Shop Manual News

ENGINE Power Equipment

News No. Issue Date
P/P-410 Apr. 2015

SOME PARTS OF CHANGES

Applicable Information Publication No. Applicable Page
GX270H/390H1 62Z7B00 1-5, 1-6

CHANGE LOCATIONS
The changed instructions are shown in .

ENGINE SPECIFICATIONS
GX270H:Page 1-5
Fuel consumption
2.5 Liters (0.66 US gal, 0.55 Imp gal)/h
(at continuous rated power)

GX390H1:Page 1-6
Fuel consumption
3.7 Liters (0.98 US gal, 0.81 Imp gal)/h
(at continuous rated power)

Honda Motor Co., Ltd.

Service Publication Office 1 2015.04
62Z7B000.book 1 ページ ２０１２年９月２７日 木曜日 午前１０時２１分

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How to use this manual

A Few Words About Safety
How to use this manual

SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.

Improper service or repairs can create an unsafe

condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.

Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted up in the air. Anytime you lift this product with a hoist, make
sure that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the
way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.

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CONTENTS
SPECIFICATIONS 1
SERVICE INFORMATION 2
MAINTENANCE 3
TROUBLESHOOTING 4
COVER 5
FUEL SYSTEM 6
GOVERNOR SYSTEM 7
CHARGING SYSTEM 8
IGNITION SYSTEM 9
STARTING SYSTEM 10
OTHER ELECTRICAL 11
MUFFLER 12
CYLINDER HEAD/VALVES 13
CRANKCASE 14
WIRING DIAGRAMS 15
INDEX
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How to use this manual

INTRODUCTION
This manual covers the service and repair procedures for the Honda GX270H/390H1.
All information contained in this manual is based on the latest product information available at the time of printing. We reserve the
right to make changes at anytime without notice.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic,
mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and
tables.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to this Honda product, other property, or the environment.

SAFETY MESSAGES
Your safety and the safety of others are very important. To help you make informed decisions, we have provided safety messages
and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards
associated with servicing these products. You must use your own good judgement.
You will find important safety information in a variety of forms, including:
• Safety Labels – on the product.
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service these products correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS, 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 WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda PRODUCTS.

© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: September 2012

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How to use this manual

SERVICE RULES
• Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design
specifications may damage the unit.
• Use the special tools designed for the product.
• Install new gaskets, O-rings, etc. when reassembling.
• When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless
a particular sequence is specified.
• Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
• After reassembly, check all parts for proper installation and operation.
• Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the
threads and ruin the hole.
Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. The
use of incorrect tools and fasteners will damage the unit.

SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it will be explained specifically in the text without the use of the symbols.

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use marine grease (water resistant urea based grease).

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

Use automatic transmission fluid.

( x )( ) Indicates the diameter, length, and quantity of metric bolts used.

page 1-1 Indicates the reference page.

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How to use this manual

ABBREVIATIONS
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbreviated. term Full term
ACG Alternator
API American Petroleum Institute
Approx. Approximately
Assy. Assembly
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
ATT Attachment
BAT Battery
BDC Bottom Dead Center
BTDC Before Top Dead Center
BARO Barometric Pressure
CKP Crankshaft Position
Comp. Complete
CMP Camshaft Position
CYL Cylinder
DLC Data Link Connector
EBT Engine Block Temperature
ECT Engine Coolant Temperature
ECM Engine Control Module
EMT Exhaust Manifold Temperature
EOP Engine Oil Pressure
EX Exhaust
F Front or Forward
GND Ground
HO2S Heated Oxygen sensor
IAB Intake Air Bypass
IAC Idle Air Control
IAT Intake Air Temperature
I.D. Inside diameter
IG or IGN Ignition
IN Intake
INJ Injection
L. Left
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
O.D. Outside Diameter
OP Optional Part
PGM-FI Programmed-Fuel Injection
P/N Part Number
Qty Quantity
R. Right
SAE Society of Automotive Engineers
SCS Service Check Signal
STD Standard
SW Switch
TDC Top Dead Center
TP Throttle Position
VTEC Variable Valve Timing & Valve Lift Electronic Control

BI Black G Green Br Brown Lg Light green

Y Yellow R Red O Orange P Pink
Bu Blue W White Lb Light blue Gr Gray

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1. SPECIFICATIONS

SERIAL NUMBER LOCATION ·····················1-2 ENGINE SPECIFICATIONS ·························· 1-5

TYPE CODE ··················································1-3 PERFORMANCE CURVES··························· 1-7

DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS························· 1-9

SPECIFICATIONS ·········································1-4
P.T.O. DIMENSIONAL DRAWINGS ··········· 1-13

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SPECIFICATIONS
SERIAL NUMBER LOCATION
SPECIFICATIONS

The engine serial number [1], type [2] and model [3] is stamped on the crankcase.
Refer to it when ordering parts or making technical inquiries.

[3]

[2]

[1]

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SPECIFICATIONS
TYPE CODE
Model GX270H
Type LH LH1 LH2 LHB5 LW PX QBE1
P. T. O. L type P type Q type

Model GX270H
Type QD QD1 QH QHB1 QHB5 QHP1 QMH
P. T. O. Q type

Model GX270H
Type QN QP QX QXC9 QXCK QXE9 QXK
P. T. O. Q type

Model GX270H
Type RD SD SD1 SH SH1 SX VMT
P. T. O. R type S type E type

Model GX270H
Type VKK VS4 VSD4 VSP VX VX1 VXK
P. T. O. V type

Model GX390H1
Type ES2 LH LH1 LH2 LHB5 LHP1 LXE9
P. T. O. E type L type

Model GX390H1
Type PX QA2 QBE1 QH QH1 QHB1 QHB3
P. T. O. P type Q type

Model GX390H1
Type QHB5 QHP1 QMH QN QP QX QXE
P. T. O. Q type

Model GX390H1
Type QXEK QXK SH SH1 SHE SM11 SWE2
P. T. O. Q type S type

Model GX390H1
Type SWX2 SX SX1 SXC SXC1 SXE1 SXE
P. T. O. S type

Model GX390H1
Type VMT3 VMQ3 VPX4 VS4 VS6 VSB4 VSP
P. T. O. E type V type

Model GX390H1
Type VTE5 VX VX1 VXE VXK VXU1
P. T. O. V type

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SPECIFICATIONS
DIMENSIONS AND WEIGHTS
SPECIFICATIONS
Model GX270H GX390H1
Overall length E type* – 365 mm (14.4 in)
L type* 405 mm (15.9 in) 440 mm (17.3 in)
P type* 380 mm (15.0 in) 405 mm (15.9 in)
Q type* 380 mm (15.0 in) 405 mm (15.9 in)
R type* 440 mm (17.3 in) –
S type* 355 mm (14.0 in) 380 mm (15.0 in)
V type* 400 mm (15.7 in) 425 mm (16.7 in)
Overall width E type* – 460 mm (18.1 in)
L type* 430 mm (16.9 in) 450 mm (17.7 in)
P type* 430 mm (16.9 in) 450 mm (17.7 in)
Q type* 430 mm (16.9 in) 450 mm (17.7 in)
R type* 430 mm (16.9 in) –
S type* 430 mm (16.9 in) 450 mm (17.7 in)
V type* 430 mm (16.9 in) 450 mm (17.7 in)
Overall height E type* – 448 mm (17.6 in)
L type* 410 mm (16.1 in) 443 mm (17.4 in)
P type* 410 mm (16.1 in) 443 mm (17.4 in)
Q type* 410 mm (16.1 in) 443 mm (17.4 in)
R type* 410 mm (16.1 in) –
S type* 410 mm (16.1 in) 443 mm (17.4 in)
VPX4 only: 447 mm (17.6 in),
V type* 410 mm (16.1 in)
Othe type: 443 mm (17.4 in)
Dry weight E type* – 31.7 kg (69.9 lbs)
L type* 26.5 kg (58.4 lbs) 35.0 kg (77.2 lbs)
P type* 25.0 kg (55.1 lbs) 31.5 kg (69.4 lbs)
Q type* 25.0 kg (55.1 lbs) 31.5 kg (69.4 lbs)
R type* 30.0 kg (66.1 lbs) –
S type* 25.0 kg (55.1 lbs) 31.5 kg (69.4 lbs)
V type* 25.0 kg (55.1 lbs) 31.5 kg (69.4 lbs)
Operating weight E type* – 37.8 kg (83.3 lbs)
L type* 31.5 kg (69.4 lbs) 41.0 kg (90.4 lbs)
P type* 29.7 kg (65.5 lbs) 37.6 kg (82.9 lbs)
Q type* 29.7 kg (65.5 lbs) 37.6 kg (82.9 lbs)
R type* 35.0 kg (77.2 lbs) –
S type* 29.7 kg (65.5 lbs) 37.6 kg (82.9 lbs)
V type* 29.7 kg (65.5 lbs) 37.6 kg (82.9 lbs)
*: P. T. O. type. (page 1-3)

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SPECIFICATIONS
ENGINE SPECIFICATIONS
GX270H
Model GX270H
Description code GCADH
Type 4 stroke, overhead valve, single cylinder, inclined by 25°
Displacement 270 cm3 (16.5 cu-in)
Bore x stroke 77.0 x 58.0 mm (3.0 x 2.3 in)
Net power (SAE J1349)* 6.0 kW (8.0 HP)/3,600 min-1 (rpm)
Continuous rated power 5.1 kW (6.8 HP)/3,600 min-1 (rpm)
Maximum net torque (SAE J1349)* 17.7 N·m (1.80 kgf·m, 13.1 lbf·ft)/2,500 min-1 (rpm)
Compression ratio 8.2 : 1
Fuel consumption (at continuous rated
5.3 Liters (1.40 US gal, 1.17 Imp gal)/h
power)
Ignition system Transistorized magneto ignition
Ignition timing B.T.D.C. 20°/1,200 – 4,000 min-1 (rpm)
Spark plug VKK, VMT, VS4,
BPR5ES (NGK)/W16EPR-U (DENSO)
VSD4
Other type BPR6ES (NGK)/W20EPR-U (DENSO)
Lubrication system Forced splash
Oil capacity 1.1 Liters (1.16 US qt, 0.97 Imp qt)
Recommended oil SAE 10W-30 API service classification SE or higher
Cooling system Forced air
Starting system Recoil, Recoil and Starter motor
Stopping system Ignition exciter coil circuit open
Carburetor Horizontal type, butterfly valve
Air cleaner Dual type, Dual silent type, Cyclone type, Oil bath type, Semi dry type,
Low profile type
Governor Mechanical centrifugal
Breather system Flat valve type
Fuel used Unleaded gasoline with a pump octane rating 86 or higher
Reduction case 1/2 reduction
Shared with engine oil
oil capacity chain type
1/2 reduction
0.3 Liter (0.32 US qt, 0.26 Imp qt)
clutch type
Reduction case 1/2 reduction
SAE 10W-30 API service classification SE or higher
recommended oil chain type
1/2 reduction Type Centrifugal
clutch type Engagement
1,800 min-1 (rpm)
start
Lock 2,200 min-1 (rpm)

*: The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine
model and measured in accordance with SAE J1349 at 3,600 rpm (net power) and at 2,500 rpm (max net torque). Mass production
engines may vary from this value. Actual power output for the engine installed in the final machine will vary depending on numerous
factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables.

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SPECIFICATIONS
GX390H1
Model GX390H1
Description code GCAFH
Type 4 stroke, overhead valve, single cylinder, inclined by 25°
Displacement 389 cm3 (23.7 cu-in)
Bore x stroke 88.0 x 64.0 mm (3.5 x 2.5 in)
Net power (SAE J1349)* 8.2 kW (11.0 HP)/3,600 min-1 (rpm)
Continuous rated power 6.6 kW (8.9 HP)/3,600 min-1 (rpm)
Maximum net torque (SAE J1349)* 25.1 N·m (2.56 kgf·m, 18.5 lbf·ft)/2,500 min-1 (rpm)
Compression ratio 8.0 : 1
Fuel consumption (at continuous rated power) 6.1 Liters (1.61 US gal, 1.34 Imp gal)/h
Ignition system Transistorrized magneto ignition
Ignition timing B.T.D.C. 25°/1,200 – 4,000 min-1 (rpm)
Spark plug ES2, VMT3, VMQ3, VS4,
BPR5ES (NGK)/W16EPR-U (DENSO)
VS6, VSB4
Other type BPR6ES (NGK)/W20EPR-U (DENSO)
Lubrication system Forced splash
Oil capacity 1.1 Liters (1.16 US qt, 0.97 Imp qt)
Recommended oil SAE 10W-30 API service classification SE or higher
Cooling system Forced air
Starting system Recoil, Recoil and Starter motor
Stopping system Ignition exciter coil circuit open
Carburetor Horizontal type, butterfly valve
Air cleaner Dual silent type, Oil bath type, Low profile type
Governor Mechanical centrifugal
Breather system Flat valve type
Fuel used Unleaded gasoline with a pump octane rating 86 or higher
Reduction case oil capacity
Shared with engine oil
(1/6 reduction gear type)
*: The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine
model and measured in accordance with SAE J1349 at 3,600 rpm (net power) and at 2,500 rpm (max net torque). Mass production
engines may vary from this value. Actual power output for the engine installed in the final machine will vary depending on numerous
factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables.

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SPECIFICATIONS
PERFORMANCE CURVES
GX270H

(kgf·m)
(lbf·ft)
(N·m) 2.0
14
18
1.8
NET TORQUE
12
TORQUE

16 1.6

14 1.4
10

12 1.2
8
(KW)
8 (HP) (PS)

10 10

6 8 8
NET POWER

6 6
OUTPUT

4 4

2 2

RECOMMENDED OPERATING SPEED RANGE

0 0 0

2000 3000 3600 4000

ENGINE SPEED (rpm)

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SPECIFICATIONS
GX390H1

(N·m)
(lbf·ft) (kgf·m)
26
19 2.6

NET TORQUE 18 2.5

24
2.4
TORQUE

17
2.3
22 16
2.2
15

20

(KW) (HP)
9 (PS)
12
12

11
11
8

NET POWER
10
10

7
OUTPUT

9
9

6 8
8

7 7
5

6 6
RECOMMENDED OPERATING SPEED RANGE

2000 3000 3600

ENGINE SPEED (rpm)

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SPECIFICATIONS
DIMENSIONAL DRAWINGS
*: P. T. O. type. (page 1-3)
GX270H (WITHOUT REDUCTION)
Unit: mm (in)
134 (5.3)

Dual, Dual silent: 273 (10.8)

Oil bath, Semi dry: 272 (10.7)
Cyclone: 375 (14.8)
99 (3.9)

150 (5.9)

With muffler cap: 448 (17.6)

Without muffler cap: 430 (16.9) CRANKSHAFT (P. T. O.) Dual, Dual silent: 183 (7.2)
CONTROL BOX Oil bath, Semi dry: 180 (7.1)
With control box type: 457 (18.0) Cyclone: 193 (7.6)
(If equipped)
STD: 116 (4.6)
100DB: 152 (6.0)

Dual, Dual silent, Oil bath, Semi dry: 407 (16.0)

410 (16.1)

Cyclone: 429 (16.9)

133.5 (5.26)

92 (3.6)
STARTER MOTOR
* P,Q: 380 (15.0)
(If equipped) 195.5 (7.70)
* S: 355 (14.0)
* V: 400 (15.7)
105 (4.1)
96 (3.8)
34.5 (1.36)
13 (0.5)

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SPECIFICATIONS
GX270H (WITH REDUCTION)
Unit: mm (in)

Dual: 204.9 (8.07)

Oil bath, Semi dry: 203.9 (8.03)

150 (5.9)
68.1 (2.7)

With muffler cap: 448 (17.6)

Without muffler cap: 430 (16.9) P. T. O. SHAFT

Dual: 183 (7.2)

116 (4.6) Oil bath, Semi dry: 180 (7.1)

407 (16.0)
410 (16.1)

133.5 (5.26)

140 (5.52)
REDUCTION UNIT
405 (15.9)
195.5 (7.70)

105 (4.1)
96 (3.8)
34.5 (1.36)
13 (0.5)

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SPECIFICATIONS
GX390H1 (WITHOUT REDUCTION)
Unit: mm (in)
122 (4.8)
98 (3.9)

Dual Silent: 297 (11.7)

156 (6.1) Oil bath: 295 (11.6)

With muffler cap: 475 (18.7)

Without muffler cap: 450 (17.7)
CONTROL BOX
With control box type: 491 (19.3)
(If equipped) CRANKSHAFT
(P. T. O.)
Dual: 194 (7.6)
141.5 (5.57) Oil bath: 192 (7.6)
Other type: 443 (17.4)

Dual silent: 443 (17.4)

Oil bath: 436 (17.2)
VPX4: 447 (17.6)

133.5 (5.26)

100 (3.9)
STARTER MOTOR
(If equipped) * P/Q: 405 (15.9)
195.5 (7.70) * S: 380 (15.0)
* V: 425 (16.7)
105 (4.1)
103 (4.1)
27 (1.1)
17 (0.7)

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SPECIFICATIONS
GX390H1 (WITH REDUCTION)
Unit: mm (in)
122 (4.8)
98 (3.9)

With muffler cap: 475 (18.7)

140 (5.5) 212.9 (8.38) Without muffler cap: 450 (17.7)

84.1 (3.31)
CONTROL BOX
With control box type: 491 (19.3)
(If equipped)
P. T. O. SHAFT

141.5 (5.57) 194 (7.6)

443 (17.4)
447 (17.6)

133.5 (5.26)

155 (6.1)
STARTER MOTOR REDUCTION UNIT
(If equipped) 440 (17.3)
195.5 (7.70)

105 (4.1)
103 (4.1)
27 (1.1)
17 (0.7)

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SPECIFICATIONS
P.T.O. DIMENSIONAL DRAWINGS
*: P. T. O. type. (page 1-3)
GX270H
E TYPE*
Unit: mm (in)

.1)
7 (8
Φ1

.20
84

P.D
(Φ

Φ 15°
(Φ 190.

(Φ1.0236 – 1.0237)
7.2

Φ26.000 – 26.003
7. 05
4)

48 M6 x 1.0
2 – – 19
7.4 0.2
90 5
) 18
(0.71) 53.5 (2.13)
TAPER
1/5 35 (1.4)

(Φ1.3759 – 1.3772)
Φ34.947 – 34.980
15°

15°
28 (1.1)

M10 x 1.25

M6 x 1.0
CRANKSHAFT (P. T. O.)
15°

L TYPE* (1/2 REDUCTION CHAIN TYPE)

45° 45° Unit: mm (in)

M8 x 1.25 (2)
M8 x 1.25 (4) M8 x 1.25
66.7 (2.63)
7.00 – 7.05
(Φ0.9821 – 0.9835)

(0.276 – 0.278) 42 (1.7)

Φ24.947 – 24.980
70 (2.8)

28 (1.1)
(0.82 – 0.83)
20.9 – 21.0

60.0 (2.36)

P. T. O. SHAFT
)
5.0
7(

10 (0.4) 68.1 (2.68)

12
D.

REDUCTION UNIT
P.

103 (4.1)

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SPECIFICATIONS
P TYPE*

0) Unit: mm (in)
45° 30° 30° 45° .5
(6
1
5.
. 16
D
P. 89 (3.5)
14NF2 Thread R. H.
5/16-24UNF-2B TAP (2)

(Φ4.3307 - 4.3327)
Φ110.00 - 110.05
70 (2.8)

26-27
(1.0-1.1)

(Φ0.9990 - 1.0000)
5/16-24UNF-2B TAP (4)

Φ25.375 - 25.400
72.5 (2.85)

3/8-16UNC-2B TAP (4)

(5.0)

103 (4.1)
CRANKSHAFT (P. T. O.)
127
P.D.

Q TYPE*
Unit: mm (in)
45° 45° 0)
30° 30° .5
(6
. 1
1 65
D.
P. 7/16-20UNF-2B TAP 88.5 (3.48)
5/16-24UNF-2B TAP (4)
56 (2.2)

6.30 – 6.35
(0.248 – 0.250)
Φ110.00 – 110.05
(Φ4.331 – 4.333)
70 (2.8)

(0.854 – 0.859)
21.69 – 21.82

28 (1.1)
(Φ0.9990 – 1.0000)
Φ25.375 – 25.400

72.2 (2.84)
5/16-24UNF-2B TAP (4)

3/8-16UNC-2B TAP (4)

103 (4.1)
(5.0)
127

CRANKSHAFT (P. T. O.)

P.D.

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SPECIFICATIONS
R TYPE* (1/2 REDUCTION CLUTCH TYPE)
Unit: mm (in)

M8 x 1.25 (4)

(0.70 – 0.71)
35 (1.4) 35 (1.4)

17.9 – 18.0
M8 x 1.25
35 (1.3)
7.000 – 7.036
25 (1.0)
(0.2756 – 0.2770)
35 (1.4) 35 (1.4)

50 (2.0)

(Φ0.8641 – 0.8654)
Φ21.947 – 21.980
53 (2.1)

P. T. O. SHAFT
90.8 (3.57)

REDUCTION UNIT

S TYPE*
Unit: mm (in)
0 )
45° 30° 30° 45° .5
(6
5.1
. 16 M8 x 1.25 (2)
D
P.
63 (2.5)
M8 x 1.25
42 (1.7)

7.00 – 7.03
Φ110.00 – 110.05

(0.276 – 0.277)
(Φ4.331 – 4.333)
70 (2.8)

28 (1.1)
(0.82 – 0.83)
20.9 – 21.0

(Φ0.9822 – 0.9835)
Φ24.947 – 24.980

60 (2.4)

M8 x 1.25 (4)

103 (4.1)
(5.0)

Φ8.5 (Φ0.34) (4)

127
P.D.

CRANKSHAFT (P. T. O.)

1-15
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SPECIFICATIONS
V TYPE*
Unit: mm (in)
2-1/4 TAPER
45° 30° 30° 45°
5/16-24UNF-2B TAP

106 (4.2)
50)
.1 (6. 18 (0.7)
5
.16 5/16-24UNF-2B TAP (2)
P.D

Φ110.00 – 110.05
(Φ4.331 – 4.333)
70 (2.8) 46.5 (1.83)

25 (1.0)

5/16-24UNF-2B TAP (4)

(Φ0.8715 – 0.8724)
Φ22.136 – 22.161
76.5 (3.01)

3/8-16UNC-2B TAP (4)

103 (4.1)
(5.0)

CRANKSHAFT (P. T. O.)

127
P.D.

GX390H1
E TYPE*
Unit: mm (in)
)
(8.1
Φ1

7
84

.20

Φ1 15° M6 x 1.0
( Φ7

P.D

(Φ 90.
7. 05
.24

48
2 – – 19
(Φ1.0236 – 1.0237)
)

Φ26.000 – 26.003

7 .4 0 .2
90 5 18.3
)
(0.72) 53.7 (2.11)
TAPER
1/5 35 (1.4)
(Φ1.3759 – 1.3772)
Φ34.947 – 34.980

15°

15°

28 (1.1)

M10 x 1.25

M6 x 1.0
CRANKSHAFT (P. T. O.)
15°

1-16
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SPECIFICATIONS
L TYPE* (1/6 REDUCTION GEAR TYPE)
Unit: mm (in)
45° 45°

64.8 (2.55)

M8 x 1.25 (2)
M8 x 1.25 (4) M8 x 1.25
7.00 – 7.03

(Φ0.9821 – 0.9835)
(0.276 – 0.277)

Φ24.947 – 24.980
41 (1.6)

70 (2.8)
28 (1.1)

(0.82 – 0.83)
20.9 – 21.0
60.0 (2.36)

P. T. O. SHAFT
)
5.0
7(

16 (0.6) 68.1 (2.68)

12

REDUCTION UNIT
D.
P.

103 (4.1)

P TYPE*
) Unit: mm (in)
45° 45° 50
30° 30° 6.
. 1(
1 65
D.
P. 89 (3.5)
14NF2 Thread R. H.
5/16-24UNF-2B TAP (2)
(Φ4.3307 – 4.3327)
Φ110.00 – 110.05
70 (2.8)

26 – 27
(1.0 – 1.1)
(Φ0.9990 – 1.0000)

5/16-24UNF-2B TAP (4)

Φ25.375 – 25.400

72.5 (2.85)

3/8-16UNC-2B TAP (4)

103 (4.1)
(5.0)

CRANKSHAFT (P. T. O.)

