A Few Words About Safety: How To Use This Manual

gx240ut2_gx270ut2_gx340ut2_gx390ut2
How to use this manual

A Few Words About Safety
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 un-

safe 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 practice, 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 pre-

cautions 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 engine-power equipment 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 battery 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.
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
CYLINDER HEAD/VALVES 12
CRANKCASE 13
MUFFLER 14
WIRING DIAGRAMS 15
INDEX
SUPPLEMENT Y

INTRODUCTION
This manual covers the service and repair procedures for Honda GX240R2/RT2/U2/UT2, GX270UT2, GX340R2/RT2/U2/UT2, and
GX390RT2/T2/UT2 engines.
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.
American Honda Motor Co., Inc. 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.
© American Honda Motor Co., Inc.

SERVICE PUBLICATION OFFICE
Date of Issue: October 2010

SERVICE RULES
• Use genuine Honda 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 would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommended 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 water resistant molybdenum disulfide grease (containing more than 3% molybdenum
disulfide, NLGI #2 or equivalent).
Example: UNILITE M No.2 manufactured by KYODO YUSHI, Japan
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.

ABBREVIATIONS
Throughout this manual, the following abbreviations are used to identify the respective parts or systems
Abbrev. term Full term
ACG Alternator
A/F Air Fuel Ratio
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 Con-
trol
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
1. SPECIFICATIONS
SERIAL NUMBER LOCATION . . . . . . . . . . 1-2 PERFORMANCE CURVES
TYPE CODE GX240. . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
GX240 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 GX270. . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
GX270 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 GX340. . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
GX340 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 GX390. . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
GX390 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 DIMENSIONAL DRAWINGS
DIMENSIONS AND WEIGHTS GX240. . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
GX240 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 GX270. . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
GX270 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 GX340. . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
GX340 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 GX390. . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
GX390 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 P.T.O. DIMENSIONAL DRAWINGS
ENGINE SPECIFICATIONS GX240. . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
GX240 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 GX240•GX270 . . . . . . . . . . . . . . . . . . . 1-26
GX270 . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 GX340•GX390 . . . . . . . . . . . . . . . . . . . 1-30
GX340 . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
GX390 . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SPECIFICATIONS
SERIAL NUMBER LOCATION
SPECIFICATIONS
The engine serial number (1), type (2), and model (3) are stamped on the crankcase.
Refer to them when ordering parts or making technical inquiries.
(3)
(2)
(1)
SPECIFICATIONS
TYPE CODE
GX240
Model GX240R2 GX240RT2 GX240U2 GX240UT2 GX240UT2
Type EDN2 VMT2 LX2 HA2 LX2
P. T. O. E type V type L type H type L type
Model GX240UT2 GX240UT2 GX240UT2 GX240UT2 GX240UT2

Type LXQ4 PA2 QA2 QAE2 QAG2
P. T. O. L type P type Q type Q type Q type

Type RA2 SXE4 SXQ4 VXB7 VXB9
P. T. O. R type S type S type V type V type
Model GX240UT2
Type WKT2
P. T. O. W type
GX270
Model GX270UT2
Type HA2 HEA2 PA2 PAE2 QA2
P. T. O. H type P type Q type
Model GX270UT2
Type QA26 QAE2 QAG2 QAQ4 QAR2
P. T. O. Q type
Model GX270UT2
Type QAW QH26 QHB4 QHQ4 QKE4
P. T. O. Q type
Model GX270UT2
Type QME2 QXB7 QXE4 QXE8 QXQ4
P. T. O. Q type
Model GX270UT2
Type QXUZ RA2 RHE4 RHQ4 SHQ4
P. T. O. Q type R type S type
Model GX270UT2
Type SMC4 SWC4 SXQ4 VA2 VKQ4
P. T. O. S type V type E type
Model GX270RT2
Type VSD7 VXB7 VXE7 VXU1
P. T. O. V type
SPECIFICATIONS
GX340
Model GX340R2 GX340RT2 GX340RT2 GX340RT2 GX340RT2
Type EDN2 VDE2 VWC VWE VWE2
P. T. O. E type V type V type V type V type
Model GX340U2 GX340UT2 GX340UT2 GX340UT2 GX340UT2

Type QA2 HA2 LXQ4 PKT2 QA2
P. T. O. Q type H type L type P type Q type

Type QAE2 QAP2 QNE2 SE SXE4
P. T. O. Q type Q type Q type S type S type
Model GX340UT2 GX340UT2 GX340UT2 GX340UT2

Type SXQ4 VA2 VX8 VXB7
P. T. O. S type V type V type V type
GX390
Model GX390RT2
Type QNB2 QTT QWA2 VAG2 VC2
P. T. O. Q type V type
Model GX390RT2
Type VDE2 VK2 VKB2 VWE VXG
P. T. O. V type
Model GX390T2 GX390UT2
Type QAPW HA2 LX2 PA2 PAE2
P. T. O. Q type H type L type P type
Model GX390UT2
Type QA2 QAA2 QAE2 QC2 QDW9
P. T. O. Q type
Model GX390UT2
Type QNE2 QNR2 QWA4 QWT2 QXC9
P. T. O. Q type
Model GX390UT2
Type SM32 SNC VA2 VM2 VXE2
P. T. O. S type V type
SPECIFICATIONS
DIMENSIONS AND WEIGHTS
GX240
P.T.O. VARIATION
Model P.T.O.* GX240R2 GX240RT2 GX240U2 GX240UT2

Overall E type 360 mm (14.2 in) - - -
length H type - - - 425 mm (16.7 in)
L type - - 405 mm (15.9 in) 405 mm (15.9 in)
P type - - - 380 mm (15.0 in)
Q type - - - 380 mm (15.0 in)
R type - - - 440 mm (17.3 in)
S type - - - 355 mm (14.0 in)
V type - 420 mm (16.5 in) - 400 mm (15.7 in)
W type - - - 370 mm (14.6 in)
width H type - - - 428 mm (16.9 in)
L type - - 428 mm (16.9 in) 428 mm (16.9 in)
P type - - - 428 mm (16.9 in)
Q type - - - 428 mm (16.9 in)
R type - - - 428 mm (16.9 in)
S type - - - 428 mm (16.9 in)
V type - 428 mm (16.9 in) - 428 mm (16.9 in)
W type - - - 428 mm (16.9 in)
height H type - - - 422 mm (16.6 in)
L type - - 422 mm (16.6 in) 422 mm (16.6 in)
P type - - - 422 mm (16.6 in)
Q type - - - 422 mm (16.6 in)
R type - - - 422 mm (16.6 in)
S type - - - 422 mm (16.6 in)
V type - 303 mm (11.9 in) - 422 mm (16.6 in)
W type - - - 422 mm (16.6 in)
Dry E type 21.4 kg (47.2 lbs) - - -
weight H type - - - 26.5 kg (58.4 lbs)
L type - - 26.5 kg (58.4 lbs) 26.5 kg (58.4 lbs)
P type - - - 25.8 kg (56.9 lbs)
Q type - - - 25.8 kg (56.9 lbs)
R type - - - 30.1 kg (66.1 lbs)
S type - - - 25.8 kg (56.9 lbs)
V type - 21.4 kg (47.2 lbs) - 25.8 kg (56.9 lbs)
W type - - - 25.8 kg (56.9 lbs)
Operating E type 26.1 kg (57.5 lbs) - - -
L type - - 31.5 kg (69.4 lbs) 31.5 kg (69.4 lbs)
P type - - - 30.5 kg (67.2 lbs)
Q type - - - 30.5 kg (67.2 lbs)
R type - - - 35.0 kg (77.2 lbs)
S type - - - 30.5 kg (67.2 lbs)
W type - - - 30.5 kg (67.2 lbs)
*: P. T. O. type (page 1-3)
SPECIFICATIONS
EQUIPMENT VARIATION
Indicates the difference compared with values shown in the table of P. T. O. variation on page 1-5.
Variation No balancer type Cyclone air Starter motor Control box type Low profile type
cleaner type type *1
Overall length - - - - + 20 mm (0.8 in)
difference
Overall width - + 96 mm (3.8 in) - + 34 mm (1.3 in) -
difference
Overall height - - - - - 119 mm (4.7 in)
difference
Dry weight - 0.9 kg (2.0 lbs) + 0.2 kg (0.4 lbs) + 2.5 kg (5.5 lbs) + 3.2 kg (7.1 lbs) - 4.4 kg (9.7 lbs)
difference
Operating - 0.9 kg (2.0 lbs) + 0.2 kg (0.4 lbs) + 2.5 kg (5.5 lbs) + 3.2 kg (7.1 lbs) - 4.4 kg (9.7 lbs)
weight
difference
*1: No fuel tank and muffler, use low profile type air cleaner.
GX270
P.T.O. VARIATION
Model P.T.O.* GX270R2/RT2/U2/UT2
Overall length E type 340 mm (13.4 in)
H type 425 mm (16.7 in)
P type 380 mm (15.0 in)
Q type
S type 355 mm (14.0 in)
V type 400 mm (15.7 in)
R type 440 mm (17.3 in)
Overall width E type 428 mm (16.9 in)
H type
P type
Q type
S type
V type
R type
Overall height E type 422 mm (16.6 in)
H type
P type
Q type
S type
V type
E type
Dry weight E type 25.0 kg (55.1 lbs)
H type 26.5 kg (58.4 lbs)
P type 25.8 kg (57.0 lbs)0
Q type
S type
V type
R type 30.0 kg (66.1 lbs)
Operating E type 29.7 kg (65.5 lbs)
weight H type 31.5 kg (69.4 lbs)
P type 30.5 kg (67.0 lbs)
Q type
S type
V type
R type 35.0 kg (77.2 lbs)
*: P. T. O. type (page 1-3)
SPECIFICATIONS
EQUIPMENT VARIATION
Variation No balancer type Cyclone air Starter motor Control box type Low profile type
cleaner type type *1
Overall length - - - - + 20 mm (0.8 in)
difference
Overall width - + 96 mm (3.8 in) - + 34 mm (1.3 in) -
difference
Overall height - - - - - 119 mm (4.7 in)
difference
Dry weight - 0.9 kg (2.0 lbs) + 0.2 kg (0.4 lbs) + 2.5 kg (5.5 lbs) + 3.2 kg (7.1 lbs) - 4.4 kg (9.7 lbs)
difference
Operating - 0.9 kg (2.0 lbs) + 0.2 kg (0.4 lbs) + 2.5 kg (5.5 lbs) + 3.2 kg (7.1 lbs) - 4.4 kg (9.7 lbs)
weight
difference
*1: No fuel tank, muffler, and low profile type air cleaner.
GX340
P.T.O. VARIATION
Model P.T.O.* GX340R2 GX340RT2 GX340U2 GX340UT2

length H type - - - 452 mm (17.8 in)
L type - - - 440 mm (17.3 in)
P type - - - 405 mm (15.9 in)
Q type - - 405 mm (15.9 in) 405 mm (15.9 in)
S type - - - 380 mm (15.0 in)
V type - 430 mm (16.9 in) - 425 mm (16.7 in)
width H type - - - 460 mm (18.1 in)
L type - - - 460 mm (18.1 in)
P type - - - 460 mm (18.1 in)
Q type - - 460 mm (18.1 in) 460 mm (18.1 in)
S type - - - 460 mm (18.1 in)
V type - 460 mm (18.1 in) - 460 mm (18.1 in)
height H type - - - 448 mm (17.6 in)
L type - - - 448 mm (17.6 in)
P type - - - 448 mm (17.6 in)
Q type - - 448 mm (17.6 in) 448 mm (17.6 in)
S type - - - 448 mm (17.6 in)
V type - 313 mm (12.3 in) - 448 mm (17.6 in)
Dry E type 27.3 kg (60.2 lbs) - - -
L type - - - 35.2 kg (77.6 lbs)
P type - - - 31.7 kg (69.9 lbs)
Q type - - 31.7 kg (69.9 lbs) 31.7 kg (69.9 lbs)
S type - - - 31.7 kg (69.9 lbs)
Operat- E type 33.4 kg (73.6 lbs) - - -
ing H type - - - 41.2 kg (90.8 lbs)
weight L type - - - 41.2 kg (90.8 lbs)
P type - - - 37.8 kg (83.3 lbs)
Q type - - 37.8 kg (83.3 lbs) 37.8 kg (83.3 lbs)
S type - - - 37.8 kg (83.3 lbs)
*: P. T. O. type. (page 1-4)
SPECIFICATIONS
EQUIPMENT VARIATION
Variation Cyclone air cleaner Starter motor type Control box type Low profile type *1
type
Overall length - - - + 6 mm (0.2 in)
difference
Overall width + 93 mm (3.7 in) ± 5 mm (0.2 in) + 39 mm (1.5 in) -
difference
Overall height - - - - 135 mm (5.3 in)
difference
Dry weight difference + 0.2 kg (0.4 lbs) + 2.5 kg (5.5 lbs) + 3.2 kg (7.1 lbs) - 4.4 kg (9.7 lbs)
Operating weight + 0.2 kg (0.4 lbs) + 2.5 kg (5.5 lbs) + 3.2 kg (7.1 lbs) - 4.4 kg (9.7 lbs)
difference
*1: No fuel tank and muffler, use low profile type air cleaner.
GX390
P.T.O. VARIATION
Model P.T.O.* GX390R2/RT2 GX390T2 GX390U2/UT2
Overall length H type - - 452 mm (17.8 in)
L type - - 440 mm (17.3 in)
P type - - 405 mm (15.9 in)
Q type 405 mm (15.9 in)
S type - - 380 mm (15.0 in)
V type 425 mm (16.7 in) - 425 mm (16.7 in)
Overall width H type - - 460 mm (18.1 in)
L type - - 460 mm (18.1 in)
P type - - 460 mm (18.1 in)
Q type 458 mm (18.0 in) 460 mm (18.1 in) 460 mm (18.1 in)
S type - - 460 mm (18.1 in)
V type 458 mm (18.0 in) - 460 mm (18.1 in)
Overall height H type - - 447 mm (17.6 in)
L type - - 448 mm (17.6 in)
P type - - 448 mm (17.6 in)
Q type 447 mm (17.6 in) 448 mm (17.6 in) 448 mm (17.6 in)
S type - - 448 mm (17.6 in)
V type 447 mm (17.6 in) - 448 mm (17.6 in)
Dry weight H type - - 35.2 kg (77.6 lbs)
L type - - 35.2 kg (77.6 lbs)
P type - - 31.7 kg (69.9 lbs)
Q type 29.9 kg (65.9 lbs) 31.7 kg (69.9 lbs) 31.7 kg (69.9 lbs)
S type - - 31.7 kg (69.9 lbs)
V type 29.9 kg (65.9 lbs) - 31.7 kg (69.9 lbs)
Operating weight H type - - 41.2 kg (90.8 lbs)
L type - - 41.2 kg (90.8 lbs)
P type - - 37.8 kg (83.3 lbs)
Q type 31.4 kg (69.2 lbs) 37.8 kg (83.3 lbs) 37.8 kg (83.3 lbs)
S type - - 37.8 kg (83.3 lbs)
V type 31.4 kg (69.2 lbs) - 37.8 kg (83.3 lbs)
*: P. T. O. type. (page 1-4)
SPECIFICATIONS
ENGINE SPECIFICATIONS
GX240
Model GX240R2 GX240RT2 GX240U2 GX240UT2
Description code GCBPK GCBJT GCBPK GCBJT
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)*1 5.9 kW (7.9 HP) / 3,600 min-1 (rpm)*2
Continuous rated power 4.6 kW (6.1 HP) / 3,600 min-1 (rpm)
Maximum net torque (SAE J1349)*1 18.3 N·m (1.86 kgf·m, 13.4 lbf·ft) / 2,500 min-1 (rpm)
Compression ratio 8.5: 1
Fuel consumption (at continuous rated 2.2 Liters (0.58 US gal, 0.48 Imp gal) / h
power)
Ignition system C.D.I.(Capacitor Discharge Ignition) type magneto ignition
Ignition timing B.T.D.C. 10° / 1,400min-1 (rpm)
Spark advancer performance B.T.D.C. 10°- 20°
Spark plug 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 SJ or later
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 element type, Cyclone type, Oil bath type, Low profile type
Governor Mechanical centrifugal
Breather system Reed valve type
Fuel used Unleaded gasoline with a pump octane rating 86 or higher
Reduction case oil capacity (1/2 reduction 0.3 Liters (0.32 US qt, 0.26 Imp qt)
with clutch)
Clutch Type Centrifugal
(1/2 reduction with Engagement start 1,800 min-1 (rpm)
clutch)
Lock 2,200 min-1 (rpm)
*1: 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 produc-
tion 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.
*2: Base type includes a balancer, dual type air cleaner, and standard type muffler.
SPECIFICATIONS
GX270
Description code GCBMK GCBGT GCBMK GCBGT
Net power (SAE J1349)*1 6.3 kW (8.4 HP) / 3,600 min-1 (rpm)
Fuel consumption 2.4 Liters (0.63 US gal, 0.53 Imp gal) / h
(at continuous rated power)
Reduction case oil capacity 0.3 Liters (0.32 US qt, 0.26 Imp qt)
(1/2 reduction with clutch)
Clutch Type Centrifugal
(1/2 reduction Engagement start 1,800 min-1 (rpm)
with clutch)
Lock 2,200 min-1 (rpm)
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.
SPECIFICATIONS
GX340

Description code GCBKK GCBET GCBKK GCBET
Net power (SAE J1349)*1 8.0 kW (10.7 HP) / 3,600 min-1 (rpm)*2
Fuel consumption (at continuous rated 3.1 Liters (0.82 US gal, 0.68 Imp gal) / h
power)
model and measured in accordance with SAE J1349 at 3,600 rpm (net power) and at 2,500 rpm (max net torque). Mass produc-
tion 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.
*2: Base type includes a balancer, dual type air cleaner, and standard type muffler.
SPECIFICATIONS
GX390
Model GX390R2 GX390RT2 GX390U2 GX390UT2 GX390T2
Description code GCBHK GCBCT GCBHK GCBCT GCBDT
Net power (SAE J1349)*1 8.7 kW (11.7 HP) / 3,600 min-1 (rpm)
Compression ratio 8.2 ± 0.2: 1
Fuel consumption 3.5 Liters (0.92 US gal, 0.77 Imp gal) / h
Ignition timing B.T.D.C. 10° / 1,400 min-1 (rpm)
Stopping system Ignition primary circuit open
Air cleaner Dual element type, Cyclone type, Low profile type
*1: 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.
SPECIFICATIONS
PERFORMANCE CURVES
GX240
(N·m) (lbf·ft) (kgf·m)

15
20
2.0
14
1.9
TORQUE
18
NET TORQUE 13 1.8
1.7
16 12
1.6
11 1.5
14
(KW)
7 (HP) (PS)
9 9
6 8 8
NET POWER
7 7
OUTPUT
6 6
4
5 5
3 4 4
RECOMMENDED OPERATING SPEED RANGE

2
2000 3000 3600
ENGINE SPEED (rpm)

SPECIFICATIONS
GX270
(N·m) (lbf·ft) (kgf·m)

15
20
2.0
14
1.9
TORQUE
18
NET TORQUE 13 1.8
1.7
16 12
1.6
11 1.5
14
(KW)
7 (HP) (PS)
9 9
6 8 8
NET POWER
7 7
OUTPUT
6 6
4
5 5
3 4 4

2
2000 3000 3600
ENGINE SPEED (rpm)

SPECIFICATIONS
GX340
(N·m)
28 (lbf·ft) (kgf·m)
20 2.8
26 2.7
19 2.6
TORQUE
24 NET TORQUE 18 2.5

2.4
17
2.3
22 16 2.2
20 15
(KW) (HP)
9 12 (PS)
12
11 11
8
NET POWER
10 10
7
OUTPUT
9 9
6 8 8
7 7
5
6 6
4
2000 3000 3600
ENGINE SPEED (rpm)
SPECIFICATIONS
GX390
(N·m) (lbf·ft)
28 21 (kgf·m)
2.8
20 2.7
26 19
NET TORQUE 2.6
TORQUE
18 2.5
24 2.4
17
16 2.3
22 2.2
15
20
(KW) (HP)
9 12
11
8
NET POWER
10
7
9
OUTPUT
6 8
7
5
RECOMMENDED OPERATING SPEED RANGE 6

4
2000 3000 3600 (min-1 [rpm])
ENGINE SPEED
SPECIFICATIONS
DIMENSIONAL DRAWINGS
*: P. T. O. type. (page 1-3)
GX240
WITHOUT REDUCTION UNIT TYPE
Unit: mm (in)
134 (5.3)
99 (3.9)
150 (5.9) 278 (10.9)
CONTROL BOX With control box type: 462 (18.2) CRANKSHAFT (P. T. O.)
(If equipped) Without control box type: 428 (16.9)
116 (4.6) 192 (7.6)

GX240R2/RT2: 303 (11.9)
GX240U2/UT2: 422 (16.6)
418 (16.5)
133.5 (5.26)
STARTER MOTOR 195.5 (7.70) 92 (3.6)

(If equipped) 105 (4.1) * E:360 (14.2)
* P/Q:380 (15.0)
* S:355 (14.0)
96 (3.8)
GX240UT2 * V:400 (15.7)

GX240RT2 *V:420 (16.5)
* W:370 (14.6)
34.5 (1.36)
13 (0.5)
SPECIFICATIONS
WITH REDUCTION UNIT TYPE
Unit: mm (in)
134 (5.3)
99 (3.9)
* L/H:209.9 (8.26)
150 (5.9) * R:187.2 (7.37)
* L/H:68.1 (2.68)
CONTROL BOX * R:90.8 (3.57)
(If equipped)
With control box type: 462 (18.2) P. T. O. SHAFT
Without control box type: 428 (16.9)
116 (4.6) 192 (7.6)
GX240U2/UT2: 422 (16.6)
418 (16.5)
133.5 (5.26)
STARTER REDUCTION UNIT * L/H:140.3 (5.52)

MOTOR * R:188.5 (7.42)
(If equipped) 195.5 (7.70)
* L:405 (15.9)
105 (4.1) * H:425 (16.7)
* R:440 (17.3)
96 (3.8)
34.5 (1.36)
13 (0.5)
SPECIFICATIONS
GX270
Unit: mm (in)
99 (3.9) 134 (5.3)
150 (5.9) 278 (10.9)
CONTROL BOX With control box type: 462 (18.2)

CRANKSHAFT (P. T. O.)
116 (4.6) 192 (7.6)

422 (16.6)
418 (16.5)
133.5 (5.26)
STARTER MOTOR 92 (3.6)

(If equipped) 195.5 (7.70)
* E:340 (13.4)
105 (4.1) * P/Q:380 (15.0)
* S:355 (14.0)
* V:400 (15.7)
96 (3.8)
34.5 (1.36)
13 (0.5)
SPECIFICATIONS
Unit: mm (in)
134 (5.3)
99 (3.9)
* H:209.9 (8.26)
150 (5.9) * R:187.2 (7.37)
CONTROL BOX * H:68.1 (2.68)
(If equipped)
* R:90.8 (3.57)
116 (4.6) 192 (7.6)
418 (16.5)
422 (16.6)
133.5 (5.26)
STARTER MOTOR * H:140.3 (5.52)

(If equipped) * R:188.5 (7.42)
REDUCTION UNIT
* H:425 (16.7)
195.5 (7.70)
* R:440 (17.3)
105 (4.1)
96 (3.8)
34.5 (1.36)
13 (0.5)
SPECIFICATIONS
GX340
Unit: mm (in)
121.8 (4.80)
98 (3.9)
159 (6.3) 301 (11.9)
CONTROL BOX With control box type: 499 (19.6) CRANKSHAFT (P. T. O.)
141.5 (5.57) 201.0 (7.91)
GX340R2/RT2: 313 (12.3)

GX340U2/UT2:448 (17.6)
447 (17.6)
133.5 (5.26)

(If equipped) 195.5 (7.70) * E:365 (14.4)
* P/Q:405 (15.9)
105 (4.1)
* S:380 (15.0)
GX340RT2 * V:430 (16.9)
103 (4.1)
GX340UT2 * V:425 (16.7)

17 (0.7)
27 (1.1)
SPECIFICATIONS
WITH REDUCTION TYPE
Unit: mm (in)
98 (3.9) 121.8 (4.80)
159 (6.3) 232.9 (9.17)

68.1 (2.68)
142 (5.6) 201 (7.9)
448 (17.6)
447 (17.6)
133.5 (5.26)
* H:148.3 (5.84)
REDUCTION UNIT * L:155 (6.1)
195.5 (7.70) * H:452 (17.8)
* L:440 (17.3)
105 (4.1)
103 (4.1)
17 (0.7)
27 (1.1)
SPECIFICATIONS
GX390
WITHOUT REDUCTION TYPE
121.8 (4.80) Unit: mm (in)

98 (3.9)
158.7 (6.25) 301.3 (11.86)
CONTROL BOX With control box type: 498.6 (19.63)

141.5 (5.57) 200.6 (7.90)
EXCEPT GX390UT2: 448 (17.6)

447 (17.6)
133.5 (5.26)

(If equipped) 195.5 (7.70)
* P/Q:405 (15.9)
105 (4.1) * S:380 (15.0)
* V:425 (16.7)
103 (4.1)
17 (0.7)
27 (1.1)
SPECIFICATIONS
Unit: mm (in)
158.7 (6.25) 233.2 (9.18)

68.1 (2.68)
P. T. O. SHAFT
460 (18.1)
141.5 (5.57) 200.6 (7.9)
447 (17.6)
133.5 (5.26)
155 (6.1)
REDUCTION UNIT
195.5 (7.70) * H:452 (17.8) * L:440 (17.3)
105 (4.1)
103 (4.1)
17 (0.7)
27 (1.1)
SPECIFICATIONS
P.T.O. DIMENSIONAL DRAWINGS
GX240
*: P. T. O. type. (page 1-3)
L TYPE* (WITH REDUCTION UNIT)
45° 45° Unit: mm (in)
M8 x 1.25
M8 x 1.25 (6
PLACES)
(ĭ0.9822 - 0.9835)
66.7 (2.63)
ĭ24.947 - 24.980
7.00- 7.05
(0.276-0.278) 42 (1.7)
70 (2.8)
28 (1.1)
(0.82 - 0.83)
20.9 - 21.0
60.0 (2.36)
P. T. O. SHAFT
.0)
7 (5
10 (0.4) 68.1 (2.68)

.12
REDUCTION UNIT
P. D
103 (4.1)
W TYPE*
45° 45° 0) Unit: mm (in)

5
30° 30° ( 6.
5.1
. 16
P.D 80 (3.1)
ĭ7.15(ĭ0.281)
(2 PLACES)
55 (2.2)
ĭ89 (ĭ3.5)
70 (2.8)
15.5 (0.61)
M8 x 1.25
M20 x 1.5
(4 PLACES) 75 (3.0)
ĭ8.51(ĭ0.335)
(4.4 .113.1
(4 PLACES)
5)
103 (4.1)
P. D

SPECIFICATIONS
GX240•GX270
*: P. T. O. type. (page 1-3)
E TYPE*
45° 45° 0) Unit: mm (in)

6. 5
.1 (
(ĭ1.0236 - 1.0237)
30° 30°
ĭ26.000 - 26.003
. 165
P.D 48.5 (1.91)
M8 x 1.25
(2 PLACES) TAPER
1/5
35
(ĭ1.1790 - 1.1803)
ĭ29.947 - 29.980
ĭ110.00 - 110.05
(1.4)
(ĭ4.331 - 4.333)
70 (2.8)
28 (1.1)
M8 x 1.25 M10 x 1.25
(4 PLACES)
ĭ8.51(ĭ0.335)
(4 PLACES)
7 (5.0)
103 (4.1)
P.D.12
H TYPE* (WITH REDUCTION UNIT)

Unit: mm (in)
45° 45°
ĭ7.15
(ĭ0.281) 85.7 (3.37)
(6 PLACES) 6.312- 6.363
(0.2485-0.2505) 63 (2.5)
(ĭ0.9990 - 1.0000)
ĭ25.374 - 25.400
70 (2.8)
(0.8540 - 0.8590)
80 (3.1)
21.692 - 21.819
P. T. O. SHAFT
.0)
7 (5
10 (0.4) 68.1 (2.68)

.12
REDUCTION UNIT
P. D
103 (4.1)
SPECIFICATIONS
P TYPE*
Unit: mm (in)
0)
45° 45° 6. 5
30° 30° .1 (
. 165
P.D 89 (3.5)
14NF2 Thread R. H.
5/16-24UNF-2B
(2 PLACES)
ĭ110.00 - 110.05
(ĭ4.331 - 4.333)
70 (2.8)
26-27
(1.0-1.1)
5/16-24UNF-2B
(ĭ0.9990 - 1.0000)
(4 PLACES)
ĭ25.375 - 25.400
72.5 (2.85)
3/8-16UNC-2B
(4 PLACES)
7 (5.0)
103 (4.1) CRANKSHAFT (P. T. O.)

