or ’ leaks.  Replace,  if  necessary. 
1 encine  dealer. The  following  adjustments  should  be  performed  by  your  Honda  gen\
eral  purpose 
ADJUST  IGNITION  TIMING  ADJUST  VALVE  CLEARANCE 
ADJUST  CARBURETOR  SCREWS 
* Carburetor  with  pilot  screw Adjust  contact  breaker  points so that  they * Measure at TDC  on comprcsslon  stroke * Start  the  englne  and  adjust  idle speed  by ’) Tighten the “IeW it just  start to open,  when “F” mark  on  whenengine  is cold.  turning  the  throttle stop screw. 
flywheel  aligns with the mark  on  crankcase. * STANDARD:  tightly,  then  back 
it off  the  number of turns 
shown  below: 
* IGNITION  TIMING:  2O”BTDC.  IN 0.05 - 0.1 1 mrn (.0020 - ,0043 in) 
EX  0.09 - 0.15 mm (.0035 - .0059 in) G300 l/E turns G400 2 turns * If  the  clearance  is  less than  the  standard 2) Adjust  idle  speed as outlined  left. ~ limit,  grind  valve stem  or  replace  valve. -. CYLINDER  HEAD 
GASKET PILOT SCREW 
N  VALVE 
i !, CONTACT 
BREAKER  ASSY 
The  CDI  type  does  not  require  adjustment. 
I 
i 
’ A throttle  control  cable (optional)  may  be  used in any one of the four pull directions  shown. Use :I either  a solid core wire,  or  a  flexible  core  wire with 4 a return spring  and  wire end. 
j THROTTLE  CONTROL 
Wire end 
e 
Flexible  wire 
core,  mounting 
BATTERY 
t Recommended  battery is 
*Use  only  automobile  12V-32AH. 
type  vinyl  covered  wire 
,fL,,/ effective  diameter  is (for low voltagej  whose 
& (0.172 in)  and  which 
utilizes  press  fit terminals 
between  the  battery  and 
the  engine.  Length  must 
,/ 7 +Protect  the  terminals 
be 
within  lm (3 Ft). 
with  grease  and  com- 
pletely  cover  the positive 
cap.  When  connecting  terminal  with 
a rubber 
and  negative  leads  are 
terminals,  ensure 
posltive 
correctly  connected. 
a j- more  than 4.4 mrn  
						

							*With  electric  starter 
c / 
G300 I G400 
Cycle,  valve arrangement 
4 cycle,  side valve 
Displacement  cc (cu 
in) 1 272 (16.6) 1 406 (24.8) 
Max.  output  hp/rpm 
I 7/3,600 
Max. torque  kg-m (ft-lb) I 1.5 (10.8) 2.3 116.6) 
10/3,600 
I ., 
Fuel consumption  g/hp-h  (lb/hp-h) 1 285  (0.62) 1 270 (0.59) 
Starting  system 
25 (55.1) 
1 33 (72.7) 
Dry 
weight  kg (Ib) 
Counterclockwise 
PTO 
shaft  rotation  D.C. 
starter  motor 
ALL  INFORMATION,  ILLUSTRATIONS,  DIREC- 
TIONS  AND SPECIFICATIONS  INCLUDED  IN THIS 
PUBLICATION  ARE BASED  ON THE  LATEST 
PRODUCT  INFORMATION  AVAILABLE  AT THE 
TIME 
OF APPROVAL  FOR  PRINTING.  HONDA 
MOTOR  CO.,  LTD.  RESERVES  THE  RIGHT  TO 
MAKE  CHANGES  AT ANY  TIME  WITHOUT  NOTICE 
AND  WITHOUT  INCURRING ANY OBLIGATION 
WHATEVER. 
NO  PART 
OF THIS  PUBLICA4TION  MAY BE RE- 
PRODUCED  WITHOUT WRITTEN PERMISSION. 
HONDA HONDA MOTOR CO., LTD. TOKYO. JAPAN  
						

							Current customer service contact information: 
 
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 
dealerships management. The Service Manager, General Manager, or Owner can help. Almost all problems 
are solved in this way.  
United States, Puerto Rico, and U.S. Virgin Islands: 
If you are dissatisfied with the decision made by the dealerships management, contact the Honda Regional 
Engine Distributor for your area (www.honda-engines.com/dea.htm
). 
If you are still dissatisfied after speaking with the Regional Engine Distributor, you may contact the Honda 
Office as shown. 
American Honda Motor Co., Inc. 
Power Equipment Division 
Customer Relations Office 
4900 Marconi Drive 
Alpharetta, GA 30005-8847 
Or telephone: (770) 497-6400 M-F, 8:30 am - 7:00 pm EST 
When you write or call, please provide the following information: 
•  Equipment manufacturers name and model number that the engine is mounted on 
•  Engine model, serial number, and type 
•  Name of the 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