127
P.D.

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SPECIFICATIONS
Q TYPE*
Unit: mm (in)
)
45° 30° 30° 45° . 50
(6
.1
1 65
D.
P. 88.5 (3.48)
3/8-24UNF-2B TAP
5/16-24UNF-2B TAP (2)
56 (2.2)

6.30 – 6.35
(0.248 – 0.250)

Φ110.00 – 110.05
(Φ4.331 – 4.333)
70 (2.8)

(0.8539 – 0.8591)
28 (1.1)

21.69 – 21.82

(Φ0.9990 – 1.0000)
5/16-24UNF-2B

Φ25.375 – 25.400
TAP (4) 72.2 (2.84)

3/8-16UNC-2B TAP (4)

103 (4.1)
(5.0)

CRANKSHAFT (P. T. O.)

127
P. D .

S TYPE*
Unit: mm (in)
)
45° 30° 30° 45° . 50
(6
.1
65
D .1
P. M8 x 1.25 (2)
63 (2.5)
M8 x 1.25
41 (1.6)

7.00 – 7.03
Φ110.00 – 110.05

(0.276 – 0.277)
(Φ4.331 – 4.333)
70 (2.8)

28 (1.1)
(0.82 – 0.83)
20.9 – 21.0

(Φ0.9822 – 0.9835)
Φ24.947 – 24.980

60 (2.4)

M8 x 1.25 (4)

103 (4.1)
(5.0)

Φ8.5 (Φ0.34) (4)

127
P.D.

CRANKSHAFT (P. T. O.)

1-18
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SPECIFICATIONS
V TYPE*
Unit: mm (in)
45° 45° 0)
30° 30° .5
(6
1 5/16-24UNF-2B TAP
5.
. 16
D
P. 105.5 (4.15)
5/16-24UNF-2B TAP (2)

18 (0.7)

Φ110.00 – 110.05
(Φ4.331 – 4.333)
70 (2.8)

(Φ0.8715 – 0.8724)
5/16-24UNF-2B TAP (4)

Φ22.136 – 22.161
75.5 (2.97)

46.5 (1.83)

3/8-16UNC-2B TAP (4)

103 (4.1)
.0)

CRANKSHAFT (P. T. O.) 2-1/4 TAPER

(5
127
P.D.

1-19
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MEMO
62Z7B000.book 1 ページ ２０１２年９月２７日 木曜日 午前１０時２１分

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2. SERVICE INFORMATION

MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-7

TORQUE VALUES ········································2-5 HARNESS AND TUBE ROUTING ·············· 2-10

LUBRICATION & SEAL POINT ····················2-6

2-1
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SERVICE INFORMATION
MAINTENANCE STANDARDS
SERVICE INFORMATION

GX270H
Unit: mm (in)
Part Item Standard Service limit
Engine Maximum speed (at no load) 3,850 ± 150 min-1 (rpm) –
Idle speed 1,400 ± 150 min-1 (rpm) –
1.37 MPa (14.0 kgf/cm2, 199 psi)/
Cylinder compression –
1,400 min-1 (rpm)
Cylinder head Warpage – 0.10 (0.004)
Cylinder Sleeve I.D. 77.000 – 77.017 (3.0315 – 3.0322) 77.17 (3.0381)
Piston Skirt O.D. 76.975 – 76.985 (3.0305 – 3.0309) 76.85 (3.026)
Piston-to-cylinder clearance 0.015 – 0.042 (0.0006 – 0.0017) 0.12 (0.005)
Piston pin bore I.D. 18.002 – 18.008 (0.7087 – 0.7090) 18.042 (0.7103)
Piston pin Pin O.D. 17.994 – 18.000 (0.7084 – 0.7087) 17.950 (0.7067)
Piston pin-to-piston pin bore clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.08 (0.003)
Piston rings Ring side clearance Top 0.015 – 0.050 (0.0006 – 0.0020) 0.15 (0.006)
Second 0.030 – 0.065 (0.0012 – 0.0026) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.550 (0.0138 – 0.0217) 1.0 (0.04)
Oil (side rail) 0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)
Ring width Top 1.170 – 1.190 (0.0460 – 0.0469) 1.140 (0.0449)
Second 1.155 – 1.175 (0.0455 – 0.0463) 1.140 (0.0449)
Connecting rod Small end I.D. 18.005 – 18.020 (0.7089 – 0.7094) 18.07 (0.711)
Big end side clearance 0.10 – 0.40 (0.004 – 0.016) 1.0 (0.04)
Big end I.D. 33.025 – 33.039 (1.3002 – 1.3007) 33.07 (1.302)
Big end oil clearance 0.040 – 0.064 (0.0016 – 0.0025) 0.12 (0.005)
Crankshaft Crankpin O.D. 32.975 – 32.985 (1.2982 – 1.2986) 32.92 (1.296)
Crankshaft runout – 0.10 (0.004)
Cylinder barrel Camshaft journal I.D. 16.000 – 16.018 (0.6299 – 0.6306) 16.05 (0.632)
(Crankcase)
Crankcase cover Camshaft journal I.D. 16.000 – 16.018 (0.6299 – 0.6306) 16.05 (0.632)
Valves Valve clearance IN 0.15 ± 0.02 –
EX 0.20 ± 0.02 –
Valve stem O.D. IN 6.575 – 6.590 (0.2588 – 0.2594) 6.44 (0.254)
EX 6.535 – 6.550 (0.2573 – 0.2579) 6.40 (0.252)
Valve guide I.D. IN/EX 6.600 – 6.612 (0.2598 – 0.2603) 6.66 (0.262)
Guide-to-stem IN 0.010 – 0.037 (0.0004 – 0.0015) 0.11 (0.004)
clearance EX 0.050 – 0.077 (0.0020 – 0.0030) 0.13 (0.005)
Valve seat width 1.0 – 1.2 (0.04 – 0.05) 2.0 (0.08)
Valve spring free length 39.0 (1.54) 37.5 (1.48)
Valve spring perpendicularity – 1.5°
Camshaft Cam height IN 31.945 – 32.145 (1.2577 – 1.2655) 31.35 (1.234)
EX 31.666 – 31.866 (1.2467 – 1.2546) 31.35 (1.234)
Camshaft O.D. 15.966 – 15.984 (0.6286 – 0.6293) 15.92 (0.627)
Carburetor Main jet BE70L A #85 –
BE70M A #92 –
BE75B C #85 –
BE75H A #88 –
BE78B A #85 –
BE98F A #90 –
BE98G A #92 –
BE98H A #92 –
Pilot screw opening BE70L A 2-1/8 turns out –
BE70M A 2-3/4 turns out –
BE75B C 2-1/8 turns out –
BE75H A 2-7/8 turns out –
BE78B A 2-1/8 turns out –
BE98F A 2-5/8 turns out –
BE98G A 2-7/8 turns out –
BE98H A 2-7/8 turns out –
Float height 13.2 (0.52) –

2-2
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SERVICE INFORMATION
Part Item Standard Service limit
Spark plug Gap 0.70 – 0.80 (0.028 – 0.031) –
Spark plug cap Resistance (20°C/68°F) 7.5 – 12.5 kΩ –
Ignition coil Air gap 0.2 – 0.6 (0.01 – 0.02) –
Primary resistance 0.4 – 0.7 Ω –
Secondary resistance 8.9 – 13.5 kΩ –
Starter motor Brush length 7.0 (0.28) 3.5 (0.14)
Mica depth 1.0 (0.04) 0.2 (0.01)
Charge coil Resistance 1A 3.00 – 4.00 Ω –
3A 0.62 – 0.93 Ω –
Lamp coil Resistance 12 V - 50 W 0.29 – 0.44 Ω –
1/2 reduction Clutch friction disc thickness 3.5 (0.14) 3.0 (0.12)
clutch type Clutch plate warpage – 0.10 (0.004)

2-3
62Z7B000.book 4 ページ ２０１２年９月２７日 木曜日 午前１０時２１分

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SERVICE INFORMATION
GX390H1
Unit: mm (in)
Part Item Standard Service limit
Engine Maximum speed (at no load) 3,850 ± 150 min-1 (rpm) –
Idle speed 1,400 ± 150 min-1 (rpm) –
1.37 MPa (14.0 kgf/cm2, 199 psi)/
Cylinder compression –
1,400 min-1 (rpm)
Cylinder head Warpage – 0.10 (0.004)
Cylinder Sleeve I.D. 88.000 – 88.017 (3.4646 – 3.4652) 88.170 (3.4710)
Piston Skirt O.D. 87.975 – 87.985 (3.4636 – 3.4640) 87.85 (3.459)
Piston-to-cylinder clearance 0.015 – 0.042 (0.0006 – 0.0017) 0.12 (0.005)
Piston pin bore I.D. 20.002 – 20.008 (0.7875 – 0.7877) 20.042 (0.7891)
Piston pin Pin O.D. 19.994 – 20.000 (0.7872 – 0.7874) 19.950 (0.7854)
Piston pin-to-piston pin bore clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.08 (0.003)
Piston rings Ring side clearance Top 0.015 – 0.050 (0.0006 – 0.0020) 0.15 (0.006)
Second 0.030 – 0.065 (0.0012 – 0.0026) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.550 (0.0138 – 0.0217) 1.0 (0.04)
Oil (side rail) 0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)
Ring width Top 1.170 – 1.190 (0.0460 – 0.0469) 1.140 (0.0449)
Second 1.155 – 1.175 (0.0455 – 0.0463) 1.140 (0.0449)
Connecting rod Small end I.D. 20.005 – 20.020 (0.7876 – 0.7882) 20.07 (0.790)
Big end side clearance 0.10 – 0.40 (0.004 – 0.016) 1.0 (0.04)
Big end I.D. 36.025 – 36.039 (1.4183 – 1.4189) 36.07 (1.420)
Big end oil clearance 0.040 – 0.064 (0.0016 – 0.0025) 0.12 (0.005)
Crankshaft Crankpin O.D. 35.975 – 35.985 (1.4163 – 1.4167) 35.93 (1.415)
Crankshaft runout – 0.10 (0.004)
Cylinder barrel Camshaft journal I.D. 16.000 – 16.018 (0.6299 – 0.6306) 16.05 (0.632)
(Crankcase)
Crankcase cover Camshaft journal I.D. 16.000 – 16.018 (0.6299 – 0.6306) 16.05 (0.632)
Valves Valve clearance IN 0.15 ± 0.02 –
EX 0.20 ± 0.02 –
Valve stem O.D. IN 6.575 – 6.590 (0.2588 – 0.2594) 6.44 (0.254)
EX 6.535 – 6.550 (0.2573 – 0.2579) 6.40 (0.252)
Valve guide I.D. IN/EX 6.600 – 6.615 (0.2598 – 0.2604) 6.66 (0.262)
Guide-to-stem IN 0.010 – 0.040 (0.0004 – 0.0016) 0.11 (0.004)
clearance EX 0.050 – 0.080 (0.0020 – 0.0032) 0.13 (0.005)
Valve seat width 1.0 – 1.2 (0.04 – 0.05) 2.0 (0.08)
Valve spring free length 39.0 (1.54) 37.5 (1.48)
Valve spring perpendicularity – 1.5°
Camshaft Cam height IN 32.498 – 32.698 (1.2794 – 1.2873) 32.198 (1.2676)
EX 31.985 – 32.185 (1.2592 – 1.2671) 29.886 (1.1766)
Camshaft O.D. 15.966 – 15.984 (0.6286 – 0.6293) 15.92 (0.627)
Carburetor Main jet BE85T B #92 –
BE85U A #95 –
BE88P A #105 –
BE88Q A #95 –
BE89K A #102 –
BE89L A #108 –
Pilot screw opening BE85T B 1-7/8 turns out –
BE85U A 2 turns out –
BE88P A 2-1/4 turns out –
BE88Q A 2 turns out –
BE89K A 2-1/4 turns out –
BE89L A 2-1/4 turns out –
Float height 13.2 (0.52) –
Spark plug Gap 0.70 – 0.80 (0.028 – 0.031) –
Spark plug cap Resistance (20°C/68°F) 7.5 – 12.5 kΩ –
Ignition coil Air gap 0.2 – 0.6 (0.01 – 0.02) –
Primary resistance 0.4 – 0.7 Ω –
Secondary resistance 8.9 – 13.5 kΩ –

2-4
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SERVICE INFORMATION
Part Item Standard Service limit
Starter motor Brush length 10.5 (0.41) 4.0 (0.16)
Mica depth 1.0 (0.04) 0.2 (0.01)
Charge coil Resistance 1A 3.00 – 4.00 Ω –
Lamp coil Resistance 12 V - 15 W 1.04 – 1.56 Ω –
12 V - 25 W 0.30 – 0.46 Ω –
12 V - 50 W 0.29 – 0.44 Ω –

TORQUE VALUES
ENGINE TORQUE VALUES
Torque values
Item Tread Dia. (mm) Remark
N·m kgf·m lbf·ft
Crankcase cover bolt M8 x 1.25 24 2.4 18
Cylinder head bolt M10 x 1.25 35 3.5 26 Apply engine oil to the
threads and seating
surface.
Oil drain bolt M12 x 1.5 23 2.3 17
Connecting rod bolt M8 x 1.25 (Special bolt) 14 1.4 10 Apply engine oil to the
threads and seating
surface.
Rocker arm pivot bolt M8 x 1.25 (Special bolt) 24 2.4 18
Rocker arm pivot lock nut M6 x 0.5 10 1.0 7
Spark plug M14 x 1.25 (Special) 18 1.8 13
Oil level switch nut M10 x 1.25 10 1.0 7
Flywheel nut M16 x 1.5 (Special nut) 113 11.5 83 Apply engine oil to the
Flywheel nut M16 x 1.5 (Special nut) 157 16.0 116 threads and seating
(With reduction, GX390H1 only) surface.
Fuel tank nut/bolt M8 x 1.25 24 2.4 18
Fuel tank joint M10 x 1.25 2.0 0.2 1.5
Air cleaner elbow nut M6 x 1.0 9.0 0.9 6.6
Muffler nut M8 x 1.25 24 2.4 18
Drive sprocket bolt M8 x 1.25 24 2.4 18
(With reduction, GX270H only)
Gear case cover bolt M8 x 1.25 24 2.4 18
(With reduction, GX390H1 only)
Primary drive gear bolt M8 x 1.25 24 2.4 18
(With reduction, GX390H1 only)
Recoil starter setting screw M5 x 0.8 (Special bolt) 5.4 0.6 4.0
Sediment cup M24 x 1.0 3.9 0.4 2.9
Starter solenoid nut (GX390H1 M6 x 1.0 2.5 0.3 1.8
only)
Starter motor housing screw M5 x 0.8 5.0 0.5 3.7
(GX390H1 only)
Starter motor terminal nut M6 x 1.0 3.7 0.4 2.7
(GX390H1 only)

2-5
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SERVICE INFORMATION
STANDARD TORQUE VALUES
Torque values
Item Tread Dia. (mm)
N·m kgf·m lbf·ft
Screw 4 mm 2.1 0.2 1.5
5 mm 4.3 0.4 3.1
6 mm 9.0 0.9 6.6
Bolt and nut 5 mm 5.3 0.5 3.9
6 mm 10 1.0 7
8 mm 22 2.2 16
10 mm 34 3.5 25
12 mm 54 5.5 40
Flange bolt and nut 5 mm 5.3 0.5 3.9
6 mm 12 1.2 9
8 mm 23 2.3 17
10 mm 40 4.0 30
SH (Small head) flange bolt 6 mm 9.0 0.90 6.6
CT (Cutting threads) flange bolt (Retightening) 5 mm 5.4 0.6 4.0
6 mm 12 1.2 9

LUBRICATION & SEAL POINT

Material Location Remarks
Engine oil Crankshaft pin and gear teeth
Piston outer surface, ring groove and piston pin hole
Piston pin outer surface
Piston ring entire surface
Cylinder inner surface
Connecting rod big and small end bearing
Connecting rod bolt threads and seating surface
Camshaft cam profile and journal
Valve lifter pivot, pivot end and slipper surface
Valve stem sliding surface and stem end
Valve rocker arm tappet surface and pivot
Rocker arm pivot threads and pivot
Flywheel nut threads and seating surface
Governor weight holder gear and sliding surface
Governor holder shaft journal
Governor arm shaft journal
Cylinder head bolt threads and seating surface
Balancer shaft bearing and gear (GX390H1)
Drive sprocket, P.T.O. shaft gear teeth and journal Reduction unit
Drive sprocket, P.T.O. shaft, clutch center gear teeth
and journal
Countershaft bearing and gears
Multi-purpose grease Oil seal lip
O-ring
Recoil starter reel sliding surface
Recoil starter ratchet sliding surface
Recoil starter ratchet guide inside
Use molybdenum oil solution Camshaft cam profile When installing a new
(mixture of the engine oil and camshaft
molybdenum grease in a ratio
of 1:1)
LOCTITE® 638 or equivalent Limiter cap inside

2-6
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SERVICE INFORMATION
TOOLS
Float level gauge Sliding hammer weight Valve guide driver, 6.45 x 11 mm
07401-0010000 07741-0010201 07742-0010200

Attachment, 32 x 35 mm Attachment, 42 x 47 mm Attachment, 52 x 55 mm

07746-0010100 07746-0010300 07746-0010400

Attachment, 72 x 75 mm Inner driver handle, 40 mm Attachment, 30 mm

07746-0010600 07746-0030100 07746-0030300

Attachment, 35 mm Pilot, 15 mm Pilot, 20 mm

07746-0030400 07746-0040300 07746-0040500

2-7
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SERVICE INFORMATION
Pilot, 25 mm Pilot, 30 mm Pilot, 35 mm
07746-0040600 07746-0040700 07746-0040800

Pilot, 14 mm Driver handle Seat cutter, 29 mm (45° IN)

07746-0041200 07749-0010000 07780-0010300

Seat cutter, 27.5 mm (45° EX) Seat cutter, 35 mm (45° IN) Seat cutter, 33 mm (45° EX)
07780-0010200 07780-0010400 07780-0010800

Flat cutter, 30 mm (32° IN) Flat cutter, 28 mm (32° EX) Flat cutter, 35 mm (32° IN)
07780-0012200 07780-0012100 07780-0012300

Flat cutter, 33 mm (32° EX) Interior cutter, 37.5 mm (60° IN/EX) Cutter holder, 6.6 mm
07780-0012900 07780-0014100 07781-0010202

2-8
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SERVICE INFORMATION
Flywheel puller set Bearing remover shaft set, 15 mm Bearing remover shaft set, 25 mm
07935-8050004 07936-KC10500 07936-ZV10100

Valve guide reamer, 6.612 mm Attachment, 45 x 50 mm Attachment, 62 x 64 mm

07984-ZE20001 07946-6920100 07947-6340400

2-9
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SERVICE INFORMATION
HARNESS AND TUBE ROUTING
Connection of regulator/rectifier, charge/lamp coil, sub wire harness, and
auto throttle solenoid are depending on the application of the engine,
therefore, it does not indicate those parts in this manual.
ALL TYPE
GOVERNOR ARM

ENGINE WIRE HARNESS

ENGINE WIRE HARNESS

Do not override on boss.

TO ENGINE
STOP SWITCH CYLINDER
BARREL RIBS
TO SPARK PLUG
Insert wire in the
recesses of ribs.

ENGINE WIRE HARNESS

TUBE CLIP

CORD HOOK
IGNITION COIL
CONNECTOR
IGNITION COIL

BREATHER TUBE

HIGH-TENSION
CORD FUEL TUBE

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SERVICE INFORMATION
COMBINATION SWITCH (CONTROL BOX) TYPE

ENGINE WIRE HARNESS

ENGINE WIRE HARNESS

CONNECTOR

OIL ALERT
TERMINAL WIRE
UNIT WIRE

FASTENER TUBE

TO STARTER MOTOR
HARNESS CLIP

STARTER MOTOR WIRE

PURSE LOCK CLIP

To starter motor

2-11
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SERVICE INFORMATION
ENGINE STOP SWITCH TYPE
WITH OIL LEVEL SWITCH:

OIL ALERT UNIT

ENGINE WIRE
ENGINE STOP HARNESS
SWITCH

ENGINE STOP
SWITCH

HARNESS CLIP

ENGINE STOP SWITCH WIRE

OIL LEVEL ENGINE STOP SWITCH WIRE
PREVENT SLACK.
DIRECTION OF SWITCH Do not contact with cylinder
CYLINDER BARREL barrel.
HARNESS CLIP
ENGINE STOP SWITCH WIRE
Clamp engine stop switch wire
at indicated position.

GX270H: GX390H1:

TO ENGINE TO OIL TO IGNITION TO ENGINE TO OIL SKY

STOP SWITCH ALERT UNIT COIL STOP SWITCH ALERT UNIT

SKY

Y Bl Bl Y Bl Bl

Y Y Bl Bl Y Y Bl

HARNESS CLIP
TO OIL LEVEL SWITCH TO OIL LEVEL SWITCH TO IGNITION COIL

2-12
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SERVICE INFORMATION
ENGINE STOP SWITCH ONLY:
ENGINE WIRE HARNESS CLAMP

ENGINE WIRE HARNESS

ENGINE STOP SWITCH WIRE CONNECTOR

WITH CHARGE COIL / LAMP COIL

12 V-50 W LAMP COIL TYPE: 1 A/3 A CHARGE COIL TYPE:

CORD 12 V-15 W/12 V-25 W LAMP COIL TYPE:

CLAMPER CORD
CLAMPER
CORD
GROMMET CORD
GROMMET

COIL
COIL CORD
CORD

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MEMO
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3. MAINTENANCE

MAINTENANCE SCHEDULE························3-2 SPARK PLUG REPLACEMENT ················· 3-11

ENGINE OIL LEVEL CHECK/CHANGE ·······3-3 SPARK ARRESTER CLEANING················ 3-12

REDUCTION CASE OIL LEVEL CHECK/ IDLE SPEED CHECK/ADJUSTMENT ········ 3-13
CHANGE························································3-4
VALVE CLEARANCE CHECK/
AIR CLEANER CHECK/CLEANING/ ADJUSTMENT ············································ 3-13
REPLACEMENT············································3-6
COMBUSTION CHAMBER CLEANING ····· 3-15
SEDIMENT CUP CLEANING ························3-9
FUEL TANK AND FILTER CLEANING ······ 3-15
SPARK PLUG CHECK/ADJUSTMENT ········3-9
FUEL TUBE CHECK ··································· 3-16

3-1
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MAINTENANCE
MAINTENANCE SCHEDULE
MAINTENANCE

REGULAR SERVICE PERIOD (2) First Every Every Every

ITEM Perform at every indicated month 3 6 year Refer
Each
month or operating hour or months months or to
use 20 hrs. or or 300 hrs.
interval, whichever comes page
first. 50 hrs. 100 hrs.
Engine oil Check level 3-3
Change 3-3
Reduction case oil Check level 3-4
(applicable types) Change 3-5
Air cleaner Check 3-6
Clean (1) (*)(1) 3-6
(Cyclone type) Every 6 months or 150 hours 3-6
Replace (**) 3-6
(Cyclone type) Every 2 years or 600 hours 3-6
Sediment cup Clean 3-9
Spark plug Check–adjust 3-9
Replace 3-11
Spark arrester Clean
(3) 3-12
(If equipped)
Idle speed Check–adjust 3-13
Valve clearance Check–adjust 3-13
Combustion chamber Clean After every 1,000 hours 3-15
Fuel tank and filter Clean 3-15
Fuel tube Check Every 2 years (Replace if necessary) 3-16
(1) Service more frequently when used in dusty areas.
(2) For commercial use, log hours of operation to determine proper maintenance intervals.
(3) In Europe and other countries where the machinery directive 2006/42/EC is enforced, this service should be done by your
servicing dealer.
(*) Internal vent carburetor with dual element type only.
(**) Replace paper element type only.

3-2
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MAINTENANCE
ENGINE OIL LEVEL CHECK/CHANGE
CHECK
Place the engine on a level surface.
[1]
Remove the oil filler cap [1] and check the oil level
shown into the oil filler neck [2]. [2]
If the oil level is low, fill with recommended oil to the
upper level of the oil filler neck (page 3-3).
Check that the oil filler packing [3] is in good condition,
replace it if necessary.
Install and tighten the oil filler cap securely.

[3]

CHANGE
Place the engine on a level surface and place a suitable
[2] [4]
container under the drain bolt [1].
Remove the oil filler cap [2], drain bolt, and sealing
washer [3] and drain the oil into a suitable container.
Please dispose of used oil in a manner that is
compatible with the environment. We suggest you take
used oil in a sealed container to your local recycling
center or service station for reclamation. Do not throw it
in the trash, pour it on the ground, or pour it down a
drain.

Used engine oil contains substances that have

been identified as carcinogenic. If repeatedly left in [1] [3]
contact with the skin for prolonged periods, it may
cause skin cancer. Wash your hands thoroughly
with soap and water as soon as possible after SAE VISCOSITY GRADES
contact with used engine oil.