P.D.12
Q TYPE*
Unit: mm (in)
0)
45° 30° 30°
45° ( 6.5
5 .1
.D .16
P 88.5 (3.48)
5/16-24UNF-2B 7/16 - 20UNF - 2B
(2 PLACES) 56 (2.2)
6.30 - 6.35
(0.248 - 0.250)
ĭ110.00 - 110.05
(ĭ4.331 - 4.333)
70 (2.8)
28 (1.1)
(0.854 - 0.859)
21.69 - 21.82
5/16-24UNF-2B
(ĭ0.9990 - 1.0000)
ĭ25.375 - 25.400
(4 PLACES) 72.2 (2.84)
3/8-16UNC-2B
(4 PLACES)
7 (5.0)
103 (4.1)
P.D.12
SPECIFICATIONS
S TYPE*
Unit: mm (in)
0)
45° 45° 6. 5
30° 30° .1 ( M8 x 1.25
1 65 (2 PLACES)
P . D. 63 (2.5)
M8-1.25
42 (1.7)
7.00 - 7.03
(0.276 - 0.277)
ĭ110.00 - 110.05
(ĭ4.331 - 4.333)
70 (2.8)
28 (1.1)
(0.82 - 0.83)
20.9 - 21.0
M8 x 1.25
(ĭ0.9822 - 0.9835)
(4 PLACES) 60 (2.4)
ĭ24.947 - 24.980
103 (4.1) ĭ8.51(ĭ0.335)
7 (5.0)
(4 PLACES)
P.D.12

V TYPE*
Unit: mm (in)
45° 45° 6. 5 0)
30° 30°
65 .1 ( 5/16 - 24UNF - 2B
.1
P.D 106 (4.2)
5/16-24UNF-2B
(2 PLACES)
18 (0.7)
ĭ110.00 - 110.05
(ĭ4.331 - 4.333)
70 (2.8)
2 1/4 TAPER
PER FOOT 76.5 (3.01)
(ĭ0.8715 - 0.8725)
46.5 (1.83)
22.136 - 22.161
5/16-24UNF-2B
(4 PLACES)
103 (4.1)
7 (5.0)
3/8-16UNC-2B
(4 PLACES)
P.D.12

SPECIFICATIONS
R TYPE* (WITH 1/2 REDUCTION UNIT)
Unit: mm (in)
M8 x 1.25 (4 PLACES)
35 (1.4) 35 (1.4)
M8 x 1.25
(0.70 - 0.71)
17.9 - 18.0
34 (1.3)
7.000 - 7.036 25 (1.0)
(0.2756 - 0.2770)
35 (1.4) 35 (1.4)
50 (2.0)
(0.8641 - 0.8654)
53 (2.1)
21.947 - 21.980
REDUCTION UNIT
90.8 (3.57) P. T. O. SHAFT
SPECIFICATIONS
GX340•GX390
*: P.T.O. type (page 1-4)
H TYPE (WITHOUT REDUCTION)
Unit: mm (in)
45° 45°
M8 x 1.25
(2 PLACES)
M8 x 1.25 85.7 (3.37)
(4 PLACES)
6.31- 6.36
(0.248-0.250) 63 (2.5)
(ĭ0.9990 - 1.0000)
ĭ25.374 - 25.400
70 (2.8) 80 (3.20)
(0.854 - 0.859)
21.69 - 21.82
P. T. O. SHAFT
)
.00
7 (5
16 (0.6) 62.1 (2.45)

.12
REDUCTION UNIT
P. D
103 (4.1)
L TYPE* (WITH REDUCTION)

Unit: mm (in)
45° 45°
64.8 (2.55)
M8 x 1.25
M8 x 1.25 (2 PLACES)
(4 PLACES) M8 x 1.25
7.00 - 7.05
(0.276 -0.278) 42 (1.7)
ĭ24.972-24.993
(0.9831-0.9840)
70 (2.8)
28 (1.1)
(0.82-0.83)
60.0 (2.36)
20.9-21.0
P. T. O. SHAFT
)
.00
7 (5
16 (0.6) 68.1 (2.68) REDUCTION UNIT

.12
P. D
103 (4.1)
SPECIFICATIONS
P TYPE*
Unit: mm (in)
0)
45° 45° 6. 5
30° 30° 5.1 (
. D .16
P 89 (3.5)
5/16-24UNF-2B 14NF2 Thread R. H.
(2 PLACES)
(ĭ4.3307 - 4.3327)
ĭ110.00 - 110.05
70 (2.8)
26-27
(1.0-1.1)
5/16-24UNF-2B
(ĭ0.9990 - 1.0000)
(4 PLACES)
ĭ25.375 - 25.400
72.5 (2.85)
3/8-16UNC-2B
(4 PLACES)
)
7 (5.00

P.D.12
Q TYPE*
Unit: mm (in)
0)
45° 45° 6. 5
30° 30° .1 (
. 165
P.D 88.5 (3.48)
5/16-24UNF-2B 3/8 - 24UNF - 2B TAP
(2 PLACES) 56 (2.2)
6.3 - 6.35
(0.2480 - 0.2500)
ĭ110.00 - 110.05
(ĭ4.331 - 4.333)
70 (2.8)
(0.8539 - 0.8591)
28 (1.1)
21.69 - 21.82
5/16-24UNF-2B
(ĭ0.9990 - 1.0000)
ĭ25.375 - 25.400
(4 PLACES) 72.2 (2.84)
3/8-16UNC-2B
(4 PLACES)
)
7 (5.00
103 (4.1)
P.D.12
SPECIFICATIONS
S TYPE*
SNC TYPE: Unit: mm (in)

0) 5/16-24UNF-2B
45° 30° 30° 45° ( 6.5 TAP (2 PLACES)
65 .1 SM32 TYPE:
.1
P.D M8 x 1.25 63 (2.5)
(2 PLACES) M8-1.25
41 (1.6)
7.00 - 7.03
(0.276 - 0.277)
ĭ110.00 - 110.05
(ĭ4.331 - 4.333)
70 (2.8) 28 (1.1)
SNC TYPE:
(0.82 - 0.83)
5/16-24UNF-2B
20.9 - 21.0
TAP
(ĭ0.9822 - 0.9835)
(4 PLACES) 60 (2.4)
ĭ24.947 - 24.980
SM32 TYPE:
M8 x 1.25
(4 PLACES)
SNC TYPE:
103 (4.1)
)
3/8-16UNC-2B
7 (5.00
TAP (4 PLACES)
SM32 TYPE:
P.D.12
ĭ8.5 (ĭ0.33)
CRANKSHAFT (P. T. O.) (4 PLACES)
V TYPE*
Unit: mm (in)
0)
45° 45° 6. 5
30° 30° 5 .1 ( 5/16 - 24UNF - 2B TAP
. 16
P.D 105.5 (4.15)
5/16-24UNF-2B
(2 PLACES)
18 (0.7)
ĭ110.00 - 110.05
(ĭ4.331 - 4.333)
70 (2.8)
5/16-24UNF-2B
(ĭ0.8715 - 0.8724)
(4 PLACES) 75.5 (2.97)

22.136 - 22.161
46.5 (1.83)
3/8-16UNC-2B
(4 PLACES)
)
7 (5.00

P.D.12
2. SERVICE INFORMATION
MAINTENANCE STANDARDS TOOLS
GX240 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . 2-10
GX270 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 COMMERCIALLY AVAILABLE

TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
GX340 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
HARNESS ROUTING
GX390 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
ENGINE STOP SWITCH TYPE. . . . . . . 2-12
TORQUE VALUES
COMBINATION SWITCH
ENGINE TORQUE VALUES . . . . . . . . . 2-8 (CONTROL BOX TYPE) . . . . . . . . . . . . 2-13
STANDARD TORQUE VALUES . . . . . . 2-8 ALL TYPES . . . . . . . . . . . . . . . . . . . . . . 2-14
LUBRICATION & SEAL POINT . . . . . . . . . . 2-9 WITH CHARGE COIL / LAMP COIL. . . 2-15
TUBE ROUTING . . . . . . . . . . . . . . . . . . . . . 2-16

SERVICE INFORMATION
MAINTENANCE STANDARDS
SERVICE INFORMATION
GX240
Unit: mm (in)
Service
Part Item Standard
limit
Engine Maximum speed (at no load) 3,850 ± 150 min-1 (rpm) –
Idle speed 1,400 ± 150 min-1 (rpm) –
0.59 - 0.83 MPa (6.0 - 8.5 kgf/cm2,
Cylinder compression –
85 - 121 psi) / 600 min-1 (rpm)
Cylinder head Warpage – 0.10 (0.004)
Cylinder Sleeve I.D. 77.000 – 77.017 (3.0315 – 3.0322) 77.17
(3.038)
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) 17.95
(0.707)
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 0.030 – 0.060 (0.0012 – 0.0024) 0.15 (0.006)
Second 0.030 – 0.060 (0.0012 – 0.0024) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.500 (0.0138 – 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)
Ring width Top 1.160 – 1.175 (0.0457 – 0.0463) 1.140
(0.0449)
Second 1.160 – 1.175 (0.0457 – 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 0.1 – 0.4 (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 Crank pin O.D. 32.975 – 32.985 (1.2982 – 1.2986) 32.92
(1.296)
Crankshaft runout – 0.1 (0.004)
Cylinder barrel Camshaft bearing I.D. 16.000 – 16.018 (0.6299 – 0.6306) 16.05
(Crankcase) (0.632)
Crankcase cover Camshaft bearing 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 (0.2589 – 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 clear- IN 0.010 – 0.040 (0.0004 – 0.0016) 0.10 (0.004)
ance EX 0.050 – 0.080 (0.0020 – 0.0031) 0.12 (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° max.
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)
SERVICE INFORMATION
Service
Part Item Standard
limit
Carburetor Main jet BE70R A: #85 –
BE71F A: #85
Pilot screw opening BE70R A: 1 turn out –
BE71F A: 1 turn out
Float height 13.2 (0.52) –
Spark plug Gap 0.7 – 0.8 (0.028 – 0.031) –
Ignition coil Air gap 0.2 – 0.6 (0.01 – 0.02) –
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 ȍ –
3A 0.62 - 0.93 ȍ –
10A 0.16 - 0.24 ȍ –
18A 0.10 - 0.30 ȍ –
Lamp coil Resistance 12V - 15 W 1.04 - 1.56 ȍ –
12V - 25 W 0.30 - 0.46 ȍ –
12V - 50 W 0.29 - 0.44 ȍ –
GX270
Unit: mm (in)
Service
Part Item Standard
limit
0.59 -0.83 MPa (6.0-8.5 kgf/cm2,
85-121 psi) / 600 min-1 (rpm)
(3.038)
Piston Skirt O.D. 76.975 – 76.985 (3.0305 – 3.0309) 76.85
(3.026)
(0.7103)
Piston pin Pin O.D. 17.994 – 18.000 (0.7084 – 0.7087) 17.95
(0.707)
Second 0.030 – 0.060 (0.0012 – 0.0024) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.500 (0.0138 – 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)
Ring width Top 1.160 – 1.175 (0.0457 – 0.0463) 1.140
(0.0449)
Second 1.160 – 1.175 (0.0457 – 0.0463) 1.140
(0.0449)
(0.711)
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)
(1.296)
(Crankcase) (0.632)
(0.632)
SERVICE INFORMATION
Service
Part Item Standard
limit
EX 0.20 ± 0.02 –
Valve stem O.D. IN 6.575 – 6.590 (0.2589 – 0.2594) 6.44 (0.254)
EX 6.535 – 6.550 (0.2573 – 0.2579) 6.40 (0.252)
Guide-to-stem IN 0.010 – 0.037 (0.0004 – 0.0015) 0.10 (0.004)
clearance EX 0.050 – 0.077 (0.0020 – 0.0030) 0.12 (0.005)
Valve seat width 1.0 – 1.2 (0.04 – 0.05) 2.0 (0.08)
(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 #88 –
Pilot screw opening BE21J A: 2 turns out –
Spark plug Gap 0.7 – 0.8 (0.028 – 0.031) –
Mica depth 1.0 (0.04) 0.2 (0.01)
3A 0.62 - 0.93 ȍ –
10A 0.16 - 0.24 ȍ –
18A 0.10 - 0.30 ȍ –
12V - 25 W 0.30 - 0.46 ȍ –
12V - 50 W 0.29 - 0.44 ȍ –
GX340
Unit: mm (in)
Service
Part Item Standard
limit
0.51 - 0.69 MPa (5.2 - 7.0 kgf/cm2,
74 - 100 psi) / 600 min-1 (rpm)
(3.4713)
Piston Skirt O.D. 87.965 – 87.985 (3.4632 – 3.4640) 87.85(3.459)
(0.7891)
Piston pin Pin O.D. 19.994 – 20.000 (0.7872 – 0.7874) 19.950
(0.7854)
Second 0.030 – 0.060 (0.0012 – 0.0024) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.500 (0.0138 – 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)
Ring width Top 1.160 – 1.175 (0.0457 – 0.0463) 1.140
(0.0449)
Second 1.160 – 1.175 (0.0457 – 0.0463) 1.140
(0.0449)
SERVICE INFORMATION
Service
Part Item Standard
limit
(0.790)
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)
(1.415)
(Crankcase) (0.632)
(0.632)
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 (0.2572 – 0.2578) 6.40 (0.252)
ance EX 0.050 – 0.080 (0.0020 – 0.0031) 0.12 (0.005)
Valve seat width 1.0 – 1.2 (0.04 – 0.05) 2.0 (0.08)
(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 BE80N A: #98 –
BE80M A: #98
BE80P A: #98
Pilot screw opening BE80N A: 1 - 3/4 turns out –
BE80M A: 1 - 3/4 turns out
BE80P A: 1 - 3/4 turns out
Spark plug Gap 0.7 – 0.8 (0.028 – 0.031) –
Mica depth 1.0 (0.04) 0.2 (0.01)
3A 0.62 - 0.93 ȍ –
10A 0.16 - 0.24 ȍ –
18A 0.10 - 0.30 ȍ –
12V - 25 W 0.30 - 0.46 ȍ –
12V - 50 W 0.29 - 0.44 ȍ –
SERVICE INFORMATION
GX390
mm (in)
Service
Part Item Standard
limit
Cylinder compression 0.51-0.69 MPa (5.2-7.0 kgf/cm2, 74-100
–
psi) / 600 min-1 (rpm)
(3.4710)
Piston Skirt O.D. 87.975 – 87.985 (3.4635 – 3.4640) 87.85
(3.459)
(0.7891)
Piston pin Pin O.D. 19.994 – 20.000 (0.7872 – 0.7874) 19.950
(0.7854)
Second 0.030 – 0.060 (0.0012 – 0.0024) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.500 (0.0138 – 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)
Ring width Top 1.160 – 1.190 (0.0457 – 0.047) 1.140
(0.0449)
Second 1.160 – 1.175 (0.0457 – 0.0463) 1.140
(0.0449)
(0.790)
Big end I.D. 36.025 – 36.039 (1.4183 – 1.4189) 36.07
(1.420)
(1.415)
(Crankcase) (0.632)
(0.632)
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 (0.2572 – 0.2578) 6.40 (0.252)
ance 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)
(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)
SERVICE INFORMATION
Service
Part Item Standard
limit
Carburetor Main jet BE84A A #100 –
BE84B A #100
BE84C A #100
BE84D A #105
BE88A A #88
BE88B A #88
BE88C A #88
BE88F A #88
BE88G A #88
BE88J A #88
BE89Y A #100
BE89Z A #105
BE94E A #108
BE94F A #108
Pilot screw opening BE84A A 2 - 1/8 turns out –
BE84B A 2 - 1/8 turns out
BE84C A 2 - 1/8 turns out
BE84D A 1 - 1/2 turns out
BE88A A 1 - 7/8 turns out
BE88B A 1 - 7/8 turns out
BE88C A 1 - 7/8 turns out
BE88F A 1 - 7/8 turns out
BE88G A 1 - 7/8 turns out
BE88J A 1 - 7/8 turns out
BE89Y A 2 - 1/8 turns out
BE89Z A 1 - 1/2 turns out
BE94E A 1 - 5/8 turns out
BE94F A 1 - 5/8 turns out
Spark plug Gap 0.7 – 0.8 (0.028 – 0.031) –
Mica depth 1.0 (0.04) 0.2 (0.01)
3A 0.62 - 0.93 ȍ –
10A 0.16 - 0.24 ȍ –
18A 0.10 - 0.30 ȍ –
Lamp coil Resistance 12V25W 0.30 - 0.46 ȍ –
SERVICE INFORMATION
TORQUE VALUES
ENGINE TORQUE VALUES
Torque values
Item Tread Dia. (mm)
N·m kgf·m lbf·ft
Crankcase cover bolt M8 x 1.25 24 2.4 17
Cylinder head bolt M10 x 1.25 35 3.5 26
Oil drain plug bolt M12 x 1.5 22.5 2.25 17
Connecting rod bolt M8 x 1.25 (Special bolt) 14 1.4 10
Rocker arm pivot bolt M8 x 1.25 (Special bolt) 24 2.4 17
Rocker arm pivot adjusting nut M6 x 0.5 10 1.0 7
Oil level switch nut M10 x 1.25 10 1.0 7
Flywheel nut (GX240, GX270) M16 x 1.5 (Special nut) 128 13.1 94
Flywheel nut (GX340, GX390) M16 x 1.5 (Special nut) 170 17.3 125
Fuel tank nut/bolt M8 x 1.25 24 2.4 18
Fuel tank joint M10 x 1.25 2 0.2 1.5
Air cleaner elbow nut M6 x 1.0 9 0.9 6.6
Muffler nut M8 x 1.25 24 2.4 17
Exhaust pipe nut M8 x 1.25 24 2.4 17
Gear case cover bolt (With reduction) M8 x 1.25 24 2.4 17
Primary drive gear bolt (With reduction) M8 x 1.25 24 2.4 17
Engine stop switch tapping screw M3 x 1.06 0.45 0.046 0.33
Recoil starter center screw M5 x 0.8 (Special bolt) 3.9 0.40 2.9
Fuel strainer cup M24 x 1.0 3.9 0.40 2.9
STANDARD TORQUE VALUES

Torque values
Item Tread Dia. (mm)
N·m kgf·m lbf·ft
Screw 4 mm 2.1 0.21 1.5
5 mm 4.3 0.43 3.1
6 mm 9.0 0.90 6.6
Bolt and nut 5 mm 5.3 0.53 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 5.4 0.55 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 0.55 4.0
6 mm 12 1.2 9
SERVICE INFORMATION
LUBRICATION & SEAL POINT
Location Material Remarks
Crankshaft pin, journal, and gear Engine oil
Crankcase bearing
Crankcase cover bearing
Piston outer surface and piston pin hole
Piston pin outer surface
Piston ring
Cylinder inner surface
Connecting rod big and small end bearing
Connecting rod bolt threads and seating surface
Camshaft cam profile, bearing, decompressor, and
gear
Valve lifter shaft and slipper
Valve stem seal contact area of seal lip
Valve stem sliding surface and stem end
Valve spring
Push rod end
Tappet adjusting screw and nut threads and seating
surface
Rocker arm shaft
Flywheel nut threads and seating surface
Governor weight holder gear and journal
Governor holder shaft
Governor slider
Governor arm shaft
Cylinder head bolt threads and seating surface
Rocker arm pivot threads and pivot
Balancer shaft bearing and gear
P.T.O. shaft bearing and gear
Drive sprocket and P.T.O. shaft
Counter shaft bearing and gears
Clutch friction disc and clutch plate (GX270) Engine oil 1/2 reduction with clutch
Oil seal lip Multi-purpose grease
O-ring
Recoil starter case cutout
Recoil starter ratchet sliding surface
Recoil starter spring retainer inside
Camshaft cam profile Use molybdenum solution When installing a new cam-
(mixture of the engine oil and shaft
molybdenum grease with the
ratio 100 g grease: 70 cc oil)
Recoil starter center screw threads Hondalock 1, Threebond®
2430 or equivalent
SERVICE INFORMATION
TOOLS
SPECIAL TOOLS
Special tools used in this manual can be ordered using normal American Honda parts ordering procedures.
Float level gauge Remover weight Valve guide driver, 6.6 mm
07401-0010000 07936-371020A 07942-6570100
Bearing driver attachment, Bearing driver attachment, Bearing driver attachment,

32 × 35 mm 42 × 47 mm 52 × 55 mm
07746-0010100 07746-0010300 07746-0010400
Bearing driver attachment, Driver, 40 mm I. D. Inner bearing driver attachment,

72 × 75 mm 07746-0030100 35 mm
07746-0010600 07746-0030400
Pilot, 15 mm Pilot, 20 mm Pilot, 30 mm

07746-0040300 07746-0040500 07746-0040700
SERVICE INFORMATION
Pilot, 35 mm Pilot, 14 mm Driver handle
07746-0040800 07746-0041200 07749-0010000
Bearing remover, 15 mm Valve guide reamer, 6.6 mm Bearing driver attachment,

07936-KC10500 07984-ZE20001 45 × 50 mm
07946-6920100
Bearing driver attachment, Puller collar set Inner bearing driver attachment,
62 × 64 mm 07APC-ZY1A100 30 mm (in combination with
07947-6340400 07746-0030100) 07746-0030300
COMMERCIALLY AVAILABLE TOOLS

Tool name Tool number Application
Digital multimeter FLU88 Electrical testing
Valve seat cutter, 30 x 45 degree NWYCU128 Valve seat reconditioning
Valve seat cutter, 60 degree NWYCU114
Solid pilot bar, 6.6 mm NWY100-6.60
T handle NWYTW505
Strap wrench S-17
Ring compressor LIL18500
Valve lapper LIL21100
Flywheel puller OTC7403 Flywheel removal
Compression gauge EEPV303A Compression testing
Leak down tester KLIAT1006M
Cylinder bore gauge FFL52548007 Cylinder honing
400-grit flex hone tool Based on bore size
Variable speed heavy-duty drill
There are two convenient ways to order: online or by toll-free phone.
• To order online, go to the iN: SERVICE>Tools>Tool and Equipment Program>Online Catalog, and then search by model number.
• To order by phone, call 1-888-424-6857.
Customer service representatives are available from 7:30 AM until 7:00 PM CT, Monday through Friday.
SERVICE INFORMATION
HARNESS ROUTING
Connection of regulator/rectifier, charge/lamp coil, sub wire harness, and auto throttle solenoid depend on the
application of the engine; therefore, this manual does not indicate those parts.
ENGINE STOP SWITCH TYPE
ENGINE STOP SWITCH
ENGINE WIRE
HARNESS
HARNESS CLIP
To engine stop To ignition coil

OIL LEVEL switch
SWITCH HARNESS CLIP
INSIDE
YELLOW RED BLACK
YELLOW RED BLACK

ENGINE STOP
SWITCH CORD
To oil level switch

SERVICE INFORMATION
COMBINATION SWITCH (CONTROL BOX) TYPE
PURSE LOCK CLIP PURSE LOCK CLIP
To starter motor To ignition coil To starter motor
(YELLOW)
To ignition coil To ignition coil

(BLACK) (RED)
ENGINE WIRE
HARNESS (To
ignition coil)
STOP SWITCH
CORD HOLDER
OIL LEVEL
SWITCH
COMBINATION
SWITCH WIRE
CABLE STRAP/ FASTENER TUBE

To 1 A / 3 A charge coil To ignition coil
CABLE STRAP
YELLOW
RED FASTENER TUBE
CABLE GRAY BLACK
STRAP
FASTENE
R TUBE
INSIDE
WHITE
COMBINATION
YELLOW
SWITCH WIRE
RED
BLACK
To control box
To oil level switch
WHITE
To starter motor
BLACK / WHITE
SERVICE INFORMATION
ALL TYPES
GOVERNOR ARM
ENGINE WIRE
HARNESS
HIGH-TENSION
CORD
CARBURETOR CONTROL BASE

INSULATOR ASSY.
CYLINDER BARREL RIB
CONTROL BASE
ASSY.
IGNITION COIL
HIGH-TENSION
CORD
SERVICE INFORMATION
WITH CHARGE COIL / LAMP COIL
18 A CHARGE COIL TYPE: 10 A CHARGE COIL TYPE:

CORD CORD
CLAMP CLAMP
COIL CORD
HARNESS GROMMET
CORD COIL
GROMMET HARNESS
1 A / 3 A CHARGE COIL TYPE:

12 V - 25 W LAMP COIL TYPE:
CORD
CLAMP
CORD
GROMMET
COIL
HARNESS
SERVICE INFORMATION
TUBE ROUTING
FUEL TUBE
TUBE CLAMP
3 mm
CARBURETOR
SIDE TUBE CLAMP
40 mm SUPPORTER RUBBER
TUBE CLIP
TUBE CLAMP
BREATHER TUBE
INSERT DEPTH MARK
3. MAINTENANCE
MAINTENANCE SCHEDULE. . . . . . . . . . . . 3-2 SPARK PLUG REPLACEMENT . . . . . . . . 3-10
ENGINE OIL LEVEL CHECK . . . . . . . . . . . . 3-3 SPARK ARRESTER CLEANING

(if equipped) . . . . . . . . . . . . . . . . . . . . . . . 3-10
ENGINE OIL CHANGE. . . . . . . . . . . . . . . . . 3-4
IDLE SPEED CHECK/ADJUSTMENT . . . . 3-12
REDUCTION CASE OIL (1/2 reduction unit
with clutch) . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 VALVE CLEARANCE CHECK/
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 3-12
AIR CLEANER CHECK/CLEANING/
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . 3-6 COMBUSTION CHAMBER CLEANING . . 3-13
SEDIMENT CUP CLEANING . . . . . . . . . . . . 3-8 FUEL TANK AND FILTER CLEANING . . . 3-14
SPARK PLUG CHECK/ADJUSTMENT . . . . 3-9 FUEL TUBE CHECK . . . . . . . . . . . . . . . . . 3-14

MAINTENANCE
MAINTENANCE SCHEDULE
MAINTENANCE
REGULAR SERVICE PERIOD (2)

ITEM Perform at every indicated month First Every Every Every
or operating hour interval, Each month 3 months 6 months year Refer to
whichever comes first. use or or or or page
20 hrs. 50 hrs. 100 hrs. 300 hrs.
Engine oil Check level 3-3
Change 3-4
Reduction case oil Check level 3-5
(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 3-8
Spark plug Check–adjust 3-9
Replace 3-10
Spark arrester Clean
3-10
(If equipped)
Idle speed Check–adjust 3-12
Valve clearance Check–adjust 3-12
Fuel tank and filter Clean 3-14
Fuel tube Check Every 2 years (Replace if necessary) 3-14
(1) Service more frequently when used in dusty areas.

(2) For commercial use, log hours of operation to determine proper maintenance intervals.
(*) Internal vent carburetor with dual element type only.
(**) Replace paper element type only.
MAINTENANCE
ENGINE OIL LEVEL CHECK
Place the engine on a level surface.
Remove the oil filler cap (1), and wipe the oil level (1)
gauge (2) clean.
Insert the oil filler cap without screwing it into the oil filler
neck (3).
Remove the oil filler cap and check oil level shown on
the oil level gauge.
If the oil level is low, fill with recommended oil to the
upper level (4) of the oil filler neck.
(2) (3)
(1)
(4)
(3)
(2)
SAE 10W - 30 is recommended for general use. Other

viscosities shown in the chart may be used when the SAE VISCOSITY GRADES
average temperature in your area is within the
recommended range.
RECOMMENDED OIL:
SAE 10W-30 API service classification SJ or later
Tighten the oil filler cap securely.
AMBIENT TEMPERATURE
MAINTENANCE
ENGINE OIL CHANGE
Drain the oil in the engine while the engine is warm.
Warm oil drains quickly and completely. (1)
Place the engine on a level surface, and place a
suitable container under the drain plug bolt.
Remove the oil filler cap (1), drain plug bolt (2), and
drain plug washer (3) to drain the oil into the suitable
container.
Please dispose of used motor 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.
(2) (3)
Used engine oil contains substances that have

been identified as carcinogenic. If repeatedly left in
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 con-
tact with used engine oil.
Install a new drain plug washer (3) and tighten the drain
plug bolt (2) to the specified torque.
TORQUE: 22.5 N·m (2.25 kgf·m, 17 lbf·ft)
Fill with recommended oil to the upper level mark of the
oil level dipstick (page 3-3).
Engine oil capacity: 1.1 (1.16 US gal, 0.97 Imp gal)
Tighten the oil filler cap securely.
MAINTENANCE
REDUCTION CASE OIL (1/2 reduction unit with clutch)
Oil level check
Place the engine on a level surface.
(1)
Remove the reduction oil 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 (2).
Remove the oil level gauge and check oil level shown
on the oil level gauge.
(2)
If the oil level is low, fill with recommended oil to the
upper level (3) of the oil level gauge. (3)
SAE 10W - 30 is recommended for general use. Other
viscosities shown in the chart may be used when the
average temperature in your area is within the
recommended range.
RECOMMENDED OIL: SAE VISCOSITY GRADES
SAE 10W-30 API service classification SE or later
Tighten the oil level gauge securely.
AMBIENT TEMPERATURE
Oil Change
Drain the oil in the engine while the engine is warm.
Warm oil drains quickly and completely. (1)
Place the engine on a level surface, and place a

suitable container under the drain plug bolt.
Remove the reduction oil cap / oil level gauge (1), drain
plug bolt (2), and drain plug washer (3) to drain the oil
into the suitable container.
Please dispose of used oil in a manner that is (2)
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.
(3)
Used engine oil contains substances that have
been identified as carcinogenic. If repeatedly left in
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 con-
tact with used engine oil.
Install a new drain plug washer and tighten the drain

plug bolt to the specified torque.
TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft)
Fill with recommended oil to the upper level mark of the
oil level gauge.
Reduction oil case capacity: 0.3 (0.32 US gal, 0.26 Imp gal)
Tighten the oil level gauge securely.
MAINTENANCE
AIR CLEANER CHECK/CLEANING/
REPLACEMENT
DUAL ELEMENT 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

filters installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely. (3)
Remove the nut (1) and the air cleaner cover (2).
Remove the wing nut (3) and air filter assembly (4)(5). (4)
Separate the inner filter (Paper) (4) from the outer filter
(Foam) (5). Carefully check both filters for holes or tears
and replace if damaged.
(5)
Clean the filters if they are to be reused (page 3-7).
Install the elements in the reverse order of removal.
CYCLONE TYPE:
(2)
Operating the engine without the air filters or with the

filters 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) and air filter assembly (4)(5).
Separate the inner filter (Paper) (4) from the outer filter (4)
(Foam) (5). Carefully check both filters for holes or tears
and replace if damaged.
Check the packing (6) for damage.
Clean the filters if they are to be reused (see below). (5)
Install the elements in the reverse order of removal.
(6)
MAINTENANCE
LOW PROFILE TYPE:
(2)
Operating the engine without the air filter or with the
filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filter securely.
Remove the air cleaner case lid spring (1) and air cleaner
cover (2).
Remove the air cleaner element (3).
Carefully check the air cleaner element and replace if
damaged.
(3)
Clean the filter if it is to be reused (see below).
Install the element in the reverse order of removal.
FILTER (FOAM) TYPE:

Clean the filter (1) in warm soapy water (2), rinse, and
allow to dry thoroughly, or clean with a non-flammable
solvent and allow to dry thoroughly. (1)
(3)
Dip the filter in oil (3), and squeeze out all the excess
oil. Clean engine oil is recommended for general use; Squeeze
Motul Air Filter Oil is recommended for operation in and dry
dusty areas.
Excess oil will restrict air flow through the foam element
and may cause the engine to smoke at startup.
(2)
Check the air cleaner case packing for deterioration or
damage. Make sure the air cleaner packing is installed
securely.
Install the cleaner in the reverse order of removal.
Squeeze thoroughly
INNER FILTER (PAPER) TYPE:

Tap the inner filter (1) lightly several times on a hard
surface to remove excess dirt, or blow compressed air (1)
lightly (207 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.
Wipe dirt from the inside of the air cleaner case and the
air cleaner cover, using a rag.
Check the air cleaner case packing for deterioration or
damage. Make sure the air cleaner packing is installed
securely.
Install the cleaner in the reverse order of removal.
MAINTENANCE
SEDIMENT CUP CLEANING
Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling ENGINE SERVICE BULLETIN #40 =>
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.

Remove the sediment cup (2) and the O-ring (3).
(1)
Release the tabs (5) and remove the cup filter (4).
Clean the sediment cup and the cup filter with
non-flammable solvent and allow them to dry
thoroughly.
Install the cup filter as the direction shown in the
illustration.
Install a new O-ring and tighten the sediment cup to the
specified torque. OFF ON
TORQUE: 3.9 N·m (0.40 kgf·m, 2.9 lbf·ft) (5)
BOSS
Check the sediment cup for any sign of fuel leakage.
(5)
(4)
(3)
(2)
CARBURETOR
(5)
(5)
BOSS
UNDER VIEW:
MAINTENANCE
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)
Visually check the spark plug. Replace the plug if it is

heavily fouled or 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 3-10).
SPARK PLUG: BPR6ES (NGK) W20EPR-U (DENSO)

(1)
Measure the plug gap with a wire-type feeler gauge. If

the measurement is out of the specification, adjust by
bending the side electrode. 0.7 – 0.8 mm
(0.028 – 0.031 in)
PLUG GAP: 0.7 – 0.8 mm (0.028 – 0.031 in)
Install the spark plug finger-tight to seat the washer,
and then tighten 1/8 – 1/4 turn with a spark plug
wrench.
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.
MAINTENANCE
SPARK PLUG REPLACEMENT
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)
Verify the new spark plug gap is correct (page 3-9).

(1)
Install a new spark plug finger-tight to seat the washer,
and then tighten 1/2 turn with a spark plug wrench.
SPARK PLUG: BPR6ES (NGK) W20EPR-U (DENSO)
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.
SPARK ARRESTER CLEANING

(if equipped)
The engine and the muffler becomes very hot dur-

ing operation and remains hot for a while after stop-
ping 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 14-2), If equipped.
(1)
Remove the 5 x 8 mm tapping screws (1), 6 x 10 mm
tapping screw (2), and muffler protector (3).
Remove the 5 x 8 mm tapping screws (4) and spark
arrester (5).
(3)
(5)
(2)
(4)
MAINTENANCE
SEPARATED PROTECTOR TYPE

Remove the muffler cover (page 14-2), If equipped.
Remove the 4 x 6 mm tapping screws (1), and exhaust
(3)
deflector (2), If equipped.
(4)
Remove the 5 x 8 mm tapping screws (3), R. muffler
protector (4), and L.muffler protector (5). (3)
Remove the 5 x 8 mm tapping screws (6) and spark
(2)
arrester (7).
(5)
(1)
(6)
(7)
(3)
CLEANING
Be careful to avoid damaging the screen.

Clean the carbon deposits from the spark arrester
screen (1) with a soft 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)
MAINTENANCE
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)
Disconnect the spark plug cap from the spark plug.

(1) (3)
Set the piston near top dead center of the cylinder
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 triangle
mark (1) on the starter pulley (2) will align with the top Pull slowly.
hole (3) on the recoil starter case (4).
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 thickness gauge (1) between the valve rocker

arm (2) and valve stem (3) to measure the valve (1) (3)
clearance.
VALVE CLEARANCE:
IN: 0.15 ± 0.02 mm
EX: 0.20 ± 0.02 mm
If adjustment is necessary, proceed as follows.
(2)
MAINTENANCE
Hold the rocker arm pivot (1) and loosen the pivot
adjusting 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 pivot
adjusting nut to the specified torque.
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.
COMBUSTION CHAMBER CLEANING

Remove the cylinder head (page 12-3 ).
Attach a soft wire brush to an electric drill and clean any
carbon deposits from the combustion chamber.
Do not remove the valves from the cylinder head when

cleaning the combustion chamber; this could damage
the valve seats.
Do not press the wire brush with force against the
combustion chamber; this could damage the cylinder
head.
MAINTENANCE
FUEL TANK AND FILTER CLEANING
ENGINE SERVICE BULLETIN #40 =>

can be burned or seriously injured when handling
fuel.
Drain the fuel into a suitable container.

Remove the fuel tank (1) and fuel tank joint (2) (1)
(page 6-3).
Clean the fuel tank joint and fuel tank with
non-flammable solvent, and allow them to dry
thoroughly.
Install the fuel tank (page 6-3).
Check the installation part of the fuel tank for any sign
of fuel leakage.
(2)
FUEL TUBE CHECK

fuel.
Check the fuel tube (1) for deterioration, cracks, or

signs of leakage.
(1)
4. TROUBLESHOOTING
BEFORE TROUBLESHOOTING . . . . . . . . . 4-2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . 4-2

TROUBLESHOOTING
BEFORE TROUBLESHOOTING
TROUBLESHOOTING
• Use a known-good battery for troubleshooting.

• Check for sufficient fresh fuel in the fuel tank.
• 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
HARD STARTING ENGINE SERVICE BULLETIN #40 =>
• Check the engine oil level before troubleshooting.
Without starter motor: Cannot be cranked Check the recoil starter (page 10-7).
Pull the recoil starter and check whether the - If the recoil starter operates correctly when
removed but is hard to pull when installed on
engine cranks. the engine, check the camshaft
decompressor operation (page 13-20).
- If the recoil starter operates correctly when
removed but cannot be pulled when installed
Cranks on the engine, disassemble the engine and
repair or replace the faulty part (s).
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 No fuel Check for clogged fuel filter, fuel tube, and
check the fuel flow from the fuel tank. fuel strainer screen (page 6-3).
Fuel
Dry
Check the spark plug (page 3-9). Check the sediment cup (page 3-8).
Disassemble the carburetor to clean the
carburetor ports, jets, and nozzles
(page 6-13).
Wet If spark plug is correct, clean and dry the

Normal electrodes, and then restart the engine,
taking care that the choke valve is not closed
too much.
If the engine does not start and the electrode
is wet again, check the carburetor float valve
(page 6-14).
No spark
Perform the spark test (page 9-4). Perform the IGNITION SYSTEM
TROUBLESHOOTING (page 9-2).
Spark
Go to page 4-3
TROUBLESHOOTING
From page 4-2
Compression
Perform the cylinder compression test is too high Check the valve clearance (page 3-12) and
(page 12-5). then perform the cylinder compression test. If
the cylinder compression is too high, remove
carbon deposits from the combustion
chamber (page 3-13).
Check the valve clearance (page 3-12), and

Compression then perform the cylinder compression test.
is too low
If the cylinder compression is too low,
perform a leak down test.
Normal If there is air leakage in the engine, check the

following.
- Valve seat width (page 12-5)
- Valve face irregularly worn (page 12-6)
- Valve spring free length (page 12-7)
- Cylinder sleeve (page 13-13)
- Piston skirt O.D. (page 13-14)
- Piston ring side clearance (page 13-15)
- Piston ring width (page 13-16)
- Piston ring end gap (page 13-16)
- Decompressor operation (page 13-20)
Restricted
Check for a restricted spark arrester Clean the spark arrester (page 3-10).
(if equipped).
Not restricted
Restart the engine according to the starting

procedure.
TROUBLESHOOTING
ENGINE SPEED DOES NOT INCREASE OR
STABILIZE
Clogged
Check the air cleaner element (page 3-6). Clean the air cleaner element (page 3-6).
Clean
Abnormal
Check the valve clearance (page 3-12). Adjust the valve clearance (page 3-12).
Normal
Abnormal
Remove the spark plug and check the Inspect the spark plug and adjust the spark
electrodes for carbon and proper gap plug gap(page 3-9). Replace if necessary
(page 3-9). (page 3-10).
Normal
Clogged
Check the main jet for blockage (page 6-13). Disassemble and clean the carburetor
(page 6-13).
Clear
Check for secondary air leaks. Is it normal?. No Check around the air intake joint and
carburetor; replace the insulator and/or
gasket if necessary.
Yes
High cylinder
compression
Check the cylinder compression Check for carbon deposits in the combustion
(page 12-5). chamber.
Low cylinder
Normal compression Check the valve clearance (page 3-12).
Check that the cylinder head is correctly
tightened (page 12-3).
Check for defective cylinder head gasket,
valves, or valve seats (page 12-4).
Check for worn piston, piston rings, or
Go to page 4-5 cylinder (page 13-13).
TROUBLESHOOTING
From page 4-4
Abnormal
Check the ignition coil air gap (page 9-4). Adjust the ignition coil air gap (page 9-4).
Normal
Check the ignition coil (page 9-5).

Replace the ignition coil if abnormalities are
found, and recheck.
ENGINE DOES NOT STOP WHEN COMBINATION/

ENGINE STOP SWITCH IS TURNED OFF
Abnormal
Check the combination/ engine stop switch Replace the combination (page 11-4)/
(page 11-5). engine stop switch (page 5-2).
Normal
Check the wire harness connecting the Abnormal

Replace or repair the engine wire harness.
combination/engine stop switch and the
ignition circuit for open or short circuit and for
proper connection.
ENGINE WIRE HARNESS
R
Bl
C1
C2
Normal

found, and recheck.
TROUBLESHOOTING
ENGINE DOES NOT STOP WHEN ENGINE OIL
LEVEL IS LOW
Abnormal
Check the oil level switch (page 11-5). Replace the oil level switch (page 13-5).
Normal
No continuity
Check the wire harness connecting the oil Replace or repair the engine wire harness.
level switch and ignition coil for open or short
circuit and proper connection.
ENGINE WIRE HARNESS
C3
Continuity

found, and recheck.
5. COVER
5
FAN COVER REMOVAL/INSTALLATION. . 5-2
COVER
COVER
FAN COVER REMOVAL/INSTALLATION

Remove the recoil starter (page 10-3).
Remove the auto throttle (If equipped).
Open the harness clip and disconnect the engine stop switch connector (Without control box type).
When installing, refer to the HARNESS AND TUBE ROUTING (page 2-12).
HARNESS CLIP
TAPPING SCREW
TUBE CLIP (3 x 6 mm) (2)
0.45 N·m (0.046 kgf·m,
0.33 lbf·ft)
BOLT
(6 x 12 mm) (6)
FAN COVER
REMOVAL:
The fan cover can be removed
with the recoil starter assembly
and tube clip installed.
ENGINE STOP SWITCH

GROMMET
(Without engine stop switch type)
6. FUEL SYSTEM
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 CARBURETOR BODY CLEANING . . . . . . 6-13 6

FUEL TANK REMOVAL/INSTALLATION . . 6-3 CARBURETOR INSPECTION . . . . . . . . . . 6-13
AIR CLEANER CHOKE DIAPHRAGM INSPECTION. . . . . 6-14

REMOVAL/INSTALLATION. . . . . . . . . . . . . 6-5
PILOT SCREW REPLACEMENT . . . . . . . 6-15
CARBURETOR
REMOVAL/INSTALLATION. . . . . . . . . . . . . 6-8 CHOKE SET REPLACEMENT . . . . . . . . . 6-16
CARBURETOR CYLINDER STUD BOLT

DISASSEMBLY/ASSEMBLY . . . . . . . . . . . 6-10 REPLACEMENT . . . . . . . . . . . . . . . . . . . . 6-16
CHOKE DIAPHRAGM DISASSEMBLY/

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 6-12
FUEL SYSTEM
FUEL SYSTEM
TOOLS
Float level gauge
07401-0010000
FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION
Gasoline is highly flammable and explosive.

You can be burned or seriously injured when
handling fuel.
Turn the fuel valve lever to the OFF position. ENGINE SERVICE BULLETIN #40 =>
Set a commercially available tube clip to the fuel tube.
FUEL FILLER CAP
FUEL GAUGE
FUEL FILLER CAP PACKING (If equipped)
INSTALLATION: INSTALLATION:
Before installing, check for Install the fuel gauge as shown.
deterioration or cracks.
FUEL FILTER
INSTALLATION: FUEL TANK
Before installing, check the
screen of the fuel filter for
clogs or damage.
O-RING
FUEL TANK JOINT
2 N·m (0.2 kgf·m, 1.5 lbf·ft)
INSTALLATION:
screen of the fuel strainer
for clogs or damage.
TUBE CLIP
BOLT (8 x 25 mm)
(2)
24 N·m (2.4 kgf·m, B8 TUBE CLAMP (2)
17 lbf·ft)
NUT (8 mm) (2)

24 N·m (2.4 kgf·m, 17 lbf·ft)
FUEL TUBE
INSTALLATION:
Before installing, check for
FUEL SYSTEM
FUEL FILLER CAP REMOVAL/ ENGINE SERVICE BULLETIN #40 =>
INSTALLATION
Turn the fuel level gauge (1) to align the fuel filler cap
tether hole (2) with the cutout (3) of the fuel filler neck, and (5) (4)
then remove the fuel filler cap (4).
Before installing, check the air vent hole of the fuel filler
cap for clogs. If necessary, clean it using low-pressure
compressed air.
Set the fuel tank cap to the fuel filler neck by aligning the
projections (5) of the cap with the cutouts of the fuel filler (1)
neck and fuel level gauge, and then turn the fuel tank cap
clockwise 180 degrees to lock it.
(2)
(3)
FUEL FILTER REMOVAL/

INSTALLATION
Remove or install the fuel filter by aligning the cutout (1) of
the fuel filter with the fuel filler cap tether (2) as shown.
Before installing, check the screen of the fuel strainer for
clogs or damage.
(1)
(2)
FUEL SYSTEM
AIR CLEANER REMOVAL/
INSTALLATION
Dual Element type:
NUT
BREATHER TUBE
AIR CLEANER
INSTALLATION: COVER
After installing the air cleaner elbow, SERVICE BULLETIN #46 =>
insert the breather tube to the hole
of the cylinder head cover as shown.
BREATHER TUBE
WING NUT
GROMMET
AIR CLEANER
ELEMENT (PAPER)
AIR CLEANER
ELEMENT (FOAM)
HIGH TENSION CORD WASHER BOLT
(6 x 22 mm)
ANGLED CUT END
COLLAR
NOISE SILENCER
AIR CLEANER
ELBOW SEAL
AIR CLEANER ELBOW

REMOVAL/
INSTALLATION:
Remove and install the air
cleaner elbow with the
fuel valve lever in the OFF
CARBURETOR SPACER position and the choke
lever in the CLOSE
INSTALLATION: position.
Before installing, check for damage. Before installation, clean
Note the installation direction. the inside of the air
cleaner elbow.
AIR CLEANER
COLLAR (2)
NUT (6 mm) (2)

Viewed from air cleaner side
9 N·m (0.9 kgf·m, 7 lbf·ft)
FUEL SYSTEM
Cyclone type:
WING NUT
PRE AIR CLEANER
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
INSTALLATION:
After installing the air cleaner elbow, AIR CLEANER
insert the breather tube to the hole of COVER SEAL RING
the cylinder head cover as shown. AIR CLEANER
COLLAR (2)
BREATHER TUBE
CARBURETOR SPACER
INSTALLATION: AIR CLEANER ELBOW
Before installing, check for damage. NUT (6 mm) (2) REMOVAL/
Note the installation direction. 9 N·m INSTALLATION:
(0.9 kgf·m, 7 lbf·ft) Remove and install the
air cleaner elbow with
the fuel valve lever in
the OFF position and
the choke lever in the
CLOSE position.
Before installation, clean
HIGH TENSION CORD the inside of the air
Viewed from air cleaner side cleaner elbow.
FUEL SYSTEM
Low profile type:
CHOKE ROD
CHOKE ROD BREATHER TUBE
INSTALLATION:
INSTALLATION: After installing the air cleaner elbow,
Position the choke rod insert the breather tube to the hole of the
as shown and insert it cylinder head cover as shown.
into the carburetor
choke arm.
BREATHER TUBE
CHOKE ARM CARBURETOR SPACER
INSTALLATION:
Before installing, check for damage.
Note the installation direction.
HIGH TENSION
CORD
GROMMET Viewed from air cleaner side
AIR CLEANER
STAY
AIR CLEANER
COLLAR (2)
CHOKE
DIAPHRAGM
ASSEMBLY
AIR CLEANER COLLAR (4)

AIR CLEANER CASE
AIR CLEANER CASE

AIR CLEANER LID SPRING (2)
BASE
NUT (6 mm) (2) AIR CLEANER

9 N·m ELEMENT
(0.9 kgf·m, 7 lbf·ft)
AIR CLEANER
CASE SEAL
SEALING CAP BOLT (6 x 32 mm)
BOLT (5 x 18 mm) (4)
AIR CLEANER
COVER SEAL
AIR CLEANER
COVER
FUEL SYSTEM
CARBURETOR REMOVAL/
INSTALLATION
Dual element or cyclone type air
cleaner:

handling fuel.
Turn the fuel valve lever to the OFF position.

Remove the air cleaner (page 6-5).
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, and then lift the governor rod out of the hole of
the throttle arm and unhook the throttle return spring.
Installation is in the reverse order of removal.
FUEL TUBE
GOVERNOR ROD
B8 / D8 TUBE CLAMP
INSULATOR
PACKING THROTTLE
RETURN SPRING
CARBURETOR INSULATOR
INSTALLATION:
Before installing, clean the passage CARBURETOR
thoroughly with compressed air.
Install the carburetor insulator with the REMOVAL/INSTALLATION:
vent groove facing toward the carburetor. Remove the fuel tube.
After installing, clamp the high tension
cord to the carburetor insulator.
FUEL TUBE
HIGH
TENSION
CORD
CARBURETOR PACKING
CARBURETOR
INSULATOR B8 / D8 TUBE CLAMP
FUEL SYSTEM
Low profile type air cleaner:

handling fuel.

Remove the air cleaner (page 6-7).
Remove the drain screw of the carburetor to drain completely.
GOVERNOR ROD/THROTTLE RETURN SPRING

Pull the carburetor assembly to a point where the
groove of the throttle arm lines up with the
governor rod, and then lift the governor rod out of
the hole of the throttle arm and unhook the throttle
return spring.
FUEL TUBE
GOVERNOR ROD
D8 TUBE CLAMP THROTTLE

RETURN
SPRING
INSULATOR DASH POT CHECK VALVE

PACKING
TUBE CLAMP
ASSEMBLY:
Install the dash pot into the
tube clamp with the black
end towards the choke
diaphragm.
CARBURETOR INSULATOR To choke diaphragm

INSTALLATION:
Before installing, clean the passage To control base stay
thoroughly with compressed air. (NON-HANDY LEVER B
Install the carburetor insulator with the
vent groove facing toward the carburetor.
After installing, clamp the high tension CARBURETOR
Remove the fuel tube.
FUEL TUBE
D8 TUBE CLAMP
HIGH
TENSION CARBURETOR PACKING
CORD
CARBURETOR
INSULATOR
FUEL SYSTEM
CARBURETOR DISASSEMBLY/
ASSEMBLY
Dual element or cyclone type air cleaner:

handling fuel.
To prevent serious eye injury, always wear

safety goggles or other eye protection when us-
ing compressed air.
Remove the carburetor (page 6-8).

Before disassembly, clean the outside of the carburetor.
PILOT JET SET SET COLLAR PAN SCREW LEVER SETTING

(3 x 6 mm) (2) PLATE
ASSEMBLY:
Before installing, clean
thoroughly with VALVE LEVER
low-pressure compressed O-RING CHOKE LEVER SPRING
air.
Lightly lubricate the THROTTLE STOP SCREW
O-ring to ensure easy ADJUSTMENT: (page 3-12) FUEL VALVE
installation into the O-RING
LEVER
PILOT SCREW FUEL VALVE

MAIN NOZZLE
REPLACEMENT PACKING
ASSEMBLY: UPPER :(page 6-15)
Before installing, clean SIDE
thoroughly with low- SPRING PIN
pressure compressed (2 x 12 mm)
air.
CUP FILTER
LIMITER CAP (page 3-8)
MAIN JET
ASSEMBLY: UPPER
thoroughly with low-
pressure compressed
air. FLOAT O-RING
SEDIMENT CUP
FLOAT PIN
FLOAT CHAMBER
FLOAT VALVE
ASSEMBLY:
Install the float chamber to the
carburetor body at an angle as O-RING FLOAT VALVE SPRING
shown.
DRAIN SCREW GASKET
SET SCREW GASKET

DRAIN SCREW
SET SCREW
FUEL SYSTEM
Low profile type air cleaner:

handling fuel.

ing compressed air.

PILOT JET SET SET COLLAR

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

ADJUSTMENT: (page 3-12)
PILOT SCREW FLOAT VALVE

REPLACEMENT: (page 6-15)
FLOAT VALVE SPRING
O-RING
LIMITER CAP FLOAT
ASSEMBLY:
Check for smooth
MAIN JET movement after
installation.
ASSEMBLY: UPPER
pressure compressed
air. MAIN NOZZLE
ASSEMBLY: UPPER
Before installing, SIDE
clean thoroughly with
FLOAT CHAMBER low-pressure
compressed air.
ASSEMBLY:
Install the float chamber to the
carburetor body at an angle as
shown.
DRAIN SCREW
O-RING
SET BOLT
FUEL SYSTEM
Main jet number
Carburetor Main Jet

identification Number (1) + (2) Number
BE21J A # 88 (1)
BE70R A # 85
BE71F A # 85
BE80N A # 98
BE80M A # 98
BE80P A # 98
BE84A A # 100 (2)
BE84B A # 100
BE84C A # 100
BE84D A # 105
BE88A A # 88
BE88B A # 88
BE89C A # 88
BE88F A # 88
BE88G A # 88
BE88J A # 88
BE89Y A # 100
BE89Z A # 105
BE94E A # 108
BE94F A # 108
CHOKE DIAPHRAGM DISASSEMBLY/ASSEMBLY

Remove the choke diaphragm assembly (page 6-7).
MANUAL CHOKE ROD
CHOKE ROD GROMMET
DIAPHRAGM STAY
E RING
CHOKE ROD GUIDE

THRUST WASHER (2.7 x 8 mm)
CHOKE ROD STOPPER

CHOKE DIAPHRAGM
E RING
RETURN SPRING
CHOKE LEVER WASHER

LEVER COLLAR
CHOKE LEVER
SCREW (5 x 12 mm) (2) ROD JOINT
CHOKE LEVER SEAL

CHOKE LEVER ROD
ARM PIVOT BUSH
CHOKE PLAIN WASHER (5 mm) E RING
LEVER SEAL
FUEL SYSTEM
CARBURETOR BODY CLEANING

ing 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)
(5)
(6)
(1)
(3)
(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
compressing the valve spring. (1)
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 6-14).
If the float valve and the float valve spring are normal,
replace the float (page 6-10).
FUEL SYSTEM
FLOAT VALVE
Check the float valve (1) and its seat (2) for wear or
contamination. CARBURETOR BODY
Before installation, check for wear or a weak spring (3).
Check the operation of the float valve.
(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.