Install the drain bolt with a new sealing washer and

tighten it to the specified torque.
TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft)

SAE 10W - 30 is Add the specified amount of recommended oil into the
recommended for engine.
general use. Other
viscosities shown in
OIL CAPACITY: 1.1 Liters (1.16 US qt, 0.97 Imp qt)
the chart may be AMBIENT TEMPERATURE
used when the
RECOMMENDED OIL:
average SAE 10W-30
temperature in your API service classification: SE or higher
area is within the
After adding the oil, check the oil level.
recommended
range. Check that the oil filler packing [4] is in good condition,
replace it if necessary.
Install and tighten the oil filler cap securely.
Make sure there are no oil leaks.

3-3
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MAINTENANCE
REDUCTION CASE OIL LEVEL CHECK/
CHANGE
• For the chain type (without clutch), refer to the
ENGINE OIL LEVEL CHECK/CHANGE because it
shares the reduction oil with the engine oil (page 3-
3).
CHECK
1/2 REDUCTION CLUTCH TYPE (GX270H ONLY)
Place the engine on a level surface.
[1]
Remove the oil filler cap/oil level gauge [1], and wipe
the oil level gauge clean.
Insert the oil level gauge without screwing it into the oil
filler neck.
Remove the oil level gauge and check oil level shown [2]
on the oil level gauge.
If the oil level is low, fill with recommended oil to the
[3]
upper level [2] of the oil level gauge (page 3-5).
Check that the O-ring [3] is in good condition, replace it
if necessary.
Install and tighten the oil filler cap/oil level gauge
securely.

3-4
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MAINTENANCE
CHANGE
1/2 REDUCTION CLUTCH TYPE (GX270H ONLY)
Place the engine on a level surface and place a suitable
[2]
container under the drain bolt [1].
Remove the oil filler cap/oil level gauge [2], drain bolt
and sealing washer [3] and drain the oil into a suitable
container.
Please dispose of used oil in a manner that is
compatible with the environment. We suggest you take
used oil in a sealed container to your local recycling
[4] [1]
center or service station for reclamation. Do not throw it
in the trash, pour it on the ground, or pour it down a
drain.

Used engine oil contains substances that have [3]

been identified as carcinogenic. If repeatedly left in
contact with the skin for prolonged periods, it may
cause skin cancer. Wash your hands thoroughly
SAE VISCOSITY GRADES
with soap and water as soon as possible after
contact with used engine oil.

Install the drain bolt with a new sealing washer and

tighten it to the specified torque.
TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft)

SAE 10W - 30 is Add the specified amount of recommended oil into the
recommended for reduction case.
general use. Other
viscosities shown in
OIL CAPACITY: 0.3 Liter (0.32 US qt, 0.26 Imp qt)
the chart may be AMBIENT TEMPERATURE
used when the
RECOMMENDED OIL:
average SAE 10W-30
temperature in your API service classification: SE or higher
area is within the
After adding the oil, check the oil level.
recommended
range. Check that the O-ring [4] is in good condition, replace it
if necessary.
Install and tighten the oil filler cap/oil level gauge
securely.
Make sure there are no oil leaks.

3-5
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MAINTENANCE
AIR CLEANER CHECK/CLEANING/
REPLACEMENT
DUAL/DUAL SILENT TYPE:
A dirty air filter will restrict air flow to the carburetor,
[1]
reducing engine performance. If the engine is operated
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE. [2]

Operating the engine without the air filters or with the

filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely.
Remove the nut [1] and the air cleaner cover [2].
Remove the wing nut [3], grommet [4] and air filter
assembly [5] [6].
Separate the inner filter (Paper) [4] from the outer filter [3]
(Foam) [5]. Carefully check both filters for holes or tears
and replace if damaged. [4]

Clean the filters if they are to be reused (page 3-8).

[5]
Install the elements in the reverse order of removal.
[6]

CYCLONE TYPE:
A dirty air filter will restrict air flow to the carburetor,
reducing engine performance. If the engine is operated [1]
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE.
[2]

Operating the engine without the air filters or with the

filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely.
[3]
Remove the wing nut [1] and the air cleaner cover [2].
Remove the wing nut [3], grommet [4] and air filter
[4]
assembly [5] [6].
Separate the inner filter (Paper) [4] from the outer filter
(Foam) [5]. Carefully check both filters for holes or tears [5]
and replace if damaged.
Clean the filters if they are to be reused (page 3-8).
[6]
Install the elements in the reverse order of removal.

3-6
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MAINTENANCE
LOW PROFILE TYPE:
A dirty air filter will restrict air flow to the carburetor, [1]
reducing engine performance. If the engine is operated
in dusty areas, clean the air cleaner more often than [3]
specified in the MAINTENANCE SCHEDULE.

Operating the engine without the air filters or with the

filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely.
Remove the air cleaner wire clip [1] and air cleaner
cover [2].
Remove the air cleaner element [3].
Carefully check air cleaner element and replace if
damaged.
Clean the filter if it is to be reused (page 3-8).
Install the element in the reverse order of removal.
[2]

OIL BATH TYPE

A dirty air filter will restrict air flow to the carburetor,
[1]
reducing engine performance. If the engine is operated
in dusty areas, clean the air cleaner more often than [2]
specified in the MAINTENANCE SCHEDULE.

Operating the engine without the air filters or with the [3]
filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely.
Remove the following:
– Wing nut [1]
– Air cleaner cap [2]
– Air cleaner cover [3] [4]
– Air cleaner element [4]
– Air cleaner grid [5]
Carefully check the element for holes or tears and
replace if damaged.
Clean the element if it is to be reused (page 3-8).
Check the oil contamination and oil level of the cleaner
oil pan [6]. [5]

If the oil level is low, fill with the recommended oil to the
upper level of the cleaner oil pan.
If the oil is dirty, clean the cleaner oil pan and add the
recommended oil to the upper level of the cleaner oil
pan.
[6]
OIL CAPACITY:
GX270H: 60 cc
GX390H1: 80 cc
Installation is in the reverse order of removal.

3-7
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MAINTENANCE
SEMI DRY TYPE
A dirty air filter will restrict air flow to the carburetor,
[3] [2] [1]
reducing engine performance. If the engine is operated
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE.

Operating the engine without the air filters or with the

filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely.
Remove the following:
– Wing nut [1] [4]
– Air cleaner cap [2]
– Air cleaner cover [3]
– Air cleaner element [4]
Carefully check the element for holes or tears and
replace if damaged.
Clean the element if it is to be reused (page 3-8).
Installation is in the reverse order of removal.

ELEMENT CLEANING
FOAM
Clean the filter [1] in warm soapy water, rinse, and allow
[1] Wash Dip
to dry thoroughly, or clean with a non-flammable
solvent and allow to dry thoroughly.
Dip the filter in clean engine oil, and squeeze out all the
excess oil. Dry thoroughly
Excess oil will restrict air flow through the foam element
and may cause the engine to smoke at startup.

Squeeze thoroughly

PAPER
Tap the inner filter [1] lightly several times on a hard
[1]
surface to remove excess dirt, or blow compressed air
lightly (206 kPa (2.11 kgf/cm2, 30 psi) or less) through
the paper filter from the inside out. Never try to brush
the dirt off; brushing will force dirt into the fibers.

3-8
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MAINTENANCE
SEDIMENT CUP CLEANING

Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Turn the fuel valve lever [1] to the OFF position.

[1]
Remove the following:
– Sediment cup [2]
– O-ring [3]
Clean the sediment cup with non-flammable solvent
and allow them to dry thoroughly.
Install a new O-ring and sediment cup.
Tighten the sediment cup to the specified torque.
TORQUE: 3.9 N·m (0.4 kgf·m, 2.9 lbf·ft)
Check the installation part of the sediment cup for any
sign of fuel leakage.

[3]

[2]

SPARK PLUG CHECK/ADJUSTMENT

If the engine has been running, the engine will be

very hot. Allow it to cool before proceeding.

Remove the spark plug cap, and then remove the spark
plug [1] using a spark plug wrench [2]. [2]

[1]

3-9
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MAINTENANCE
Visually check the spark plug. Replace the plug if the
insulator [1] is cracked or chipped. [2]
Check the sealing washer [2] for damage.
Replace the spark plug if the sealing washer is
damaged (page 3-11).
SPARK PLUG:
GX270H (VKK, VMT, VS4, VSD4):
BPR5ES (NGK)/W16EPR-U (DENSO)
GX270H (OTHER TYPE):
[1]
BPR6ES (NGK)/W20EPR-U (DENSO)
GX390H1 (ES2, VMT3, VMQ3, VS4, VS6, VSB4):
BPR5ES (NGK)/W16EPR-U (DENSO)
GX390H1 (OTHER TYPE):
BPR6ES (NGK)/W20EPR-U (DENSO)
Measure the plug gap with a wire-type feeler gauge. If
the measurement is out of the specification, adjust by
bending the side electrode. 0.70 – 0.80 mm
(0.028 – 0.031 in)
PLUG GAP: 0.70 – 0.80 mm (0.028 – 0.031 in)
Install the spark plug (page 3-11).

A loose spark plug can become very hot and can

damage the engine. Overtightening can damage the
threads in the cylinder block.
Install the spark plug cap securely.

3-10
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MAINTENANCE
SPARK PLUG REPLACEMENT
REMOVAL

The engine and 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. Allow it to cool before
proceeding.

Disconnect the spark plug cap [1] and remove the spark
plug [2] using a spark plug wrench [3]. [2]

• Clean around the spark plug base with compressed [1]

air before removing the spark plug and be sure that
no debris is allowed to enter into the combustion
chamber.
INSTALLATION
Install and hand tighten the spark plug to the cylinder
head.
SPARK PLUG:
GX270H (VKK, VMT, VS4, VSD4):
BPR5ES (NGK)/W16EPR-U (DENSO)
GX270H (OTHER TYPE):
BPR6ES (NGK)/W20EPR-U (DENSO)
GX390H1 (ES2, VMT3, VMQ3, VS4, VS6, VSB4):
BPR5ES (NGK)/W16EPR-U (DENSO)
GX390H1 (OTHER TYPE):
BPR6ES (NGK)/W20EPR-U (DENSO)
Tighten the spark plug to the specified torque.
TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft)
Connect the spark plug cap.

3-11
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MAINTENANCE
SPARK ARRESTER CLEANING

The engine and 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. Allow it to cool before
proceeding.

SOLID PROTECTOR TYPE

Remove the muffler cover (page 12-2), If equipped. [1]
Remove the tapping screws (5 x 8 mm) [1], tapping
screw (6 x 10 mm) [2], and muffler protector [3].
Remove the screw (5 x 8 mm or 4 x 6 mm) [4] and spark
arrester [5].
[3]

[4]

[2]

[5]

INNER/OUTER PROTECTOR TYPE

Remove the bolts (6 x 10 mm or 6 x 12 mm) [1], and
outer muffler protector [2].
[3]
Remove the tapping screw (4 x 8 mm) [3], and spark
arrester [4].

[4]

[2] [1]

3-12
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MAINTENANCE
CLEANING

Be careful to avoid damaging the screen.

Clean the carbon deposits from the spark arrester
screen [1] with a wire brush [2]. [2]
Check the spark arrester screen for damage. If the
screen is damaged, replace the spark arrester.
Install the spark arrester in the reverse order of
removal.

[1]

IDLE SPEED CHECK/ADJUSTMENT

Start the engine and allow it to warm up to normal
operating temperature. For units equipped with auto
throttle, turn the auto throttle switch ON.
Turn the throttle stop screw [1] to obtain the specified
idle speed.
IDLE SPEED: 1,400 ± 150 min-1 (rpm)

[1]

VALVE CLEARANCE CHECK/

ADJUSTMENT
Remove the head cover bolt [1], the head cover [2], and
the head cover packing [3]. [3] [2]

[1]

3-13
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MAINTENANCE
Set the piston near top dead center of the cylinder
[1] [3]
compression stroke (both valves fully closed) by pulling
the recoil starter slowly. When the piston is near top
dead center of the compression stroke, the cutout [1] on
the starter pulley [2] will align with the top hole [3] on the
recoil starter case [4]. Pull slowly.

If the exhaust valve is open, use the recoil starter to turn

the crankshaft one additional turn and align the triangle
mark on the starter pulley with the top hole on the recoil
starter case again.

[4] [2]

Insert a feeler gauge [1] between the valve rocker arm

[2] and valve stem [3] to measure the valve clearance. [1] [3]

VALVE CLEARANCE:
IN: 0.15 ± 0.02 mm
EX: 0.20 ± 0.02 mm
If adjustment is necessary, proceed as follows.

[2]

Hold the rocker arm pivot [1] and loosen the rocker arm
pivot lock nut [2]. [2]

Turn the rocker arm pivot to obtain the specified

clearance.
VALVE CLEARANCE:
IN: 0.15 ± 0.02 mm
EX: 0.20 ± 0.02 mm
Hold the rocker arm pivot and retighten the rocker arm
pivot lock nut to the specified torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
Recheck the valve clearance, and if necessary, readjust
the clearance.
Check the head cover packing for damage or
deterioration, and install it to the head cover.
VALVE STEM
Attach the cylinder head cover to the cylinder head, and
tighten the head cover bolt securely.

[1]

[2]
To increase valve clearance: screw out.
To decrease valve clearance: screw in.

3-14
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MAINTENANCE
COMBUSTION CHAMBER CLEANING
Remove the cylinder head (page 13-3).
[1]
Clean any carbon deposits from the combustion
chamber [1].

FUEL TANK AND FILTER CLEANING

Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Drain the fuel into a suitable container.

[3]
Remove the fuel tank (page 6-3).
Remove the fuel tank joint [1] and O-ring [2] from the
fuel tank [3].
Clean the fuel tank joint and fuel tank with non- [2]
flammable solvent, and allow them to dry thoroughly.
Check the screen of the fuel tank joint for clogs or
damage, replace if necessary.
Install a new O-rings to the fuel tank joint and install
them to the fuel tank.
Tighten the fuel tank joint to the specified torque.
[1]
TORQUE: 2.0 N·m (0.2 kgf·m, 1.5 lbf·ft)
Install the fuel tank (page 6-3).
After installation, check for any signs of fuel leakage.

3-15
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MAINTENANCE
FUEL TUBE CHECK

Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Check the fuel tube [1] for deterioration, cracks or signs

of leakage.

[1]

3-16
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4. TROUBLESHOOTING

BEFORE TROUBLESHOOTING···················4-2 TROUBLESHOOTING ·································· 4-2

4-1
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TROUBLESHOOTING
BEFORE TROUBLESHOOTING
TROUBLESHOOTING

• Use a known-good battery for troubleshooting.

• Check that the connectors are connected securely.
• Check for sufficient fresh fuel in the fuel tank.
• Read the circuit tester's operation instructions carefully, and observe the instructions during inspection.
• Disconnect the battery cable before continuity inspection.

TROUBLESHOOTING
HARD STARTING
• Check the engine oil level before troubleshooting.

Without starter motor: Cannot be cranked Check the recoil starter (page 10-8).
Pull the recoil starter and check whether the - If the recoil starter operates correctly when
engine cranks. removed but is hard to pull when installed on
the engine, check the decompressor
operation of the camshaft (page 14-20).
- If the recoil starter operates correctly when
Cranks removed but cannot be pulled when installed
on the engine, disassemble the engine and
repair or replace the faulty part(s) (page 14-6).

With starter motor: Does not crank Perform the STARTING SYSTEM
Turn the combination switch to the START TROUBLESHOOTING (page 10-2).
position and check whether the engine
cranks.

Cranks

Loosen the carburetor drain screw, and Does not flow Check for clogged fuel filter, fuel tube, and
check the fuel flow from the fuel tank. fuel strainer screen (page 6-3).

Flows

Dry
Check the spark plug (page 3-9). Disassemble the carburetor to clean the
carburetor ports, jets, and nozzles (page 6-
15).

Wet If spark plug is correct, clean and dry the

electrodes, and then restart the engine,
Normal taking care that the choke valve is not closed
too much.
If the engine does not start and the electrode
are wet again, check the carburetor float
valve (page 6-16).

No spark
Perform the spark test (page 9-5). Perform the IGNITION SYSTEM
TROUBLESHOOTING (page 9-3).
Spark

Go to page 4-3

4-2
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TROUBLESHOOTING

From page 4-2

Compression
Perform the cylinder compression test (page is too high Check the valve clearance (page 3-13) and
13-5). then perform the cylinder compression test. If
the cylinder compression is too high, remove
carbon deposits in the combustion chamber
(page 3-15).

Check the valve clearance (page 3-13), and

Compression then perform the cylinder compression test.
is too low
If the cylinder compression is too low,
perform a leak down test.
If there is no air leakage in the engine, check
Normal
the following.
- Valve spring free length (page 13-7)
- Valve seat width (page 13-5)
- Valve face irregularly worn (page 13-6)
- Decompressor operation (page 14-20)
- Piston ring side clearance (page 14-16)
- Piston ring width (page 14-17)
- Piston ring end gap (page 14-17)
- Piston skirt O.D. (page 14-15)
- Cylinder sleeve I.D. (page 14-14)

Restricted
Check for a restricted spark arrester Clean the spark arrester (page 3-13).
(applicable types).

Not restricted

Restart the engine according to the starting

procedure.

4-3
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TROUBLESHOOTING
ENGINE SPEED DOES NOT INCREASE OR
STABILIZE

Clogged
Check the air cleaner element (page 3-6). Clean the air cleaner element (page 3-8).

Clean

Check the spark plug (page 3-9). Abnormal Inspect the spark plug and adjust the spark
plug gap. Replace if necessary (page 3-10).

Normal

Clogged
Check the main jet for blockage (page 6-11). Disassemble and clean the carburetor
(page 6-15).
Clear

Check for secondary air leak. Air leaking Check around the air intake joint and
carburetor; replace the insulator and/or
gasket if necessary.
No air leaking

Abnormal
Check the valve clearance (page 3-13). Adjust the valve clearance (page 3-13).

Normal
Compression
is too high
Check the cylinder compression (page 13-5). Check for carbon deposits in the combustion
chamber (page 3-15).

Check that the cylinder head is correctly

Compression tightened (page 13-3).
Normal is too Low Check for defective cylinder head gasket,
valves, or valve seats (page 13-3, 13-5, 13-6,
13-7).
Check for worn piston, piston rings, or
cylinder inner surface (page 14-6, 14-12).

Check the governor system is installed correctly Abnormal Adjust or replace the faulty part(s).
(page 7-2, 7-3, 7-4).

Normal

Abnormal
Check the ignition coil air gap (page 9-5). Adjust the ignition coil air gap (page 9-5).

Normal

Check the ignition coil (page 9-6).

Replace the ignition coil if abnormalities are
found, and recheck.

4-4
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TROUBLESHOOTING
ENGINE DOES NOT STOP WHEN COMBINATION/
ENGINE STOP SWITCH IS TURNED OFF

Check the engine stop switch (If equipped) (page Replace the engine stop switch (page 5-2)/
Abnormal
11-6)/combination switch (If equipped) (page 11- combination switch (page 11-3).
6).

Normal

Check the wire harness connecting the Replace the engine wire harness.
No continuity
combination/ engine stop switch and the ignition
coil for open or short circuit.

Continuity

Check the ignition coil primary side (page 9-6).

Replace the ignition coil if abnormalities are found,
and recheck.

ENGINE DOES NOT STOP WHEN ENGINE OIL

LEVEL IS LOW

Check the oil level switch (page 11-5). Abnormal Replace the oil level switch (page 14-6).

Normal

Check the oil alert unit (If equipped) (page 11-5). Abnormal Replace the oil alert unit.
– Without control box (page 11-5)
– With control box (page 11-4)

Normal

Check the wire harness connecting the oil level No continuity Replace the engine wire harness.
switch and ignition coil for open or short circuit.

Continuity

Check the ignition coil primary side (page 9-6).

Replace the ignition coil if abnormalities are found,
and recheck.

4-5
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MEMO
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5. COVER

FAN COVER REMOVAL/INSTALLATION····5-2

5-1
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COVER
FAN COVER REMOVAL/INSTALLATION
COVER

Remove the recoil starter (page 10-3).

Remove the auto throttle (If equipped) (page 7-5).
Open the harness clip and disconnect the engine wire
harness connector (Without control box type).
When installing, refer to the HARNESS AND TUBE
ROUTING (page 2-10).

HARNESS CLIP
TUBE CLIP

FLANGE BOLT
(6 x 12 mm) (6)

FAN COVER
REMOVAL:
The fan cover can be removed GX270H (VSD4 ONLY)
ENGINE STOP SWITCH
with the recoil starter assembly
installed.

ENGINE STOP SWITCH

5-2
62Z7B000.book 1 ページ ２０１２年９月２７日 木曜日 午前１０時２１分

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6. FUEL SYSTEM

TOOL ·····························································6-2 CARBURETOR BODY CLEANING ············ 6-15

FUEL TANK REMOVAL/INSTALLATION ····6-3 CARBURETOR INSPECTION ···················· 6-15

AIR CLEANER REMOVAL/ CHOKE DIAPHRAGM INSPECTION·········· 6-16

INSTALLATION·············································6-4
PILOT SCREW REPLACEMENT ··············· 6-17
CARBURETOR REMOVAL/
INSTALLATION·············································6-9 CHOKE SET REPLACEMENT ··················· 6-18

CARBURETOR DISASSEMBLY/ CYLINDER STUD BOLT

ASSEMBLY ·················································6-11 REPLACEMENT ········································· 6-18

CHOKE DIAPHRAGM DISASSEMBLY/

ASSEMBLY ·················································6-14

6-1
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FUEL SYSTEM
TOOL
FUEL SYSTEM

Float level gauge

07401-0010000

6-2
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FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION

Gasoline is highly flammable and explosive.You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Turn the fuel valve lever to the OFF position.

Set a commercially available tube clip to the fuel tube.

FUEL FILLER CAP

FUEL FILTER
FUEL FILLER CAP PACKING
INSTALLATION:
Before installing, check for
deterioration or cracks.

B8/D8 TUBE CLAMP (2)

FUEL TUBE (6.3 x 50 mm)
(If equipped) FUEL TANK

O-RING

FUEL STRAINER
(If equipped)

FUEL TANK JOINT (If equipped)

2.0 N·m (0.2 kgf·m, 1.5 lbf·ft)
INSTALLATION:
Before installing, check the screen
of the fuel strainer for clogs or
TUBE CLIP damage.

B8/D8 TUBE CLAMP (2)

FLANGE NUT (8 mm) (2)

FLANGE BOLT (8 x 25 mm) (2) 24 N·m (2.4 kgf·m, 18 lbf·ft)
24 N·m (2.4 kgf·m, 18 lbf·ft)

FUEL TUBE
INSTALLATION:
Before installing, check for
deterioration or cracks.

6-3
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FUEL SYSTEM
AIR CLEANER REMOVAL/
INSTALLATION
DUAL/DUAL SILENT TYPE:

NUT
BREATHER TUBE
INSTALLATION:
AIR CLEANER
After installing the air cleaner elbow,
COVER
insert the breather tube to the hole
of the cylinder head cover as shown.

BREATHER TUBE
GROMMET
WING NUT

AIR CLEANER
ELEMENT (FOAM)
AIR CLEANER
ELEMENT (PAPER)

HIGH-TENSION CORD

SLANT OUTSIDE WASHER BOLT (6 x 22 mm) NOISE SILENCER

COLLAR

GX270H:

AIR CLEANER
ELBOW SEAL

AIR CLEANER ELBOW

REMOVAL/
INSTALLATION:
CARBURETOR SPACER Remove and install the air
(If equipped) cleaner elbow with the
INSTALLATION: fuel valve lever in the OFF
Before installing, check for damage. position and the choke
lever in the CLOSE
Note the installation direction. position.
Before installation, clean
AIR CLEANER the inside of the air
COLLAR (2) cleaner elbow.

FLANGE NUT (6 mm) (2)

Viewed from air cleaner side 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)

6-4
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FUEL SYSTEM
CYCLONE TYPE:
PRE AIR CLEANER WING NUT
CASE COVER

SCREW(5 x 16.5 mm) (5) AIR CLEANER

COVER

PRE AIR CLEANER GUIDE

WING NUT

PRE AIR CLEANER CASE GROMMET

ASSEMBLY:
Align the pre air cleaner case
cover tab with the groove in the
pre air cleaner case. AIR CLEANER
ELEMENT (PAPER)
TAB

AIR CLEANER
ELEMENT (FOAM)

WASHER BOLT
GROOVE (6 x 22 mm)

COLLAR

AIR CLEANER
ELBOW SEAL

BREATHER TUBE
AIR CLEANER
INSTALLATION: COVER SEAL RING
After installing the air cleaner elbow, AIR CLEANER
insert the breather tube to the hole of COLLAR (2)
the cylinder head cover as shown.