FUEL SYSTEM
PILOT SCREW REPLACEMENT
Leave the pilot screw (1) and limiter cap (2) in place
Pilot screw will break at narrow point.
during carburetor cleaning. Remove only if necessary
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.
CARBURETOR
Model Carburetor identification Pilot screw BODY
Number (3) + (4) opening
GX240 BE70R A 1
BE71F A 1 STOP
GX270 BE21J A 2
GX340 BE80N A 1 - 3/4
BE80M A 1 - 3/4
BE80P A 1 - 3/4
(2)
GX390 BE21J A 2
BE84A A 2 - 1/8
BE84B A 2 - 1/8
BE84C A 2 - 1/8
BE84D A 1 - 1/2
BE88A A 1 - 7/8
BE88B A 1 - 7/8
BE89C A 1 - 7/8
BE88F A 1 - 7/8
BE88G A 1 - 7/8
BE88J A 1 - 7/8
BE89Y A 2 - 1/8
BE89Z A 1 - 1/2
BE94E A 1 - 5/8
BE94F A 1 - 5/8
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.
FUEL SYSTEM
CHOKE SET REPLACEMENT
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)
(1) (4)
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 STUD BOLT (8 x 98): 82.0 mm (3.90 in)
out. STUD BOLT (8 x 106): 90.0 mm (3.90 in)
Install new stud bolts. STUD BOLT (8 x 115): 99.0 mm (4.55 in)
STUD BOLT (8 x 123): 107.0 mm (3.90 in)
SPECIFIED LENGTH STUD BOLT (8 x 131.5): 115.5 mm (4.55 in)
STUD BOLT (8 x 98) 82.0 mm (3.23 in)
STUD BOLT (8 x 106) 90.0 mm (3.54 in)
STUD BOLT (8 x 115) 99.0 mm (3.90 in)
STUD BOLT (8 x 123) 107.0 mm (4.21 in)
STUD BOLT (8 x 131.5) 115.5 mm (4.55 in)
7. GOVERNOR SYSTEM
GOVERNOR ARM/CONTROL BASE ASSY. CONTROL BASE ASSY. DISASSEMBLY/

REMOVAL/INSTALLATION ASSEMBLY
MANUAL OPERATION TYPE . . . . . . . . 7-2 MANUAL OPERATION TYPE . . . . . . . . 7-6

7
FIXED THROTTLE OPERATION TYPE. 7-3 REMOTE LEVER A TYPE . . . . . . . . . . . 7-7
AUTO THROTTLE (IF EQUIPPED) REMOVAL/ REMOTE LEVER B TYPE . . . . . . . . . . . 7-7

INSTALLATION
MAXIMUM SPEED ADJUSTMENT . . . . . . . 7-8
GX240•GX270. . . . . . . . . . . . . . . . . . . . . 7-4
SOLENOID (AUTO THROTTLE)
GX340•GX390. . . . . . . . . . . . . . . . . . . . . 7-5 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 7-10
GOVERNOR SYSTEM
GOVERNOR ARM/CONTROL BASE ASSY.
GOVERNOR SYSTEM
REMOVAL/INSTALLATION
MANUAL OPERATION TYPE
Remove the following parts.
– Air cleaner (page 6-5)
– Muffler (page 14-2)
– Fuel tank (page 6-3)
– Tube clamp (page 6-8)
Installation is in the reverse of removal.
SERVICE BULLETIN #47 =>
Adjust the maximum speed (page 7-8).
SCREW (5 x 16 mm)
(If equipped)
CABLE HOLDER CONTROL BASE ASSY.

(If equipped)
SCREW (4 x 6 mm)
(If equipped)
REMOTE CABLE
(Commercially available)
(If equipped)
GOVERNOR ROD/THROTTLE
RETURN SPRING GOVERNOR SPRING
REMOVAL/INSTALLATION: INSTALLATION:
Pull the carburetor assy. (1) away
from the engine to a point where Install with the long end
the groove (2) of the throttle arm of the spring toward the
lines up with the governor rod (3), control base assy.
and then lift the governor rod out
of the hole of the throttle arm and Hook the governor spring
unhook the throttle return spring to the outer hole of the
(4). governor arm.
(3)
(4) OUTER HOLE
(1) NUT (6 mm)
(2)
GOVERNOR ARM
GOVERNOR ARM
BOLT
GOVERNOR ARM
SHAFT
BOLT (6 x 12 mm) (3)

GOVERNOR SYSTEM
FIXED THROTTLE OPERATION TYPE
Remove the following parts.
– Tube clamp (page 6-8) (If equipped)
GOVERNOR ROD/THROTTLE
RETURN SPRING
REMOVAL/INSTALLATION: SERVICE BULLETIN #47 =>
Pull the carburetor assy. (1) out 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 the hole of the CONTROL BASE ASSY.
throttle arm and unhook the throttle
return spring (4). (If equipped)
(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.
OUTER HOLE NUT (6 mm)
GOVERNOR ARM
(If equipped)
BOLT (6 x 12 mm) (3)
GOVERNOR ARM
(If equipped)
GOVERNOR ARM
BOLT
GOVERNOR ARM
SHAFT
GOVERNOR SYSTEM
AUTO THROTTLE (IF EQUIPPED)
Remove the fuel tank (page 6-3).
GX240•GX270
GOVERNOR SYSTEM
GX340•GX390
CHOKE RETURN
SPRING
SCREW (5 x 8 mm) (2)

BOLT (6 x 12 mm) (2)
THROTTLE LEVER
To the units connected
from engine.
SOLENOID
GOVERNOR SYSTEM
CONTROL BASE ASSY.
DISASSEMBLY/ASSEMBLY
MANUAL OPERATION TYPE
Remove the control base assy (page 7-2).
SELF-LOCK NUT (6 mm)
ASSEMBLY:
After tightening the nut fully,
loosen it 1-1/2 turns.
CONTROL LEVER
WASHER
SCREW (4 x 6 mm)
ASSEMBLY: (If equipped)
Install the control lever
washer by aligning the
cutout of the control
lever washer with the
claw of the control
base.
WIRE HOLDER
(If equipped)
LEVER SPRING
ASSEMBLY:
Note the installation
direction.
CIRCLIP (5 mm)
(If equipped)
CONTROL LEVER
CABLE RETURN SPRING

CONTROL LEVER INSTALLATION:
SPACER
Install with the short end
of the spring toward the
control base.
CONTROL BASE CLAW Hook the cable return
spring to the hole of the
CONTROL ADJUST control lever.
SPRING
SCREW (5 x 32 mm)
(If equipped)
ASSEMBLY:
Adjust the maximum
speed(page 7-8).
SCREW (5 x 25 mm) STOPPER COLLAR

(If equipped) (If equipped)
GOVERNOR SYSTEM
REMOTE LEVER A TYPE
CONTROL BASE
CONTROL ADJUST
SPRING
SCREW (5 x 32 mm)
ASSEMBLY:
Adjust the maximum
speed (page 7-8).
REMOTE LEVER B TYPE

CONTROL BASE
CONTROL ADJUST
SPRING
SCREW (5 x 32 mm)
ASSEMBLY:
Adjust the maximum
speed (page 7-8).
GOVERNOR SYSTEM
MAXIMUM SPEED ADJUSTMENT
MANUAL CONTROL TYPE
Remove the fuel tank (page 6-3). (3)
Loosen the 6 mm nut (1) of the governor arm. (5)
Turn the governor arm (2) counter clockwise to fully

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 6 mm nut 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 5 x 32 mm screw or 5 x 25 mm (6) of the
control to obtain the specified maximum speed.
MAXIMUM SPEED: 3,850 ± 150 min-1 (rpm)
(6)
(4)
(2)
(1)
AUTO THROTTLE TYPE

PINCH BOLT NUT
Loosen the two 6 x 12 mm flange bolts, and move the
Auto Throttle solenoid away from the governor arm. AUTO
THROTTLE
Loosen the nut on the governor arm pinch bolt. SOLENOID
6 x 12 mm
FLANGE BOLT (2)
GOVERNOR SYSTEM
Move the governor rod end of the governor arm in
the direction shown.
Move the governor spring end of the governor arm in
the direction shown.
PINCH BOLT NUT
Holding both sections of the governor arm in alignment
so that the two stops are in contact with one another, GOVERNOR
ARM SHAFT
" STOP ! STOP
move the governor arm in the direction shown until the
throttle is completely open, and hold it in that position. GOVERNOR
Rotate the governor arm shaft (4) as far as it will go in SPRING
the same direction it was just moved by the governor
arm, and then tighten the governor arm pinch bolt. "
There may be a slight bend in the governor arm when it
is released; this will not affect governor operation.
!
GOVERNOR
ROD
Move the Auto Throttle solenoid until its actuator arm

just contacts the governor arm, and tighten the two 6 x 12 mm
LIMITING FLANGE
6 x 12 mm flange bolts. SCREW BOLT (2)
Install the gas 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 (5) to run the engine at the
specified maximum speed, and hold the control lever.
Turn the limiting screw to obtain the specified maximum
speed.
MAXIMUM SPEED: 3,850 ± 150 min-1 (rpm)
Check the Auto Throttle speed, and adjust if necessary CONTACT
(Refer to page 3-12). AREA ACTUATOR
GOVERNOR ARM ARM
GOVERNOR SYSTEM
SOLENOID (AUTO THROTTLE)
INSPECTION
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)
8. CHARGING SYSTEM
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 COOLING FAN/FLYWHEEL REMOVAL/

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8-7
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . 8-3
CHARGE / LAMP COIL (IF EQUIPPED)
BEFORE TROUBLESHOOTING . . . . . . . . . 8-6 REMOVAL/INSTALLATION . . . . . . . . . . . . 8-9
8
CHARGING SYSTEM CHARGE COIL INSPECTION . . . . . . . . . . 8-10
TROUBLESHOOTING . . . . . . . . . . . . . . . . . 8-6
CHARGING SYSTEM
TOOLS
CHARGING SYSTEM
Puller collar set

07APC-ZY1A100
CHARGING SYSTEM
SYSTEM DIAGRAM
NO CHARGE COIL TYPE
C3 C1
C2
Y
Bl
Bl
R
R
Y
1
ENGINE STOP SWITCH
4 3 1 2 EXT ( + ) EXT ( - )
LED
EXT ( - )
EXT ( + )
OIL_ALT
OFF
ON
Bl Black Br Brown
Y Yellow O Orange
Bu Blue Lb Light blue
ENGINE STOP G Green Lg Light green
SWITCH R Red P Pink
W White Gr Gray
OIL LEVEL SPARK IGNITION TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
SWITCH PLUG COIL
1/3A CHARGE COIL TYPE
CONTROL BOX
C1
Bl Bl
C3 C2
R R
C5
W Gr
Bl/W
W
Bl
R
Y
C4
T1
1
Gr
W
Bl/W
T2
W
Bl
R
4 3 1 2
LED
EXT ( - )
EXT ( + )
OIL_ALT
2
W
C6 C7
2 1
ST
EXT ( + )
EXT ( - )
BAT
T3 MAIN FUSE CIRCUIT SILICON

PROTECTOR RECTIFIER COMBINATION
FLYWHEEL SWITCH
OIL LEVEL SPARK IGNITION BATTERY STARTER MOTOR

SWITCH PLUG COIL
COMBINATION
SWITCH Bl Black Br Brown
CHARGE COIL Y Yellow O Orange
EXT ( + ) EXT ( - ) ST BAT
OFF G Green Lg Light green
R Red P Pink
ON W White Gr Gray
TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
START
CHARGING SYSTEM
10A CHARGE COIL TYPE
CONTROL BOX
C10
(W) (W)
W
MAIN FUSE
W
C1
Bl Bl
R R
C3 C2
Bl
C11
Gr
W
( Bl/W )
(W)
Gr
W
W
W
Bl
4
3
Bl
R
Y
T1 C4
Y
1 2
1
( Bl )
4 6 1 2 3 5
Bl/W
W
Bl
R
T2
Gr
W
4 3 1 2
W/Bu
LED
EXT ( + )
EXT ( - )
Bl/Y
OIL_ALT
Gr
Gr
W
Bl
T4
FLYWHEEL
ST
EXT ( + )
EXT ( - )
BAT
CHARGE COIL
T3
COMBINATION
SWITCH
OIL LEVEL SPARK IGNITION REGULATOR/ BATTERY STARTER MOTOR
SWITCH PLUG COIL RECTIFIER
COMBINATION
Bl Black Br Brown
SWITCH
Y Yellow O Orange
EXT ( + ) EXT ( - ) ST BAT Bu Blue Lb Light blue
G Green Lg Light green
OFF R Red P Pink
W White Gr Gray
ON
START
CHARGING SYSTEM
18A CHARGE COIL TYPE
CONTROL BOX
C10
(W) (W)
W
MAIN FUSE
W
C1
Bl Bl
R R
C3 C2
Bl
C11
Gr
Gr
( Bl/W )
(W)
Gr
Gr
W
W
Bl
C8 C9
3
Bl
R
Y
T1 C4
Y
CHARGE
1
COIL
( Bl )
4 6 1 2 3 5
Bl/W
W
Bl
R
T2
Gr
Gr
4 3 1 2
W/Bu
LED
EXT ( + )
EXT ( - )
Bl/Y
OIL_ALT
Gr
Gr
W
Bl
T4
ST
EXT ( + )
EXT ( - )
BAT
T3
COMBINATION
FLYWHEEL SWITCH
CHARGE
COIL
COMBINATION
Bl Black Br Brown
SWITCH
Y Yellow O Orange
OFF R Red P Pink
W White Gr Gray
ON
START
CHARGING SYSTEM
CHARGING SYSTEM
TROUBLESHOOTING
Abnormal
Check the fuse (page 11-7). Replace the fuse (page 11-4).
Normal
Abnormal
Check the charge / lamp coil (page 8-10). Replace the charge coil / lamp coil
(page 8-9).
Normal
1A / 3A charge coil type: Abnormal

Replace the circuit protector (page 11-4).
Check the circuit protector (page 11-6).
Normal
1A / 3A charge coil type: Abnormal Replace the silicon rectifier (page 11-4).
Check the silicon rectifier (page 11-6).
Normal
Abnormal
10A / 18A charge coil type: Replace the regulator rectifier (page 11-4).
Check the regulator rectifier (page 11-7).
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.
CHARGING SYSTEM
COOLING FAN/FLYWHEEL REMOVAL/
INSTALLATION
REMOVAL
Remove the following parts:
– Fan cover (page 5-2).
– Ignition coil (page 9-3).
FLYWHEEL
SPECIAL (With starter)
WOODRUFF KEY
(25 x 18 mm)
STARTER PULLEY
(With screen)
FLYWHEEL
(Without starter)
STARTER PULLEY
(Without screen)
COOLING FAN
FLYWHEEL SPECIAL NUT (16 mm)
REMOVAL: REMOVAL:
Remove the flywheel using the special and commercially Hold the flywheel with a commercially available strap
available tools shown below. wrench S-17 and remove the 16 mm special nut.
Do not hit the flywheel with a hammer. Take care not to damage the cooling fan.
STRAP WRENCH
FLYWHEEL PULLER SET S-17
OCT-7403 (Commercially (Commercially
available) available)
STRAP WRENCH S-17 SPECIAL NUT
(Commercially available) (16 mm)
FLYWHEEL
FLYWHEEL
TOOL:
Puller collar set 07APC-ZY1A100
CHARGING SYSTEM
INSTALLATION
Clean the tapered parts (1) of dirt, oil, grease, and other
(3) (6)
foreign material before installation. Be sure there are no
metal parts or other foreign material on the magnet part
(2) of the flywheel.
Set the 25 x 18 mm special woodruff key (3) in the key
groove (4) of the crankshaft securely.
Install the flywheel (5) by aligning the key slot (6) with
special woodruff key on the crankshaft.
(2)
The flywheel may push the 25 x 18 mm special (4)
woodruff key 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

surface of the 16 mm special nut (1), and loosely (2) (1)
tighten the nut.
Hold the flywheel (2) with a commercially available
strap wrench S-17 (3), and tighten the 16 mm special
nut to the specified torque.
Install the following parts: (3)
– Ignition coil (page 9-3).
– Fan cover (page 5-2).
CHARGING SYSTEM
CHARGE / LAMP COIL (IF EQUIPPED)
– Fan cover (page 5-2)
– Ignition coil (page 9-3)
– Remove the flywheel (page 8-7)
Remove the coil connector or connectors.
Install the cord clamp (page 2-12).
10A CHARGE
CORD GROMMET COIL TYPE:
10A CHARGE COIL
BOLT (6 x 40 mm) (4)
CORD CLAMP
BOLT (6 x 12 mm)
18A CHARGE COIL TYPE: 1A/3A CHARGE

1A/3A CHARGE COIL TYPE:
18A CHARGE COIL
CORD COIL
GROMMET CORD CLAMP
CORD BOLT (6 x 12 mm)

CLAMP
CORD
GROMMET
BOLT (6 x 12 mm)
3A CHARGE COIL TYPE: BOLT (6 x 40 mm) (2)
1A CHARGE COIL TYPE: BOLT (6 x 35 mm) (2)
LAMP COIL TYPE:
BOLT (6 x 40 mm) (4) LAMP COIL TYPE

CORD CLAMP
BOLT (6 x 12 mm)
CORD
BOLT (6 x 40 mm) (2) GROMMET
CHARGING SYSTEM
CHARGE COIL INSPECTION
10A/18A CHARGE COIL/LAMP COIL TYPE
Disconnect the charge/lamp coil connectors.
10 A / 18 A CHARGE COIL / LAMP COIL TYPE:
Measure the resistance between the terminals of the
charge/lamp coil.
18A CHARGE
Resistance: COIL / LAMP
Charge coil 10 A: 0.16 - 0.24 ȍ COIL TYPE:
Charge coil 18 A: 0.10 - 0.30 ȍ
Lamp coil 12 V-25 W: 0.30 - 0.46 ȍ
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 charge coil (page 8-9).
• If the resistance is good and the flywheel is ok,
replace the charge coil and retest.
10 A CHARGE
COILTYPE:
Inspect between
each terminals.
1A/3ACHARGE COIL TYPE

Disconnect the charge coil connector.
1A / 3A CHARGE COIL TYPE:
Check for continuity between terminal and engine
ground.
Resistance:
Charge coil 1 A: 3.00 - 4.00 ȍ
Charge coil 3 A: 0.62 - 0.93 ȍ
If the resistance is good and the flywheel is ok, replace
the charge coil and retest.
9. IGNITION SYSTEM
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . 9-2 IGNITION COIL INSTALLATION . . . . . . . . . 9-4
IGNITION SYSTEM TROUBLESHOOTING. 9-2 SPARK TEST . . . . . . . . . . . . . . . . . . . . . . . . 9-4
IGNITION COIL REMOVAL/ SPARK PLUG CAP INSPECTION. . . . . . . . 9-4

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 9-3
IGNITION COIL INSPECTION . . . . . . . . . . . 9-5
9
IGNITION COIL
IGNITION COIL
SYSTEM DIAGRAM
Bl Black Br Brown
C1 Y Yellow O Orange
Bl Bl Bu Blue Lb Light blue
C3 C2 G Green Lg Light green
R R R Red P Pink
W White Gr Gray
Bl
R
Y
Bl
R
1
Bl
R
4 3 1 2
LED
EXT ( + )
OIL_ALT
EXT ( - )
ST
EXT ( + )
EXT ( - )
BAT
ENGINE STOP
COMBINATION SWITCH TYPE
SWITCH
OIL LEVEL SPARK IGNITION

SWITCH PLUG COIL
IGNITION SYSTEM
TROUBLESHOOTING
NO SPARK AT SPARK PLUG
Abnormal
Check continuity between the oil level Replace the oil level switch (page 13-5).
switch terminal and engine ground
(page 11-5).
Normal
Abnormal
Check the harness connecting the ignition Replace or repair the engine wire harness.
coil and the combination/engine stop switch
for open or short circuit and for proper
connection (page 4-5).
Normal
Abnormal
Check the engine stop switch (page 11-5)/ Replace the engine stop switch (page 5-2)/
combination switch (page 11-5). combination switch (page 11-4).
Normal
Abnormal
Check the ignition coil (page 9-5). Replace the ignition coil (page 9-3).
IGNITION COIL
IGNITION COIL REMOVAL/
INSTALLATION
ENGINE WIRE HARNESS

INSTALLATION:
Clamp the engine wire harness to the ribs
of the cylinder barrel as shown.
ENGINE WIRE HARNESS
RIB
Viewed from above
SPARK PLUG CAP
IGNITION COIL
INSTALLATION: BREATHER
Install the Ignition coil as TUBE
shown.
HIGH-TENSION
CORD
BOLT (6 x 28 mm) (2)
CARBURETOR HIGH-TENSION
INSULATOR CORD
IGNITION COIL
IGNITION COIL INSTALLATION
Attach the ignition coil (1) and loosely tighten the two 0.2 – 0.6 mm
6 x 28 mm flange bolts (2). (0.01 – 0.02 in)
Insert the thickness gauge (3) of proper thickness
between the ignition coil and the flywheel.
(1)
IGNITION COIL AIR GAP:
0.2 – 0.6 mm (0.01 – 0.02 in)
Adjust the ignition coil air gap equally on both sides. (2)
Push the ignition coil firmly against the flywheel and 0.2 – 0.6 mm
(0.01 – 0.02 in)
tighten the 6 x 28 mm flange bolts securely.
Remove the thickness gauge. (3)
(1)
(2)
SPARK TEST
Inspect the following before performing the 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.
Remove the spark plug and reattach the spark plug
cap.
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.
If there is no spark, replace the spark plug with a known
good one and retest.
SPARK PLUG CAP INSPECTION

Remove the spark plug cap from the high tension cord.
Attach the tester probes to the terminal connected to
the spark plug and terminal connected to the high
tension cord of the spark plug cap.
There should be a continuity between the terminals.
If there is no continuity, replace the spark plug cap.
IGNITION COIL
IGNITION COIL INSPECTION
(1)
Remove the spark plug cap from the high tension cord
(1).
Disconnect the engine wire harness connector (2) from
the ignition coil.
Measure the resistance between the terminals and be
sure that the measurements are within the
specifications in the below.
Use a tester that is equivalent to or higher than the
performance specified, internal resistance: 20 kȍ/VDC,
9 kȍ/VAC
Be careful not to touch the metallic part of the tester
probe with your fingers; otherwise, the correct
resistance value cannot be obtained. (2)
2
Read the tester manufacturer‘s operation instructions
carefully before operating the tester. Follow the
instructions of the Service Manual. Be sure the tester‘s
1
battery is fully charged, and check the meter before
using the tester.
4 3
GND
Unit: kȍ
(+) Prove
HIGH- Terminal number
GND TENSION EXT (+) EXT (-) LED OIL ALT
CORD 2 1 4 3
GND
6 - 11 1 - 10 7 - 45 5 - 30
HIGH-TENSION
6 - 11 7 - 24 14 - 72 12 - 47
CORD
EXT (+)
(-) Probe
5 - 14 10 - 26 15 - 76 6 - 26
2
EXT (-)
Terminal
number
1
LED
4
OIL ALT
3
MEMO
10. STARTING SYSTEM
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . 10-2 RECOIL STARTER INSPECTION . . . . . . . 10-7
STARTING SYSTEM STARTER MOTOR REMOVAL/

TROUBLESHOOTING . . . . . . . . . . . . . . . . 10-2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . 10-8
RECOIL STARTER REMOVAL/ STARTER MOTOR DISASSEMBLY/

INSTALLATION . . . . . . . . . . . . . . . . . . . . . 10-3 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 10-9
RECOIL STARTER DISASSEMBLY . . . . . 10-4 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 10-10

10
RECOIL STARTER ASSEMBLY . . . . . . . . 10-5
STARTING SYSTEM
SYSTEM DIAGRAM
STARTING SYSTEM
CONTROL BOX
Bl/W
W
C4
T1
T2
Bl/W
W
W
ST
EXT ( + )
EXT ( - )
BAT
Bl Black Br Brown
Y Yellow O Orange
T3 MAIN FUSE Bu Blue Lb Light blue
(5A BLADE TYPE) COMBINATION
(15A BLADE TYPE) G Green Lg Light green
SWITCH R Red P Pink
(25A BLADE TYPE)
BATTERY STARTER MOTOR W White Gr Gray
STARTING SYSTEM
TROUBLESHOOTING
STARTER MOTOR DOES NOT OPERATE
Abnormal
Check the battery condition. Replace with a known-good battery.
If the battery runs down again, perform the
Normal CHARGING SYSTEM
Low voltage
Check the battery voltage between the starter Replace battery positive (+) cable.
motor side positive (+) battery cable terminal
and engine ground.
Normal
No continuity
Check the continuity between BAT terminal
(White) and ST terminal (Black/white) of the Check the blade fuse in the control box
combination switch in the START position (page 11-7).
(page 11-5).
Not blown Blown
Continuity Replace the combination switch (page 11-4). Replace the blade fuse (page 11-4).
Abnormal
Check the starter solenoid (page 10-10). Replace the starter solenoid (page 10-9).
Normal
Perform the starter motor performance test

(page 10-10). If necessary disassemble the
starter motor (page 10-8) and check each
part (page 10-10).
STARTING SYSTEM
RECOIL STARTER REMOVAL/
INSTALLATION
RECOIL STARTER
INSTALLATION:
Remove dirt and debris before installation.
Position the recoil starter case for best starter grip location.
BOLT (6 x 10 mm) (3)

STARTING SYSTEM
RECOIL STARTER DISASSEMBLY

ing compressed air.
CENTER SCREW
3.9 N·m (0.40 kgf·m, 2.9 lbf·ft)
SPRING RETAINER
FRICTION SPRING RATCHET (2)
RECOIL STARTER PULLEY RATCHET SPRING (2)
STARTER RETURN
RECOIL STARTER ROPE SPRING
RECOIL STARTER CASE
STARTER GRIP
GRIP REINFORCEMENT
STARTING SYSTEM
RECOIL STARTER ASSEMBLY

ing compressed air.
Pass the recoil starter rope (1) through the hole (2) of the recoil starter
pulley (3), and then tie the rope as shown.
(3)
10 mm
(0.4 in)
Before installing the recoil starter rope, check for fray or wear.
Wind the recoil starter rope onto the recoil starter pulley counterclockwise.
(2)
(1)
Hook the outer hook (1) of the starter return spring (2) to the groove (3) of
the recoil starter pulley (4), and then install the starter return spring by (2)
winding it in the starter pulley.
(3)
(1)
(4)
Apply grease to the cutout (1) of the recoil starter case (2).
Set the recoil starter pulley (3) to the recoil starter case by aligning the inner (2)
hook (4) of the starter return spring with the cutout of the recoil starter case.
(4)
(1) (3)
STARTING SYSTEM
Apply grease to the two ratchets (1).
(1)
Install the two ratchets and the two ratchet springs (2)
to the recoil starter pulley as shown.
(2)
Apply grease to the inside of the spring retainer (1).

(3)
Set the friction spring (2) and the spring retainer to the
recoil starter pulley in the direction as shown.
(1)
Apply locking agent (Hondalock 1, Threebond® 2430 or
equivalent) to the threads of the center screw (3). (2)
Hold the spring retainer and tighten the center screw to
the specified torque.
TORQUE: 3.9 N·m (0.40 kgf·m, 2.9 lbf·ft)
Turn the recoil starter pulley (1) more than 2 turns

counterclockwise to preload the starter return spring.
Be sure to hold the recoil starter pulley.
(1)
Pass the recoil starter rope through hole (1) of the recoil
starter case, the starter grip (2), and reinforcement grip
(3), and then tie the rope as shown.
Check the recoil starter operation (page 10-7).
(1)
(2)
20 mm
(0.8 in) (3)
STARTING SYSTEM
RECOIL STARTER INSPECTION
RECOIL STARTER OPERATION
(2)
Pull the starter grip several times to inspect that the
ratchets (1) are operated properly (the ratchet ends
come out from the spring retainer (2).
(1)
STARTER PULLEY
Inspect the square holes (1) of the starter pulley (2) for (1)
deformation.
(2)
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
STARTER SOLENOID
WIRE
BOLT (8 x 35 mm)
STARTING SYSTEM
STARTER MOTOR DISASSEMBLY/ASSEMBLY
Remove the starter motor (page 10-8).
HOUSING
WASHER ASSEMBLY:
SCREW Make sure there is no
(5 x 14 mm) (2) obstruction on the magnets.
INSULATOR
ARMATURE INSPECTION:
Check for cracks or damage.
SCREW WASHER
NUT (5 x 32 mm) (4)
(6 mm) SCREW WASHER
(2) (4 x 14 mm) (2)
STARTER
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
STARTING SYSTEM
BRUSH HOLDER INSTALLATION
Install the insulator (1), brush holder (2), negative brush
terminals (3), and two 4 x 14 mm screws (4) to the (4)
center bracket as shown.
(3)
Install the brush springs (5) and brushes, and push the
brushes in the holders with a suitable wire (6) so that (2)
they do not interfere with the commutator.
(1)
(5)
(6)
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 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 12V 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)
STARTING SYSTEM
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: 7.0 mm (0.28 in)

SERVICE LIMIT: 3.5 mm (0.14 in)
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 10-9).
If the correct continuity of the negative (-) brushes is not
obtain, replace the negative (-) brushes.
ARMATURE MICA DEPTH

Visually inspect the commutator 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.
When the mica is clogged, or its depth is smaller than
the service limit value, recut the grooves using a
hacksaw blade or a small file.