AIR CLEANER ELBOW

BREATHER TUBE
CARBURETOR SPACER REMOVAL/
INSTALLATION: INSTALLATION:
Before installing, check for damage. FLANGE NUT Remove and install the
Note the installation direction. (6 mm) (2) air cleaner elbow with
9.0 N·m the fuel valve lever in
(0.9 kgf·m, 6.6 lbf·ft) the OFF position and
the choke lever in the
CLOSE position.
Before installation, clean
the inside of the air
HIGH-TENSION CORD cleaner elbow.
Viewed from air cleaner side

6-5
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FUEL SYSTEM
LOW PROFILE TYPE:
BREATHER TUBE
INSTALLATION:
After installing the air cleaner elbow,
insert the breather tube to the hole of the
cylinder head cover as shown.

BREATHER TUBE

HIGH-TENSION
CORD CARBURETOR SPACER

INSTALLATION:
GROMMET Before installing, check for damage.
Note the installation direction.

CHOKE
DIAPHRAGM

Viewed from air cleaner side

FLANGE NUT (6 mm) AIR CLEANER

COLLAR (2)

AIR CLEANER CASE

FLANGE NUT (6 mm) (2) AIR CLEANER SEAL

9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
AIR CLEANER STAY AIR CLEANER SEPARATOR

FLANGE NUT (5 mm) (6)

AIR CLEANER WIRE

CLIP B (2)

AIR CLEANER
WIRE CLIP A (2)

DRAIN TUBE FILTER

AIR CLEANER ELEMENT

AIR CLEANER COVER

6-6
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FUEL SYSTEM
OIL BATH TYPE:
BREATHER TUBE WING NUT
INSTALLATION: WING NUT
After installing the air cleaner elbow, AIR CLEANER CAP
insert the breather tube to the hole
of the cylinder head cover as shown. AIR CLEANER CAP
GX270H:
BREATHER TUBE AIR CLEANER
COVER
AIR CLEANER COVER

CLEANER OIL PAN

AIR CLEANER
ELEMENT
WASHER BOLT
HIGH-TENSION CORD (6 x 22 mm)
AIR CLEANER
COLLAR GRID

CLEANER OIL
PAN

AIR CLEANER
ELBOW SEAL

AIR CLEANER
ELBOW SEAL

AIR CLEANER ELBOW

CARBURETOR SPACER AIR CLEANER REMOVAL/INSTALLATION:

INSTALLATION: COLLAR (2) Remove and install the air cleaner

elbow with the fuel valve lever in the
Before installing, check for damage. OFF position and the choke lever in the
Note the installation direction. CLOSE position.
FLANGE NUT (6 mm) (2) Before installation, clean the inside of
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft) the air cleaner elbow.

Viewed from air cleaner side

6-7
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FUEL SYSTEM
SEMI DRY TYPE:
BREATHER TUBE
INSTALLATION:
After installing the air cleaner elbow,
insert the breather tube to the hole WING NUT
of the cylinder head cover as shown.

BREATHER TUBE
AIR CLEANER CAP

WASHER BOLT (6 x 22 mm)

AIR CLEANER COVER

HIGH-TENSION CORD
COLLAR

AIR CLEANER
ELEMENT

AIR CLEANER GRID

AIR CLEANER
CARBURETOR SPACER COLLAR (2)
INSTALLATION: AIR CLEANER ELBOW
Before installing, check for damage. REMOVAL/
Note the installation direction. INSTALLATION:
Remove and install the air
cleaner elbow with the fuel
valve lever in the OFF
AIR CLEANER ELBOW NUT (6 mm) (2) position and the choke
9.0 N·m (0.9 kgf·m, 6.6 lbf·ft) lever in the CLOSE
position.
Before installation, clean
Viewed from air cleaner side the inside of the air cleaner
elbow.

6-8
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FUEL SYSTEM
CARBURETOR REMOVAL/
INSTALLATION
DUAL/DUAL SILENT/CYCLONE/OIL
BATH/SEMI DRY TYPE AIR CLEANER:

Gasoline is highly flammable and explosive.You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Turn the fuel valve lever to the OFF position.

Remove the air cleaner (page 6-4).
Set a commercially available tube clip to the fuel tube.
Disconnect the fuel tube from the carburetor.
Remove the drain screw of the carburetor to drain
completely.

GOVERNOR ROD/THROTTLE RETURN SPRING

REMOVAL/INSTALLATION:
Pull the carburetor assembly to a point where the
groove of the throttle arm lines up with the governor
FUEL TUBE
rod [1], and then lift the governor rod out of the hole
of the throttle arm and unhook the throttle return
spring [2].
Installation is in the reverse order of removal.

[1]

INSULATOR
PACKING [2]

B8/D8 TUBE CLAMP

CARBURETOR INSULATOR
CARBURETOR
INSTALLATION:
Before installing, clean the passage REMOVAL/INSTALLATION:
thoroughly with compressed air. Remove the fuel tube.
Install the carburetor insulator [1] with the
vent groove facing toward the carburetor.
FUEL TUBE
After installing, clamp the high-tension
cord [2] to the carburetor insulator.

CARBURETOR PACKING

[1] B8/D8 TUBE CLAMP

[2]

6-9
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FUEL SYSTEM
LOW PROFILE TYPE AIR CLEANER:

Gasoline is highly flammable and explosive.You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Turn the fuel valve lever to the OFF position.

Remove the air cleaner (page 6-6).
Set a commercially available tube clip to the fuel tube.
Disconnect the fuel tube from the carburetor.
Remove the drain screw of the carburetor to drain
completely.

GOVERNOR ROD/THROTTLE RETURN SPRING

REMOVAL/INSTALLATION:
Pull the carburetor assembly to a point where the
groove of the throttle arm lines up with the
governor rod [1], and then lift the governor rod out
of the hole of the throttle arm and unhook the
throttle return spring [2].
Installation is in the reverse order of removal.
FUEL TUBE
[1]

[2]

INSULATOR
PACKING DASH POT CHECK VALVE

TUBE CLAMP

CARBURETOR ASSEMBLY:
B8/D8 TUBE
PACKING Install the dash pot into
CLAMP
the tube clamp with the
black end towards the
CARBURETOR INSULATOR choke diaphragm.
INSTALLATION:
Before installing, clean the passage
To Choke diaphragm
thoroughly with compressed air.
Install the carburetor insulator [1] with the
vent groove facing toward the carburetor. To control base stay (NON-
CARBURETOR
After installing, clamp the high-tension HANDY LEVER B TYPE)
cord [2] to the carburetor insulator. REMOVAL/INSTALLATION:
Remove the fuel tube.

FUEL TUBE

To the units connected

from the engine.

[1]
[2]
SOLENOID VALVE
B8/D8 TUBE CLAMP (If equipped)

6-10
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FUEL SYSTEM
CARBURETOR DISASSEMBLY/
ASSEMBLY
DUAL/DUAL SILENT/CYCLONE/OIL
BATH/SEMI DRY TYPE AIR CLEANER:

Gasoline is highly flammable and explosive.You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

To prevent serious eye injury, always wear safety

goggles or other eye protection when using
compressed air.

Remove the carburetor (page 6-9).

Before disassembly, clean the outside of the carburetor.

PILOT JET SET SCREW LEVER SETTING PLATE

ASSEMBLY: (3 x 6 mm) (2)
Before installing, clean VALVE LEVER
thoroughly with low-pressure SPRING
compressed air. CHOKE LEVER
Lightly lubricate the O-ring O-RING FUEL VALVE LEVER
[1] to ensure easy installation
into the carburetor body. [1] THROTTLE STOP SCREW
FUEL VALVE
ADJUSTMENT: (page 3-13)
PACKING
PILOT SCREW CHECK:
REPLACEMENT: (page 6-17) Replace if necessary.
MAIN NOZZLE SPRING PIN
ASSEMBLY: UPPER LIMITER CARBURETOR BODY
SIDE CAP
Before installing, clean
thoroughly with low- O-RING
pressure compressed air.
PILOT SCREW SEDIMENT CUP
SPRING 3.9 N·m (0.4 kgf·m, 2.9 lbf·ft)

MAIN JET FLOAT VALVE

ASSEMBLY: UPPER INSPECTION: (page 6-16)
Before installing, clean SIDE
thoroughly with low GX390H1:
compressed air. (BE85T B,
FLOAT BE88Q A ONLY)
FLOAT VALVE
FLOAT CHAMBER SPRING
FLOAT PIN
ASSEMBLY:
Install the float chamber to the O-RING
carburetor body at an angle as shown.
20°

SET BOLT GASKET FLOAT

DRAIN SCREW GASKET

SET BOLT DRAIN SCREW

6-11
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FUEL SYSTEM
LOW PROFILE TYPE AIR CLEANER:

Gasoline is highly flammable and explosive.You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

To prevent serious eye injury, always wear safety

goggles or other eye protection when using
compressed air.

Remove the carburetor (page 6-9).

Before disassembly, clean the outside of the carburetor.

PILOT JET SET

SET COLLAR
ASSEMBLY:
Before installing, clean
thoroughly with low-pressure
FLOAT PIN
compressed air.
Lightly lubricate the O-ring to
ensure easy installation into
the carburetor body.
O-RING
O-RING

THROTTLE STOP SCREW FLOAT VALVE

ADJUSTMENT: (page 3-13) INSPECTION: (page 6-16)
FLOAT VALVE SPRING
LIMITER CAP
FLOAT
ASSEMBLY:
MAIN JET PILOT SCREW Check for smooth movement
REPLACEMENT: (page 6-17) after installation.
ASSEMBLY: UPPER
Clean thoroughly with SIDE
compressed air before
installation.

MAIN NOZZLE
ASSEMBLY: UPPER
FLOAT CHAMBER SIDE
Before installing,
ASSEMBLY:
clean thoroughly with
Install the float chamber to the carburetor body DRAIN SCREW low-pressure
at an angle as shown. compressed air.
[1] GX270H VMT, VS4: 18°
[2] GX270H VSD4: 290°
GX390H1: 252°

O-RING
[2]
SET BOLT
[1]
O-RING
O-RING

SOLENOID VALVE WASHER SCREW (5 x 12 mm) (2)

(If equipped)

6-12
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FUEL SYSTEM
MAIN JET NUMBER:
GX270H:
Carburetor Main Jet
identification Number [1] + [2] Number
BE70L A #85
BE70M A #92 [1]
BE75B C #85
BE75H A #88
BE78B A #85
BE98F A #90
BE98G A #92
BE98H A #92 [2]

GX390H1:
Carburetor Main Jet
identification Number [1] + [2] Number
BE85T B #92
BE85U A #95
BE88P A #105
BE88Q A #95
BE89K A #102
BE89L A #108

6-13
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FUEL SYSTEM
CHOKE DIAPHRAGM DISASSEMBLY/
ASSEMBLY

MANUAL CHOKE ROD

CHOKE ROD GROMMET

DIAPHRAGM STAY

E-RING

CHOKE ROD GUIDE

THRUST WASHER (2.7 x 8 mm)

CHOKE DIAPHRAGM CHOKE ROD STOPPER

E-RING
RETURN SPRING

LEVER COLLAR

CHOKE LEVER
SCREW (5 x 12 mm) (2)

CHOKE LEVER WASHER ROD JOINT

CHOKE LEVER SEAL

CHOKE LEVER ROD

ARM PIVOT BUSH

CHOKE LEVER SEAL

E-RING
PLAIN WASHER (5 mm)

6-14
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FUEL SYSTEM
CARBURETOR BODY CLEANING

To prevent serious eye injury, always wear safety

goggles or other eye protection when using
compressed air.

• Some commercially available chemical cleaners are

very caustic. These cleaners may damage plastic
parts such as the O-ring, the float and the float seat
of the carburetor. Check the container for
instructions. If you are in doubt, do not use these
products to clean Honda carburetors.
• High air pressure may damage the carburetor body.
Use low air pressure (30 psi or less) when cleaning
passages and ports.
Clean the carburetor body with non-flammable solvent.
Clean thoroughly the following passages and ports with [8]
low-pressure compressed air.
– Pilot screw hole [1]
– Pilot jet hole [2]
– Pilot air jet [3]
– Main air jet [4]
– Transition ports [5]
– Pilot outlet [6]
– Main nozzle holder [7]
– External vent port [8]
– Internal vent port [9] [5]

[6]

[1]

[3] [9]

[4]
[2]
[7]

CARBURETOR INSPECTION
FLOAT LEVEL HEIGHT
Place the carburetor in the position as shown. Measure
the distance between the float top and carburetor body
when the float just contacts the seat without
[1]
compressing the valve spring.

TOOL:
Float level gauge [1] 07401-0010000

FLOAT HEIGHT: 13.2 mm (0.52 in)

If the measured float height is out of specification,
check the float valve and the float valve spring (page 6-
16).
If the float valve and the float valve spring are normal,
replace the float (page 6-11).

6-15
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FUEL SYSTEM
FLOAT VALVE
Check the float valve [1] and its seat [2] for wear or
GX390H1 (BE85T B, BE88Q A):
contamination.
Before installation, check for wear or a weak spring [3]. CARBURETOR BODY

Check the operation of the float valve.

[1] [2]

[3]

OK CLEAN REPLACE

OTHER TYPE:
CARBURETOR BODY

[1] [2]

[3]

OK CLEAN REPLACE

CHOKE DIAPHRAGM INSPECTION

Check for smooth operation by pressing the rod with a
finger.
Connect a vacuum pump to the choke diaphragm and
apply vacuum.The diaphragm should hold.
Replace the choke diaphragm if necessary.

6-16
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FUEL SYSTEM
PILOT SCREW REPLACEMENT
Leave the pilot screw [1] and limiter cap [2] in place
during carburetor cleaning. Remove only if necessary Pilot screw will break at narrow point.
for carburetor repair.
Removal of the limiter cap requires breaking the pilot
screw. A new pilot screw and limiter cap must be
installed.
When the limiter cap has been broken off, remove the
broken pilot screw.
Place the spring on the replacement pilot screw, and
install it on the carburetor. [2]
Turn the pilot screw in until it is lightly seated, then turn
[1]
the screw out the required number of turns.
GX270H: CARBURETOR
BODY
Carburetor Pilot screw
identification Number = [3] + [4] opening
BE70L A 2-1/8 turns out STOP
BE70M A 2-3/4 turns out
BE75B C 2-1/8 turns out
BE75H A 2-7/8 turns out
BE78B A 2-1/8 turns out
BE98F A 2-5/8 turns out [2]
BE98G A 2-7/8 turns out
BE98H A 2-7/8 turns out
GX390H1:
Carburetor Pilot screw
identification Number = [3] + [4] opening [4] [3]
BE85T B 1-7/8 turns out
BE85U A 2 turns out
BE88P A 2-1/4 turns out
BE88Q A 2 turns out
BE89K A 2-1/4 turns out
BE89L A 2-1/4 turns out
Refer to the appropriate shop manual for carburetor
pilot? screw initial opening setting.
Apply LOCTITE® 638 to the inside of the limiter cap,
then install the cap so the stop prevents the pilot screw
from being turned counterclockwise.
Be careful to avoid turning the pilot screw while
installing the limiter cap. The pilot screw must stay at its
required setting.

6-17
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FUEL SYSTEM
CHOKE SET REPLACEMENT
Remove the carburetor (page 6-9).
Pull out the choke valve plate [1]. [2]
Remove the choke shaft [2] and install a new choke [3]
shaft.
Insert a new choke valve plate into the slit [3] of the
choke shaft.
Be sure the choke shaft is in the position between the
projections [4] of the choke valve plate.

[1]

[2]

[4]

[4]
[1]

CYLINDER STUD BOLT

REPLACEMENT
Thread two nuts onto the stud bolt and tighten them
together, and then use a wrench to turn the stud bolt
out.
Install new stud bolts.
SPECIFIED LENGTH
GX270H
8 x 98 mm: 82 mm (3.23 in)
8 x 123 mm: 107 mm (4.21 in)
GX390H1
8 x 106 mm: 90.0 mm (3.54 in)
8 x 131.5 mm: 115.5 mm (4.55 in)

6-18
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7. GOVERNOR SYSTEM

GOVERNOR ARM/CONTROL BASE ASSY. CONTROL BASE ASSY. DISASSEMBLY/ 7

REMOVAL/INSTALLATION··························7-2 ASSEMBLY ··················································· 7-6

AUTO THROTTLE (IF EQUIPPED) REMOVAL/ MAXIMUM SPEED ADJUSTMENT ·············· 7-8
INSTALLATION·············································7-5
SOLENOID (AUTO THROTTLE)
INSPECTION················································· 7-9

7-1
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GOVERNOR SYSTEM
GOVERNOR ARM/CONTROL BASE
GOVERNOR SYSTEM

ASSY. REMOVAL/INSTALLATION
MANUAL OPERATION TYPE
Remove the following parts.
– Air cleaner (page 6-4)
– Muffler (page 12-2)
– Fuel tank (page 6-3)
– Tube clamp (page 6-9)
Installation is in the reverse of removal.
Adjust the maximum speed (page 7-8).

SCREW (5 x 16 mm)
(If equipped)

CABLE HOLDER CONTROL BASE ASSY.

(If equipped)

REMOTE CABLE SCREW (4 x 6 mm)

(If equipped) (If equipped)
(Commercially available)

GOVERNOR ROD/THROTTLE
RETURN SPRING GOVERNOR SPRING
REMOVAL/INSTALLATION: INSTALLATION:
Pull the carburetor assy. [1] Install with the long end of
toward to a point where the groove the spring toward the
[2] of the throttle arm lines up with control base assy.
the governor rod [3], and then lift Hook the governor spring
the governor rod out of the hole of to the outer hole of the
the throttle arm and unhook the governor arm.
throttle return spring [4].

OUTER HOLE
[3]
[4]

[1] NUT (6 mm)

GOVERNOR ARM
[2]

GOVERNOR ARM
BOLT

GOVERNOR ARM
SHAFT

BOLT (6 x 12 mm) (3)

7-2
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GOVERNOR SYSTEM
MANUAL OPERATION A TYPE
Remove the following parts.
– Air cleaner (page 6-4)
– Muffler (page 12-2)
– Fuel tank (page 6-3)
– Tube clamp (page 6-9)
Installation is in the reverse of removal.
Adjust the maximum speed (page 7-8).

SCREW (5 x 16 mm)
(If equipped)

CABLE HOLDER
(If equipped) CONTROL BASE ASSY.

REMOTO CABLES
(If equipped)
(Commercially available)

SCREW (4 x 6 mm)
(If equipped) GOVERNOR SPRING
INSTALLATION:
GOVERNOR ROD/THROTTLE Install with the long end of
RETURN SPRING the spring toward the
control base assy.
REMOVAL/INSTALLATION:
Hook the governor spring
Pull the carburetor assy. [1] to a
to the outer hole of the
point where the groove [2] of the
governor arm.
throttle arm lines up with the
governor rod [3], and then lift the
governor rod out of the hole of the OUTER HOLE
throttle arm and unhook the
throttle return spring [4].
[3]
[4] NUT (6 mm)

[1]

[2] GOVERNOR ARM

GOVERNOR ARM
BOLT

GOVERNOR ARM
SHAFT

BOLT (6 x 12 mm) (3)

7-3
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GOVERNOR SYSTEM
EXCEPT MANUAL OPERATION TYPE
Remove the following parts.
– Air cleaner (page 6-4)
– Muffler (page 12-2)
– Fuel tank (page 6-3)
– Tube clamp (page 6-9) (If equipped)
Installation is in the reverse of removal.
Adjust the governor (page 7-8)

GOVERNOR ROD/THROTTLE
RETURN SPRING
REMOVAL/INSTALLATION:
Pull the carburetor assy. [1] to a point
where the groove [2] of the throttle
arm lines up with the governor rod [3],
and then lift the governor rod out of CONTROL BASE ASSY.
the hole of the throttle arm and (If equipped)
unhook the throttle return spring [4].
[4] [3]

[1]
CONTROL BASE ASSY.
[2] (If equipped)

GOVERNOR SPRING
INSTALLATION:
Install with the long end
of the spring toward the
control base assy.
Hook the governor spring
to the outer hole of the
governor arm.
NUT (6 mm)

GOVERNOR ARM
(If equipped)

BOLT (6 x 12 mm) (3)

GOVERNOR ARM
(If equipped)

GOVERNOR ARM
BOLT

GOVERNOR ARM
SHAFT

7-4
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GOVERNOR SYSTEM
AUTO THROTTLE (IF EQUIPPED)
REMOVAL/INSTALLATION
Remove the fuel tank (page 6-3).

CHOKE RETURN
SPRING

BOLT (6 x 12 mm) (2) SCREW (5 x 8 mm) (2)

THROTTLE LEVER
To the units connected
from the engine.

SOLENOID

7-5
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GOVERNOR SYSTEM
CONTROL BASE ASSY.
DISASSEMBLY/ASSEMBLY
MANUAL OPERATION TYPE
Remove the control base assy (page 7-2).

CONTROL LEVER WASHER SELF-LOCK NUT (6 mm)

ASSEMBLY: ASSEMBLY:
Install the control lever washer by After tightening the nut fully,
aligning the cutout of the control loosen it 1–1/2 turns.
lever washer with the claw of the
control base.

LEVER SPRING
ASSEMBLY: SCREW (4 x 6 mm)
(If equipped)
Note the installation direction.

WIRE HOLDER
(If equipped)
SCREW (4 x 6 mm)
(If equipped)

WIRE HOLDER
(If equipped) CIRCLIP (5 mm)
(If equipped)
CONTROL LEVER
SPACER

CIRCLIP (5 mm)
(If equipped)

CONTROL LEVER
CLAW

CONTROL BASE

CONTROL ADJUST
SPRING

SCREW
(GX270H: 5 x 28 mm,
GX390H1: 5 x 32 mm)
(If equipped)
ASSEMBLY:
Adjust the maximum
speed (page 7-8). CABLE RETURN SPRING
INSTALLATION:
Install with the short end of
the spring toward the
control base.
Hook the cable return
STOPPER COLLAR spring to the hole of the
SCREW (5 x 25 mm) control lever.
(If equipped)
(If equipped)

7-6
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GOVERNOR SYSTEM
NON-HANDY LEVER A TYPE
Remove the control base assy (page 7-2).

CONTROL BASE

CONTROL ADJUST
SPRING

SCREW
(GX270H: 5 x 35 mm,
GX390H1: 5 x 45 mm)
ASSEMBLY:
Adjust the maximum
speed (page 7-8).

NON-HANDY LEVER B TYPE

Remove the control base assy (page 7-2).

CONTROL BASE

CONTROL ADJUST
SPRING

SCREW (5 x 35 mm)
ASSEMBLY:
Adjust the maximum
speed (page 7-8).

7-7
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GOVERNOR SYSTEM
MAXIMUM SPEED ADJUSTMENT
MANUAL CONTROL TYPE
Remove the fuel tank (page 6-3).
Loosen the nut (6 mm) [1] of the governor arm.
[3]
Turn the governor arm [2] counter clockwise to fully [5]
open the carburetor throttle valve [3].
Rotate the governor arm shaft [4] as far as it will go in
the same direction the governor arm moved to open the
throttle valve.
Tighten the nut (6 mm) securely.
Install the fuel tank (page 6-3).
Start the engine and allow it to warm up to normal
operating temperature.
Move the control lever [5] to run the engine at the
specified maximum speed, and hold the control lever.
Turn the screw [6] of the control to obtain the specified
maximum speed.
MAXIMUM SPEED: 3,850 ± 150 min-1 (rpm)
[4]

[6]

[2]

[1]

AUTO THROTTLE TYPE

Remove the fuel tank (page 6-3).
[3]
Loosen the two bolts (6 x 12 mm) [1], and move the
auto throttle assy. [2] away from the governor arm. [2]
Loosen the nut (6 mm) [3] on the governor arm bolt.

[1]

7-8
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GOVERNOR SYSTEM
Move the governor rod [1] end [2] of the governor arm in
the direction shown.
Move the governor spring [3] end [4] of the governor
arm in the direction shown.
Holding both sections of the governor arm in alignment [6]
so that the two stops are in contact with one another, [4] [2]
move the governor arm in the direction shown until the [5]
throttle is completely open, and hold it in that position.
[3]
Rotate the governor arm shaft [5] as far as it will go in
the same direction it was just moved by the governor
arm, and then tighten the nut (6 mm) [6].
There may be a slight bend in the governor arm when it
is released; this will not affect governor operation.

[1]

Move the auto throttle assy. [1] until its throttle lever [2]
just contacts the governor arm [3], and tighten the two
bolts (6 mm) [4].
[5] [4]
Install the fuel tank (page 6-3).
Turn the auto throttle switch to the OFF position, and
start the engine. Allow it to warm to normal operating
temperature.
Move the control lever to run the engine at the specified
[1]
maximum speed, and hold the control lever.
Turn the screw [5] to obtain the specified maximum
speed.
MAXIMUM SPEED: 3,850 ± 150 min-1 (rpm) CONTACT
Check the auto throttle speed, and adjust if necessary AREA
[3] [2]
(page 3-13).

SOLENOID (AUTO THROTTLE)

INSPECTION
Remove the fuel tank (page 6-3).
Connect a 12V battery [1] to the solenoid terminals [2]
and check for proper operation.
The throttle lever [3] and governor arm [4] should move
with the battery connected. The choke return spring [5]
should bring the throttle lever and governor arm to its
normal position when the battery is removed.
[5] [2]

[3]

[4]

[1]

7-9
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MEMO
62Z7B000.book 1 ページ ２０１２年９月２７日 木曜日 午前１０時２１分

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8. CHARGING SYSTEM

TOOL ·····························································8-2 COOLING FAN/FLYWHEEL REMOVAL/

INSTALLATION ············································ 8-5
8
SYSTEM DIAGRAM ······································8-3
CHARGE/LAMP COIL (IF EQUIPPED)
BEFORE TROUBLESHOOTING···················8-4 REMOVAL/INSTALLATION ························· 8-7

TROUBLESHOOTING···································8-4 CHARGE/LAMP COIL INSPECTION ··········· 8-8

8-1
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CHARGING SYSTEM
TOOL
CHARGING SYSTEM

Flywheel puller set

07935-8050004

8-2
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CHARGING SYSTEM
SYSTEM DIAGRAM
1 A/3 A CHARGE COIL TYPE:

Gr

(W)
(W)

(Gr)
(W)

(W)

(W)

(W)

(W)
MAIN FUSE CIRCUIT SILICON
CHARGE COIL PROTECTOR RECTIFIER
BATTERY

CONTROL BOX

8-3
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CHARGING SYSTEM
BEFORE TROUBLESHOOTING
• Use a known-good battery for troubleshooting.
• Check that the connectors are connected securely.
• Read the circuit tester's operation instructions carefully, and observe the instructions during inspection.
• Disconnect the battery cable before continuity inspection.

TROUBLESHOOTING
Abnormal
Check the fuse (page 11-7). Replace the fuse (page 11-4).

Normal

Abnormal
Check the charge / lamp coil (page 8-8). Replace the charge coil / lamp coil (page 8-7).

Normal

Abnormal
Check the circuit protector (page 11-7). Replace the circuit protector (page 11-4).

Normal

Abnormal
Check the silicon rectifier (page 11-6). Replace the silicon rectifier (page 11-4).

Normal

Check the harness connecting the charge

coil and battery for open or short circuit and
for proper connection.
If necessary, replace or repair the harness.

8-4
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CHARGING SYSTEM
COOLING FAN/FLYWHEEL REMOVAL/
INSTALLATION
REMOVAL
Remove the following parts:
– Fan cover (page 5-2).
– Ignition coil (page 9-4).

FLYWHEEL
SPECIAL WOODRUFF KEY (With starter)
(25 x 18 mm)

STARTER PULLEY
(With screen)

FLYWHEEL
(Without starter)

STARTER PULLEY
(Without screen)

COOLING FAN

FLYWHEEL SPECIAL NUT (16 mm)

REMOVAL: REMOVAL:
Hold the flywheel [1] with a commercially available strap wrench Hold the flywheel [1] with a commercially available
[2] and use the special tool to remove the flywheel. strap wrench [2] and remove the special nut (16
Do not hit the flywheel with a hammer. mm) [3].

TOOL: Take care not to damage the cooling fan.

FLYWHEEL PULLER SET [3] 07935-805004

[2]
[3] [3]

[1]

[2] [1]

8-5
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CHARGING SYSTEM
INSTALLATION
Clean the tapered parts [1] of dirt, oil, grease, and other
foreign material before installation. Be sure there are no [3]
metal parts or other foreign material on the magnet part [6]
[2] of the flywheel.
Set the special woodruff key (25 x 18 mm) [3] in the key
groove [4] of the crankshaft securely.
Set the flywheel [5] by aligning the key slot [6] with
special woodruff key on the crankshaft.

[4] [2]
The flywheel may push the special woodruff key (25 x
18 mm) out of its slot; check after installation.
[1] [5]

Attach the cooling fan [1] to the flywheel [2] by aligning

the three projections of the cooling fan with the holes of Align [3]
the flywheel.
Attach the starter pulley [3] by aligning the hole of the
pulley with the projection at the center of the cooling
fan.

Align

[2] [1]

Apply a light coat of oil to the threads and the seating (Threads and
surface of the special nut (16 mm) [1], and loosely [2]
[1] seating surface)
tighten the nut.
Hold the flywheel [2] with a commercially available strap
wrench [3], and tighten the special nut (16 mm) to the
specified torque.
WITH REDUCTION (GX390H1 ONLY):
TORQUE: 157 N·m (16.0 kgf·m, 116 lbf·ft)
[3]
OTHER TYPE:
TORQUE: 113 N·m (11.5 kgf·m, 83 lbf·ft)
Install the following parts:
– Ignition coil (page 9-4).
– Fan cover (page 5-2).

8-6
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CHARGING SYSTEM
CHARGE/LAMP COIL (IF EQUIPPED)
REMOVAL/INSTALLATION
Remove the following parts:
– Fan cover (page 5-2).
– Ignition coil (page 9-4).
– Remove the flywheel (page 8-5).
Remove the coil connector or connectors.
Installation is in the reverse of removal.
Install the cord clamp. (page 2-10)
Adjust the maximum speed (page 7-8)

12 V-50 W LAMP COIL TYPE:

CORD GROMMET

12 V-50 W LAMP COIL

BOLT (6 x 40 mm) (4)

CORD CLAMP

BOLT (6 x 12 mm)

1 A/3 A CHARGE COIL TYPE: 12 V-15 W/12 V-25 W LAMP COIL TYPE:
1 A/3 A
12 V-15 W/12 V-25 W LAMP COIL
CHARGE COIL CORD CLAMP CORD CLAMP

BOLT (6 x 12 mm) BOLT (6 x 12 mm)

CORD
CORD
GROMMET
GROMMET
3 A CHARGE COIL TYPE: BOLT (6 x 40 mm) (2) 12 V-15 W LAMP COIL TYPE: BOLT (6 x 32 mm) (2)
1 A CHARGE COIL TYPE: BOLT (6 x 35 mm) (2) 12 V-25 W LAMP COIL TYPE: BOLT (6 x 40 mm) (2)

8-7
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CHARGING SYSTEM
CHARGE/LAMP COIL INSPECTION
12 V-15 W/12 V-25 W LAMP COIL TYPE
Disconnect the lamp coil connectors [1].
[1]
Measure the resistance between the terminals of the
charge/lamp coil.
Resistance:
lamp coil 12 V-15 W: 1.04 – 1.56 Ω
lamp coil 12 V-25 W: 0.30 – 0.46 Ω
Check for continuity between each terminal and engine
ground.
There should be no continuity.
• If the measured resistance is not within the range
specification or if any wire has continuity to engine
ground, replace the lamp coil (page 8-7).
• If the resistance is good and the flywheel is ok,
replace the lamp coil and retest.

1 A/3 A CHARGE COIL/12 V-50 W

LAMP COIL TYPE
Disconnect the charge/lamp coil connector [1].
Check for continuity between terminal and engine
ground.
Resistance:
charge coil 1 A: 3.00 – 4.00 Ω
charge coil 3 A: 0.62 – 0.93 Ω
Lamp coil 12 V-50 W: 0.29 – 0.44 Ω [1]
There should be no continuity.
If the resistance is good and the flywheel is ok, replace
the charge/lamp coil and retest.

8-8
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9. IGNITION SYSTEM

SYSTEM DIAGRAM ······································9-2 IGNITION COIL AIR GAP CHECK/

ADJUSTMENT ·············································· 9-5
TROUBLESHOOTING···································9-3
SPARK TEST ················································ 9-5 9
IGNITION COIL REMOVAL/
INSTALLATION·············································9-4 SPARK PLUG CAP INSPECTION················ 9-5

IGNITION COIL INSPECTION ······················ 9-6

9-1
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IGNITION SYSTEM
SYSTEM DIAGRAM
IGNITION SYSTEM

ENGINE STOP SWITCH TYPE:

Bl
Bl

Y
Bl
Y
SPARK PLUG IGNITION COIL ENGINE STOP OIL ALERT UNIT OIL LEVEL SWITCH
SWITCH

CONTROL BOX TYPE:

Bl/R

(W)
Bl
Y

(Bl/Y)
(W)

(W)

(W)

(Bl)
(Y)

COMBINATION MAIN FUSE

OIL LEVEL SPARK IGNITION COIL SWITCH OIL ALERT UNIT
BATTERY
SWITCH PLUG

CONTROL BOX

9-2
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IGNITION SYSTEM
TROUBLESHOOTING
NO OR WEAK SPARK AT SPARK PLUG
Check the following before troubleshooting:
– Loose connectors
– Spark plug (page 3-9)
– Engine oil level (page 3-3)

Check the oil level switch (If equipped) (page 11-5)/ Replace the oil level switch (page 14-6).
Abnormal
oil alert unit (If equipped) (page 11-5). Replace the oil alert unit.
– Without control box (page 11-5)
– With control box (page 11-4)
Normal

Check for continuity between the engine wire Replace the engine wire harness.
Abnormal
harness connectors.

Normal

Check the engine stop switch (If equipped) (page 11- Abnormal Replace the engine stop switch (page 5-2)/
6)/combination switch (If equipped) (page 11-6). combination switch (page 11-4).

Normal

Check the ignition coil (page 9-6). Abnormal Replace the ignition coil (page 9-4).

Normal

Check the spark plug cap (page 3-9).

If necessary, replace the spark plug cap.

9-3
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IGNITION SYSTEM
IGNITION COIL REMOVAL/
INSTALLATION
Remove the following parts:
– Air cleaner (page 6-4)
– Fuel tank (page 6-3)
– Fan cover (page 5-2)

IGNITION COIL WIRE

INSTALLATION:
Clamp the ignition coil wire to the ribs of
the cylinder barrel as shown.

IGNITION COIL WIRE

RIBS

Viewed from above

SPARK PLUG CAP

IGNITION COIL
INSTALLATION: BREATHER
Install the Ignition coil as shown. TUBE

HIGH-TENSION
CORD FLANGE BOLT (6 x 28 mm) (2)

CARBURETOR HIGH-TENSION
INSULATOR CORD

9-4
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IGNITION SYSTEM
IGNITION COIL AIR GAP CHECK/
ADJUSTMENT
Remove the fan cover (page 5-2).
[2] 0.2 – 0.6 mm (0.01 – 0.02 in)
Insert the feeler gauge [1] of proper thickness between
the ignition coil [2] and the flywheel [3].
IGNITION COIL AIR GAP:
0.2 – 0.6 mm (0.01 – 0.02 in)

• Avoid the magnet part of the flywheel when

adjusting.
• Adjust the ignition coil air gap equally on both side.
If measured clearance is out of specification, adjust the
air gap. 0.2 – 0.6 mm
Loosen the two bolts (6 x 25 mm) [4]. [3] (0.01 – 0.02 in)
[1]
Insert the feeler gauge of proper thickness between the
ignition coil and flywheel.
Push the ignition coil firmly against the flywheel and
tighten the ignition coil bolts securely.
Remove the feeler gauge.

[4]

SPARK TEST
Inspect the following before spark test.
• Faulty spark plug
• Loose spark plug cap
• Water in the spark plug cap (Leaking the ignition coil
secondary voltage)
• Loose ignition coil connector.
Disconnect the spark plug cap from the spark plug.
Connect a known-good spark plug to the spark plug cap
and ground the spark plug to the cylinder head.
Crank the engine by pulling the recoil starter forcefully
and check whether sparks jump across the electrode.

SPARK PLUG CAP INSPECTION

Measure the resistance of the spark plug cap [1] by
attaching one ohmmeter probe to the terminal in the
spark plug cap and the other to the high-tension cord
terminal.

RESISTANCE: 7.5 – 12.5 kΩ (20°C/68°F)

If measured resistance is out of specification, replace
the spark plug cap.

9-5
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IGNITION SYSTEM
IGNITION COIL INSPECTION
Remove the fan cover (page 5-2).
PRIMARY SIDE
Disconnect the ignition coil connector [1].
[3]
Measure the resistance of primary coil by attaching one
ohmmeter probe to the ignition coil terminal [2] and the
other at the iron core [3].
RESISTANCE: 0.4 – 0.7 Ω
If measured resistance is out of specification, replace
the ignition coil.

[1] [2]

SECONDARY SIDE
Disconnect the spark plug cap from the high-tension
[1]
cord [1].
Measure the resistance of secondary coil by attaching
one ohmmeter probe to the high-tension cord and the
other at the iron core.
RESISTANCE: 8.9 – 13.5 kΩ
If measured resistance is out of specification, replace
the ignition coil.

9-6
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10. STARTING SYSTEM

SYSTEM DIAGRAM ····································10-2 RECOIL STARTER INSPECTION ·············· 10-8

TROUBLESHOOTING·································10-2 STARTER MOTOR REMOVAL/

INSTALLATION ·········································· 10-9
RECOIL STARTER REMOVAL/
INSTALLATION···········································10-3 STARTER MOTOR DISASSEMBLY/ 10
ASSEMBLY ··············································· 10-10
RECOIL STARTER Assy. DISASSEMBLY/
ASSEMBLY ·················································10-4 STARTER MOTOR INSPECTION ············ 10-12

10-1
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STARTING SYSTEM
SYSTEM DIAGRAM
STARTING SYSTEM

(Bl/W)

(Bl/W)
(W)

(W)

(W)

(W)
COMBINATION MAIN FUSE
STARTER SWITCH
BATTERY
MOTOR
CONTROL BOX

TROUBLESHOOTING
STARTER MOTOR DOES NOT OPERATE
Check the battery condition. Replace with a known-good battery.
Abnormal
If the battery runs down again, perform
the CHARGING SYSTEM
TROUBLESHOOTING (page 8-4).
Normal

Check the fuse (page 11-7). Replace the fuse (page 11-4).
Abnormal

Normal

Check the combination switch (page 11- Abnormal Replace the combination switch (page
6). 11-4).

Normal

Check the starter solenoid (page 10-12). Abnormal Replace the starter solenoid (page 10-10,
10-11).

Normal

Check the wire harness. Abnormal Replace the wire harness.

Normal

Disassemble the starter motor (page 10-

10, 10-11) and check the each parts
(page 10-12).

10-2
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STARTING SYSTEM
RECOIL STARTER REMOVAL/
INSTALLATION

RECOIL STARTER

FLANGE BOLT
(6 x 10 mm) (3)

10-3
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STARTING SYSTEM
RECOIL STARTER Assy.
DISASSEMBLY/ASSEMBLY

• Wear gloves and eye protection.

• During disassembly/assembly, take care not to
allow the spring to come out.

DISASSEMBLY
Remove the recoil starter Assy. (page 10-3).

RECOIL STARTER SETTING SCREW

RATCHET GUIDE

FRICTION SPRING

RATCHET (2) RETURN SPRING (2)

RECOIL STARTER REEL

RECOIL STARTER ROPE

RECOIL STARTER SPRING

STARTER GRIP

RECOIL STARTER CASE

10-4
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STARTING SYSTEM
ASSEMBLY

• Wear gloves and eye protection.

• During reassembly, take care not to allow the
spring to come out.

Hook the outer hook [1] of the recoil starter spring [2] to
[2] [3] [1]
the groove [3] in the recoil starter reel [4], and install the
spring by winding it.

[4]

Check the recoil starter rope [1] and replace it if it is

[2]
frayed or worn. [3]
Pass the rope through the hole [2] in the reel [3] and
then tie the rope as shown.
Wind the rope onto the reel 1-3/4 turns [4]
counterclockwise as shown and hook it to the notch [4]
in the reel.

[1]

Pass the rope [1] through hole [2] of the recoil starter [2]
[3] [1]
case [3] and starter grip [4] and then tie the rope as
shown.

[4]

10-5
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STARTING SYSTEM
Apply 1 – 2 g (0.04 – 0.07 oz) of grease to the shaft [1] [3]
of the case, and 1 – 2 g (0.04 – 0.07 oz) to the reel
sliding surface [2]
[1]
Install the reel [3] into the case by aligning the inner
hook [4] of the spring with the boss [5] of the case as
shown.

[4]

[2]
[5]
Apply grease to the sliding surface of the ratchets [1].
[2] [1]
Install the return springs [2] and ratchets into the reel as [1]
shown.

[2]

[2]
Install the friction spring [1] so that the end gap [2] is
[1]
positioned 90° from the cutout [3] in the ratchet guide [2]
[4].
[4]

90°

[3]

Install the ratchet guide [1] onto the reel. [2]

Install the setting screw [2] and tighten it to the specified
torque while holding the ratchet guide.
[1]
TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)

10-6
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STARTING SYSTEM
With the slack in the rope, turn the recoil starter reel [1] [3]
counterclockwise until the notch [2] align with the hole [1]
[3], then further turn it 3 turns to preload the recoil
starter spring.

[2]

Remove the slack by pulling the rope [1], unhook it from

[1]
the notch [2], and release the rope to wind in the reel
[3]. [3]

[2]
Pull the rope out of the reel [1] completely and check
[1] [2]
that the knot [2] of the rope comes to the hole [3] in the
case.
If the reel can be further turned from this position, the
assembly is normal. [3]
If the knot does not come to the hole, the recoil starter
spring is excessively preloaded.

Pull the starter grip [1] several times to inspect that the [3] [2]
ratchets [2] are operated properly (the ratchet ends [1]
come out from the ratchet guide [3]).

[2]

10-7
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STARTING SYSTEM
RECOIL STARTER INSPECTION
RECOIL STARTER OPERATION
Remove the recoil starter Assy. (page 10-3).
[2]
Pull the starter grip [1] several times to inspect that the
ratchets [2] are operated properly (the ratchet ends
come out from the ratchet guide [3]). [1]

[2] [3]

STARTER PULLEY
Remove the recoil starter Assy. (page 10-3).
[2]
Inspect the square dogs [1] of the starter pulley [2] for
deformation.

[1]

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STARTING SYSTEM
STARTER MOTOR REMOVAL/
INSTALLATION
Disconnect the starter motor wires from the starter
motor.
Remove the fan cover (page 5-2).

STARTER MOTOR

STARTER MOTOR

TERMINAL WIRE

STARTER MOTOR WIRE

FLANGE BOLT
(GX270H: 8 x 40 mm,
GX390H1: 8 x 35 mm) (2)

10-9
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STARTING SYSTEM
STARTER MOTOR DISASSEMBLY/
ASSEMBLY
Remove the starter motor (page 10-9).
GX270H:
HOUSING
ASSEMBLY:
WASHER
Make sure there is no
SCREW
obstruction on the magnets.
(5 x 14 mm) (2)
INSULATOR
ARMATURE INSPECTION:
SCREW WASHER Check for cracks or damage.
(5 x 32 mm) (4)
FLANGE
SCREW WASHER
NUT STARTER (4 x 14 mm) (2)
(6 mm) (2) SOLENOID
NEGATIVE
POSITIVE BRUSH BRUSH (2)

GASKET
DRIVE PINION
GEAR

OVERRUNNING CLUTCH

SCREW
(4 x 6 mm)
(2) REDUCTION
GEAR
BRUSH
STARTER
SPRING (4)
SOLENOID WIRE WASHER BRUSH HOLDER
DRIVE SIDE
HOUSING

CENTER BRACKET
PINION GEAR

10-10
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STARTING SYSTEM
GX390H1:

SCREW (5 x 32 mm) (4) HOUSING

5.0 N·m (0.5 kgf·m, 3.7 lbf·ft) ASSEMBLY:
NUT (6 mm) (2) Make sure there is no
2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) obstruction on the magnets.

LOCK WASHER (2)

GASKET
WASHER (4)

SCREW (5 x 14 mm) (2)

ARMATURE
5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)

DRIVE PINION
GEAR
STARTER RETAINER
SOLENOID WIRE CENTER BRACKET RING NUT (6 mm)
ASSY. 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft)

WASHER
STARTER
SOLENOID REDUCTION
GEAR
OVERRUNNING
CLUTCH
DRIVE SIDE
PINION GEAR HOUSING

STARTER
SOLENOID WIRE

BRUSH HOLDER INSTALLATION

(GX270H ONLY)
Note the installation direction.
[4]
Install the insulator [1], brush holder [2], negative brush
terminals [3], and two 4 x 14 mm screws [4] to the
center bracket as shown. [3]
[2]
Install the brush springs [5] and brushes, and push the
brushes in the holders with a suitable wire [6] so that
they do not interfere with the commutator.
[1]

[6] [5]

10-11
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STARTING SYSTEM
STARTER MOTOR INSPECTION
PERFORMANCE TEST
Measure starter performance while cranking the engine.
STARTER MOTOR PERFORMANCE:
UNDER LOAD:
CRANKING VOLTAGE: 9.9 V
CRANKING CURRENT: 103 A
ENGINE CRANKING SPEED: 2,300 min-1 (rpm) min.
NO LOAD:
CRANKING VOLTAGE: 11.5 V
CRANKING CURRENT: 31 A max.
• To get accurate results, the test must be conducted
in the normal ambient temperature.
• Battery: 55B24 (12 V 36 AH/5 HR)
• Battery cable: 15 sq. x 1.5 m (4.9 ft.) each for battery
positive cable and battery negative cable.
If the measurement is out of specification, disassemble
and inspect the starter motor.

STARTER SOLENOID
Remove the starter solenoid wire [1] from the starter
solenoid [2].
Connect the positive (+) lead of a 12 V battery to the
solenoid terminal and the negative (–) lead to the [2]
solenoid body. Measure the resistance between the
battery and starter motor terminals as shown.
Continuity should exist when the battery is connected
and not exist when the battery is disconnected.

[1]

BRUSH LENGTH
Measure the brush length.
If the negative brush length is less than the service limit,
replace the brush and brush holder.
If the positive brush length is less than the service limit,
replace the center bracket and brush holder.
STANDARD:
GX270H: 7.0 mm (0.28 in)
GX390H1: 10.5 mm (0.41 in)
SERVICE LIMIT:
GX270H: 3.5 mm (0.14 in)
GX390H1: 4.0 mm (0.16 in)

10-12
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STARTING SYSTEM
BRUSH CONTINUITY CHECK
Check for continuity between the positive (+) brushes [1]
[1] and negative (–) brushes [2].
There should be continuity between both the positive [2]
brushes.
There should be continuity between both the negative
brushes.
There should be no continuity from either positive brush [2]
to either negative brush.
[1]
If the correct continuity of the positive (+) brushes is not
obtained, replace the center bracket (page 10-10).
If the correct continuity of the negative (–) brushes is
not obtain, replace the negative (–) brushes.

ARMATURE
Visually inspect the commutator [1] surface for dust,
rust, or other damage.
If necessary, wipe it with a clean lint-free cloth.
If rusted or damaged, dress with a fine emery cloth.
[3] [2]
Measure the mica depth.
STANDARD: 1.0 mm (0.04 in)
SERVICE LIMIT: 0.2 mm (0.01 in)
[1]
If the mica depth is less than the service limit, replace
the armature.
Check the continuity as follows:
– There should be continuity between each segment
[2].
– There should be no continuity between each
segment and armature core [3].
– There should be no continuity between each [4]
segment and armature shaft [4].

OVERRUNNING CLUTCH
Check the pinion gear shaft [1] for smooth axial
movement. [2]

Apply oil or replace the overrunning clutch if necessary.

Check the pinion gear [2] operation by holding the
pinion gear shaft and turning the pinion gear. The pinion
gear should turn counterclockwise freely and should not
turn clockwise.
Check the pinion gear for wear or damage, and replace
the overrunning clutch if necessary.
If the pinion gear is worn or damaged, the flywheel ring
gear must be inspected. [1]

10-13
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STARTING SYSTEM
STARTER SOLENOID WIRE
Check the starter solenoid wire for continuity.