STARTING SYSTEM
ARMATURE CONTINUITY CHECK -
COMMUTATOR TO SHAFT
Check for continuity between the commutator and the
armature shaft.
Replace the armature if continuity exists between any
of the commutator segments and the armature shaft
(page 10-9).

COMMUTATOR SEGMENTS
Check for continuity between segments. If an open
circuit (no continuity) exists between any two segments,
replace the armature (page 10-9).
OVERRUNNING CLUTCH
Check the pinion gear shaft (1) for smooth (2)
axial movement.
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 (1)
flywheel ring gear must be inspected.
STARTER SOLENOID WIRE
Check the starter solenoid wire for continuity.
11. OTHER ELECTRICAL
COMPONENT LOCATION . . . . . . . . . . . . . 11-2 COMBINATION SWITCH INSPECTION . . 11-5
CONTROL BOX REMOVAL/ SILICON RECTIFIER INSPECTION . . . . . 11-6

INSTALLATION . . . . . . . . . . . . . . . . . . . . . 11-3
CIRCUIT PROTECTOR INSPECTION. . . . 11-6
CONTROL BOX DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 11-4 FUSE INSPECTION . . . . . . . . . . . . . . . . . . 11-7
OIL LEVEL SWITCH INSPECTION . . . . . . 11-5 REGULATOR/RECTIFIER INSPECTION . 11-7
ENGINE STOP SWITCH INSPECTION . . . 11-5

11
OTHER ELECTRICAL
COMPONENT LOCATION
OTHER ELECTRICAL
ENGINE STOP SWITCH
OIL LEVEL SWITCH
CONTROL BOX
OTHER ELECTRICAL
CONTROL BOX REMOVAL/INSTALLATION
Disconnect the control box wires.
When installing, refer to the HARNESS AND TUBE ROUTING (with circuit protector) (page 2-12).
IGNITION COIL WIRES
COMBINATION SWITCH
WIRE
BOLT (6 x 12 mm) (2)
CHARGE COIL WIRE
CONTROL BOX (Without Circuit Protector)
Connection of control box

wires are depending on the
application of the engine,
therefore, it does not indicate
CONTROL BOX (With Circuit Protector)
those parts in this manual.
OTHER ELECTRICAL
CONTROL BOX DISASSEMBLY/ASSEMBLY
Remove the control box (page 11-3).
10 A REGULATOR/RECTIFIER 18 A REGULATOR/RECTIFIER
(If equipped) (If equipped)
SILICON RECTIFIER To the units connected from the engine.

(If equipped)
CONTROL CASE
CASE MOUNTING BRACKET To the units connected
from the engine.
BLADE TYPE FUSE
SPECIAL SCREW (5A / 15A / 25A)
(6 x 12 mm)
(If equipped)
CONTROL PANEL
COMBINATION
WIRE BAND SWITCH WASHER
COMBINATION SWITCH
ASSEMBLY: CIRCUIT PROTECTOR

Align the tab with the cut out in (If equipped)
the case mounting bracket and
the control panel. ASSEMBLY:
PROTECTOR LENS
(If equipped)
COMBINATION SWITCH
PAN SCREW
SHORT
(3 x 12 mm) (2)
(If equipped)
LONG
COMBINATION
TAB SWITCH NUT
OTHER ELECTRICAL
OIL LEVEL SWITCH INSPECTION
Disconnect the engine wire harness from the oil level
switch.
Check 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 3-4).
Check continuity between the switch terminal and
engine ground.
There should be continuity.
Check continuity between the switch terminals while
filling the engine 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 13-5).
ENGINE STOP SWITCH INSPECTION

Remove the engine stop switch connectors.
Check continuity between the terminals at each switch
position.
Switch position Continuity
ON Yes
OFF No
If the correct continuity is not obtained, replace the
engine stop switch (page 5-2).
COMBINATION SWITCH INSPECTION

With Circuit Protector
position. ST
(Bl/W)
If the correct continuity is not obtained, replace the BAT
combination switch (page 11-3). (W)
EXT(+)
(R)
EXT(-)
(Bl)
CIRCUIT PROTECTOR
EXT(+) EXT(-) ST BAT

OFF
ON
START
OTHER ELECTRICAL
Without Circuit Protector
ST BAT
position.
(Bl/W) (W)
combination switch (page 11-3).
BAT
(W) EXT(+)
(R)
EXT(-)
(Bl)
EXT(+) EXT(-) ST BAT

OFF
ON
START
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.
CIRCUIT PROTECTOR INSPECTION

Remove the circuit protector (page 11-4).
Check continuity between the terminals. There should
be continuity in the ON position (button in) and no
continuity in the OFF position (button out). Replace the
circuit breaker if the correct continuity is not obtained.
OTHER ELECTRICAL
FUSE INSPECTION
Remove the blade type fuse (page 11-4).
Visually inspect the fuse to see if it is blown. Check BLOWN
continuity across the two blades. Replace the fuse if it is
blown or there is no continuity across the blades.
REGULATOR/RECTIFIER INSPECTION
sure that the measurements conform to the ranges
shown in the table.
10A TYPE
Unit: kȍ
4 6 1 3
4
6
1 1 - 200 1 - 200 0.5 - 100
3 0.1 - 50 0.1 - 50 Not used
1 3
4 6
18A TYPE
Unit: kȍ
4 6 1 2 3
4 4 - 400 2 - 230 1 2 3
6 4 - 400 2 - 230
1
2 2 - 230 2 - 230 1 - 600
3 0.09 - 0.09 -
400 400
Use a tester that is equivalent to or higher than the 4 6
performance specified, internal resistance: 20 kȍ/VDC,
9 kȍ/VAC
Not used
resistance value cannot be obtained.
carefully before operating the tester. Follow the
battery is fully charged, and check the meter before
using the tester.
MEMO
12. CYLINDER HEAD/VALVES
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 CYLINDER HEAD/VALVES INSPECTION 12-5
CYLINDER HEAD REMOVAL/ VALVE GUIDE REPLACEMENT . . . . . . . . 12-8

INSTALLATION . . . . . . . . . . . . . . . . . . . . . 12-3
VALVE GUIDE REAMING . . . . . . . . . . . . . 12-9
CYLINDER HEAD DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 12-4 VALVE SEAT RECONDITIONING. . . . . . 12-10
12
CYLINDER HEAD/VALVES
TOOLS
Valve guide driver, 6.6 mm Valve guide reamer, 6.6 mm

07942-6570100 07984-ZE2000D
CYLINDER HEAD REMOVAL/INSTALLATION
Set the piston at top dead center of the cylinder compression stroke (page 3-12).
– Carburetor (page 6-10)
– Control base assy (page 7-2)
Check the valve clearance, and if necessary, adjust the clearance.(page 3-12).
HEAD COVER PACKING

INSTALLATION:
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
threads and any carbon deposits from the combustion
BOLT seating surface) chamber (page 3-13), and inspect the valve
(10 x 80) (4) seat.
REMOVAL/INSTALLATION: After installing the cylinder head, measure
HEAD COVER Loosen and tighten the four 10 x 80 mm the cylinder compression.
flange bolts in a crisscross pattern in 2 – 3
steps.
HEAD COVER WASHER
CYLINDER HEAD DISASSEMBLY/
ASSEMBLY
Remove the cylinder head (page 12-3).
INTAKE/EXHAUST VALVE SPRING RETAINER EXHAUST VALVE

DISASSEMBLY: ASSEMBLY:
Push down and slide the valve spring retainer Do not interchange
to the side so that the valve stem slips through with the intake valve.
the hole at the side of the valve spring retainer. The exhaust valve is
Do not remove the valve spring retainer while smaller than the
the cylinder head is installed to the cylinder intake valve.
barrel, or the valve will drop into the cylinder. VALVE HEAD
DIAMETER: 31mm
VALVE SPRING
SEAT EXHAUST VALVE CYLINDER HEAD
GUIDE
SPARK
PLUG
VALVE
GUIDE
CLIP
INTAKE VALVE
ASSEMBLY:
Do not interchange with
the exhaust valve.
The intake valve is
larger than the exhaust
valve.
VALVE HEAD
DIAMETER: 33mm
INTAKE VALVE GUIDE
SHROUD
VALVE STEM SEAL
6 x 12 (CT bolt)
PUSH ROD
GUIDE PLATE
PIVOT ADJUSTING
NUT (2) PIVOT BOLT 8 mm (2) VALVE SPRING (2)
24 N·m (2.4 kgf·m, 17 lbf·ft)
10 N·m (1.0 kgf·m,
7 lbf·ft) PUSH ROD (2)
ASSEMBLY:
ROCKER ARM Before installing the push rods, check the ends of the push
PIVOT (2) rods for wear.
(Apply oil to the Be sure the ends of the push rods are firmly seated in the
threads and pivot) valve lifters.
(Apply to the tappet surface and pivot)

VALVE ROCKER ARM
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.
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
loosen 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 set (1)
EEPV303A (2) to the spark plug hole.
Pull the recoil starter forcefully to measure stable
cylinder compression.
CYLINDER COMPRESSION:
0.51 - 0.69 MPa (5.2 - 7.0 kgf/cm2, 74 - 100 psi) /
600 min-1 (rpm)
CYLINDER HEAD WARPAGE

Remove the carbon deposits from the combustion
chamber (page 3-13). (2) (1)
Check the spark plug hole and valve areas for cracks.
Check the cylinder head warpage using a straightedge
(1) and thickness gauge (2).
If the measurement is more than the service limit,
replace the cylinder head (page 12-3).
VALVE SEAT WIDTH

Remove the carbon deposits from the combustion
chamber(page 3-13). VALVE LAPPER
LIL21100
Inspect each valve for face irregularities. (Commercially
available)
If necessary, replace the valve (page 12-4).
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.
STANDARD: 1.0 – 1.2 mm (0.04 – 0.05 in) CONTACT TOO HIGH
recondition the valve seat (page 12-10).
Check whether the valve seat contact area of the valve
is too high or too low. VALVE SEAT
If the valve seat is too high or too low, recondition the WIDTH
valve seat (page 12-10).
VALVE GUIDE I.D.
Ream the valve guide (1) to remove any carbon
deposits before measuring. HANDLE
NWYTW505
(Commercially
TOOL: available)
Valve guide reamer 6.6 (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.

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 12-8).
VALVE FACE
Inspect each valve for face irregularities.
VALVE FACE
VALVE STEM O.D.
Inspect each valve for bending or abnormal stem wear.
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 (0.2572 – 0.2578 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 12-4).
GUIDE-TO-STEM CLEARANCE
Subtract each valve stem O.D. from the corresponding
guide I.D. to obtain the stem-to-guide clearance.
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 12-4)
– Valve guide (page 12-8)
VALVE SPRING FREE LENGTH
Measure the valve spring free length.
If the measured length is less than the service limit,
replace the valve spring (page 12-4).
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 12-4).
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 12-4).
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 han-

dling 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.
Drive the valve guides (1) out of the cylinder head from
the combustion chamber side. (2) COMBUSTION
CHAMBER SIDE
TOOL:
Valve guide driver 6.6 mm (2) 07942-6570100
(1)
When driving the valve guides out, be careful not to
damage the cylinder head.
Remove the new valve guides from the refrigerator one

VALVE SPRING (3)
at a time as needed.
SIDE
Install the new valve guides from the valve spring side (1)
of the cylinder head.
TOOL:
Valve guide driver 6.6 mm (1) 07742-6570100 (4)
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). 5 mm (0.2 in)
IN VALVE INSTALLATION HEIGHT:
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 (page 12-9).
VALVE GUIDE REAMING

For best results, be sure the cylinder head is at room
temperature before reaming valve guides. HANDLE
NWYTW505
Coat the reamer and valve guide with cutting oil. (Commercially
available)
TOOL:
Valve guide reamer 6.6 mm (1) 07984-ZE2000D
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.
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 3-13). VALVE LAPPER
(Commercially
Apply a light coat of Prussian Blue or erasable available)
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 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)
recondition the valve seat.
Check whether the valve seat contact area of the valve
is too high or too low.
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.
The 30° cutter removes material from the top edge
CONTACT OK
(contact too high).
TOOLS:
Cutter, 30 x 45 degrees NWYCU128
The 60° cutter removes material from the bottom edge VALVE FACE
(contact too low).
TOOLS:
Cutter, 60 degree NWYCU114
Be sure that the width of the finished valve seat is within
specification.
CONTACT TOO HIGH CONTACT TOO LOW
STANDARD: 1.0 – 1.2 mm (0.04 – 0.05 in)
Make a light pass with the 45° cutter to remove any
possible burrs at the edge of the seat.
TOOLS:
Solid pilot bar, 6.6 mm NWY100-6.60 VALVE FACE VALVE FACE
Cutter, 30 x 45 degrees NWYCU128
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 VALVE FACE VALVE FACE
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 32°
way around.
Thoroughly clean the cylinder head to remove all 60°
cutting residue.
Lap the valves into their seats, using a commercially

available valve lapper and lapping compound.
After lapping, wash all residual compound off the
cylinder head and valve. VALVE LAPPER
LIL21100
(Commercially
• Do not push the valve against the seat with force available)
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 3-12).
MEMO
13. CRANKCASE
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 GX240/GX270 CRANKSHAFT/BALANCER

WEIGHT BEARING/OIL SEAL
CRANKCASE COVER REMOVAL/ REPLACEMENT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . 13-4 (CRANKCASE COVER SIDE) . . . . . . . . . 13-25
CRANKSHAFT/BALANCER WEIGHT/PISTON GX340/GX390 CRANKSHAFT/BALANCER

REMOVAL/INSTALLATION. . . . . . . . . . . . 13-5 WEIGHT BEARING/OIL SEAL
REPLACEMENT
(CRANKCASE COVER SIDE) . . . . . . . . . 13-27
BALANCER WEIGHT/CAMSHAFT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . 13-6
GX240/GX270 CRANKSHAFT BEARING
REPLACEMENT (FLYWHEEL SIDE) . . . 13-30
1/2 OR 1/6 REDUCTION UNIT DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 13-7
REPLACEMENT (FLYWHEEL SIDE) . . . 13-31
1/2 REDUCTION UNIT (CHAIN TYPE)
(GX240 ONLY) . . . . . . . . . . . . . . . . . . . . . . 13-8 GX270 CRANKSHAFT/BALANCER WEIGHT
BEARING/OIL SEAL REPLACEMENT
(CYLINDER BARREL SIDE) . . . . . . . . . . 13-32
1/2 REDUCTION UNIT WITH CLUTCH
DISASSEMBLY/ASSEMBLY 13
(GX270 ONLY) . . . . . . . . . . . . . . . . . . . . . . 13-9 GX340/GX390 CRANKSHAFT/BALANCER
WEIGHT BEARING/OIL SEAL
REPLACEMENT
GOVERNOR DISASSEMBLY (CYLINDER BARREL SIDE) . . . . . . . . . . 13-33
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 13-11
COUNTER SHAFT/P.T.O. SHAFT BEARING/
PISTON DISASSEMBLY/ASSEMBLY. . . 13-12 OIL SEAL REPLACEMENT
(GEAR CASE COVER SIDE) . . . . . . . . . . 13-35
CRANKCASE COVER/CYLINDER BARREL/
PISTON/CONNECTING ROD/CRANKSHAFT/ GX240/GX270 COUNTER SHAFT/P.T.O.
CAMSHAFT INSPECTION . . . . . . . . . . . . 13-13 SHAFT BEARING REPLACEMENT
(CRANKCASE COVER SIDE) . . . . . . . . . 13-37
1/2 OR 1/6 REDUCTION UNIT
INSPECTION . . . . . . . . . . . . . . . . . . . . . . 13-22 GX340/GX390 COUNTER SHAFT/P.T.O.
SHAFT BEARING REPLACEMENT
1/2 REDUCTION UNIT (CHAIN TYPE) (CRANKCASE COVER SIDE) . . . . . . . . . 13-38
INSPECTION (GX240 ONLY). . . . . . . . . . 13-23
GX240/GX270 CRANKSHAFT/P.T.O. SHAFT
1/2 REDUCTION UNIT WITH CLUTCH OIL SEAL REPLACEMENT (1/2 REDUCTION
INSPECTION (GX270 ONLY). . . . . . . . . . 13-24 WITH CLUTCH) . . . . . . . . . . . . . . . . . . . . 13-40
CRANKCASE
TOOLS
CRANKCASE
Remover weight Bearing driver attachment, Bearing driver attachment,

07936-371020A 32×35 mm 42×47 mm
07746-0010100 07746-0010300
Bearing driver attachment, Bearing driver attachment, Driver, 40 mm I.D.

52×55 mm 72×75 mm 07746-0030100
07746-0010400 07746-0010600
Inner bearing driver attachment, Pilot, 15 mm Pilot, 20 mm

35 mm 07746-0040300 07746-0040500
07746-0030400
Pilot, 30 mm Pilot, 35 mm Pilot, 14 mm

07746-0040700 07746-0040800 07746-0041200
CRANKCASE
Driver Bearing remover, 15 mm Bearing driver attachment,
07749-0010000 07936-KC10500 45×50 mm
07946-6920100
Bearing driver attachment, Inner bearing driver attachment,

62×64 mm 30 mm [in combination with
07947-6340400 07746-0030300]
CRANKCASE
CRANKCASE COVER REMOVAL/INSTALLATION
Drain the engine oil (page 3-4).
Remove the key (7 x 7 x 33 mm) / (6.3 x 6.3 x 43 mm) (If equipped).
CRANKCASE COVER
(Without reduction type)
KEY (7 x 7 x 33 mm)
/ (6.3 x 6.3 x 43 mm)
(If equipped)
OIL FILLER CAP
(Oil seal lip)
(Bearing)
BOLT (8 x 40 mm) (7)

24 N·m (2.4 kgf·m, 17 lbf·ft)
CASE COVER PACKING
CRANKCASE COVER
(With reduction type)
OIL FILLER CAP

(With oil level gauge)
OIL FILLER CAP PACKING (2)

CRANKCASE
CRANKSHAFT/BALANCER WEIGHT/PISTON
– Cylinder head (page 12-3)
– Flywheel (page 8-7)
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
The 10 mm lock pin must be installed with the straight side of the head toward the push rod hole of the
10 mm lock pin against the groove of the governor arm shaft. cylinder head.
MARK
DRAIN PLUG (Oil seal lip)

WASHER (12 mm) (2)
Viewed from cylinder head side

OIL LEVEL
SWITCH NUT VALVE LIFTER
(10 mm) REMOVAL:
10 N·m (1.0 kgf·m, When removing the
7 lbf·ft) valve lifters, mark so
that the intake and
exhaust sides can be
distinguished.
INSTALLATION:
Attach the valve lifters
to the cylinder barrel
GROOVE immediately before
DRAIN PLUG installing the camshaft.
BOLT (2)
22.5 N·m (2.25 CAMSHAFT
kgf·m, 17 lbf·ft) See BALANCER
WEIGHT/CAMSHAFT
WASHER (8.2 x 17 x 0.8 mm) INSTALLATION on
page 13-6.
GOVERNOR ARM SHAFT
CRANKSHAFT
INSTALLATION:
BALANCER Before installing the crankshaft,
OIL LEVEL SW WEIGHT check the oil seal of the cylinder
barrel for damage or hardening.
Be careful not to damage the oil
BOLT (6 X 12 mm) (2) seal when installing the crankshaft.
CONNECTING ROD LOWER

CONNECTING ROD BOLT (2)
INSTALLATION:
14 N·m (1.4 kgf·m, 10 lbf·ft) Set the connecting rod lower with
the oil dipper toward the camshaft.
(Apply oil to the threads
and seating surface)
CRANKCASE
BALANCER WEIGHT/CAMSHAFT INSTALLATION
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)).
(4)
(2)
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)
CRANKCASE
BOLT (8 x 25 mm) PRIMARY DRIVE GEAR

DISASSEMBLY/ASSEMBLY:
Hold the 16 mm special nut of the KEY
flywheel and remove/install the 8 x 25 mm (7 x 7 x 33 /
flange bolt. WASHER
(8 mm) 6.3 x 6.3 x 43 mm)
16 mm SPECIAL NUT
DOWEL PIN
(8 x 14 mm)
P.T.O. SHAFT
GEAR CASE COVER
COUNTER SHAFT
BOLT (8 x 35 mm) (6) (GX270)

BOLT (8 x 40 mm) (6) (GX390)
24 N·m (2.4 kgf·m, 17 lbf·ft)
CHAIN CASE COVER PACKING

CRANKCASE
DISASSEMBLY/ASSEMBLY (GX240 ONLY)
DOWEL PIN
DRIVE SPROCKET
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.
P.T.O. DRIVE CHAIN

ASSEMBLY:
P.T.O. shaft and sprocket, and install
in the crankcase cover as a set.
WASHER (8 mm)
BOLT (8 x 25 mm)
24 N·m (2.4 kgf·m, 17 lbf·ft)
DOWEL PIN
P.T.O. SHAFT
ASSEMBLY:
P.T.O. shaft and sprocket, and install
in the crankcase cover as a set.
KEY (7 x 7 x 33 mm)
CHAIN CASE COVER

PACKING
P.T.O. SHAFT OIL SEAL

(30 x 46 x 8 mm)
CHAIN CASE COVER

ASSEMBLY:
Be careful not to damage the lip of the oil
seal when installing the P.T.O. shaft to
the chain case cover.
BOLT (8 x 40 mm) (6)

CRANKCASE
DISASSEMBLY/ASSEMBLY (GX270 ONLY)
Drain the oil (page 3-5).
After installation, fill the oil (page 3-5).
REDUCTION CASE
ASSEMBLY: REDUCTION OIL CAP /
Be careful not to damage the lip of the oil OIL LEVEL GAUGE
seal when installing it onto the crankshaft.
O-RING
DRIVE SPROCKET
ASSEMBLY: CRANKSHAFT OIL
Attach the drive chain SEAL (30 x 46 x 8 mm)
to the P.T.O. shaft and
sprocket and install in
the reduction case as a CLUTCH
set. CENTER
KEY
THRUST
WASHER
CLUTCH
CENTER
DOWEL
PIN (2)
CLUTCH FRICTION
BEARING (6205) DISC (2)
BOLT (8 x 32 mm) (4) ASSEMBLY:
Note the installation
sequence.
DRIVE CHAIN
CLUTCH PLATE (2)
P.T.O. SHAFT ASSEMBLY:
BEARING (6206) Note the installation
sequence.
BOLT (6 x 50 mm) (9) CLUTCH WEIGHT

HOLDER Assy.
SPRING ASSEMBLY:
WASHER Align the groove of the
P.T.O. SHAFT OIL SEAL clutch weight holder with
(30 x 50 x 7 mm) BOLT (8 x 35 mm) clutch center key when
installing.
REDUCTION COVER REDUCTION COVER

ASSEMBLY: PACKING
Be careful not to damage the lip of the oil
DRAIN PLUG DRAIN BOLT
seal when installing the P.T.O. shaft into
WASHER 23 N·m (2.3 kgf·m, 17 lbf·ft)
the reduction cover.
CRANKCASE
CLUTCH WEIGHT HOLDER ASSY.
CLUTCH WEIGHT (4)
CLUTCH FREE
SPRING (4)
CLUTCH SPRING
HOLDER (4)
CLUTCH PRESSURE
PLATE
CLUTCH WEIGHT
CENTER
CLUTCH WEIGHT
HOLDER
CRANKCASE
GOVERNOR DISASSEMBLY/ASSEMBLY
Remove the crankcase cover (page 13-4).
GOVERNOR SLIDER
ASSEMBLY:
Spread the governor weight to install
the governor sliders.
After installing the governor slider,
check to be sure it moves smoothly. GOVERNOR HOLDER CLIP
ASSEMBLY:
Install firmly into the groove of
the governor shaft.
GOVERNOR WEIGHT(3)
REASSEMBLY:
After installing the governor
weight, check to be sure they
moves smoothly. GOVERNOR WEIGHT HOLDER
GOVERNOR WEIGHT PIN (3)
CRANKCASE COVER
PLAIN WASHER (6 mm)
GROOVE
CRANKCASE
PISTON DISASSEMBLY/ASSEMBLY
Remove the piston (page 13-5).
NOTE: Honing should be performed on engines with cast iron sleeves (page 13-16) whenever the piston rings are replaced and
the existing cylinder is within service limits and reused.
MAKER MARK
TOP RING
PISTON RING SET
(Chrome plated)
ASSEMBLY:
Be sure that the top ring and second ring are 120°
SECOND RING
not interchanged. 120°
Install the top ring and second ring on the 120°
piston with the maker mark side facing up.
Check that the piston rings rotate smoothly
after installing them.
Space the piston ring end gaps 120 degrees
apart, and do not align the ring end gaps with SIDE RAIL
the piston pin bore.
10 mm (0.4 in) OIL RING
(COMBINATION
RING)
PISTON
SPACER
TOP RING 10 mm (0.4 in) SIDE RAIL
SECOND RING
MARK
OIL RING
PISTON PIN PISTON
PISTON PIN CLIP (20 mm) (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 CONNECTING ROD UPPER
pliers, and rotating the clip in. ASSEMBLY:
Do not align the end gap of the piston pin Set the connecting rod upper with
clip with the cutout of the piston pin bore. the long end toward the mark on
the piston head.
END GAP
LONG END
CUTOUT PISTON PIN CLIP

CRANKCASE
CRANKCASE COVER/CYLINDER
BARREL/PISTON/CONNECTING ROD/
CRANKSHAFT/CAMSHAFT
INSPECTION
CAM SHAFT HOLDER I.D.:
CRANKCASE COVER SIDE
Measure the camshaft holder I.D. of the crankcase
cover.
STANDARD: 16.000 – 16.018 mm

(0.6299 – 0.6306 in)
replace the crankcase cover (page 13-4).
Inspect the camshaft O. D. with this inspection
(page 13-20).
CAMSHAFT HOLDER I.D.: CYLINDER

BARREL SIDE
Measure the camshaft holder I.D. of the cylinder barrel
assembly.
STANDARD: 16.000 – 16.018 mm

(0.6299 – 0.6306 in)
replace the cylinder barrel (page 13-5).
Inspect the camshaft O. D. with this inspection
(page 13-20).
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.
Y TOP
GX240/GX270
STANDARD: 77.000 – 77.017 mm
(3.0315 – 3.0322 in) MIDDLE
GX340/GX390 BOTTOM
STANDARD: 88.000 – 88.017 mm
(3.4646 – 3.4652 in)
replace the cylinder barrel (page 13-5).
Inspect the piston skirt O.D. with this inspection
(page 13-14).
CRANKCASE
PISTON SKIRT O.D.
Measure and record the piston O.D. at a point 10 mm
(0.4 in) from the bottom of the skirt and 90 degrees to
the piston pin bore.
If the measurement is less than the service limit, 90°

replace the piston (page 13-5).
Inspect the cylinder sleeve I. D. with this inspection
(page 13-13).
GX240/GX270
STANDARD: 76.975 – 76.985 mm
(3.0305 – 3.0309 in)
GX340/GX390 10 mm
STANDARD: 87.975 – 87.985 mm (0.4 in)
(3.4636 – 3.4640 in)

Inspect the cylinder sleeve I. D. with this inspection
(page 13-13).
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 – 0.0016 in)
If the calculated clearance is more than the service
limit, replace the piston (page 13-12) and recheck the
clearance.
If the clearance is still more than the service limit with
the new piston, replace the cylinder barrel (page 13-5).
PISTON PIN BORE I.D.

Measure and record the piston pin bore I.D. of the
piston.
GX240/GX270
STANDARD: 18.002 – 18.008 mm
(0.7087 – 0.7090 in)
GX340/GX390
STANDARD: 20.002 – 20.008 mm
(0.7875 – 0.7877 in)
Inspect the piston pin O. D. with this inspection
(page 13-15).
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.
GX240/GX270
STANDARD: 17.994 – 18.000 mm
(0.7084 – 0.7087 in)
GX340/GX390
STANDARD: 19.994 – 20.000 mm
(0.7872 – 0.7874 in)
replace the piston pin (page 13-12)
Inspect the piston pin bore I.D. (page 13-14).
Inspect the connecting rod small end I. D. (page 13-17)
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)
If the calculated clearance is more than the service limit,
replace the piston pin (page 13-12) and recheck the
clearance.
the new piston pin, replace the piston (page 13-12).
PISTON RING SIDE CLEARANCE

Measure the clearance between each piston ring and
ring groove of the piston using a feeler gauge.
STANDARD:
Top (GX240/GX270): 0.030 – 0.060 mm
(0.0012 – 0.0024 in)
Top (GX340/GX390): 0.015 – 0.060 mm
(0.0006 – 0.0024 in)
Second: 0.030 – 0.060 mm
(0.0012 – 0.0024 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 13-12) and reinspect the clearance.
If necessary, replace the piston rings (top, second, oil)
as a set (page 13-12) 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 13-12).
CRANKCASE
PISTON RING WIDTH
Measure each piston ring width.
STANDARD:
Top (GX240/GX270): 1.160 – 1.175 mm
(0.0457 – 0.0463 in)
Top (GX340/GX390): 1.160 – 1.19 mm
(0.0457 – 0.047 in)
Second: 1.160 – 1.175 mm
(0.0457 – 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 13-12).
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 – 0.500 mm
(0.0138 – 0.0197 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)
Oil (side rail) 1.0 mm (0.04 in) PISTON RING
If any of the measurements is more than the service

limit, replace the piston rings (top, second, oil) as a set
(page 13-12).
Cast iron sleeves should be honed whenever the piston
rings are replaced and the existing cylinder is within
service limits and reused.
CYLINDER HONING
Apply honing oil to the 400-grit flex honing tool Cross-hatch pattern
and cylinder wall.
Using a 400 grit honing tool, lightly hone the
cylinder in a smooth up-down motion only long
enough to remove the surface glaze.
Check your progress often to avoid removing more 60°
material than required.
Follow the tool manufacturer's instructions for drill
motor speed.
The surface should not be too smooth, but exhibit
fine scores in a 60-degree cross-hatch pattern.
When honing is complete, thoroughly clean the cylinder with hot soapy water and then immediately
dry with a lint-free towel.
Never use solvent to clean the cylinder wall as it will redistribute the grit on the cylinder walls.
Check the cylinder I.D. and taper again to make sure they are within service limits.
Apply clean motor oil to the freshly honed surface to prevent oxidation.
CRANKCASE
CONNECTING ROD BIG END SIDE
CLEARANCE
Measure the clearance between the connecting rod big
end and crankshaft using a feeler gauge.
STANDARD: 0.1 – 0.4 mm (0.004 – 0.016 in)

replace the connecting rod (page 13-12) and recheck
the clearance.
the new connecting rod, replace the crankshaft
(page 13-5).
CONNECTING ROD SMALL END I.D.

Measure the connecting rod small end I.D.
GX240/GX270
STANDARD: 18.005 – 18.020 mm
(0.7089 – 0.7094 in)
GX340/GX390
STANDARD: 20.005 – 20.020 mm
(0.7876 – 0.7882 in)
replace the connecting rod (page 13-12).
CONNECTING ROD BIG END I.D.

Set the connecting rod lower to the connecting rod
upper and tighten the connecting rod bolts to the
specified torque.
Measure the connecting rod big end I.D.
GX240/GX270
STANDARD: 33.025 – 33.039 mm
(1.3002 – 1.3007 in)
GX340/GX390
STANDARD: 36.025 – 36.039 mm
(1.4183 – 1.4189 in)
replace the connecting rod (page 13-12).
CRANKCASE
CRANK PIN O.D.
Measure the crank pin O.D. of the crankshaft.
GX240/GX270
STANDARD: 32.975 – 32.985 mm
(1.2982 – 1.2986 in)
GX340/GX390
STANDARD: 35.975 – 35.985 mm
(1.4163 – 1.4167 in)
replace the crankshaft (page 13-5).
CONNECTING ROD BIG END OIL

CLEARANCE
Clean all oil from the crank pin and connecting rod big
end surface.
Place a piece of plastigauge on the crank pin, install the
connecting rod upper and the connecting rod lower, and
tighten the connecting rod bolts to the specified torque.
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)
If the clearance is more than the service limit, inspect
the connecting rod big end I.D. and the crank pin O.D.
If necessary replace the part that is not within the
service limit and reinspect the clearance.
CRANKCASE
CRANKSHAFT RUNOUT
Set the crankshaft on V-blocks and measure the runout
using a dial indicator. EXCEPT L/P/W TYPE:
L/P/W TYPE ONLY: MEASURE POINT
SERVICE LIMIT: 0.1 mm (0.003 in) MEASURE POINT
If the measured runout is more than the service limit,

replace the crankshaft (page 13-5).
GX240/270
L TYPE:
31 mm (1.2 in)
16 mm GX240/270: GX340/390
(0.6 in) 16 mm L TYPE:
(0.6 in) 36 mm (1.4 in)
P TYPE:
GX340/390:
32 mm (1.3 in)
17 mm
W TYPE:
(0.7 in)
24 mm (0.9 in)
CRANKCASE
CAMSHAFT CAM HEIGHT
Measure the cam height of the camshaft.
GX240/GX270
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)
GX340/GX390
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)
replace the camshaft (page 13-5).
CAMSHAFT O.D.
Measure the camshaft O.D.of the camshaft.
STANDARD: 15.966 – 15.984 mm
(0.6286 – 0.6293 in)
replace the camshaft (page 13-5).
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 13-5). (1)
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.
CRANKCASE
INSPECTION
RADIAL BALL BEARING
Turn the inner race of the radial ball bearing with your
finger and check for play.
excessive play.
PRIMARY DRIVE GEAR

Check for worn and weakened primary drive gear.
If necessary, replace the primary drive gear
(page 13-7).
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 13-7).
COUNTER SHAFT
Check for worn and weakened gears of the counter
shaft.
If necessary, replace the counter shaft (page 13-7).
CRANKCASE
INSPECTION (GX240 ONLY)
RADIAL BALL BEARING
excessive play.
DRIVE SPROCKET/P.T.O. SHAFT/

DRIVE CHAIN
Check for worn or damaged teeth on the drive sprocket
(1) and P.T.O. shaft (2). (1)
Check for a worn or damaged drive chain (3).
If necessary, replace the drive sprocket, P.T.O. shaft,
and drive chain as a set (page 13-8).
(2)
(3)
CRANKCASE
INSPECTION (GX270 ONLY)
RADIAL BALL BEARING
excessive play.
CLUTCH FRICTION DISC

Measure the clutch friction disk thickness.

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

CRANKCASE
GX240/GX270 CRANKSHAFT/BALANCER WEIGHT BEARING/
OIL SEAL REPLACEMENT (CRANKCASE COVER SIDE)
LOCATION
(OUTSIDE) EXCEPT REDUCTION TYPE: (INSIDE)
CRANKSHAFT OIL SEAL BALANCER WEIGHT BEARING

(30 x 46 x 8 mm) (6202) (If equipped) (page 13-28) CRANKSHAFT
BEARING (6206)
REDUCTION TYPE: (INSIDE)
BALANCER WEIGHT BEARING

(6202) (If equipped) (page 13-28)
CRANKSHAFT
BEARING (6206)
CRANKCASE
CRANKSHAFT BEARING (6206)
Drive out the radial ball bearing (1).
Apply oil to the circumference of a new bearing (2). (1)
Drive the radial ball bearing 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 15 x 135 mm (5) 07749-0010000
(5)
(3)
(2)
CIRCUMFERENCE (4)
CRANKSHAFT OIL SEAL

(30 x 46 x 8 mm)
Remove the oil seal from the crankcase cover.
Apply grease to the lip of a new oil seal (1).
Drive the oil seal in the position as shown using the (3)
special tools.
TOOLS:
(2)
Attachment 45 x 50 mm (2) 07946-6920100
Driver 15 x 135 mm (3) 07749-0010000
EXCEPT
WKT2 TYPE: (1)
1 mm (0.04 in)
WET2 TYPE:
6 mm (0.2 in)
OIL SEAL LIP

CRANKCASE
OIL SEAL REPLACEMENT (CRANKCASE COVER SIDE)
LOCATION
ALL TYPES: (OUTSIDE) EXCEPT REDUCTION TYPE: (INSIDE)
CRANKSHAFT OIL SEAL CRANKSHAFT BEARING

BALANCER WEIGHT
(35 x 52 x 8 mm) (6207)
BEARING (6202)
REDUCTION TYPE: (INSIDE)
BALANCER WEIGHT
BEARING (6202)
CRANKSHAFT
BEARING (6207)
REDUCTION TYPE ONLY

CRANKCASE
BALANCER WEIGHT BEARING (6202)
Pull out the radial ball bearing (1) using the special
tools.
TOOLS:
Bearing remover, 15 mm (2) 07936-KC10500 (3)
Remover weight (3) 07936-371020A
Apply oil to the circumference of a new bearing (4).
TOOLS: (2)
Attachment, 32 x 35 mm (5) 07746-0010100
Pilot, 15 mm (6) 07746-0040300
Driver (7) 07749-0010000
(1)
(7)
(5)
(4)
CIRCUMFERENCE
(6)
CRANKCASE
Apply oil to the circumference of a new bearing (2). (1)

TOOLS:
Attachment, 72 x 75 mm (3) 07746-0010600
Pilot 35 mm (4) 07746-0040800
Driver (5) 07749-0010000
(5)
(3)
(2)
CIRCUMFERENCE
(4)
CRANKSHAFT OIL SEAL

(35 x 52 x 8 mm)
(3)
Drive the oil seal in the position as shown using the
special tools.
TOOLS:
(2)
Attachment 52 x 55 mm (2) 07746-0010400
(1)
Driver (3) 07749-0010000
2 mm (0.08 in)
OIL SEAL LIP

CRANKCASE
REPLACEMENT (FLYWHEEL SIDE)
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).
Apply oil to the inner surface of the new bearing (4)
inner race (5).
end of the crankshaft using the special tools and
hydraulic press.
TOOLS:
Attachment 30 mm I.D. (6) 07746-0030300
Inner driver 40 mm I.D. (7) 07746-0030100
(3)
(7)
(6) (5)
(4)
CRANKCASE
REPLACEMENT (FLYWHEEL SIDE)
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).
Apply oil to the inner surface of the new bearing (4)
inner race (5).
end using the special tools and hydraulic press.
TOOLS:
Attachment, 35 mm I.D. (6) 07746-0030400
Driver, 40 mm I.D. (7) 07746-0030100
(3)
(7)
(6) (5)
(4)
CRANKCASE
GX270 CRANKSHAFT/BALANCER WEIGHT BEARING/
OIL SEAL REPLACEMENT (CYLINDER BARREL SIDE)
LOCATION
CRANKSHAFT OIL SEAL (30 x 46 x 8 mm) BALANCER WEIGHT BEARING (6202)

(If equipped) (page 13-33)
CRANKSHAFT OIL SEAL

(30 x 46 x 8 mm)
Remove the oil seal from the cylinder barrel.
(3)
special tools.
(2)
TOOLS:
Attachment 45 x 50 mm (2) 07946-6920100
Driver 15 x 135 mm (3) 07749-0010000 (1)
2 mm (0.08 in)
OIL SEAL RIP

CRANKCASE
OIL SEAL REPLACEMENT (CYLINDER BARREL SIDE)
LOCATION
CRANKSHAFT OIL SEAL (35X52X8 mm) BALANCER WEIGHT BEARING (6202)
GOVERNOR ARM SHAFT OIL SEAL (8X14X5 mm)
BALANCER WEIGHT BEARING (6202)

tools.
TOOLS:
Bearing remover, 15 mm (2) 07936-KC10500 (3)
TOOLS:
(2)
Attachment, 32 x 35 (5) 07746-0010100
Pilot, 15 mm (6) 07746-0040300
Driver (7) 07749-0010000 (1)
(7)
(5)
(4)
CIRCUMFERENCE
(6)
CRANKCASE
GOVERNOR ARM SHAFT OIL SEAL
(8 x 14 x 5 mm)
(3)
special tools.
TOOLS: (2) (1)
Pilot, 14 mm (2) 07746-0041200
Driver (3) 07749-0010000
0 – 0.5 mm
(0 – 0.02 in)
OIL SEAL LIP
CRANKSHAFT OIL SEAL

(35 x 52 x 8 mm)
(3)
special tools.
TOOLS: (2)
Attachment, 52 x 55 mm (2) 07746-0010400
Driver (3) 07749-0010000 (1)
2 mm (0.08 in)
OIL SEAL LIP

CRANKCASE
COUNTER SHAFT/P.T.O. SHAFT BEARING/
OIL SEAL REPLACEMENT (GEAR CASE COVER SIDE)
LOCATION
COUNTER SHAFT
P.T.O. SHAFT OIL SEAL BEARING
(30 x 46 x 8 mm) P.T.O. SHAFT BEARING
(6202) (6302)
(6206)
COUNTER SHAFT BEARING (6202) (6302)

tools.
TOOLS: (3)
Bearing remover, 15 mm (2) 07936-KC10500
(2)
TOOLS:
Attachment, 32 x 35 mm (5) 07746-0010100
Pilot, 15 mm (6) 07746-0040300
Driver (7) 07749-0010000 (1)
(7)
(4)
(5)
CIRCUMFERENCE
(6)
CRANKCASE
P.T.O. SHAFT BEARING (6206)
TOOLS:
Attachment, 62 x 64 mm (3) 07947-6340400
Pilot, 30 mm (4) 07746-0040700
Driver (5) 07749-0010000
(1)
(5) (2)
(3)
CIRCUMFERENCE (4)

(30 x 46 x 8 mm)
(3)
special tools.
TOOLS: (2)
Attachment, 45 x 50 mm (2) 07946-6920100
Driver (3) 07749-0010000
* L TYPE:
P.T.O type (page 1-3). 2 mm (0.08 in)
* H TYPE:
3 mm (0.11 in)
(1)
OIL SEAL LIP

CRANKCASE
GX240/GX270 COUNTER SHAFT/P.T.O. SHAFT
BEARING REPLACEMENT (CRANKCASE COVER SIDE)
LOCATION
COUNTER SHAFT
BEARING (6302)
P.T.O. SHAFT BEARING

(6204) (page 13-39)
COUNTER SHAFT BEARING (6302)

Remove the crankcase cover.
Drive out the radial ball bearing (1) using the special
tools.
TOOLS: (1)
Attachment 42 x 47 mm (3) 07746-0010300
Pilot 15 mm (4) 07746-0040300
Driver 15 x 135 mm (5) 07749-0010000
(5)
(3)
CIRCUMFERENCE
(4) (2)
CRANKCASE
GX340/GX390 COUNTER SHAFT/P.T.O. SHAFT
BEARING REPLACEMENT (CRANKCASE COVER SIDE)
LOCATION
P.T.O. SHAFT BEARING

(6204)
COUNTER SHAFT
BEARING (6202)
COUNTER SHAFT BEARING (6202)

Drive out the radial ball bearing (1) using the special
tools.
TOOLS:
Attachment, 32 x 35 mm (3) 07746-0010100 (1)
Pilot, 15 mm (4) 07746-0040300
Driver (5) 07749-0010000
(5)
(3)
CIRCUMFERENCE
(4) (2)
CRANKCASE
P.T.O. SHAFT BEARING (6204)
TOOLS:
Attachment, 42 x 47 mm (3) 07746-0010300 (1)
Pilot, 20 mm (4) 07746-0040500
Driver (5) 07749-0010000
(5)
(2)
(3)
CIRCUMFERENCE (4)
CRANKCASE
GX240/GX270 CRANKSHAFT/P.T.O. SHAFT OIL SEAL
REPLACEMENT (1/2 REDUCTION WITH CLUTCH)
LOCATION
REDUCTION COVER REDUCTION CASE
P.T.O. SHAFT OIL SEAL CRANKSHAFT OIL SEAL

(30 x 50 x 7 mm) (30 x 46 x 8 mm)

(30 x 50 x 7 mm)
Remove the oil seal from the reduction cover.
(3)
special tools.
(2)
TOOLS:
Attachment 45 x 50 mm (2) 07946-6920100
Driver 15 x 135 mm (3) 07749-0010000 (1)
OIL SEAL LIP

CRANKSHAFT OIL SEAL
(30 x 46 x 8 mm)
Remove the oil seal from the reduction case.
(3)
special tools.
(2)
TOOLS:
Attachment 45 x 50 mm (2) 07946-6920100 (1)
Driver 15 x 135 mm (3) 07749-0010000
OIL SEAL LIP

14. MUFFLER
MUFFLER REMOVAL/INSTALLATION. . . 14-2 EXHAUST PIPE STUD BOLT

REPLACEMENT . . . . . . . . . . . . . . . . . . . . 14-5
MUFFLER COVER REMOVAL/INSTALLATION
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . 14-4
14
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

Remove the muffler cover (if equipped) (page 14-4).
SPARK ARRESTER (If equipped) (GX340/GX390 shown)
CLEANING: see page 3-11
MUFFLER PROTECTOR TAPPING SCREW GX240/GX270 SPARK ARRESTER

(5 x 8 mm) (4)
TAPPING SCREW
(6 x 10 mm) BAFFLE FLANGE
(If equipped)
TAPPING SCREW
MUFFLER (5 x 8 mm) (2)
(If equipped)
MUFFLER
GASKET
(If equipped)
MUFFLER
GASKET
(If equipped)
EXHAUST
EXHAUST PIPE PIPE
PROTECTOR
(If equipped)
BOLT (6 x 12 mm)
NUT (8 mm) (3)

NUT (8 mm) (2)
EXHAUST
24 N·m (2.4 kgf·m, 24 N·m (2.4 kgf·m, 17 lbf·ft) PIPE GASKET
17 lbf·ft)
MUFFLER
SEPARATED PROTECTOR TYPE
SPARK ARRESTER (If equipped)

R. MUFFLER PROTECTOR
CLEANING:
TAPPING SCREW
(5 x 8 mm) (4)
L. MUFFLER PROTECTOR
MUFFLER CAP
(If equipped)
TAPPING SCREW
(5 x 8 mm) (2)
TAPPING SCREW
(4 x 6 mm)
(If equipped)
TAPPING SCREW
(5 x 8 mm) (2)
(If equipped)
MUFFLER
MUFFLER
GASKET
(If equipped)
EXHAUST PIPE
PROTECTOR
(If equipped)
EXHAUST
BOLT (6 x 12 mm) PIPE GASKET
EXHAUST
PIPE
NUT (8 mm) (3)
NUT (8 mm) (2)
24 N·m (2.4 kgf·m,
24 N·m (2.4 kgf·m, 17 lbf·ft)
17 lbf·ft)
MUFFLER
MUFFLER COVER REMOVAL/
INSTALLATION (IF EQUIPPED)
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.
MUFFLER COVER
NUT (5 mm) (3) REAR MUFFLER COVER

NUT (6 mm) (3)
WASHER (5 mm) (3)
SCREW (6 x 20 mm)
MUFFLER COVER
STAY
SPRING WASHER
(5 mm)
SCREW (5 x 12 mm)
MUFFLER COVER
SPACER (3)
TAPPING SCREW TAPPING SCREW

(5 x 25 mm) (5 x 8 mm) (2)
MUFFLER COVER
BASE
COLLAR (2)
SET PLATE
MUFFLER PROTECTOR
MUFFLER
EXHAUST PIPE STUD BOLT
REPLACEMENT
Thread two nuts onto the exhaust pipe stud bolt (1) and
tighten them together, and then use a wrench to turn
the stud bolt out.
Install new stud bolts as shown.
SPECIFIED LENGTH:
STUD BOLT (8 x 41): 25 mm (0.98 in)
STUD BOLT (8 x 48): 32mm (1.26 in) (1)
SHORT
LONG
STUD BOLT (8 x 41): 25 mm (0.98 in)

STUD BOLT (8 x 48): 32mm (1.26 in)
(1)
MEMO
15. WIRING DIAGRAMS
HOW TO READ A WIRING DIAGRAM & 10A CHARGE COIL TYPE WIRING
RELATED INFORMATION. . . . . . . . . . . . . 15-2 DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
NO CHARGE COIL TYPE WIRING 18A CHARGE COIL TYPE WIRING

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4 DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
1A/3A CHARGE COIL TYPE WIRING

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
15
WIRING DIAGRAMS
HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION
WIRING DIAGRAMS
This section explains how to use the connector drawings, symbols, and wiring diagram, when troubleshooting.
HOW TO READ CONNECTOR DRAWINGS

Connector drawings show the terminal number, pin arrangement, number of pins, and the type of the 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.
Double frame connectors represent male connectors and the single frame connectors represent female connectors.
The gender of the connector is determined by the type of terminals the connector contains. Male connectors have male terminals.
Female connectors have female terminals. Typically, the smaller plastic plastic shell of a female connector inserts inside the larger
plastic shell of a male connector when they are joined.
Terminals in a female connector are numbered from left to right, top to bottom looking at the wire side. Terminals in a male
connector are numbered from left to right, top to bottom looking at the terminal side.
Both the male and female connectors are shown by viewing them from the terminal side.
FEMALE CONNECTOR
(Female terminals)
FEMALE CONNECTOR
33
(Female terminals)
10 5 9 4 6 1 2 7
G/W G/W
R/W R/W
G/R G/R
LOCKS G/Bl G/Bl
VIEWING DIRECTION Br Br
Br Br
Y Y
G G
MALE CONNECTOR
(Male terminals)
MALE CONNECTOR
(Male terminals)
VIEWING DIRECTION
FEMALE LOCK 3 CONNECTOR No.
5 4 2 1 FEMALE CONNECTOR DRAWING

(SINGLE FRAME)
Female connector viewed from the
10 9 7 6 terminal side.
TERMINAL ARRANGEMENT
This drawing shows the No. 9 terminal of the 3 female connector
with the lock of the connector UP.
MALE LOCK
3 CONNECTOR No.
MALE CONNECTOR DRAWING

1 2 4 5 (DOUBLE FRAME)
Male connector viewed from the
terminal side.
6 7 9 10
TERMINAL No.
This drawing shows the No. 9 terminal of the 3 male connector
with the lock of the connector UP.
WIRING DIAGRAMS
HOW TO READ A WIRING DIAGRAM
TERMINAL SYMBOL
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. G
T5 G
C8 T3 C9 T8
R T7
20A 30A W
T4 R
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
PL G/Bl 2
Bu R
6 2 3 4 1
VCC B ES
N.C. B Y G IND(-)
N.C. A R Y IND(+)
V2 A W Y LS
RXD G E Reg
CPU IGNITION CONTROL MODULE
1 2
TXD ES R
G Bl/Bu
7 10 5
E EX
4 Bl/R IC
Bu PC
G
G FRAME GND
2 7 4 5 9 10 1 6
Br
Br
Y
G GND2
Bl/Bu
Bu T1
W/R W/R (+)
Bl/R Bl/R (-) DC RECEPTACLE
C1 1 T2
Bl 1
2 1 4 3
W
1 2
(Bl/R) Bl/R
R Bl Bl ENGINE STOP SWITCH
Y
Bu
Bl Black Br Brown
2
Y Yellow O Orange
Indicates a ground. G Green Lg Light green
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)
WIRING DIAGRAMS
NO CHARGE COIL TYPE WIRING DIAGRAM
C3 C1
Y C2
Bl
Bl
R
R
Y
1
ENGINE STOP SWITCH
4 3 1 2 EXT ( + ) EXT ( - )
LED
EXT ( - )
EXT ( + )
OIL_ALT
OFF
ON
Bl Black Br Brown
Y Yellow O Orange
ENGINE STOP G Green Lg Light green
SWITCH R Red P Pink
W White Gr Gray
OIL LEVEL SPARK IGNITION TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
SWITCH PLUG COIL
1A/3A CHARGE COIL TYPE WIRING DIAGRAM

CONTROL BOX
C1
Bl Bl
C3 C2
R R
C5
W Gr
Bl/W
W
Bl
R
Y
C4
T1
1
Gr
W
Bl/W
T2
W
Bl
R
4 3 1 2
LED
EXT ( - )
EXT ( + )
OIL_ALT
2
W
C6 C7
2 1
ST
EXT ( + )
EXT ( - )
BAT
T3 MAIN FUSE CIRCUIT SILICON