10-14
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11. OTHER ELECTRICAL

COMPONENT LOCATION ··························11-2 OIL LEVEL SWITCH INSPECTION ············ 11-5

CONTROL BOX REMOVAL/ ENGINE STOP SWITCH INSPECTION ······ 11-6

INSTALLATION···········································11-3
COMBINATION SWITCH INSPECTION ····· 11-6
CONTROL BOX DISASSEMBLY/
ASSEMBLY ·················································11-4 SILICON RECTIFIER INSPECTION ··········· 11-6 11
OIL ALERT UNIT REMOVAL/ CIRCUIT PROTECTOR INSPECTION········ 11-7
INSTALLATION···········································11-5
FUSE INSPECTION ···································· 11-7
OIL ALERT UNIT INSPECTION··················11-5

11-1
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OTHER ELECTRICAL
COMPONENT LOCATION
OTHER ELECTRICAL

WITHOUT CONTROL BOX:

OIL ALERT UNIT (If equipped)

ENGINE STOP SWITCH

(If equipped)

OIL LEVEL SWITCH (If equipped)

WITH CONTROL BOX:

CONTROL BOX

11-2
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OTHER ELECTRICAL
CONTROL BOX REMOVAL/
INSTALLATION
Disconnect the control box wires.
When installing, refer to the HARNESS AND TUBE
ROUTING (with circuit protector) (page 2-10).

ENGINE WIRE HARNESS

STARTER MOTOR WIRE

TERMINAL WIRE

OIL LEVEL
SWITCH WIRE

CHARGE COIL CORD

FLANGE BOLT (6 x 12 mm) (2)

CONTROL BOX

11-3
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OTHER ELECTRICAL
CONTROL BOX DISASSEMBLY/
ASSEMBLY
Remove the control box (page 11-3).

SPECIAL SCREW SILICON RECTIFIER

(6 x 12 mm) INSPECTION: (page 11-6) MAIN FUSE
INSPECTION: (page 11-7)
GX270H:
CONTROL BOX CASE QBE1, QXE9: 5 A
VKK: 15 A
GX390H1: 5 A

CASE MOUNTING BRACKET

OIL ALERT UNIT

INSPECTION: (page 11-5)

CONTROL PANEL

COMBINATION
SWITCH WASHER

COMBINATION SWITCH
INSPECTION: (page 11-6)
INSTALLATION:
CIRCUIT PROTECTOR
Align the tab [1] with the cutout
(If equipped)
in the case mounting bracket
and the control panel. INSPECTION: (page 11-7)
INSTALLATION:
COMBINATION SWITCH PROTECTOR LENS
Note the installation direction.
(If equipped)

SCREW (3 x 12 mm) (2)

SHORT
COMBINATION
SWITCH NUT
LONG
[1]

CONTROL PANEL

11-4
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OTHER ELECTRICAL
OIL ALERT UNIT REMOVAL/
INSTALLATION
With control box: Disassemble the control box (page 11-4). [2] [3]
Without control box: Disconnect the oil alert unit connectors [1].
Remove the bolt (6 x 12 mm) [2] and oil alert unit [3].
Installation is in the reverse order of removal.

• Route the wire harness properly (page 2-10).

[1]

OIL ALERT UNIT INSPECTION

Remove the oil alert unit.
[2] [3]
– Without control box (page 11-5)
– With control box (page 11-4)
Check the continuity between the terminals, and oil
alert unit body.
Unit: kΩ
(+)
Bl [1] Y [2] Body [3]
Bl [1] – 0.5 – 10
(–) Y [2] 0.5 – 10 –
Body [3] –

[1]

OIL LEVEL SWITCH INSPECTION

Check the oil level (page 3-3).
Without control box: Disconnect the oil alert unit connector [1].
With control box: Disconnect the oil level switch connector [1].
Check the continuity between the switch terminal and
engine ground.
There should be no continuity when the engine is full of
oil.
Drain the engine oil completely (page 3-3).
Check the continuity between the switch terminal and
engine ground.
There should be continuity.
Check the continuity between the switch terminals while [1]
filling the engine with oil.
The ohmmeter reading should go from continuity to no
continuity as the oil is filled.
If the correct continuity is not obtained, replace the oil
level switch (page 14-6).

11-5
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OTHER ELECTRICAL
ENGINE STOP SWITCH INSPECTION
Remove the engine wire harness connector [1].
Check the continuity between the terminals at each
switch position.
Switch position Continuity
ON No
OFF Yes
If the correct continuity is not obtained, replace the
engine stop switch (page 5-2).

[1]

COMBINATION SWITCH INSPECTION

Disconnect the combination switch connectors.
Check the continuity between the terminals at each
[3]
switch position.
[2]
Bl/R [1] Ground W [2] Bl/W [3]
OFF
ON
START
[1]
If the correct continuity is not obtained, replace the
combination switch (page 11-4).

CIRCUIT PROTECTOR

SILICON RECTIFIER INSPECTION

Remove the silicon rectifier (page 11-4).
Check continuity between the terminals. There should
be continuity in one direction only. Replace the rectifier
if there is continuity in both directions or in neither
direction.

11-6
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OTHER ELECTRICAL
CIRCUIT PROTECTOR INSPECTION
Remove the circuit protector (page 11-4).
Check the continuity between the terminals.
Switch position Continuity
ON Yes
OFF No
If the correct continuity is not obtained, replace the
circuit protector. ON

OFF

FUSE INSPECTION
Remove the main fuse (page 11-4).
Visually inspect the fuse to see if it is blown. BLOWN

Check continuity across the two blades.

Replace the fuse if it is blown or there is no continuity
across the blades.
MAIN FUSE:
GX270H:
QBE1, QXE9: 5 A
VKK: 15 A
GX390H1: 5A

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MEMO
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12. MUFFLER

MUFFLER REMOVAL/INSTALLATION······12-2 EXHAUST PIPE STUD BOLT

REPLACEMENT ········································· 12-4

12

12-1
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MUFFLER
MUFFLER REMOVAL/INSTALLATION
MUFFLER

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.
Allow it to cool before proceeding.

SOLID PROTECTOR TYPE

SPARK ARRESTER (If equipped)
TAPPING SCREW
(5 x 8 mm) (4) CLEANING:
Before installing, clean the spark arrester.
TAPPING SCREW
MUFFLER PROTECTOR
(4 x 6 mm) (3)
(If equipped)

TAPPING SCREW
(6 x 10 mm) GX270H:
TAPPING SCREW
(4 x 6 mm)
GX390H1:
TAPPING SCREW
MUFFLER CAP (5 x 8 mm)
(If equipped)
MUFFLER

MUFFLER GASKET
(If equipped)

MUFFLER
GASKET
(If equipped) EXHAUST
PIPE

EXHAUST PIPE
PROTECTOR
(If equipped)

EXHAUST
BOLT (6 x 12 mm) PIPE GASKET

NUT (8 mm) NUT (8 mm) (2)

24 N·m (2.4 kgf·m, 18 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft)

12-2
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MUFFLER
INNER/OUTER PROTECTOR TYPE

INNER MUFFLER PROTECTOR EXHAUST

PIPE GASKET
MUFFLER EXHAUST
PROTECTOR PIPE
SEALS
NUT (8 mm) (2)
24 N·m (2.4 kgf·m, 18 lbf·ft)

BOLT (8 x 20 mm) (2)

MUFFLER GASKET

TAPPING SCREW
(4 x 8 mm)

BOLT (6 x 10 mm)
MUFFLER
(If equipped)

TAPPING SCREW
(4 x 6 mm)

BOLTS (6 x 10 mm)

OUTER MUFFLER PROTECTOR

MUFFLER A
SPARK ARRESTER (If equipped)
(If equipped)
SPARK ARRESTER A (If equipped)

CLEANING:
Before installing, clean the spark arrester.

12-3
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MUFFLER
EXHAUST PIPE STUD BOLT
REPLACEMENT
Thread two nuts onto the exhaust pipe stud bolt [1] and
tighten them together, then use a wrench to turn the
stud bolt out.
Install new stud bolts.
SPECIFIED LENGTH:
8 x 32 mm: 16 mm (0.63 in)
[1]
SHORT

LONG

[1]

12-4
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13. CYLINDER HEAD/VALVES

TOOLS·························································13-2 CYLINDER HEAD/VALVES

INSPECTION··············································· 13-5
CYLINDER HEAD REMOVAL/
INSTALLATION···········································13-3 VALVE GUIDE REPLACEMENT ················ 13-8

CYLINDER HEAD DISASSEMBLY/ VALVE GUIDE REAMING ·························· 13-9

ASSEMBLY ·················································13-4
VALVE SEAT RECONDITIONING············ 13-10

13

13-1
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CYLINDER HEAD/VALVES
TOOLS
CYLINDER HEAD/VALVES

Valve guide driver, 6.45 x 11 mm Seat cutter, 29 mm (45° IN) Seat cutter, 27.5 mm (45° EX)
07742-0010200 07780-0010300 07780-0010200

Seat cutter, 35 mm (45° IN) Seat cutter, 33 mm (45° EX) Flat cutter, 30 mm (32° IN)
07780-0010400 07780-0012900 07780-0012200

Flat cutter, 28. mm (32° EX) Flat cutter, 35 mm (32° IN) Flat cutter, 33 mm (32° EX)
07780-0012100 07780-0012300 07780-0010800

Interior cutter, 37.5 mm (60° IN/EX) Cutter holder, 6.6 mm Valve guide reamer, 6.612 mm
07780-0014100 07781-0010202 07984-ZE20001

13-2
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CYLINDER HEAD/VALVES
CYLINDER HEAD REMOVAL/
INSTALLATION
Set the piston at top dead center of the cylinder
compression stroke (page 3-13).
Remove the following parts:
– Air cleaner (page 6-4)
– Carburetor (page 6-9)
– Control base assy (page 7-2)
– Muffler (page 12-2)
Installation is in the reverse order of removal.
Check the valve clearance, and if necessary, adjust the
clearance.

HEAD COVER PACKING

INSTALLATION:
Note the installation direction.

DOWEL PIN (12 x 20 mm) (2)

HEAD
COVER
PACKING

HEAD COVER

HEAD COVER
BOLT

FAN COVER

CYLINDER HEAD GASKET

CYLINDER HEAD
INSTALLATION:
(Apply to the Before installing the cylinder head, remove
FLANGE BOLT threads and any carbon deposits from the combustion
(10 x 80) (4) seating surface) chamber, and inspect the valve seat.
35 N·m (3.5 kgf·m, 26 lbf·ft) After installing the cylinder head, measure
HEAD COVER the cylinder compression.
REMOVAL/INSTALLATION:
Loosen and tighten the four 10 x 80 mm
HEAD COVER WASHER flange bolts in a crisscross pattern in 2 – 3
steps.

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CYLINDER HEAD/VALVES
CYLINDER HEAD DISASSEMBLY/
ASSEMBLY
Remove the cylinder head (page 13-3).

VALVE SPRING RETAINER

REMOVAL:
Push down and slide the valve spring retainer [1] EXHAUST VALVE
to the side so that the valve stem [2] slips (Sliding surface and stem end)
[2]
through the hole at the side of the valve spring ASSEMBLY:
retainer. Do not interchange with the intake valve.
Do not remove the valve spring retainers while
The exhaust valve is smaller than the
the cylinder head is installed to the cylinder
intake valve.
barrel, or the valve will drop into the cylinder.
INSTALLATION:
Do not interchange the intake and exhaust
retainers.
[1]

IN EX
SPARK PLUG CYLINDER HEAD
18 N·m (1.8 kgf·m, 13 lbf·ft)

VALVE SPRING SEAT

EXHAUST VALVE GUIDE

VALVE GUIDE CLIP

INTAKE VALVE
(Sliding surface and stem end)

ROTATOR ASSEMBLY:
Do not interchange with the
exhaust valve.
The intake valve is larger than
the exhaust valve.

INTAKE VALVE GUIDE

SHROUD

VALVE STEM SEAL

CT BOLT (6 x 12 mm)
PUSH ROD
GUIDE PLATE VALVE SPRING (2)
ROCKER ARM PIVOT
LOCK NUT (2) PUSH ROD (2)
ROCKER ARM PIVOT
10 N·m (1.0 kgf·m, 7 lbf·ft) BOLT (2) ASSEMBLY:
24 N·m (2.4 kgf·m, 18 lbf·ft) Before installing the push rods, check the ends of the push
rods for wear.
ROCKER ARM Be sure the ends of the push rods are firmly seated in the
PIVOT (2) valve lifters.
(Apply to the
threads and pivot) (Apply to the
tappet surface
VALVE ROCKER ARM and pivot)
ASSEMBLY:
Before installing the rocker arm, check for wear on
the surfaces of the rocker arm that contact the pivot
bolt, push rod, and valve stem.

13-4
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CYLINDER HEAD/VALVES
CYLINDER HEAD/VALVES
INSPECTION
CYLINDER COMPRESSION CHECK
Start the engine and warm up to normal operating
temperature. [2]
Turn the fuel valve lever to the OFF position, and then
remove the drain screw to drain the carburetor.
Remove the spark plug cap [1] from the spark plug.
Remove the spark plug using a spark plug wrench.
Pull the recoil starter several times to expel unburned
gas.
Attach a commercially available compression gauge [2]
to the spark plug hole.
[1]
Pull the recoil starter forcefully to measure stable
cylinder compression.
CYLINDER COMPRESSION:
1.37 MPa (14.0 kgf/cm2, 199 psi) / 1400 min-1 (rpm)

CYLINDER HEAD WARPAGE

Remove the carbon deposits from the combustion
chamber (page 3-15). [2] [1]
Check the spark plug hole and valve areas for cracks.
Check the cylinder head warpage using a straightedge
[1] and feeler gauge [2].
SERVICE LIMIT: 0.10 mm (0.004 in)
If the measurement is more than the service limit,
replace the cylinder head (page 13-4).

VALVE SEAT WIDTH

Remove the carbon deposits from the combustion
chamber (page 3-15). VALVE LAPPER
(Commercially
Inspect each valve for face irregularities. available)
If necessary, replace the valve (page 13-4).
Apply a light coat of Prussian Blue or erasable felt-
tipped marker ink to each valve seat.
Insert the valve, and snap it closed against its seat
several times. Be sure the valve does not rotate on the
seat.
The transferred marking compound will show any area
of the valve face that is not concentric.
Measure the valve seat width of the cylinder head. CONTACT TOO HIGH
STANDARD: 1.0 – 1.2 mm (0.04 – 0.05 in)
SERVICE LIMIT: 2.0 mm (0.08 in)
If the measurement is more than the service limit,
recondition the valve seat (page 13-10).
Check whether the valve seat contact area of the valve VALVE SEAT
is too high. WIDTH
If the valve seat is too high or too low, recondition the
valve seat (page 13-10).

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CYLINDER HEAD/VALVES
VALVE GUIDE I.D.
Ream the valve guide [1] to remove any carbon HANDLE
deposits before measuring.
(Commercially
TOOL: available)
Valve guide reamer, 6.612 mm [2] 07984-ZE20001
[2]

Turn the special tool (Valve guide reamer) clockwise, COMBUSTION

never counterclockwise. CHAMBER SIDE
Continue to rotate the special tool while removing it
from the valve guide. [1]

VALVE SPRING
SIDE

Measure and record each valve guide I.D.

GX270H:
STANDARD:
6.600 – 6.612 mm (0.2598 – 0.2603 in)
SERVICE LIMIT: 6.66 mm (0.262 in)
GX390H1:
STANDARD:
6.600 – 6.615 mm (0.2598 – 0.2604 in)
SERVICE LIMIT: 6.66 mm (0.262 in)
If the measured valve guide I.D. is more than the
service limit, replace the valve guide (page 13-8).

VALVE FACE
Inspect each valve for face irregularities.
If necessary, replace the valve (page 13-4).

VALVE FACE

13-6
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CYLINDER HEAD/VALVES
VALVE STEM O.D.
Inspect each valve for bending or abnormal stem wear.
If necessary, replace the valve (page 13-4).
Measure and record each valve stem O.D.
STANDARD:
IN: 6.575 – 6.590 mm (0.2588 – 0.2594 in)
EX: 6.535 – 6.550 mm (0.2573 – 0.2579 in)
SERVICE LIMIT:
IN: 6.44 mm (0.254 in)
EX: 6.40 mm (0.252 in)
If the measurement is less than the service limit,
replace the valve (page 13-4).

GUIDE-TO-STEM CLEARANCE
Subtract each valve stem O.D. from the corresponding
guide I.D. to obtain the guide-to-stem clearance.
GX270H:
STANDARD:
IN: 0.010 – 0.037 mm (0.0004 – 0.0015 in)
EX: 0.050 – 0.077 mm (0.0020 – 0.0032 in)
SERVICE LIMIT:
IN: 0.11 mm (0.004 in)
EX: 0.13 mm (0.005 in)
GX390H1:
STANDARD:
IN: 0.010 – 0.040 mm (0.0004 – 0.0016 in)
EX: 0.050 – 0.080 mm (0.0020 – 0.0032 in)
SERVICE LIMIT:
IN: 0.11 mm (0.004 in)
EX: 0.13 mm (0.005 in)
If the calculated clearance is more than the service limit,
replace the following:
– Valves (page 13-4)
– Valve guide (page 13-8)

VALVE SPRING FREE LENGTH

Measure the valve spring free length.

STANDARD: 39.0 mm (1.54 in)

SERVICE LIMIT: 37.5 mm (1.48 in)
If the measured length is less than the service limit,
replace the valve spring (page 13-4).

13-7
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CYLINDER HEAD/VALVES
VALVE SPRING PERPENDICULARITY
Measure the valve spring perpendicularity.

SERVICE LIMIT: 1.5°

If the measured perpendicularity is more than the
service limit, replace the valve spring (page 13-4).

PUSH ROD RUNOUT

Check both ends of the push rod for wear.
Check the push rod for straightness.
If necessary, replace the push rod (page 13-4).

VALVE GUIDE REPLACEMENT

Chill the replacement valve guides in the freezer
section of a refrigerator for about an hour.
Use a hot plate or oven to heat the cylinder head evenly
to 150°C (300°F).

To avoid burns, use heavy gloves when handling

the heated cylinder head.

• Do not use a torch to heat the cylinder head;

warpage of the cylinder head may result.
• Do not get the cylinder head hotter than 150°C
(300°F); excessive heat may loosen the valve seat.
Remove the heated cylinder head from the hot plate
and support it with wooden blocks.

13-8
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CYLINDER HEAD/VALVES
Drive the valve guides [1] out of the cylinder head from
the combustion chamber side. [2]

TOOL:
Valve guide driver, 6.45 x 11 mm [2] 07742-0010200 COMBUSTION
CHAMBER SIDE
[1]
When driving the valve guides out, be careful not to
damage the cylinder head.

Remove new valve guides from the refrigerator one at a

[1] [3]
time as needed.
Install new valve guides from the valve spring side of
the cylinder head.
TOOL: VALVE SPRING
Valve guide driver, 6.45 x 11 mm [1] 07742-0010200 SIDE
Exhaust valve guide [2]:
Drive the exhaust valve guide until the valve guide clip
[3] is fully seated as shown. [2]

Intake valve guide (4):

Drive the intake valve guide to the specified height
(measured from the end of the valve guide to the
cylinder head as shown). GX270H: 6 mm (0.2 in)
IN VALVE INSTALLATION HEIGHT: GX390H1: 5 mm (0.2 in)
GX270H: 6 mm (0.2 in)
GX390H1: 5 mm (0.2 in)
After installing the valve guide, check the guide for
damage.
Replace the valve guide if damaged.
Let the cylinder head cool to room temperature.
Ream the valve guide.

VALVE GUIDE REAMING

For best results, be sure the cylinder head is at room
temperature before reaming valve guides.
HANDLE
Coat the reamer and valve guide with cutting oil. (Commercially
available)
TOOL:
Valve guide reamer, 6.612 mm [1] 07984-ZE20001
COMBUSTION
Rotate the reamer clockwise through the valve guide
the full length of the reamer. CHAMBER SIDE
[1]

Turn the special tool (valve guide reamer) clockwise,

never counterclockwise.
Continue to rotate the special tool while removing it
from the valve guide. VALVE SPRING
SIDE
Thoroughly clean the cylinder head to remove any
cutting residue.

13-9
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CYLINDER HEAD/VALVES
Check the valve guide bore; it should be straight, round
and centered in the valve guide. Insert the valve and
check operation. If the valve does not operate
smoothly, the guide may have been bent during
installation.
Replace the valve guide if it is bent or damaged.
Check the valve guide-to-stem clearance.

VALVE SEAT RECONDITIONING

Thoroughly clean the combustion chamber and valve
seats to remove carbon deposits (page 3-15). VALVE LAPPER
(Commercially
Apply a light coat of Prussian Blue or erasable felt- available)
tipped marker ink to the valve seat.
Insert the valve, and snap it closed against its seat
several times. Be sure the valve does not rotate on the
seat. The transferred marking compound will show any
area of the seat that is not concentric.
Measure the valve seat width of the cylinder head.
STANDARD: 1.0 – 1.2 mm (0.04 – 0.05 in)
SERVICE LIMIT: 2.0 mm (0.08 in)
If the measurement is more than the service limit,
recondition the valve seat.
Check whether the valve seat contact area of the valve
is too high.
If the valve seat is too high or too low, recondition the
valve seat.
Valve seat cutters [1]/grinder or equivalent valve seat
refacing equipment is recommended to correct a worn
valve seat.
[1]

Turn the cutter clockwise, never counterclockwise.

Continue to turn the cutter as you lift it from the valve
seat.

13-10
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CYLINDER HEAD/VALVES
The 32° cutter removes material from the top edge
CONTACT TO STANDARD
(contact too high).
TOOLS (GX270H):
Cutter holder, 6.6 mm 07781-0010202
Flat cutter, 28 mm (32° EX) 07780-0012100
Flat cutter, 30 mm (32° IN) 07780-0012200
TOOLS (GX390H1):
Cutter holder, 6.6 mm 07781-0010202
VALVE FACE
Flat cutter, 33 mm (32° EX) 07780-0012900
Flat cutter, 35 mm (32° IN) 07780-0012300
The 60° cutter removes material from the bottom edge
(contact too low).
TOOLS: CONTACT TOO HIGH CONTACT TOO LOW
Cutter holder, 6.6 mm 07781-0010202
Interior cutter, 37.5 mm (60° IN/EX) 07780-0014100
Be sure that the width of the finished valve seat is within
specification.
STANDARD: 1.0 – 1.2 mm (0.04 – 0.05 in)
VALVE FACE VALVE FACE
SERVICE LIMIT: 2.0 mm (0.08 in)
Make a light pass with the 45° cutter to remove any
possible burrs at the edge of the seat.
TOOLS (GX270H):
Cutter holder, 6.6 mm 07781-0010202
Seat cutter, 27.5 mm (45° EX) 07780-0010200 VALVE FACE VALVE FACE
Seat cutter, 29 mm (45° IN) 07780-0010300
TOOLS (GX390H1):
Cutter holder, 6.6 mm 07781-0010202
Seat cutter, 33 mm (45° EX) 07780-0010800 32°
Seat cutter, 35 mm (45° IN) 07780-0010400
60°
After resurfacing the seats, inspect for even valve
seating.
Apply Prussian Blue compound or erasable felt-tipped
marker ink to the valve seat. Insert the valve, and snap
it closed against its seat several times. Be sure the
valve does not rotate on the seat.
The seating surface, as shown by the transferred
marking compound, should have good contact all the
way around.
Thoroughly clean the cylinder head to remove any
cutting residual.
Lap the valves into their seats, using a commercially
available valve lapper [1] and lapping compound. [1]
After lapping, wash all residual compound off the
cylinder head and valve.

• Do not push the valve against the seat with force

during lapping. Apply a light pass with the valve
lapper.
• Avoid lapping the valve in the same position as it
causes uneven wear. Lap the valve by turning the
lapper slowly.
• Take care not to allow the lapping compound to
enter the gap between the stem and guide.
Adjust the valve clearance after assembly (page 3-13).