PROTECTOR RECTIFIER COMBINATION
FLYWHEEL SWITCH
OIL LEVEL SPARK IGNITION BATTERY STARTER MOTOR

SWITCH PLUG COIL
COMBINATION
SWITCH Bl Black Br Brown
CHARGE COIL Y Yellow O Orange
EXT ( + ) EXT ( - ) ST BAT
OFF G Green Lg Light green
R Red P Pink
ON W White Gr Gray
START
WIRING DIAGRAMS
10A CHARGE COIL TYPE WIRING DIAGRAM
CONTROL BOX
C10
(W) (W)
W
MAIN FUSE
W
C1
Bl Bl
R R
C3 C2
Bl
C11
Gr
W
( Bl/W )
(W)
Gr
W
W
W
Bl
4
3
Bl
R
Y
T1 C4
Y
1 2
1
( Bl )
4 6 1 2 3 5
Bl/W
W
Bl
R
T2
Gr
W
4 3 1 2
W/Bu
LED
EXT ( + )
EXT ( - )
Bl/Y
OIL_ALT
Gr
Gr
W
Bl
T4
FLYWHEEL
ST
EXT ( + )
EXT ( - )
BAT
CHARGE COIL
T3
COMBINATION
SWITCH
COMBINATION
Bl Black Br Brown
SWITCH
Y Yellow O Orange
OFF R Red P Pink
W White Gr Gray
ON
START
WIRING DIAGRAMS
18A CHARGE COIL TYPE WIRING DIAGRAM
CONTROL BOX
C10
(W) (W)
W
MAIN FUSE
W
C1
Bl Bl
R R
C3 C2
Bl
C11
Gr
Gr
( Bl/W )
(W)
Gr
Gr
W
W
Bl
C8 C9
3
Bl
R
Y
T1 C4
Y
CHARGE
1
COIL
( Bl )
4 6 1 2 3 5
Bl/W
W
Bl
R
T2
Gr
Gr
4 3 1 2
W/Bu
LED
EXT ( + )
EXT ( - )
Bl/Y
OIL_ALT
Gr
Gr
W
Bl
T4
ST
EXT ( + )
EXT ( - )
BAT
T3
COMBINATION
FLYWHEEL SWITCH
CHARGE
COIL
COMBINATION
Bl Black Br Brown
SWITCH
Y Yellow O Orange
OFF R Red P Pink
W White Gr Gray
ON
START
INDEX
Numerics CYLINDER HEAD REMOVAL/INSTALLATION . . . . . . 12-3
1/2 REDUCTION UNIT (CHAIN TYPE) DISASSEMBLY/ CYLINDER HEAD/VALVES INSPECTION . . . . . . . . . 12-5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8 CYLINDER STUD BOLT REPLACEMENT . . . . . . . . . 6-16
1/2 REDUCTION UNIT DISASSEMBLY/ASSEMBLY . 13-9 D
1/2 REDUCTION UNIT INSPECTION . . . . . . 13-23, 13-24 DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . 1-17
10A / 18A CHARGE COIL TYPE . . . . . . . . . . . . 15-5, 15-6 DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . 1-5, 1-6
1A / 3A CHARGE COIL TYPE . . . . . . . . . . . . . . 15-4, 15-6
E
A ENGINE OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
A Few Words About Safety . . . . . . . . . . . . . . . . . . . . . . 0-1 ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . 3-3
AIR CLEANER CHECK/CLEANING . . . . . . . . . . . . . . . . 3-6 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . 1-9, 1-10
AIR CLEANER REMOVAL/INSTALLATION . . . . . . . . . 6-5 EXHAUST PIPE STUD BOLT REPLACEMENT . . . . . 14-5
AUTO THROTTLE (IF EQUIPPED) REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 F
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
B FUEL FILLER CAP REMOVAL/INSTALLATION . . . . . . 6-4
BALANCER WEIGHT/CAMSHAFT INSTALLATION . . 13-6 FUEL FILTER REMOVAL/INSTALLATION . . . . . . . . . . 6-4
BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . 4-2, 8-6 FUEL TANK REMOVAL/INSTALLATION . . . . . . . . . . . 6-3
C FUEL TUBE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
CARBURETOR BODY CLEANING . . . . . . . . . . . . . . . 6-13 FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
CARBURETOR DISASSEMBLY/ASSEMBLY . . . . . . . 6-10 G
CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . 6-13 GOVERNOR ARM/CONTROL REMOVAL/INSTALLATION
CARBURETOR REMOVAL/INSTALLATION . . . . . . . . . 6-8 7-2
CHARGE / LAMP COIL (IF EQUIPPED) REMOVAL/ GOVERNOR DISASSEMBLY/ASSEMBLY . . . . . . . . 13-11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 GX270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CHARGE / LAMP COIL REMOVAL/INSTALLATION . . . 8-9
CHARGE COIL INSPECTION . . . . . . . . . . . . . . . . . . . 8-10 H
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 HARNESS AND TUBE ROUTING . . . . . . . . . . . . . . . . 2-12
CHOKE DIAPHRAGM DISASSEMBLY/ASSEMBLY . . 6-12 HOW TO READ WIRING DIAGRAM & RELATED
CHOKE DIAPHRAGM INSPECTION . . . . . . . . . . . . . . 6-14 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
CHOKE SET REPLACEMENT . . . . . . . . . . . . . . . . . . . 6-16
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
I
COMBINATION SWITCH INSPECTION . . . . . . . . . . . 11-5 IDLE SPEED CHECK/ADJUSTMENT . . . . . . . . . . . . . 3-12
COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . 3-13 IGNITION COIL INSPECTION . . . . . . . . . . . . . . . . . . . . 9-5
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . 11-2 IGNITION COIL INSTALLATION . . . . . . . . . . . . . . . . . . 9-4
CONTROL BASE ASSY. DISASSEMBLY/ASSEMBLY . 7-6 IGNITION COIL REMOVAL/INSTALLATION . . . . . . . . . 9-3
CONTROL BOX DISASSEMBLY/ASSEMBLY . . . . . . . 11-4 IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . 9-2
CONTROL BOX REMOVAL/INSTALLATION . . . . . . . 11-3 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
COOLING FAN/FLYWHEEL REMOVAL/INSTALL . . . . 8-7 L
COUNTER SHAFT/P.T.O. SHAFT BEARING LUBRICATION & SEAL POINT . . . . . . . . . . . . . . . . . . . 2-9
REPLACEMENT (CRANKCASE COVER SIDE) (GX270)
13-37 M
COUNTER SHAFT/P.T.O. SHAFT BEARING MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . 3-2
16
REPLACEMENT (CRANKCASE COVER SIDE) (GX390) MAINTENANCE STANDARDS . . . . . . . . . . . . . . . . . . . 2-2
13-38 MAXIMUM SPEED ADJUSTMENT . . . . . . . . . . . . . . . . 7-8
COUNTER SHAFT/P.T.O. SHAFT BEARING/OIL SEAL MUFFLER COVER REMOVAL/INSTALLATION (IF
REPLACEMENT (GEAR CASE COVER SIDE) . . . 13-35 EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
CRANKCASE COVER REMOVAL/INSTALLATION . . 13-4 MUFFLER REMOVAL/INSTALLATION . . . . . . . . . . . . 14-2
CRANKCASE COVER/CYLINDER BARREL/PISTON/
CONNECTING ROD/CRANKSHAFT/CAMSHAFT
N
NO CHARGE COIL TYPE . . . . . . . . . . . . . . . . . . . . . . 15-4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
CRANKSHAFT BEARING REPLACEMENT (CRANKSHAFT O
SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30, 13-31 OIL LEVEL SWITCH INSPECTION . . . . . . . . . . . . . . . 11-5
CRANKSHAFT/BALANCER WEIGHT BEARING/OIL SEAL OIL PRESSURE SWITCH INSPECTION . . . . . . . . . . . 11-5
REPLACEMENT (CRANKCASE COVER SIDE) . . 13-25,
13-27 P
CRANKSHAFT/BALANCER WEIGHT BEARING/OIL SEAL P.T.O. DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . 1-25
REPLACEMENT (CYLINDER BARREL SIDE) 13-32, 13-33 PERFORMANCE CURVES . . . . . . . . . . . . . . . . . . . . . 1-13
CRANKSHAFT/BALANCER/PISTON REMOVAL/ PILOT SCREW REPLACEMENT . . . . . . . . . . . . . . . . . 6-15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5 PISTON DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . 13-12
CRANKSHAFT/P.T.O. SHAFT OIL SEAL REPLACEMENT (1/ R
2 REDUCTION WITH CLUTCH) . . . . . . . . . . . . . . . 13-40
RECOIL STARTER ASSEMBLY . . . . . . . . . . . . . . . . . 10-5
CYLINDER HEAD DISASSEMBLY/ASSEMBLY . . . . . 12-4
RECOIL STARTER DISASSEMBLY . . . . . . . . . . . . . . 10-4 SPARK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

RECOIL STARTER INSPECTION . . . . . . . . . . . . . . . . 10-7 STARTER MOTOR DISASSEMBLY/ASSEMBLY . . . . 10-9
RECOIL STARTER REMOVAL/INSTALLATION . . . . 10-3 STARTER MOTOR REMOVAL/INSTALLATION . . . . . 10-8
RECOIL STARTER/FAN COVER REMOVAL/ SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 10-2
REDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
REDUCTION CASE OIL . . . . . . . . . . . . . . . . . . . . . . . . 3-5
T
REDUCTION CASE OIL (1/2 reduction unit with clutch) 3-5 TOOLS . . . . . . . . . . . . . . . . . . . 2-10, 6-2, 8-2, 12-2, 13-2
REDUCTION UNIT DISASSEMBLY/REASSEMBLY . 13-7 TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
REDUCTION UNIT INSPECTION . . . . . . . . . . . . . . . 13-22 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
REGULATOR/RECTIFIER INSPECTION . . . . . . . . . . 11-7 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 10-2
S TUBE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
SEDIMENT CUP CLEANING . . . . . . . . . . . . . . . . . . . . 3-8 TYPE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . 1-2
SOLENOID (AUTO THROTTLE) INSPECTION . . . . . 7-10
V
SPARK ARRESTER CLEANING . . . . . . . . . . . . . . . . . 3-10 VALVE CLEARANCE CHECK/ADJUSTMENT . . . . . . 3-12
SPARK PLUG CAP INSPECTION . . . . . . . . . . . . . . . . 9-4 VALVE GUIDE REAMING . . . . . . . . . . . . . . . . . . . . . . 12-9
SPARK PLUG CHECK/ADJUSTMENT . . . . . . . . . . . . . 3-9 VALVE GUIDE REPLACEMENT . . . . . . . . . . . . . . . . . 12-8
SPARK PLUG REPLACEMENT . . . . . . . . . . . . . . . . . 3-10 VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . 12-10
SUPPLEMENT Y TO: P/N 61Z5F00

• iGX SERIES
iGX270UT2 • iGX390T2/UT2
61Z5F00Y
© 2010 Honda Motor Co., Inc.—All Rights Reserved

SERVICE INFORMATION
require the use a 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.
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 man-
ual and other service materials carefully.
For Your Safety
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Failure to properly follow instructions and precau-

tions can cause you to be seriously hurt or killed.
ual carefully.
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when

INTRODUCTION OUTLINE OF CHANGES
This supplement covers the construction, function, and
servicing procedures of the Honda
SPECIFICATIONS 1
iGX270UT2·iGX390T2/UT2 Engines.
For service information that is not covered in this
SERVICE INFORMATION 2
supplement, please refer to the
GX270UT2·GX390RT2/T2/UT2 base shop manuals
MAINTENANCE 3
(part number 61Z5F00Z·61Z5F00). TROUBLESHOOTING 4
All information contained in this manual is based on the
latest product information available at the time of
FAN COVER 5
printing. We reserve the right to make changes at
anytime without notice.
FUEL SYSTEM 6
No part of this publication may be reproduced, stored in
GOVERNOR SYSTEM 7
a retrieval system, or transmitted, in any form, by any
means, electronic, mechanical, photocopying,
CHARGING SYSTEM 8
recording, or otherwise, without prior written permission IGNITION SYSTEM
of the publisher. This includes text, figures, and tables. 9
As you read this manual, you will find information that is STARTING SYSTEM 10
preceded by a symbol. The purpose of this
message is to help prevent damage to this Honda
OTHER ELECTRICAL 11
product, other property, or the environment. CYLINDER HEAD/VALVES 12
SAFETY MESSAGES CRANKCASE 13
Your safety and the safety of others are very important.
To help you make informed decisions, we have MUFFLER 14
provided safety messages and other safety information
throughout this manual. Of course, it is not practical or WIRING DIAGRAMS 15
possible to warn you about all the hazards associated
with servicing these products. You must use your own INDEX
good judgement.
The marked sections contain no changes.
You will find important safety information in a variety of They are not covered in this supplement.
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
You CAN be HURT if you don’t follow
instructions.
· Instructions – how to service these products correctly
and safely.
© Honda Motor Co., Ltd.

Date of Issue: September 2010

SYMBOLS
these symbols, it will be explained specifically in the text without the use of the symbols.
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).
Apply sealant.

OUTLINE OFHowCHANGES
to use this manual
ITEM MODEL
GX270UT2·GX390UT2/T2 iGX270UT2·iGX390UT2/T2
Fan cover
Carburetor
ECM
Control base
Assy. MANUAL OPERATION TYPE:
UPPER SHROUD
EXCEPT MANUAL OPERATION TYPE:
INSULATOR (If equipped)

OUTLINE
How to useOFthis
CHANGES
manual
ITEM MODEL
Charge/lamp coil
10 A CHARGE COIL TYPE:
18 A CHARGE COIL TYPE:
POWER COIL
1 A/3 A CHARGE COIL TYPE:
0.9 A CHARGE COIL
LAMP COIL TYPE:
Governor arm/
governor rod GOVERNOR ROD
GOVERNOR ARM
OUTLINE OFthis
How to use CHANGES
manual
ITEM MODEL
Engine wire
harness
Recoil starter
Starter motor
Control box
With circuit protector type
Without circuit protector type

OUTLINE
How to useOFthis
CHANGES
manual
ITEM MODEL
Auto throttle
solenoid
Case cover
packing
Crankcase/
oil level switch/ CRANKCASE CRANKCASE
governor arm
shaft
OIL LEVEL SWITCH
GOVERNOR ARM SHAFT

OIL LEVEL SWITCH
Crankcase cover
GOVERNOR WEIGHT CRANKCASE COVER
CRANKCASE COVER
GOVERNOR
WEIGHT
HOLDER
1. SPECIFICATIONS
1
SERIAL NUMBER LOCATION ·····················1-2 ENGINE SPECIFICATIONS··························1-3

TYPE CODE ··················································1-2 DIMENSIONAL DRAWINGS·························1-4
DIMENSIONS AND WEIGHTS P.T.O. DIMENSIONAL DRAWINGS ·············1-5
SPECIFICATIONS·········································1-3
SPECIFICATIONS
SERIAL NUMBER LOCATION SPECIFICATIONS
The engine serial number (1), description code (2) and type (3) are stamped
on the crankcase.
Refer to it when ordering parts or making technical inquiries.
(1)
(2)
(3)
TYPE CODE
Model GX270UT2
Type QZX4 VZX7
P. T. O. Q type V type
Model GX390T2
Type VZX
P. T. O. V type
Model GX390UT2
Type VZX7 VZX8
P. T. O. V type
SPECIFICATIONS
DIMENSIONS AND WEIGHTS SPECIFICATIONS
P.T.O. VARIATION
Model GX270UT2 GX390UT2·GX390T2
Overall length Q type* 380 mm (15.0 in) –
V type* 400 mm (15.7 in) 425 mm (16.7 in)
Overall width Q type* 462 mm (18.2 in) –
V type* 462 mm (18.2 in) 484 mm (19.1 in)
Overall height Q type* 422 mm (16.6 in) –
V type* 422 mm (16.6 in) 448 mm (17.6 in)
Dry weight Q type* 29.4 kg (64.8 lbs) –
V type* 29.4 kg (64.8 lbs) 36.4 kg (80.2 lbs)
Operating Q type* 34.2 kg (75.4 lbs) –
weight V type* 34.2 kg (75.4 lbs) 41.7 kg (91.9 lbs)
*: P. T. O. type (page 1-2).
Model GX270UT2 GX390UT2 GX390T2
Description code GCBGT GCBCT GCBDT
Displacement 270 cm3 (16.5 cu–in) 389 cm3 (23.7 cu–in)
Bore x stroke 77.0 x 58.0 mm (3.0 x 2.3 in) 88.0 x 64.0 mm (3.5 x 2.5 in)
Net power (SAE J1349)*1 6.3 kW (8.4 HP) / 8.7 kW (11.7 HP) / 3,600 min-1 (rpm)
3,600 min-1 (rpm)
Continuous rated power 5.1 kW (6.8 HP) / 7.0 kW (9.4 HP) / 3,600 min-1 (rpm)
3,600 min-1 (rpm)
Maximum net torque 19.1 N·m
(SAE J1349)*1 (1.95 kgf·m, 14.1 lbf·ft) / 26.5 N·m (2.7 kgf·m, 19.5 lbf·ft)/ 2,500 min-1 (rpm)
2,500 min-1 (rpm)
Compression ratio 8.5 : 1 8.2 : 1
Fuel consumption 2.4 Liters 3.5 Liters (0.92 US gal, 0.77 Imp gal) / h
(at continuous rated power) (0.63 US gal, 0.53 Imp gal)/h
Ignition timing B.T.D.C. 10° / 1,400 min-1 (rpm)
Spark advancer performance B.T.D.C. 10° – 20° B.T.D.C. 10° – 22°
Starting system Recoil and Starter motor
Air cleaner Dual element type
Governor STR (Self Tuning Regulator) governor
model and measured in accordance with SAE J1349 at 3,600 min-1 (rpm) (net power) and at 2,500 min-1 (rpm) (maximum 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, mainte-
nance, and other variables.
SPECIFICATIONS
*: P. T. O. type (page 1-2).
Unit: mm (in)
GX390T2/UT2: 76 (3.0) GX390T2/UT2: 135 (5.3)
GX270UT2: 84 (3.3) GX270UT2: 137 (5.4)
184 (7.2) GX270UT2: 278 (10.9)

GX390T2/UT2: 300 (11.8)
GX270UT2: 462 (18.2)

GX390T2/UT2: 484 (19.1)
GX270UT2: 116 (4.6) GX270UT2: 192 (7.6)
CONTROL GX390T2/UT2: 142 (5.6) GX390T2/UT2: 201 (7.9)
BOX
GX390T2/UT2: 447 (17.6)
GX390T2/UT2: 448 (17.6)

GX270UT2: 422 (16.6)
GX270UT2: 418 (16.5)

CRANKSHAFT
(P. T. O.)
70 (2.8)
133.5 (5.26)
GX390T2/UT2: 27 (1.1)
GX270UT2: 34.5 (1.36)

GX270UT2: 92.5 (3.64)
GX390T2/UT2: 17 (0.7)
GX390T2/UT2: 100 (3.9)

GX270UT2: 13 (0.5)
GX270UT2:
* Q: 380 (15.0)
* V: 400 (15.7)
GX390T2/UT2:
* V: 425 (16.7)
GX390T2/UT2: 103 (4.1)
GX270UT2: 96 (3.8)
105 (4.1)
195.5 (7.70)
SPECIFICATIONS
*: P. T. O. type (page 1-2).
Q TYPE* (GX270UT2)
Unit: mm (in)
45° 45°
30° 30°
(6 .50)
16 5.1 5/16 - 24UNF - 2B TAP
. (2 PLACES)
P.D 6.3 – 6.35 88.5 (3.48)
(0.2480 – 0.2500)
56 (2.2)
70 (2.8)
(ĭ0.9990 – 1.0000)
28 (1.1)
ĭ 25.375 – 25.400
(0.8539 – 0.8591)
21.69 – 21.82
72.2 (2.84)
5/16 - 24UNF - 2B TAP
(4 PLACES)
7/16 - 20UNF 2B TAP

.33 .05
3)
– 4 10
31 – 1
3/8 - 16UNC - 2B TAP

(4 PLACES)
4.3 .00
0)
(ĭ 110
(5.0
103 (4.1)
ĭ
127
P . D.
V TYPE*
Unit: mm (in)
45° 45°
30° 30°
0)
. 1 (6.5
5 5/16 - 24UNF - 2B TAP
. 16
P.D (2 PLACES)
105.5 (4.15)
(ĭ0.8715 – 0.8725)
ĭ 22.136 – 22.161
18 (0.7)
70 (2.8)
46.5 (1.83)
GX270UT2: 76.5 (3.01)

5/16 - 24UNF 2B TAP
5/16 - 24UNF - 2B TAP GX390T2/UT2: 75.5 (2.97)

(4 PLACES)
.33 .05
3)
– 4 10
31 – 1
3/8 - 16UNC - 2B TAP

(4 PLACES)
4.3 .00
)
(5.00
(ĭ 110
103 (4.1)
ĭ
127
P.D.
MEMO
MAINTENANCE STANDARDS·····················2-2 LUBRICATION & SEAL POINT····················2-2

TORQUE VALUES ········································2-2 HARNESS AND TUBE ROUTING ················2-3
SERVICE INFORMATION
SERVICE INFORMATION
Unit: mm (in)
Part Item Standard Service limit
Engine Maximum speed (at no load) 3,600 min-1 (rpm)* –
Cylinder GX270UT2 1.31 MPa (13.4 kgf/cm2, 190 psi) / 1,400 min-1 (rpm) –
compression GX390T2/UT2 1.29 MPa (13.2 kgf/cm2, 187 psi) / 1,400 min-1 (rpm) –
Carburetor Main jet GX270UT2 BE90A A: #85 –
GX390T2/UT2 BE92B A: #100 –
Pilot screw GX270UT2 BE90A A: 1 - 1/2 turns out –
opening GX390T2/UT2 BE92B A: 3 turns out –
Starter Brush length 10 (0.4) 6 (0.2)
motor Mica depth – 0.2 (0.01)
Charge Resistance 0.9 A 5.1 - 7.7 ȍ –
coil
Power coil Resistance 2.9 - 4.5 ȍ –
*: This figure is caused by basic program in the ECM. The engine speed is different depending on the program in the ECM.
TORQUE VALUES
Item Tread Dia. (mm) Torque values
N·m kgf·m lbf·ft
Starter motor stud bolt M10 x 1.25 40 4.1 30
Fan cover stud bolt M8 x 1.25 23 2.3 17
Combination switch nut M18 x 1.0 4.9 0.50 3.6
ECM screw/washer M4 x 0.7 2.1 0.21 1.5
Motor case set screw A/B M4 x 0.7 2.1 0.21 1.5
Starter motor nut M8 x 1.25 8.8 0.90 6.5
Jet set screw M5 x 0.8 0.3 0.03 0.22
LUBRICATION & SEAL POINT

Crankcase cover mating surface Liquid sealant
(Hondabond HT, Hondabond 4, or
equivalent)
SERVICE INFORMATION
HARNESS AND TUBE ROUTING
POWER COIL CORD
HARNESS CLIP
ENGINE WIRE HARNESS
ENGINE WIRE HARNESS
HIGH TENSION CORD

IGNITION COIL
BREATHER TUBE
HIGH TENSION CORD
POWER COIL CORD

ENGINE WIRE HARNESS
FUEL TUBE
SERVICE INFORMATION
CORD GROMMET
POWER COIL CORD
CORD CLAMP
CORD CLAMP
POWER COIL
CORD CLAMP
CORD GROMMET
0.9 A CHARGE COIL CHARGE COIL CORD

SERVICE INFORMATION
COMBINATION
TO ECM SWITCH HARNESS
Y/Bl Lg (ENGINE CONTROL MODULE)
G P
Y/Bl
Lg
G
TO IGNITION COIL OIL LEVEL SWITCH

STARTER MOTOR
Bu
Bl
R
Y
3P
COUPLER
TO OIL LEVEL SWITCH
TO CONTROL BOX /
Gr TO CHARGE COIL
Gr
SERVICE INFORMATION
RECTIFIER
CUTOUT INDICATOR
/
GROUND WIRE
RECTIFIER CORD
TO ENGINE WIRE HARNESS CHARGE COIL WIRES
TO STARTER MOTOR
SERVICE INFORMATION
COMBINATION SWITCH
COMBINATION SWITCH HARNESS
FUSE BOX
RECTIFIER
TO STARTER MOTOR
Gr
Gr
W
G
TO ENGINE WIRE HARNESS
INDICATOR COMBINATION
SWITCH
Gr
Gr
Bl/W
W
R
Bl
Bu
MAIN FUSE 30 A
TO CHARGE COIL
Bl/W
Bu
W
R
Bl
3P
COUPLER
TO STARTER MOTOR
TO IGNITION COIL
MEMO
3. MAINTENANCE
MAINTENANCE SCHEDULE························3-2 COMBUSTION CHAMBER CLEANING ·······3-4

VALVE CLEARANCE CHECK/ FUEL TUBE CHECK·····································3-5
ADJUSTMENT···············································3-3
MAINTENANCE SCHEDULE
MAINTENANCE
REGULAR SERVICE PERIOD (2)

ITEM First Every 3 Every 6 Every Refer
Perform at every indicated month or oper- Each month or months months year to page
ating hour interval, whichever comes first. use 20 hrs. or or or
50 hrs. 100 hrs. 300 hrs.
Engine oil Check level
Change 3-3*
Air cleaner Check
Clean (1) 3-6*
Replace
Sediment cup Clean 3-8*
Spark plug Check–adjust 3-9*
Replace 3-10*
Spark arrester Check–clean 3-10*
(Applicable types)
Valve clearance Check–adjust 3-3
Fuel tank and filter Clean 3-14*
Fuel tube Check Every 2 years (Replace if necessary) 3-5
(1) Service more frequently when used in dusty areas.
(2) For commercial use, log hours of operation to determine proper maintenance intervals.
(*) Refer to page of base shop manual (GX390RT2/T2/UT2: 61Z5F00)
VALVE CLEARANCE CHECK/

ADJUSTMENT
Remove the head cover bolt (1), the head cover (2), (3) (2)
and the head cover packing (3).
(1)
Disconnect the spark plug cap from the spark plug. (3)
Set the piston near top dead center of the cylinder com- Pull slowly
pression stroke (both valves fully closed) by pulling the
recoil starter slowly. When the piston is near top dead
center of the compression stroke, the triangle mark (1)
on the starter pulley (2) will align with the projection (3)
on the fan cover (4).
If the exhaust valve is opened, use the recoil starter to
turn the crankshaft one additional turn and align the tri- (1)
angle mark on the starter pulley with the projection on
the fan cover again.
(2) (4)
Insert a thickness gauge (1) between the valve rocker (1) (3)
arm (2) and valve stem (3) to measure the valve clear-
ance.
VALVE CLEARANCE:
IN: 0.15 ± 0.02 mm
EX: 0.20 ± 0.02 mm
If adjustment is necessary, refer to page 3-4.
(2)
Hold the rocker arm pivot (1) and loosen the pivot
adjusting nut (2).
Turn the rocker arm pivot to obtain the specified clear-
ance.
VALVE CLEARANCE:
IN: 0.15 ± 0.02 mm
EX: 0.20 ± 0.02 mm
Hold the rocker arm pivot and retighten the pivot adjust-
ing nut to the specified torque.
Recheck the valve clearance, and if necessary, readjust (2)
the clearance.
Check the head cover packing for damage or deteriora- VALVE STEM
tion, and install it to the head cover.
Attach the cylinder head cover to the cylinder head, and (2)
tighten the head cover bolt securely.
(1)
To increase valve clearance: screw out.
To decrease valve clearance: screw in.
COMBUSTION CHAMBER CLEANING

Remove the cylinder head (page 12-2). (1)
Clean any carbon deposits from the combustion cham-
ber (1).
FUEL TUBE CHECK

fuel.
Remove the harness cover (1) (page 6-2). (2)
Check the fuel tube (2) for deterioration, cracks, or
signs of leakage.
Install the harness cover (page 6-2).
(1)
MEMO
4. TROUBLESHOOTING
BEFORE TROUBLESHOOTING···················4-2 TROUBLESHOOTING ··································4-2

TROUBLESHOOTING
TROUBLESHOOTING

TROUBLESHOOTING
* Refer to page of base shop manual (GX390RT2/T2/UT2: 61Z5F00E3)
GENERAL SYMPTOMS AND POSSIBLE CAUSES
Engine does not start ENGINE OIL level low.
or is hard to start. Inspection: (page 3-3)*
FUEL FILTER clogged. Engine will not rev
Cleaning: (page 3-14)* sufficiently.
SPARK PLUG faulty.
Inspection: (page 3-9)*
IGNITION COIL faulty.
OIL LEVEL SWITCH faulty.
Inspection: page (page 11-5)
WIRE HARNESS faulty.
Check the wire harness connecting the ECM,
combination switch, oil level switch, and the ignition
coil for open or short circuit and for proper connection.
Inspection:
–Engine wire harness (page 4-4, 4-5, 4-6)
–Charging coil wire (page 8-5)
CHARGE/POWER COIL faulty.
Inspection: (page 8-5)
Engine lacks power. CONTROL GEAR BOX faulty.

COMBINATION SWITCH faulty.
ECM faulty.
Replacement: (page 6-4)
AIR CLEANER ELEMENT clogged.
Cleaning: (page 3-6)*
SPARK ARRESTER clogged.
Cleaning: (page 3-10)*
CARBURETOR faulty.
Disassemble: (page 6-4)
VALVE CLEARANCE incorrect.
Readjustment: (page 3-3)
VALVE or VALVE SEAT worn or damaged.
Recondition: (page 12-10)*
CYLINDER, PISTON, or PISTON RING worn.

Disassembly: (page 13-3, 13-12*)
TROUBLESHOOTING
HARD STARTING
ON
Check whether the oil level indicator is ON. Add the recommended engine oil (page 3-3)*.
OFF
Turn the combination switch to the START position Does not crank
and check whether the engine cranks. Check the battery or battery cable connection.
Cranks Perform the STARTING SYSTEM

Loosen the carburetor drain screw, and check the fuel No fuel
flow from the fuel tank. Check for clogged fuel tube, fuel filter, and fuel valve.
Fuel If the engine is stalled in a cold weather application,

check for a frozen clog in the breather tube.
Dry Disassemble the carburetor to check for clogged

Check the spark plug (page 3-9)*. ports, jets, and nozzles (page 6-13)*.
If spark plug gap is correct, clean and dry the

Wet electrodes, and then restart the engine.
Normal If the engine does not start and the electrodes are wet
again, check the carburetor float valve (page 6-14)*.
No spark Perform the IGNITION SYSTEM

Perform the spark test (page 9-4)*. TROUBLESHOOTING (page 9-2).
Spark
Perform the cylinder compression test (page 12-5)*. Compression Check the valve clarence (page 3-3) and then perform
GX270UT2: is too high the cylinder compression test. If the cylinder
1.31 MPa (13.4 kgf/cm2, 190 psi)/1,400 min-1 (rpm) compression is too high, remove carbon deposits in
GX390T2/UT2: the combustion chamber (page 3-4).
1.29 MPa (13.2 kgf/cm2, 187 psi)/1,400 min-1 (rpm)
Go to page 4-4 Go to page 4-4

TROUBLESHOOTING
From page 4-3 From page 4-3
Check the valve clearance (page 3-3), and then

perform the cylinder compression test (page 12-5)*.
If the cylinder compression is too low, perform a leak
down test.
If there is no air leakage in the engine, check the
following:
Compression Compression –Valve spring free length (page 12-7)*
is normal is too low –Valve seat width (page 12-5)*
–Valve face irregularly worn (page 12-6)*
–Decompressor operation (page 13-20)*
–Piston ring side clearance (page 13-15)*
–Piston ring width (page 13-16)*
–Piston ring end gap (page 13-16)*
–Piston skirt O.D. (page 13-14)*
–Cylinder sleeve I.D. (page 13-13)*
Check for continuity between the oil level switch Continuity

terminal and cylinder barrel. Replace the oil level switch (page 11-5).
No continuity
Check for engine wire harness connecting the No continuity
combination switch and the ignition coil for continuity. Replace the engine wire harness (page 11-7).
Bl
Bu
R
ENGINE WIRE HARNESS
Continuity
Check for continuity between the EXT (+) wire (Red) No continuity
and EXT (–) wire (Black) with the combination switch Replace the combination switch (page 11-3).
in the ON position (page 11-6).
Continuity
Remove the air cleaner elbow (page 6-5)* and check Abnormal
that the choke valve is closed when turning the starter Check the control gear box and ECM (page 6-5).
motor or pulling the recoil starter.
Normal
Replace the ignition coil (page 9-3).