13-11
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MEMO
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14. CRANKCASE

TOOLS·························································14-2 CRANKSHAFT/BALANCER WEIGHT

BEARING/OIL SEAL REPLACEMENT
CRANKCASE COVER REMOVAL/ (CRANKCASE COVER SIDE) ·················· 14-24
INSTALLATION···········································14-4
CRANKSHAFT BEARING REPLACEMENT
CRANKSHAFT/BALANCER/PISTON (FLYWHEEL SIDE) ··································· 14-26
REMOVAL/INSTALLATION························14-6
GX270H CRANKSHAFT OIL SEAL
BALANCER WEIGHT/CAMSHAFT REPLACEMENT (CYLINDER BARREL
INSTALLATION (GX390H1 ONLY)·············14-7 SIDE) ························································· 14-27

REDUCTION UNIT DISASSEMBLY/ GX390H1 BALANCER WEIGHT BEARING/

ASSEMBLY ·················································14-8 GOVERNOR ARM SHAFT OIL SEAL/ 14
CRANKSHAFT OIL SEAL REPLACEMENT
(CYLINDER BARREL SIDE)····················· 14-27
CLUTCH WEIGHT HOLDER Assy.
DISASSEMBLY/ASSEMBLY ····················14-11
GX270H CRANKSHAFT/P.T.O.SHAFT OIL
SEAL REPLACEMENT (1/2 REDUCTION
GOVERNOR DISASSEMBLY/ CLUTCH TYPE) ········································ 14-28
ASSEMBLY ···············································14-12
GX390H1 COUNTERSHAFT/P.T.O. SHAFT
PISTON DISASSEMBLY/ASSEMBLY······14-13 BEARING/OIL SEAL REPLACEMENT (1/6
REDUCTION GEAR TYPE) ······················ 14-30
CRANKCASE COVER/CYLINDER BARREL/
PISTON/CONNECTING ROD/CRANKSHAFT/ GX270H COUNTERSHAFT/P.T.O. SHAFT
CAMSHAFT INSPECTION ························14-14 BEARING REPLACEMENT (CRANKCASE
COVER SIDE) ··········································· 14-32
REDUCTION UNIT INSPECTION ·············14-21
GX390H1 COUNTERSHAFT/P.T.O. SHAFT
BEARING REPLACEMENT (CRANKCASE
COVER SIDE) ··········································· 14-33

14-1
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CRANKCASE
TOOLS
CRANKCASE

Sliding hammer weight Bearing driver attachment, 32 x 35 mm Attachment, 42 x 47 mm

07741-0010201 07746-0010100 07746-0010300

Attachment, 52 x 55 mm Attachment, 72 x 75 mm Inner driver handle, 40 mm

07746-0010400 07746-0010600 07746-0030100

Attachment, 30 mm Attachment, 35 mm Pilot, 15 mm

07746-0030300 07746-0030400 07746-0040300

Pilot, 20 mm Pilot, 30 mm Pilot, 35 mm

07746-0040500 07746-0040700 07746-0040800

14-2
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CRANKCASE
Pilot, 14 mm Driver handle Bearing remover shaft set, 15 mm
07746-0041200 07749-0010000 07936-KC10500

Bearing remover shaft set, 25 mm Attachment, 45 x 50 mm Attachment, 62 x 64 mm

07936-ZV10100 07946-6920100 07947-6340400

14-3
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CRANKCASE
CRANKCASE COVER REMOVAL/
INSTALLATION
EXCEPT E TYPE
Drain the engine oil (page 3-3).
Remove the key (7 x 7 x 33 mm)/(6.3 x 6.3 x 43 mm) (If
equipped).

CRANKCASE COVER
(Without reduction)

KEY (7 x 7 x 33 mm)/
(6.3 x 6.3 x 43 mm)
(If equipped)

OIL FILLER CAP

DOWEL PIN (8 x 12 mm) (2)

BOLT (8 x 40 mm) (7)

24 N·m (2.4 kgf·m, 18 lbf·ft)

CASE COVER PACKING

CRANKCASE COVER
(With reduction)

OIL FILLER CAP

(With oil level gauge)

OIL FILLER CAP PACKING (2)

14-4
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CRANKCASE
E TYPE
Drain the engine oil (page 3-3).

DOWEL PIN (8 x 12 mm) (2)

CASE COVER PACKING

BOTTOM RUBBER
(LARGE) (2)

CRANKCASE COVER

BOTTOM RUBBER
(SMALL)

OIL FILLER CAP

OIL FILLER CAP

PACKING

DUCT COVER
(If equipped)

BOLT (5 x 10 mm) (3)

(If equipped)
BOLT (8 x 40 mm) (7)
24 N·m (2.4 kgf·m, 18 lbf·ft)

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CRANKCASE
CRANKSHAFT/BALANCER/PISTON
REMOVAL/INSTALLATION
Remove the following:
– Cylinder head (page 13-3)
– Fuel tank (page 6-3)
– Flywheel (page 8-5)

PISTON
LOCK PIN (10 mm)
INSTALLATION: INSTALLATION:
Install the lock pin immediately after installing the governor arm Install the piston to the cylinder
shaft in the direction as shown. barrel with the mark on the piston
head toward the push rod hole of the
The 10 mm lock pin must be installed with the straight side of the cylinder head.
10 mm lock pin against the groove of the governor arm shaft.

MARK

SEALING WASHER
(12 mm) (2)

Viewed from cylinder head side

OIL LEVEL
SWITCH
VALVE LIFTER
NUT (10 mm)
REMOVAL:
10 N·m (1.0
When removing the
kgf·m, 7 lbf·ft)
valve lifters, mark so
that the intake and
exhaust sides can be
distinguished.
INSTALLATION:
GROOVE
OIL DRAIN Attach the valve lifters
BOLT (2) to the cylinder barrel
23 N·m (2.3 immediately before
kgf·m, 17 lbf·ft) installing the camshaft.
WASHER
(8.2 x 17 x 0.8 mm)
GOVERNOR ARM SHAFT
CAMSHAFT

CRANKSHAFT
O-RING INSTALLATION:
BALANCER Before installing the crankshaft,
OIL LEVEL SWITCH check the oil seal of the cylinder
WEIGHT
(If equipped) barrel for damage or hardening.
(GX390H1 ONLY)
FLANGE BOLT Be careful not to damage the oil
(6 x 12 mm) (2) seal when installing the crankshaft.

CONNECTING ROD BOLT

14 N·m (1.4 kgf·m, 10 lbf·ft) CONNECTING ROD LOWER
(Apply to the threads and INSTALLATION:
seating surface) Set the connecting rod lower with
the oil dipper toward the camshaft.

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CRANKCASE
BALANCER WEIGHT/CAMSHAFT
INSTALLATION (GX390H1 ONLY)
Install the balancer weight [1] to the cylinder barrel by
[1] [3]
aligning the punch marks [2] of the balancer weight and
the crankshaft [3] (marked on the balancer drive gear
[4]).

[2] [4]

Install the camshaft [1] to the cylinder barrel by aligning

the punch marks [2] of the camshaft and the crankshaft [3] [4]
[3] (marked on the timing gear [4]).

[2]

[1]

14-7
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CRANKCASE
REDUCTION UNIT DISASSEMBLY/
ASSEMBLY
Remove the recoil starter (page 10-3).
Drain the oil (page 3-3).
After installation, fill the oil (page 3-3).
1/2 REDUCTION CHAIN TYPE (GX270H
ONLY)

DRIVE SPROCKET
(Gear teeth)
INSPECTION: (page 14-21)

P.T.O. DRIVE CHAIN

INSPECTION: (page 14-21)
ASSEMBLY:
Attach the P.T.O. drive chain to the P.T.O.
shaft and sprocket, and install in the
crankcase cover as a set.

KEY
(7 x 7 x 33 mm)

WASHER (8 mm)

DOWEL PIN (2)

BOLT (8 x 25 mm)
P.T.O. SHAFT
24 N·m (2.4 kgf·m, 18 lbf·ft) (Gear teeth and journal)
INSPECTION: (page 14-21)

CHAIN CASE COVER PACKING

OIL SEAL (30 x 46 x 8 mm) BEARING (6206)

CHAIN CASE COVER

ASSEMBLY:
Be careful not to damage the oil seal lips.

BOLT (8 x 40 mm) (6)

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CRANKCASE
1/2 REDUCTION CLUTCH TYPE
(GX270H ONLY)

REDUCTION OIL CAP/

OIL LEVEL GAUGE
REDUCTION CASE O-RING
ASSEMBLY:
Be careful not to damage the lip of the oil
seal when installing it onto the crankshaft. CRANKSHAFT OIL
SEAL (30 x 46 x 8 mm)

DRIVE SPROCKET
ASSEMBLY:
Attach the drive chain to
the P.T.O. shaft and DOWEL
CLUTCH
sprocket and install in the PIN (2)
CENTER
reduction case as a set. KEY

THRUST
WASHER

CLUTCH CLUTCH FRICTION DISC (2)

CENTER ASSEMBLY:
Note the installation sequence.

BEARING (6205)
BOLT (8 x 32 mm) (4)

DRIVE CHAIN
BEARING (6206)
SPRING WASHER
P.T.O. SHAFT CLUTCH PLATE (2)
ASSEMBLY:
Note the installation sequence.
BOLT (6 x 50 mm) (9)
CLUTCH WEGHT HOLDER Assy.
ASSEMBLY:
Align the groove of the clutch weight holder
P.T.O. SHAFT OIL SEAL with clutch center key when installing.
(30 x 50 x 7 mm)
BOLT (8 x 35 mm)

KEY (7 x 7 x 33 mm)

SEALING WASHER REDUCTION COVER PACKING

REDUCTION COVER
ASSEMBLY:
Be careful not to damage the lip of the oil OIL DRAIN BOLT
seal when installing the P.T.O. shaft into 23 N·m (2.3 kgf·m, 17 lbf·ft)
the reduction cover.

14-9
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CRANKCASE
1/6 REDUCTION GEAR TYPE
(GX390H1 ONLY)

BOLT (8 x 25 mm)
24 N·m (2.4 kgf·m, 18 lbf·ft) PRIMARY DRIVE GEAR
DISASSEMBLY/ASSEMBLY: KEY
Hold the 16 mm special nut of the WASHER (7 x 7 x 33mm/
flywheel and remove/install the 8 x 25 mm
(8 mm) 6.3 X 6.3 X 43mm)
flange bolt.
16 mm SPECIAL NUT

DOWEL PIN
(8 x 14 mm) (2)

P.T.O. SHAFT

GEAR CASE COVER

COUNTERSHAFT

FLANGE BOLT (8 x 40 mm) (6)

24 N·m (2.4 kgf·m, 18 lbf·ft)

CHAIN CASE COVER PACKING

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CRANKCASE
CLUTCH WEIGHT HOLDER Assy.
DISASSEMBLY/ASSEMBLY
Remove the clutch weight holder Assy. (page 14-9).

CLUTCH WEIGHT (48)

CLUTCH FREE SPRING (4)

CLUTCH SPRING HOLDER (4)

CLUTCH PRESSURE PLATE

CLUTCH WEIGHT CENTER

CLUTCH WEIGHT HOLDER

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CRANKCASE
GOVERNOR DISASSEMBLY/
ASSEMBLY
Remove the crankcase cover (page 14-4).

GOVERNOR SLIDER
GOVERNOR HOLDER CLIP ASSEMBLY:
ASSEMBLY: Spread the governor weight to
GOVERNOR SLIDER Install firmly into the groove of install the governor slider.
ASSEMBLY: the governor shaft. After installing the governor slider,
Spread the governor weight to check to be sure it moves smoothly.
install the governor slider.
After installing the governor slider, GX270H:
check to be sure it moves smoothly.
GOVERNOR HOLDER CLIP
ASSEMBLY:
Install firmly into the groove of
the governor shaft.
GOVERNOR WEIGHT (3)
REASSEMBLY: GOVERNOR WEIGHT (2)
After installing the governor weight, REASSEMBLY:
check to be sure they moves After installing the governor weight,
smoothly. check to be sure they moves
smoothly.

GOVERNOR WEIGHT PIN (2)

GOVERNOR WEIGHT HOLDER

GOVERNOR WEIGHT PIN (3) PLAIN WASHER (6 mm)

GOVERNOR WEIGHT HOLDER

PLAIN WASHER (6 mm)

GROOVE

CRANKCASE COVER

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CRANKCASE
PISTON DISASSEMBLY/ASSEMBLY
Remove the piston(page 14-6).

MAKER MARK
TOP RING
PISTON RING SET
(Chrome plated)
ASSEMBLY:
120°
Be sure that the top ring and second ring are SECOND RING
120°
not interchanged. 120°
Install the top ring and second ring on the
piston with the maker mark side facing up.
Check that the piston rings rotate smoothly SIDE RAIL
after installing them.
Space the piston ring end gaps 120 degrees 10 mm (0.4 in) OIL RING
apart, and do not align the ring end gaps with SPACER (COMBINATION
the piston pin bore. RING)
SIDE RAIL
PISTON
10 mm (0.4 in)
TOP RING

SECOND RING
MARK
OIL RING

PISTON
PISTON PIN

PISTON PIN CLIP (2)

ASSEMBLY:
Install by setting one end of the piston pin
clip in the groove of the piston pin bore,
holding the other end with long needle
pliers, and rotating the clip in.
Do not align the end gap of the piston pin
clip with the cutout of the piston pin bore.

END GAP LONG END CONNECTING ROD UPPER

ASSEMBLY:
Set the connecting rod upper with
the long end toward the mark on
the piston head.

CUTOUT PISTON PIN CLIP

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CRANKCASE
CRANKCASE COVER/CYLINDER
BARREL/PISTON/CONNECTING ROD/
CRANKSHAFT/CAMSHAFT
INSPECTION
CAMSHAFT JOURNAL I.D.:
CRANKCASE COVER SIDE
Measure the camshaft journal I.D. of the crankcase
cover.

STANDARD: 16.000 – 16.018 mm

(0.6299 – 0.6306 in)
SERVICE LIMIT: 16.05 mm (0.632 in)
If the measurement is more than the service limit,
replace the crankcase cover (page 14-4).
Inspect the camshaft O.D. with this inspection (page
14-20).

CAMSHAFT JOURNAL I.D.:

CYLINDER BARREL SIDE
Measure the camshaft journal I.D. of the cylinder barrel
assembly.

STANDARD: 16.000 – 16.018 mm

(0.6299 – 0.6306 in)
SERVICE LIMIT: 16.05 mm (0.632 in)
If the measurement is more than the service limit,
replace the cylinder barrel.
Inspect the camshaft O.D. with this inspection (page
14-20).

CYLINDER SLEEVE I.D.

Measure and record the cylinder I.D. at three levels in
both the “X” axis (perpendicular to crankshaft) and the
“Y” axis (parallel to crankshaft). Take the maximum X
reading to determine cylinder wear and taper.
GX270H: Y TOP
STANDARD: 77.000 – 77.017 mm
(3.0315 – 3.0322 in)
SERVICE LIMIT: 77.17 mm (3.0381 in) MIDDLE

GX390H1:
STANDARD: 88.000 – 88.017 mm BOTTOM
(3.4646 – 3.4652 in)
SERVICE LIMIT: 88.170 mm (3.4710 in)
If the measurement is more than the service limit,
replace the cylinder barrel (page 14-6).
Inspect the piston skirt O.D. with this inspection (page
14-15).

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CRANKCASE
PISTON SKIRT O.D.
Measure and record the piston skirt O.D. at a point 10
mm (0.4 in) from the bottom of the skirt and 90 degrees
to the piston pin bore.
GX270H:
90°
STANDARD: 76.975 – 76.985 mm
(3.0305 – 3.0309 in)
SERVICE LIMIT: 76.85 mm (3.026 in)
GX390H1:
STANDARD: 87.975 – 87.985 mm
(3.4636 – 3.4640 in)
SERVICE LIMIT: 87.85 mm (3.459 in)
If the measurement is less than the service limit,
replace the piston (page 14-13).
10 mm
Inspect the cylinder sleeve I.D. with this inspection (0.4 in)
(page 14-14).

PISTON-TO-CYLINDER CLEARANCE
Subtract the piston skirt O.D. from the cylinder sleeve
I.D. to obtain the piston-to-cylinder clearance.
STANDARD: 0.015 – 0.042 mm
(0.0006 – 0.0017 in)
SERVICE LIMIT: 0.12 mm (0.005 in)
If the calculated clearance is more than the service
limit, replace the piston (page 14-13) and recheck the
clearance.
If the clearance is still more than the service limit with
the new piston, replace the cylinder barrel (page 14-6).

PISTON PIN BORE I.D.

Measure and record the piston pin bore I.D. of the
piston.
GX270H:
STANDARD: 18.002 – 18.008 mm
(0.7087 – 0.7090 in)
SERVICE LIMIT: 18.042 mm (0.7103 in)
GX390H1:
STANDARD: 20.002 – 20.008 mm
(0.7875 – 0.7877 in)
SERVICE LIMIT: 20.042 mm (0.7891 in)
If the measurement is less than the service limit,
replace the piston (page 14-13).
Inspect the piston pin O.D. with this inspection (page
14-16).

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CRANKCASE
PISTON PIN O.D.
Measure and record the piston pin O.D. at three points
(both ends and middle). Take the minimum reading to
determine piston pin O.D.
GX270H:
STANDARD: 17.994 – 18.000 mm
(0.7084 – 0.7087 in)
SERVICE LIMIT: 17.950 mm (0.7067 in)
GX390H1:
STANDARD: 19.994 – 20.000 mm
(0.7872 – 0.7874 in)
SERVICE LIMIT: 19.950 mm (0.7854 in)
If the measurement is less than the service limit,
replace the piston pin.
Inspect the piston pin bore I.D. (page 14-15).
Inspect the connecting rod small end I. D. (page 14-18)
with this inspection.

PISTON PIN-TO-PISTON PIN BORE

CLEARANCE
Subtract the piston pin O.D. from the piston pin bore
I.D. to obtain the piston pin-to-piston pin bore
clearance.
STANDARD:
0.002 – 0.014 mm (0.0001 – 0.0006 in)

SERVICE LIMIT: 0.08 mm (0.003 in)

If the calculated clearance is more than the service limit,
replace the piston pin (page 14-13) and recheck the
clearance.
If the clearance is still more than the service limit with
the new piston pin, replace the piston (page 14-13).

PISTON RING SIDE CLEARANCE

Measure the clearance between each piston ring and
ring groove of the piston using a feeler gauge.

STANDARD:
Top: 0.015 – 0.050 mm
(0.0006 – 0.0020 in)
Second: 0.030 – 0.065 mm
(0.0012 – 0.0026 in)
SERVICE LIMIT:
Top/second: 0.15 mm (0.006 in)
If any of the measurements is more than the service
limit, inspect the piston ring width.
If the piston ring width is normal, replace the piston
(page 14-13) and reinspect the clearance.
If necessary, replace the piston rings (top, second, oil)
as a set (page 14-13) and reinspect the clearance.
If any of the measurements is still more than the service
limit with the new piston rings, replace the piston (page
14-13).

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CRANKCASE
PISTON RING WIDTH
Measure each piston ring width.
STANDARD:
Top: 1.170 – 1.190 mm
(0.0460 – 0.0469 in)
Second: 1.155 – 1.175 mm
(0.0455 – 0.0463 in)
SERVICE LIMIT:
Top: 1.140 mm (0.0449 in)
Second: 1.140 mm (0.0449 in)
If any of the measurements is less than the service
limit, replace the piston rings (top, second, oil) as a set
(page 14-13).

PISTON RING END GAP

Before inspection, check whether the cylinder sleeve
I.D. is within the specification.
Measure each piston ring end gap using a feeler gauge.
STANDARD:
Top: 0.200 – 0.350 mm
(0.0079 – 0.0138 in)
Second: 0.350 – 0.550 mm
(0.0138 – 0.0217 in)
Oil (side rail) 0.2 – 0.7 mm (0.01 – 0.03 in)
SERVICE LIMIT:
Top: 1.0 mm (0.04 in)
Second: 1.0 mm (0.04 in)
PISTON RING
Oil (side rail) 1.0 mm (0.04 in)
If any of the measurements is more than the service
limit, replace the piston rings (top, second, oil) as a set
(page 14-13).

CONNECTING ROD BIG END SIDE

CLEARANCE
Measure the clearance between the connecting rod big
end and crankshaft using a feeler gauge.
STANDARD: 0.10 – 0.40 mm (0.004 – 0.016 in)
SERVICE LIMIT: 1.0 mm (0.04 in)
If the measurement is more than the service limit,
replace the connecting rod (page 14-13) and recheck
the clearance.
If the clearance is still more than the service limit with
the new connecting rod, replace the crankshaft (page
14-6).

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CRANKCASE
CONNECTING ROD SMALL END I.D.
Measure the connecting rod small end I.D.
GX270H:
STANDARD: 18.005 – 18.020 mm
(0.7089 – 0.7094 in)
SERVICE LIMIT: 18.07 mm (0.711 in)
GX390H1:
STANDARD: 20.005 – 20.020 mm
(0.7876 – 0.7882 in)
SERVICE LIMIT: 20.07 mm (0.790 in)
If the measurement is more than the service limit,
replace the connecting rod (page 14-13).

CONNECTING ROD BIG END I.D.

Apply engine oil to the connecting rod bolt threading
surface.
Set the connecting rod lower to the connecting rod
upper and tighten the connecting rod bolts to the
specified torque.
TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft)
Measure the connecting rod big end I.D.
GX270H:
STANDARD: 33.025 – 33.039 mm
(1.3002 – 1.3007 in)
SERVICE LIMIT: 33.07 mm (1.302 in)
GX390H1:
STANDARD: 36.025 – 36.039 mm
(1.4183 – 1.4189 in)
SERVICE LIMIT: 36.07 mm (1.420 in)
If the measurement is more than the service limit,
replace the connecting rod (page 14-13).

CRANKPIN O.D.
Measure the crankpin O.D. of the crankshaft.
GX270H:
STANDARD: 32.975 – 32.985 mm
(1.2982 – 1.2986 in)
SERVICE LIMIT: 32.92 mm (1.296 in)
GX390H1:
STANDARD: 35.975 – 35.985 mm
(1.4163 – 1.4167 in)
SERVICE LIMIT: 35.93 mm (1.415 in)
If the measurement is less than the service limit,
replace the crankshaft (page 14-6).

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CRANKCASE
CONNECTING ROD BIG END OIL
CLEARANCE
Clean all oil from the crankpin and connecting rod big
end surface.
Apply engine oil to the connecting rod bolt threading
surface.
Place a piece of plastigauge on the crankpin, install the
connecting rod upper and the connecting rod lower, and
tighten the connecting rod bolts to the specified torque.
TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft)

Do not rotate the crankshaft while the plastigauge is in

place.

Remove the connecting rod and measure the

plastigauge.

STANDARD: 0.040 – 0.064 mm

(0.0016 – 0.0025 in)
SERVICE LIMIT: 0.12 mm (0.005 in)
If the clearance is more than the service limit, inspect
the connecting rod big end I.D. and the crankpin O.D.
If necessary replace the part that is not within the
service limit and reinspect the clearance.

CRANKSHAFT RUNOUT
Set the crankshaft on V-blocks and measure the runout
L, P TYPE ONLY:
using a dial indicator.
MEASURE POINT
[1] 16 mm (0.6 in)
[2] GX270H: 16 mm (0.6 in)
GX390H1: 17 mm (0.7 in)
[3] GX270H L TYPE: 31 mm (1.2 in)
GX270H P TYPE: 32 mm (1.3 in)
GX390H1 L TYPE: 36 mm (1.4 in) [3]
GX390H1 P TYPE: 32 mm (1.3 in)

SERVICE LIMIT: 0.10 mm (0.004 in)

If the measured runout is more than the service limit, [1] [2]
replace the crankshaft (page 14-6).

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CRANKCASE
CAMSHAFT CAM HEIGHT
Measure the cam height of the camshaft.
GX270H:
STANDARD:
IN: 31.945 – 32.145 mm (1.2577 – 1.2655 in)
EX: 31.666 – 31.866 mm (1.2467 – 1.2546 in)
SERVICE LIMIT:
IN: 31.35 mm (1.234 in)
EX: 31.35 mm (1.234 in)
GX390H1:
STANDARD:
IN: 32.498 – 32.698 mm (1.2794 – 1.2873 in)
EX: 31.985 – 32.185 mm (1.2592 – 1.2671 in)
SERVICE LIMIT:
IN: 32.198 mm (1.2676 in)
EX: 29.886 mm (1.1766 in)
If the measurement is less than the service limit,
replace the camshaft(page 14-6).

CAMSHAFT O.D.
Measure the camshaft O.D.of the camshaft.

STANDARD: 15.966 – 15.984 mm

(0.6286 – 0.6293 in)
SERVICE LIMIT: 15.92 mm (0.627 in)
If the measurement is less than the service limit,
replace the camshaft (page 14-6).

DECOMPRESSOR WEIGHT
Check for worn and weakened spring.
If the return spring [1] is worn or weakened, replace the
weight return spring.
Check that the decompressor weight moves smoothly.
If the decompressor weight does not move correctly,
replace the camshaft (page 14-6). [1]

14-20
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CRANKCASE
RADIAL BALL BEARING
Clean the bearing with solvent and dry it thoroughly.
Turn the inner race (outer race: cylinder barrel side
crankshaft bearing only) of the radial ball bearing with
your finger and check for play.
Replace the radial ball bearing if it is noisy or has
excessive play.

REDUCTION UNIT INSPECTION

RADIAL BALL BEARING
Clean the bearing with solvent and dry it thoroughly.
Turn the inner race of the radial ball bearing with your
finger and check for play.
Replace the radial ball bearing if it is noisy or has
excessive play.

CHAIN TYPE
P.T.O. SHAFT, DRIVE SPROCKET, DRIVE CHAIN
Check the following for wear or damage:
[2]
– P.T.O. shaft [1]
– Drive sprocket [2]
– Drive chain [3]

• Replace the P.T.O. shaft, drive sprocket and drive

chain as a set.

[3] [1]

14-21
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CRANKCASE
CLUTCH TYPE
CLUTCH FRICTION DISC
Measure the clutch friction disc thickness.

STANDARD: 3.5 mm (0.14 in)

SERVICE LIMIT: 3.0 mm (0.12 in)

CLUTCH PLATE
Check the clutch plate warpage on a flat plate using a
feeler gauge.

SERVICE LIMIT: 0.1 mm (0.004 in)

P.T.O. SHAFT, DRIVE SPROCKET, DRIVE CHAIN,

CLUTCH CENTER
Check the following for wear or damage:
[4]
– P.T.O. shaft [1]
– Drive sprocket [2]
– Drive chain [3]
– Clutch center [4]

• Replace the P.T.O. shaft, drive sprocket and drive

chain as a set.
Check the grooves of the drive sprocket for damage or
wear caused by the clutch plate, replace it if necessary.
Check the drive sprocket bushing [5] for damage or
excessive wear, replace the drive sprocket if necessary.
[1] [2] [5] [3]

14-22
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CRANKCASE
GEAR TYPE
PRIMARY DRIVE GEAR
Check for worn and weakened primary drive gear.
If necessary, replace the primary drive gear (page 14-
10).

P.T.O. SHAFT
Check for worn and weakened gear of the P.T.O. shaft.
If necessary, replace the P.T.O. shaft (page 14-10).

COUNTERSHAFT
Check for worn and weakened gears of the
countershaft.
If necessary, replace the countershaft (page 14-10).

14-23
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CRANKCASE
CRANKSHAFT/BALANCER WEIGHT
BEARING/OIL SEAL REPLACEMENT
(CRANKCASE COVER SIDE)
CRANKSHAFT BEARING
Drive out the radial ball bearing [1].
Drive a new bearing [2] until it is fully seated on the end [1]
using the special tools.
TOOLS:
GX270H (6206):
Attachment, 62 x 64 mm [3] 07947-6340400
Pilot, 30 mm [4] 07746-0040700
Driver handle [5] 07749-0010000

GX390H1 (6207):
Attachment, 72 x 75 mm [3] 07746-0010600
Pilot, 35 mm [4] 07746-0040800
Driver handle [5] 07749-0010000

[5]

[3]

[2]

[4]

CRANKSHAFT OIL SEAL

Remove the oil seal from the crankcase cover.
Drive a new oil seal [1] in the position as shown using
the special tools. [3]

TOOLS:
GX270H (30 x 46 x 8 mm):
Attachment, 45 x 50 mm [2] 07946-6920100 [2]
Driver handle [3] 07749-0010000 [1]
GX270H:
GX390H1 (35 x 52 x 8 mm): 1.0 mm (0.04 in)
Attachment, 52 x 55 mm [2] 07746-0010400
GX390H1:
Driver handle [3] 07749-0010000
2.0 mm (0.08 in)
Apply grease to the lip of a oil seal.

(Lips)

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CRANKCASE
BALANCER WEIGHT BEARING (6202)
(GX390H1 ONLY)
Pull out the radial ball bearing [1] using the special
tools.

TOOLS:
Bearing remover shaft set, [3]
15 mm [2] 07936-KC10500
Sliding hammer weight [3] 07741-0010201
Drive a new bearing [4] until it is fully seated on the end
using the special tools.
TOOLS:
Attachment, 32 x 35 mm [5] 07746-0010100 [2]
Pilot, 15 mm [6] 07746-0040300
Driver handle [7] 07749-0010000

[1]

[7]

[5]

[4]

[6]

14-25
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CRANKCASE
CRANKSHAFT BEARING
REPLACEMENT (FLYWHEEL SIDE)
CRANKSHAFT BEARING (6206)
Install the 16 mm special nut [1] tightening the flywheel
to protect the crankshaft threads.
[2] [1]
Pull out the radial ball bearing [2] using a commercially
available bearing puller [3].
Drive a new bearing [4] until it is fully seated on the end
using the special tools and hydraulic press.
TOOLS:
GX270H (6206):
Attachment, 30 mm [5] 07746-0030300
Inner driver handle, 40 mm [6] 07746-0030100

GX390H1 (6207):
Attachment, 35 mm [5] 07746-0030400 [3]
Inner driver handle, 40 mm [6] 07746-0030100

[6]

[5]

[4]

14-26
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CRANKCASE
GX270H CRANKSHAFT OIL SEAL
REPLACEMENT (CYLINDER BARREL
SIDE)
CRANKSHAFT OIL SEAL (30 x 46 x 8
mm)
Remove the oil seal from the cylinder barrel.
[3]
Drive a new oil seal [1] in the position as shown using
the special tools.
TOOLS:
Attachment, 45 x 50 mm [2] 07946-6920100 [2]
Driver handle [3] 07749-0010000
[1]
Apply grease to the lip of a oil seal.
2.0 mm (0.08 in)

(Lips)

GX390H1 BALANCER WEIGHT

BEARING/GOVERNOR ARM SHAFT OIL
SEAL/CRANKSHAFT OIL SEAL
REPLACEMENT (CYLINDER BARREL
SIDE)
BALANCER WEIGHT BEARING (6202)
Pull out the radial ball bearing [1] using the special
tools.

TOOLS: [3]
Bearing remover shaft set,
15 mm [2] 07936-KC10500
Sliding hammer weight [3] 07741-0010201
Drive a new bearing [4] until it is fully seated on the end
using the special tools.
TOOLS: [2]
Attachment, 32 x 35 mm [5] 07746-0010100
Pilot, 15 mm [6] 07746-0040300
Driver handle [7] 07749-0010000 [1]

[7]

[5]

[4]

[6]

14-27
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CRANKCASE
GOVERNOR ARM SHAFT OIL SEAL (8
x 14 x 5 mm)
Remove the oil seal from the cylinder barrel.
Drive a new oil seal [1] in the position as shown using [3]
the special tools.
TOOLS:
Pilot, 14 mm [2] 07746-0041200 [2] [1]
Driver handle [3] 07749-0010000
Apply grease to the lip of a oil seal.
0 – 0.5 mm
(0 – 0.02 in)

(Lips)
CRANKSHAFT OIL SEAL (35 x 52 x 8
mm)
Remove the oil seal from the cylinder barrel.
[3]
Drive a new oil seal [1] in the position as shown using
the special tools.
TOOLS:
Attachment, 52 x 55 mm [2] 07746-0010400 [2]
Driver handle [3] 07749-0010000
[1]
Apply grease to the lip of a oil seal.
2.0 mm (0.08 in)

(Lips)

GX270H CRANKSHAFT/P.T.O.SHAFT
OIL SEAL REPLACEMENT (1/2
REDUCTION CLUTCH TYPE)
P.T.O.SHAFT OIL SEAL (30 x 50 x 7
mm)
Remove the oil seal from the reduction cover.
Drive a new oil seal [1] in the position as shown using
the special tools. [3]
TOOLS:
Attachment, 45 x 50 mm [2] 07946-6920100
Driver handle [3] 07749-0010000
[2]
Apply grease to the lip of a oil seal.
[1]

(Lips)

14-28
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CRANKCASE
CRANKSHAFT OIL SEAL (30 x 46 x 8
mm)
Remove the oil seal from the reduction case.
Drive a new oil seal [1] in the position as shown using
the special tools. [3]
TOOLS:
Attachment, 45 x 50 mm [2] 07946-6920100
Driver handle [3] 07749-0010000
[2]
Apply grease to the lip of a oil seal.
[1]

(Lips)

P.T.O. SHAFT BEARING (6205)

Pull out the P.T.O. shaft bearing [1] using the special
tools.

TOOLS:
Bearing remover shaft set,
25 mm [2] 07936-ZV10100
Sliding hammer weight [3] 07741-0010201 [3]
Drive a new P.T.O. shaft bearing [4] until it is fully
seated on the end using the special tools.
TOOLS:
Bearing driver attachment, [2]
52 x 55 mm [5] 07746-0010400
Pilot, 25 mm [6] 07746-0040600
Driver handle [7] 07749-0010000
[1]

[7]

[5]
[4]

REDUCTION COVER SIDE P.T.O.

SHAFT BEARING (6206)
REDUCTION COVER SIDE P.T.O. SHAFT BEARING
(6206)
Remove the oil seal and drive out the P.T.O. shaft
[4] [2]
bearing.
Drive a new P.T.O. shaft bearing [1] until it is fully
seated on the end using the special tools.
TOOLS:
Bearing driver attachment,
62 x 64 mm [2] 07947-6340400
Pilot, 30 mm [3] 07746-0040700
Driver handle [4] 07749-0010000

[3] [1]

14-29
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CRANKCASE
GX390H1 COUNTERSHAFT/P.T.O.
SHAFT BEARING/OIL SEAL
REPLACEMENT (1/6 REDUCTION
GEAR TYPE)
COUNTERSHAFT BEARING (6202)
(6302)
Pull out the radial ball bearing [1] using the special
tools.

TOOLS: [3]
Bearing remover shaft set,
15 mm [2] 07936-KC10500
Sliding hammer weight [3] 07741-0010201
Drive a new bearing [4] until it is fully seated on the end
using the special tools.
TOOLS: [2]
Attachment, 32 x 35 mm [5] 07746-0010100
Pilot, 15 mm [6] 07746-0040300
Driver handle [7] 07749-0010000
[1]

[7]

[4]
[5]

[6]

14-30
62Z7B000.book 31 ページ ２０１２年９月２７日 木曜日 午前１０時２１分

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CRANKCASE
P.T.O. SHAFT BEARING (6206)
Drive out the radial ball bearing [1].
Drive a new bearing [2] until it is fully seated on the end
using the special tools.
TOOLS:
Attachment, 62 x 64 mm [3] 07947-6340400
Pilot, 30 mm [4] 07746-0040700
Driver handle [5] 07749-0010000

[1]

[5] [2]

[3]

[4]
P.T.O. SHAFT OIL SEAL (30 x 46 x 8
mm)
Remove the oil seal from the crankcase cover.
[3]
Drive a new oil seal [1] in the position as shown using
the special tools. [2]
TOOLS:
Attachment, 45 x 50 mm [2] 07946-6920100
Driver handle [3] 07749-0010000
Apply grease to the lip of a oil seal.
2.0 mm (0.08 in)

(Lips) [1]

14-31
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CRANKCASE
GX270H COUNTERSHAFT/P.T.O.
SHAFT BEARING REPLACEMENT
(CRANKCASE COVER SIDE)
P.T.O. SHAFT BEARING (6204)
Remove the crankcase cover (page 14-4).
Drive out the radial ball bearing [1].
Drive a new bearing [2] until it is fully seated on the end
using the special tools.
TOOLS:
Attachment, 42 x 47 mm [3] 07746-0010300
Pilot, 20 mm [4] 07746-0040500 [1]
Driver handle [5] 07749-0010000

[5]

[3]

[2]

[4]

14-32
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CRANKCASE
GX390H1 COUNTERSHAFT/P.T.O.
SHAFT BEARING REPLACEMENT
(CRANKCASE COVER SIDE)
COUNTERSHAFT BEARING (6202)
Remove the crankcase cover (page 14-4).
Drive out the radial ball bearing [1] using the special
tools.
Drive a new bearing [2] until it is fully seated on the end
using the special tools.
TOOLS:
Attachment, 32 x 35 mm [3] 07746-0010100
Pilot, 15 mm [4] 07746-0040300
Driver handle [5] 07749-0010000 [1]

[5]

[3]

[4] [2]

14-33
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CRANKCASE
P.T.O. SHAFT BEARING (6204)
Remove the crankcase cover (page 14-4).
Drive out the radial ball bearing [1].
Drive a new bearing [2] until it is fully seated on the end
using the special tools.
TOOLS:
Attachment, 42 x 47 mm [3] 07746-0010300
Pilot, 20 mm [4] 07746-0040500 [1]
Driver handle [5] 07749-0010000

[5]

[3]
[2]

[4]

14-34
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15. WIRING DIAGRAMS

HOW TO READ A WIRING DIAGRAM & WIRING DIAGRAMS ··································· 15-4

RELATED INFORMATION··························15-2

15

15-1
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WIRING DIAGRAMS
HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION
WIRING DIAGRAMS

The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained
in this section.
HOW TO READ CONNECTOR DRAWINGS
Connector drawings show the terminal arrangement, terminal No., number of pins, and the shape of terminal (male or female).
Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors are
shown for the dedicated connectors.
The double frame connectors represent the male connectors and the single frame connectors represent the female connectors.
Both the male and female connectors are shown by viewing them from the terminal side.

FEMALE CONNECTOR VIEWING DIRECTION

LOCK

VIEWING DIRECTION MALE CONNECTOR

CONNECTOR No.
TERMINAL ARRANGEMENT
The connector drawing shows the terminal arrangement of
the connector with the lock of the connector toward up.

FEMALE CONNECTOR DRAWING

(SINGLE FRAME)
Female connector viewed from the
terminal side.
CONNECTOR No.
LOCK
MALE CONNECTOR DRAWING
(DOUBLE FRAME)
Male connector viewed from the
terminal side.

TERMINAL No.
The system drawing shows the No.9 terminal of the
connector.

15-2
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WIRING DIAGRAMS
HOW TO READ WIRING DIAGRAM

SYMBOL OF TERMINAL
It shows the shape of each
terminal to identify whether it is a
male or female terminal.
3
10 5 9 4 6 1 2 7

G/Bl
G/W
R/W
G/R

Br
Br

G
Y
TERMINAL No. T5
G
G
C8 T3 C9 T8
R T7
20A 30A W
R
T4
10 INVERTER UNIT C7 W C10 T6
13
1 4 3 2

MAIN(U)
2 1 3

MAIN(V) AC1 R R R R
MAIN(W) AC2 W W W
-vdc G G

5
2 1

SUB(V)
SUV(N)
10 9 7 8 2 1 5 3 4

ECO (G / W)
11 HZ
VCC (R/W)
PL (G / R )
2
PL (G / B l )

6 2 3 4 1
VCC B (Bu) R ES
N.C. B (Y) G IND(-)
N.C. A (R) Y IND(+)
V2 A (W) Y LS
RXD G E CPU IGNITION CONTROL MODULE
1 2

Reg
TXD ES (R)

7 10 5
E G Bl/Bu EX
Bl/R IC
4 Bu PC
G

G FRAME GND
2 7 4 5 9 10 1 6

(Br)
(Br)
(Y)
GND2
G
(B l / B u)
(Bu) T1
W/ R W /R (+)
(-) DC RECEPTACLE
Bl/R B l /R
C1 1 T2
(Bl) 1
2 1 4 3

1 2

W (B l / R ) Bl /R
ENGINE STOP SWITCH
R Bl Bl
Y
Bu
Bl Black Br Brown
2
Y Yellow O Orange
Bu Blue Lb Light blue
G Green Lg Light green
Indicates the ground.
R Red P Pink
(Circled GND followed with W White Gr Gray
No. in white background)

CONNECTOR/TERMINAL No.
Every connector and terminal has a number to help the users find the location and shape of
the connector and the terminal arrangement by referring to the “Connector general layout
drawing” and/or the “Connector drawing.” All the connector/terminal numbers shown in this
Service Manual are either of those shown in this section.

: Connector that relays from a harness to a harness (Circled No. in black background)
: Connector that connects to electrical equipment (Circled No. in white background)
: Connector (Circled C followed with No. in white background)
: Terminal (Circled T followed with No. in white background)
: Ground (Circled GND followed with No. in white background)

15-3
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WIRING DIAGRAMS
WIRING DIAGRAMS
NO CHARGE COIL TYPE

1 A/3 A CHARGE COIL TYPE

15-4
62Z7B000.book 1 ページ ２０１２年９月２７日 木曜日 午前１０時２１分

INDEX
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INDEX
AIR CLEANER CHECK/CLEANING/REPLACEMENT ···3-6 GX390H1 BALANCER WEIGHT BEARING/GOVERNOR
A

AIR CLEANER REMOVAL/INSTALLATION ···················6-4 ARM SHAFT OIL SEAL/CRANKSHAFT OIL SEAL
AUTO THROTTLE (IF EQUIPPED) REMOVAL/ REPLACEMENT (CYLINDER BARREL SIDE) ·········· 14-27
INSTALLATION·······························································7-5 GX390H1 COUNTERSHAFT/P.T.O. SHAFT BEARING
BALANCER WEIGHT/CAMSHAFT INSTALLATION REPLACEMENT (CRANKCASE COVER SIDE)········ 14-33
B

(GX390H1 ONLY) ·························································14-7 GX390H1 COUNTERSHAFT/P.T.O. SHAFT BEARING/OIL

BEFORE TROUBLESHOOTING SEAL REPLACEMENT (1/6 REDUCTION GEAR
CHARGING SYSTEM ················································8-4 TYPE) ········································································· 14-30
TROUBLESHOOTING ···············································4-2 HARNESS AND TUBE ROUTING································ 2-10
H

CARBURETOR BODY CLEANING ······························6-15 HOW TO READ WIRING DIAGRAM & RELATED
C

CARBURETOR DISASSEMBLY/ASSEMBLY ··············6-11 INFORMATION····························································· 15-2

CARBURETOR INSPECTION ······································6-15 IDLE SPEED CHECK/ADJUSTMENT·························· 3-13
I

CARBURETOR REMOVAL/INSTALLATION··················6-9 IGNITION COIL AIR GAP CHECK/ADJUSTMENT ········ 9-5

CHARGE/LAMP COIL (IF EQUIPPED) REMOVAL/ IGNITION COIL INSPESTION········································ 9-6
INSTALLATION·······························································8-7 IGNITION COIL REMOVAL/INSTALLATION ················· 9-4
CHARGE/LAMP COIL INSPECTION······························8-8 LUBRICATION & SEAL POINT ······································ 2-6
L

CHOKE DIAPHRAGM DISASSEMBLY/ASSEMBLY····6-14 MAINTENANCE SCHEDULE ········································· 3-2

M

CHOKE DIAPHRAGM INSPECTION····························6-16 MAINTENANCE STANDARDS ······································ 2-2

CHOKE SET REPLACEMENT ·····································6-18 MAXIMUM SPEED ADJUSTMENT ································ 7-8
CIRCUIT PROTECTOR INSPECTION ·························11-7 MUFFLER REMOVAL/INSTALLATION························ 12-2
CLUTCH WEIGHT HOLDER Assy. DISASSEMBLY/ OIL ALERT UNIT INSPECTION ··································· 11-5
O

ASSEMBLY·································································14-11 OIL ALERT UNIT REMOVAL/INSTALLATION············· 11-5

COMBINATION SWITCH INSPECTION·······················11-6 OIL LEVEL SWITCH INSPECTION······························ 11-5
COMBUSTION CHAMBER CLEANING ·······················3-15 P.T.O. DIMENSIONAL DRAWINGS····························· 1-13
P

COMPONENT LOCATION PERFORMANCE CURVES············································ 1-7

OTHER ELECTRICAL ··············································11-2 PILOT SCREW REPLACEMENT ································· 6-17
CONTROL BASE ASSY. DISASSEMBLY/ PISTON DISASSEMBLY/ASSEMBLY························ 14-13
ASSEMBLY·····································································7-6 RECOIL STARTER Assy. DISASSEMBLY/
R

CONTROL BOX DISASSEMBLY/ASSEMBLY ·············11-4 ASSEMBLY ·································································· 10-4

CONTROL BOX REMOVAL/INSTALLATION···············11-3 RECOIL STARTER INSPECTION································ 10-8
COOLING FAN/FLYWHEEL REMOVAL/ RECOIL STARTER REMOVAL/INSTALLATION ········· 10-3
INSTALLATION·······························································8-5 REDUCTION CASE OIL LEVEL CHECK/CHANGE······· 3-4
CRANKCASE COVER REMOVAL/INSTALLATION·····14-4 REDUCTION UNIT DISASSEMBLY/REASSEMBLY ··· 14-8
CRANKCASE COVER/CYLINDER BARREL/PISTON/ REDUCTION UNIT INSPECTION ······························ 14-21
CONNECTING ROD/CRANKSHAFT/CAMSHAFT SEDIMENT CUP CLEANING ········································· 3-9
S

INSPECTION ······························································14-14 SERIAL NUMBER LOCATION ······································· 1-2

CRANKSHAFT BEARING REPLACEMENT (FLYWHEEL SILICON RECTIFIER INSPECTION ···························· 11-6
SIDE)···········································································14-26 SOLENOID (AUTO THROTTLE) INSPECTION············· 7-9 16
CRANKSHAFT/BALANCER WEIGHT BEARING/OIL SEAL SPARK ARRESTER CLEANING·································· 3-12
REPLACEMENT (CRANKCASE COVER SIDE) ········14-24 SPARK PLUG CAP INSPECTION ································· 9-5
CRANKSHAFT/BALANCER/PISTON REMOVAL/ SPARK PLUG CHECK/ADJUSTMENT ·························· 3-9
INSTALLATION·····························································14-6 SPARK PLUG REPLACEMENT··································· 3-11
CYLINDER HEAD DISASSEMBLY/ASSEMBLY ··········13-4 SPARK TEST ································································· 9-5
CYLINDER HEAD REMOVAL/INSTALLATION············13-3 STARTER MOTOR DISASSEMBLY/ASSEMBLY······ 10-10
CYLINDER HEAD/VALVES INSPECTION ···················13-5 STARTER MOTOR INSPECTION······························ 10-12
CYLINDER STUD BOLT REPLACEMENT···················6-18 STARTER MOTOR REMOVAL/INSTALLATION ········· 10-9
DIMENSIONAL DRAWINGS···········································1-9 SYSTEM DIAGRAM
D

DIMENSIONS AND WEIGHTS SPECIFICATIONS ········1-4 CHARGING SYSTEM ················································ 8-3

ENGINE OIL LEVEL CHECK/CHANGE ·························3-3 IGNITION SYSTEM ··················································· 9-2
E

ENGINE SPECIFICATIONS ···········································1-5 STARTING SYSTEM ··············································· 10-2

ENGINE STOP SWITCH INSPECTION ·······················11-6 TOOL
T

EXHAUST PIPE STUD BOLT REPLACEMENT···········12-4 CHARGING SYSTEM ················································ 8-2

FAN COVER REMOVAL/INSTALLATION ······················5-2 FUEL SYSTEM ·························································· 6-2
F

FUEL TANK AND FILTER CLEANING ·························3-15 TOOLS

FUEL TANK REMOVAL/INSTALLATION ·······················6-3 CRANKCASE··························································· 14-2
FUEL TUBE CHECK·····················································3-16 CYLINDER HEAD/VALVES ····································· 13-2
FUSE INSPECTION······················································11-7 SERVICE INFORMATION ········································· 2-7
GOVERNOR ARM/CONTROL BASE ASSY. REMOVAL/ TORQUE VALUES ························································· 2-5
G

INSTALLATION·······························································7-2 TROUBLESHOOTING
GOVERNOR DISASSEMBLY/ASSEMBLY ················14-12 CHARGING SYSTEM ················································ 8-4
GX270H COUNTERSHAFT/P.T.O. SHAFT BEARING IGNITION SYSTEM ··················································· 9-3
REPLACEMENT (CRANKCASE COVER SIDE) ········14-32 STARTING SYSTEM ··············································· 10-2
GX270H CRANKSHAFT OIL SEAL REPLACEMENT TROUBLESHOOTING ··············································· 4-2
(CYLINDER BARREL SIDE)·······································14-27 TYPE CODE ··································································· 1-3
GX270H CRANKSHAFT/P.T.O.SHAFT OIL SEAL VALVE CLEARANCE CHECK/ADJUSTMENT ············ 3-13
V

REPLACEMENT (1/2 REDUCTION CLUTCH VALVE GUIDE REAMING ············································ 13-9

TYPE)··········································································14-28 VALVE GUIDE REPLACEMENT·································· 13-8
VALVE SEAT RECONDITIONING ····························· 13-10
WIRING DIAGRAMS ···················································· 15-4
W

16-1