TROUBLESHOOTING
ENGINE SPEED DOES NOT INCREASE OR STABILIZE SERVICE BULLETIN #47 =>
ON
OFF
Check the external connected switch and wire Abnormal

harness for failure or open circuit. Replace the external switch and/or wire harness.
Normal
Check the engine wire harness connecting the ECM No continuity
and each switch for continuity. Replace the engine wire harness (page 11-7).
P Lg G Y/Bl
ENGINE WIRE HARNESS

Continuity
Check whether the engine retains 1,400 min-1 (rpm) Constant
constantly when the external connected switch is Replace the ECM (page 6-4).
operated.
Not constant
Remove the air cleaner elbow (page 6-5)* and check Abnormal
whether the choke valve is closed when turning on Check the control gear box (page 6-5).
the starter motor or pulling the recoil starter.
TROUBLESHOOTING
ENGINE DOES NOT STOP WHEN COMBINATION SWITCH IS TURNED OFF
Check the engine wire harness connecting the Continuity
combination switch and the ignition coil for continuity Replace the engine wire harness (page 11-7).
between the EXT (+) wire (Red) and EXT (–) (Black).
Bl
R
ENGINE WIRE HARNESS
No continuity
Check the combination switch connecting the engine
wire harness for continuity between the EXT (+) wire Continuity
(Red) and EXT (–) wire (Black) with the combination Replace the combination switch (page 11-3).
switch in the OFF position (page 11-6).
No continuity
ENGINE DOES NOT STOP WHEN ENGINE OIL LEVEL IS LOW

ON
OFF

terminal and the cylinder barrel (page 4-4). Replace the oil level switch (page 11-5).
No continuity
Check the engine wire harness between the oil level No continuity
switch and the ignition coil for continuity. Replace the engine wire harness (page 11-7).
Y
ENGINE WIRE HARNESS
Continuity

5. FAN COVER
FAN COVER REMOVAL/INSTALLATION····5-2

FAN COVER
FAN COVER REMOVAL/INSTALLATION
FAN COVER
Remove the following:

– Recoil starter (page 10-3)
– Control box (page 11-3)
When installing, refer to HARNESS AND TUBE ROUTING (page 2-3).
FAN COVER SHROUD
COLLAR (4)
FAN COVER STUD BOLT (8 mm) (2)

23 N·m (2.3 kgf·m, 17 lbf·ft)
TAPPING SCREW (5 x 20 mm)
SPECIAL BOLT (6 mm) FAN COVER
BOLT (6 x 25 mm)
6. FUEL SYSTEM
6
FUEL TANK REMOVAL/INSTALLATION ····6-2 CHOKE SET REPLACEMENT ·····················6-9
CARBURETOR REMOVAL/ CONTROL MOTOR/WAX HEATER
INSTALLATION·············································6-3 INSPECTION·················································6-9
CARBURETOR DISASSEMBLY/ TECHNICAL FEATURES/STR (Self Tuning
ASSEMBLY ···················································6-4 Regulator) GOVERNOR·····························6-10
FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION
FUEL SYSTEM

You can be burned or seriously injured when han-
dling fuel.
Set a commercially available tube clamp to the fuel
tube.
FUEL FILLER CAP
FUEL FILLER CAP PACKING

INSTALLATION:
Before installing, check for
FUEL TANK
O-RING
FUEL TANK JOINT

2 N·m (0.2 kgf·m, 1.5 lbf·ft)
INSTALLATION:
screen of the fuel strainer
for clogs or damage.
BOLT (8 ɘ 25 mm) (2)

24 N·m (2.4 kgf·m, 17 lbf·ft)
HARNESS COVER
NUT (8 mm) (2)
FUEL TUBE 24 N·m (2.4 kgf·m, 17 lbf·ft)
TAPPING SCREW INSTALLATION: B8 TUBE CLAMP
(5 x 20 mm) (2) Before installing, check for
deterioration or cracks. FUEL TUBE CLAMP
FUEL SYSTEM
CARBURETOR REMOVAL/
INSTALLATION
(*) Refer to page of base shop manual (GX240/GX270/GX340/GX390UT2, P/N 61Z5F00E3)

dling fuel.
Remove the harness cover (page 6-2).
Remove the air cleaner (page 6-5)*.
Remove the ECM connector and power coil connector.
Set a commercially available tube clamp to the fuel
tube.
Remove the drain bolt to drain the carburetor completely.
ECM CONNECTOR FUEL TUBE
POWER COIL CONNECTOR
FUEL TUBE CLAMP
B8 / D8 TUBE CLAMP
INSULATOR PACKING
INSTALLATION:
Before installing, clean the passage
thoroughly with compressed air.
Install the carburetor insulator with the
vent groove facing toward the carburetor.
After installing, clamp the high tension
CARBURETOR PACKING
CARBURETOR HIGH TENSION

INSULATOR CORD CARBURETOR ASSY.
DRAIN BOLT
FUEL SYSTEM
ASSEMBLY
ECM REMOVAL/INSTALLATION
Carefully pull the control motor connector from the

ECM. Do not pull on the wires; you might break them or
damage the connector.
ECM SCREW/WASHER (4 x 20 mm) (4)

2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
ECM
CONTROL MOTOR CONNECTOR
O-RING
Replace if necessary.
CARBURETOR ASSY./
CONTROL GEAR BOX ASSY.
FUEL SYSTEM
CONTROL GEAR BOX DISASSEMBLY/
ASSEMBLY
CONTROL GEAR BOX DISASSEMBLY
Remove the ECM (page 6-4).
When removing the motor case set, hold the choke
valve fully open as shown.
MOTOR CASE SET SCREW A (4 x 17 mm) (2) SPECIAL CLIP B

MIDDLE GEAR
CHOKE CONTROL LEVER A
INSPECTION:
CHOKE LEVER ARM Check for damage or warpage.
SPECIAL CLIP A SPRING
CHOKE CONTROL LEVER B

WASHER (4 mm) (2)
PLATE
MOTOR CASE SET
O-RING
MOTOR CASE SET SCREW B (4 mm) (2)
CHOKE LEVER O-RING
CARBURETOR ASSY.
THROTTLE GEAR
INSPECTION:
Check for damage or warpage.
CHOKE VALVE
FUEL SYSTEM
CONTROL GEAR BOX ASSEMBLY
Apply grease to the O-rings.
Install the O-ring to the groove of the carburetor Assy.
securely.
Install the O-ring and choke lever to the motor case set.
Align the cutouts of Install the plate to the choke lever arm and install the
choke lever arm and choke lever arm/plate to the choke lever.
choke lever.
When installing the motor case set, hold the choke
valve fully open as shown.
Install the washers and motor case set screws A/B.
Tighten the motor case set screws A/B to the specified
torque.
TORQUE:2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
MOTOR CASE SET SCREW A (4 x 17 mm) (2)

CHOKE LEVER ARM 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
WASHER (4 mm) (2)
MOTOR CASE SET SCREW B (4 mm) (2)

2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
PLATE MOTOR CASE SET
O-RING O-RING
Replace if necessary. Replace if necessary.
CARBURETOR ASSY.
CUTOUT
CHOKE LEVER
CHOKE VALVE
FUEL SYSTEM
Hook the spring (1) to the choke control lever B (2) and (3) (1)
choke control lever A (3).
(2)
Install the choke control lever (1) and a new special (1) (2)
clip B (2) securely.
Install the middle gear (1) to the throttle gear (2). (1) (3)
• Engage the middle gear and throttle gear as shown.
Install a new special clip A (3) securely.
(1)
(2)
FUEL SYSTEM
ASSEMBLY

dling fuel.
To prevent serious eye injury, always wear safety

goggles or other eye protection when using com-
pressed air.
Remove the control gear box (page 6-5).
PILOT JET SET PAN SCREW (3 ɘ 6 mm) (2) VALVE LEVER

ASSEMBLY: SPRING
Before installing, clean JET SET SCREW (5 mm)
pressure compressed air. 0.3 N·m (0.03 kgf·m, 0.22 lbf·ft)
Lightly lubricate the O-ring FUEL VALVE
to ensure easy installation LEVER SETTING LEVER
into the carburetor body. O-RING PLATE
O-RING
PILOT SCREW
REPLACEMENT: (page 6-15*)
PILOT SCREW OPENING: (page 2-2) FUEL VALVE
MAIN NOZZLE PACKING
ASSEMBLY: UPPER CUP FILTER
Before installing, SIDE REMOVAL/INSTALLATION:
clean thoroughly with SPRING (page 3-8)*
low- pressure
compressed air. LIMITER CAP
FLOAT VALVE
MAIN JET O-RING

ASSEMBLY: UPPER FLOAT VALVE
Before installing, clean SIDE SPRING
pressure compressed air.
FLOAT
FLOAT CHAMBER FLOAT PIN
ASSEMBLY:
Install the float chamber to the SEDIMENT CUP
carburetor body at an angle as O-RING
shown. 20°
DRAIN BOLT GASKET
SET BOLT GASKET
SET BOLT DRAIN BOLT

FUEL SYSTEM
CHOKE SET REPLACEMENT
Remove the control gear box (page 6-5). (2)
Hold the choke valve fully open and pull out the choke
valve plate (1). (4)
Remove the choke shaft (2) and return spring (3).
Install the return spring and new choke shaft with the (3)
return spring ends hooked to the bosses.
Insert a new choke valve plate into the slit (4) of the Hook
choke shaft.
Be sure the choke shaft is in the position between the Hook
projections (5) of the choke valve plate. (1)
(1)
(5) (5)
CONTROL MOTOR/WAX HEATER
INSPECTION
Remove the ECM (page 6-4).
Measure the resistance between the control motor con-
nector terminals.
Unit: ȍ
No.5 (R) No.6 (G) No.8 (Bu)
No.1 (Y) 52 – 90 – –
No.2 (O) 52 – 90 – –
No.3 (Br) – 52 – 90 –
No.4 (Bl) – 52 – 90 –
No.7 (W) – – 36 – 98
If the measured resistance is out of the specification,
replace the motor case set (page 6-5).
CONTROL MOTOR CONNECTOR
Measure point
No.8
No.1
No.2 No.7
No.3 No.4 No.5 No.6
FUEL SYSTEM
TECHNICAL FEATURES/STR (Self Tuning Regulator) GOVERNOR
OUTLINE
This engine has a STR (Self Tuning Regulator) governor that enables stable engine starting and fast engine warm-up with no man-
ual operation before and after engine starting.
The STR governor controls both throttle valve and choke valve with one throttle control motor inside the carburetor. The heater,
combined with a thermally-linked wax unit (Heater Assy.), controls the choke valve while starting a warm or cold engine.
The battery is not required to actuate the STR governor. The recoil starter allows the STR to function.
ECM
AIR TEMPERATURE SENSOR
ECM TEMPERATURE
SOURCE SUPPLY
HEATER CONTROL
CONTROL MOTOR HEATER ASSY.
THROTTLE/CHOKE CONTROL CHOKE CONTROL
POWER COIL
THROTTLE CHOKE
FUEL SYSTEM
CONSTRUCTION
CHOKE SHAFT
Transmits the driving power from the choke control lever to the choke valve.
EXTRA CHOKE LEVER
Supports starting by manual opening the choke valve when the engine is warmed.
CHOKE CONTROL LEVER
Transmits the driving power from the control motor or heater Assy. to the choke shaft.
THROTTLE GEAR
Transmits driving power to the throttle valve.
MIDDLE GEAR
• Transmits the driving power to the throttle gear.
• Adjusts the driving power from the choke control lever to the choke lever with its cam.
CONTROL MOTOR
Controls the throttle and choke opening value after starting the engine.
HEATER ASSY.
– THERMALLY-LINKED WAX UNIT
– Adjusts the choke valve opening value by its characteristics when starting.
– HEATER
– Warms up the thermally-linked wax by current from the ECM.
EXTRA CHOKE LEVER THROTTLE GEAR
CHOKE SHAFT
CHOKE SIDE THROTTLE SIDE
CHOKE CONTROL
LEVER
MIDDLE GEAR
HEATER ASSY. CONTROL MOTOR

FUEL SYSTEM
FUNCTION
When starting:
1. The thermally-linked wax (1) is expanded due to the ambient temperature, so the shaft (2) connected to the wax is moved.
2. The shaft connected to the wax pushes the choke control lever (3), which moves the choke shaft (4) to adjust the choke valve
(5) opening.
1.: 2.: (4) (3)
(2)
(1)
(5)
After starting – Engine warming up:

The ECM turns the control motor (1) to adjust the throttle valve (2) opening with the middle gear (3) engaging to the control motor
and the throttle gear (4) linking to the throttle valve. At this time, the engine speed is maintained constantly at approximately
3,600 min-1 (rpm) since the choke valve (5) opening is restricted with the choke control cam (6) on the middle gear.
(3)
(6) (4)
(1)
(5) (2)
FUEL SYSTEM
Engine warming up – Normal running:
The ECM applies current to the Positive Temperature Coefficient Heater in the heater Assy. (1) to warm up the thermally-linked
wax, by calculating the data from temperature sensor in the ECM, finally open the choke valve (2). The ECM shifts to normal
running mode after detecting that warm-up is complete by receiving the temperature data from the sensor, and stops the current to
the heater.
(1)
(2)
When stopping:
To stop the engine, turn the engine stop switch off to open the throttle valve (1) beyond the fully open position.
(1)
MEMO
8. CHARGING SYSTEM
SYSTEM DIAGRAM ······································8-2 CHARGE / POWER COIL REMOVAL/

INSTALLATION ············································8-4
BEFORE TROUBLESHOOTING···················8-2 8
CHARGE/POWER COIL INSPECTION ········8-5
CHARGING SYSTEM
TROUBLESHOOTING···································8-3
CHARGING SYSTEM
SYSTEM DIAGRAM
CHARGING SYSTEM
RECTIFIER
Gr G Gr W
Gr Gr
Gr Gr
W
W (W)
Bl
MAIN FUSE (30A)
ECM
(ENGINE CONTROL MODULE) Bl W Gr Gr
POWER
COIL W Bl/W
Bl/W W
CHARGE
COIL
COMBINATION
Black Brown SWITCH
Yellow Orange
Blue Light blue CONTROL BOX
Green Light green
Red Pink
White Gray BATTERY STARTER MOTOR
CHARGING SYSTEM
CHARGING SYSTEM TROUBLESHOOTING
Abnormal
Check the main fuse 30 A (page 11-3). Replace the main fuse 30 A (page 11-3).
Normal
Abnormal
Check the charge coil (page 8-5). Replace the charge coil (page 8-4).
Normal
Abnormal
Check the rectifier (page 11-6). Replace the rectifier(page 11-3).
Normal
Abnormal
Check the power coil (page 8-5). Replace the power coil (page 8-4).
Normal
Replace the ECM (page 6-4) and recheck the power

coil (page 8-5).
Normal
Check the harness connecting to the charge coil and
battery for open or short circuit and for proper
connection.
If necessary, replace or repair the harness.
CHARGING SYSTEM
CHARGE / POWER COIL REMOVAL/
INSTALLATION
(*) Refer to page of base shop manual (GX240/GX270/GX340GX390UT2, part number 61Z5F00E3).
– Ignition coil (page 9-3)
– Starter motor (page 10-8)
– Flywheel (page 8-7)*
When installing the cord clamp, refer to HARNESS AND TUBE ROUTING
(page 2-3).
CORD GROMMET
CORD CLAMP
BOLT (6 x 12 mm)
GX270UT2:
BOLT (6 x 28 mm) (2)
GX390T2/UT2:
BOLT (6 x 40 mm) (2)
POWER COIL
GX270UT2:
BOLT (6 x 25 mm) (2)
GX390T2/UT2: BOLT (6 x 12 mm)
BOLT (6 x 35 mm) (2)
0.9 A CHARGE COIL CORD CLAMP
CORD GROMMET
CHARGING SYSTEM
CHARGE/POWER COIL INSPECTION
POWER COIL
(*) Refer to page of base shop manual (GX240/GX270/
GX340/390UT2, P/N 61Z5F00E3).
Remove the air cleaner element (page 6-5)*.
Disconnect the power coil connector.
Check for continuity between the terminals of power coil
connector. (Engine wire harness side)
Resistance: 2.9 – 4.5 ȍ
ground.
ground, replace the power coil (page 8-4).
replace the ECM and recheck.
CHARGE COIL
charge coil.
Resistance: 5.1 – 7.7 ȍ
ground.
replace the rectifier and recheck.
MEMO
9. IGNITION SYSTEM
SYSTEM DIAGRAM ······································9-2 IGNITION COIL REMOVAL/

INSTALLATION ············································9-3
IGNITION SYSTEM
TROUBLESHOOTING···································9-2 9
IGNITION SYSTEM
SYSTEM DIAGRAM
IGNITION SYSTEM
Bl Bl
R R
Y Bl R Y
R Bl
Black Brown
Yellow Orange
COMBINATION Blue Light blue
SWITCH Green Light green
Red Pink
SPARK IGNITION OIL LEVEL CONTROL BOX White Gray
PLUG COIL SWITCH
IGNITION SYSTEM TROUBLESHOOTING

NO SPARK AT SPARK PLUG

terminal and engine ground (page 4-4). Replace the oil level switch (page 11-5).
No continuity
Check the engine wire harness connecting the Abnormal Replace or repair the engine wire harness
ignition coil and the combination switch for open or (page 11-7).
short circuit and for proper connection (page 4-4).
Normal
Abnormal
Check the combination switch (page 11-6). Replace the combination switch (page 11-3).
Normal
Abnormal
Check the ignition coil (page 9-5)*. Replace the ignition coil (page 9-3).
IGNITION SYSTEM
IGNITION COIL REMOVAL/
INSTALLATION
When installing the ignition coil, refer to IGNITION COIL INSTALLATION
(page 9-4)*.
ENGINE WIRE HARNESS

IGNITION COIL CONNECTOR
SPARK PLUG CAP
HIGH TENSION CORD
BOLT (6 x 28 mm) (2)

IGNITION COIL
INSTALLATION:
Install the Ignition coil as shown. SPARK PLUG
HIGH TENSION CORD BREATHER TUBE
CARBURETOR
INSULATOR HIGH TENSION CORD
MEMO
10. STARTING SYSTEM
SYSTEM DIAGRAM ····································10-2 RECOIL STARTER INSPECTION ··············10-7

STARTING SYSTEM STARTER MOTOR REMOVAL/
TROUBLESHOOTING·································10-2 INSTALLATION ··········································10-8
RECOIL STARTER REMOVAL/ STARTER MOTOR DISASSEMBLY/ 10
INSTALLATION···········································10-3 ASSEMBLY·················································10-9
RECOIL STARTER DISASSEMBLY···········10-4 INSPECTION·············································10-10
RECOIL STARTER ASSEMBLY·················10-5 BRUSH REPLACEMENT··························10-13
STARTING SYSTEM
SYSTEM DIAGRAM
STARTING SYSTEM
MAIN FUSE (30A)

W W
W Bl/W
Bl/W W
Black Brown
Yellow Orange
Blue Light blue
COMBINATION Green Light green
SWITCH Red Pink
CONTROL BOX White Gray
BATTERY STARTER MOTOR
STARTING SYSTEM TROUBLESHOOTING

STARTER MOTOR DOES NOT OPERATE
Replace with a known-good battery.
Abnormal If the battery runs down again, perform
Check the battery condition. the CHARGING SYSTEM
Normal
Check the battery voltage between the Low voltage
starter motor side positive (+) battery Replace positive (+) battery cable.
cable terminal and engine ground.
Normal
Check the continuity between BAT No continuity
terminal (White) and ST terminal Check the main fuse in the control box
(Black/white) of the combination switch (page 11-7)*.
in the START position (page 11-6).
Not blown Blown

Continuity
Replace the combination switch Replace the main fuse (page 11-3).
(page 11-3).
Check the starter solenoid Abnormal Replace the starter solenoid

(page 10-10). (page 10-9).
Normal
Perform the starter motor performance
test (page 10-10). If necessary
disassemble the starter motor and
check the each parts (page 10-10).
STARTING SYSTEM
RECOIL STARTER REMOVAL/
INSTALLATION
NUT (8 mm) (4)
RECOIL STARTER
STARTING SYSTEM
RECOIL STARTER DISASSEMBLY
pressed springs.
CENTER SCREW
SPRING RETAINER
FRICTION SPRING
RATCHET (2)
RECOIL STARTER PULLEY
RATCHET SPRING (2)
RECOIL STARTER ROPE
STARTER RETURN SPRING
CLIP (4)
ROPE COVER (4)
RECOIL STARTER CASE
REINFORCEMENT GRIP
STARTER GRIP RECOIL STARTER COVER

STARTING SYSTEM
RECOIL STARTER ASSEMBLY
pressed springs.
Install the recoil starter cover (1) to the recoil starter (7)
case (2).
• Align the recoil starter cover pawls (3) with the recoil
starter case tabs (4).
Install the rope cover (5) to the recoil starter cover
bosses (6).
Install the clips (7) securely.
• Replace the clips if necessary.
(5)
(5) (2)
(3)
(4)
(6) (1)
Pass the recoil starter rope (1) through the hole (2) of (3)
the recoil starter pulley (3), and then tie the rope as 10 mm
shown. (0.4 in)
(1)
Before installing the recoil starter rope, check for fray or
wear.
Wind the recoil starter rope onto the recoil starter pulley
counterclockwise.
(2)
STARTING SYSTEM
Hook the outer hook (1) of the starter return spring (2) (2) (3)
to the groove (3) of the recoil starter pulley (4), and then
install the starter return spring by winding it.
(4) (1)
Apply grease to the cutout (1) of the recoil starter case (2) (3)
(2).
Set the recoil starter pulley (3) to the recoil starter case
by aligning the inner hook (4) of the starter return spring
with the cutout of the recoil starter case.
(1) (4)
Apply grease to the two ratchets (1). (1)
Install the two ratchets and the two ratchet springs (2)
to the recoil starter pulley (3) as shown.
(2)
(3)
Apply grease to the inside of the spring retainer (1). (1) (3)
Set the friction spring (2) and the spring retainer to the
recoil starter pulley in the direction as shown.
Apply locking agent (Hondalock 1, Threebond® 2430,
or equivalent) to the threads of the center screw (3). (2)
Hold the spring retainer and tighten the center screw
securely.
STARTING SYSTEM
Turn the recoil starter pulley (1) more than 2 turns coun- (1)
terclockwise to preload the starter return spring. Be
sure to hold the recoil starter pulley.
Pass the recoil starter rope through hole (1) of the recoil
starter case, the starter grip (2), and reinforcement grip
(3), and then tie the rope as shown.
Check the recoil starter operation (page 10-7).
(1)
(2)
20 mm
(0.8 in) (3)
RECOIL STARTER INSPECTION
RECOIL STARTER OPERATION
Remove the recoil starter (page 10-3). (2)
Pull the starter grip several times to inspect that the
ratchets (1) are operated properly (the ratchet ends
come out from the spring retainer (2).
(1)
STARTER PULLEY
Remove the recoil starter (page 10-3). (1)
Inspect the square holes (1) of the starter pulley (2) for
deformation.
(2)
STARTING SYSTEM
STARTER MOTOR REMOVAL/
INSTALLATION
Disconnect the starter solenoid wires from the starter
motor.
STARTER MOTOR
STARTER SOLENOID WIRE
STARTER MOTOR
STARTER MOTOR STUD BOLT (10 mm)

40 N·m (4.1 kgf·m, 30 lbf·ft)
BOLT (10 x 40 mm)

STARTING SYSTEM
STARTER MOTOR DISASSEMBLY/
ASSEMBLY
Remove the starter motor (page 10-8).
LOCK RING YOKE
DISASSEMBLY: LOCK RING ASSEMBLY:
Hold the armature upright, Make sure there is no
place an offset wrench obstruction on the magnets.
over the pinion stop collar,
and drive the collar down
exposing the lock ring. BRUSH TERMINAL
Remove the lock ring; then NUT (8 mm)
remove the collar and
overrunning clutch. PINION
STOP
COLLAR
ARMATURE
STARTER
SOLENOID
PINION DRIVE LEVER
OVERRUNNING
CLUTCH
PINION GEAR
NUT (6 mm) (2)
PINION STOP
COLLAR
THRUST
COLLAR THROUGH BOLT
(5 x 99 mm) (2)
BEARING A BEARING B REAR BRACKET

FRONT BRACKET
COVER
BRUSH SPRING (4)

BRUSH (4) BRUSH HOLDER
INSULATOR
BRUSH HOLDER INSPECTION:
Check for cracks or damage.
STARTING SYSTEM
FRONT BRACKET/REAR BRACKET
ASSEMBLY
Install the rear bracket (1) to the armature/yoke (2) by
aligning the brush terminal grommet (3) with the cutout (8)
(4) of the rear bracket. (7)
Attach the pinion drive lever (5) to the starter solenoid (2)
(6). Set the pinion drive lever to the overrunning clutch
(7).
Hold the pinion drive lever, starter solenoid, and yoke (4)
together, and install the front bracket (8).
Tighten the through bolts to secure the front bracket (1)
and rear bracket (page 10-9).
(5)
(3)
(6)
INSPECTION
PERFORMANCE TEST
Measure starter performance while cranking the engine.
STARTER MOTOR PERFORMANCE:
UNDER LOAD:
CRANKING CURRENT: 150 A
ENGINE CRANKING SPEED: 1,900 min-1 (rpm) min.
NO LOAD:
CRANKING CURRENT: 50 A max.
• To get accurate results, the test must be conducted
in the normal ambient temperature.
• Battery: 32A19 (12 V 24AH/5HR)
• Battery cable: 8 sq. x 1.5 m (4.9 ft.) total length of
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 (1) (page 10-9).
Connect a 12 V battery between the starter terminal
and the switch body and check for continuity between
the terminals.
Continuity should exist when the battery is connected
and not exist when the battery is disconnected.
(1)
STARTING SYSTEM
BRUSH LENGTH
Measure the brush length.
If the brush length is less than the service limit, replace
the brush (page 10-13).
STANDARD: 10 mm (0.4 in)
SERVICE LIMIT: 6 mm (0.2 in)
BRUSH CONTINUITY CHECK

Check for continuity between the brushes.
There should be continuity between both the positive
brushes.
There should be continuity between both the negative
brushes.
There should be no continuity from either positive brush
to either negative brush.
If the correct continuity of the brushes is not obtained,
replace the brushes (page 10-13).
ARMATURE MICA DEPTH

Visually inspect the commutator 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.
When the mica is clogged, or its depth is smaller than
the service limit value, recut the grooves using a hack-
saw blade or a small file.

COMMUTATOR TO SHAFT
Check for continuity between the commutator and the
armature shaft.
of the commutator segments and the armature shaft
(page 10-9).
STARTING SYSTEM
COMMUTATOR SEGMENTS
Check for continuity between segments. If an open cir-
cuit (no continuity) exists between any two segments,
replace the armature (page 10-9).

COMMUTATOR TO CORE
Check for continuity between the commutator segments
and the armature coil core.
of the commutator segments and the armature coil core
(page 10-9).
OVERRUNNING CLUTCH
Hold the pinion gear (1) as shown and check that the (1)
gear turns clockwise and slides smoothly.
If necessary, apply oil or replace the overrunning clutch.
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.
STARTING SYSTEM
BRUSH REPLACEMENT
Cut off the brush lead (1) at the point shown and (3) Cut here (2)
remove the brush (2).
Remove the remaining brush lead and deposited solder
from the terminal (3).
(1)
Hold a new brush (1) in the same direction of the (3)

removed brush and put a new plate (2) over the new Press here
brush and terminal (3), and press it using a pair of pliers
as shown.
(2) Press here
(1)
Solder the plate (1) on the terminal (2). Solder here

• Before soldering, heat the pressed part of the plate
well to mark sure solder (3) reaches the end of the
pressed part.
• Prevent solder from flowing down the brush lead.
• Do not allow solder to run down onto the field wind- (1)
ing of the yoke.
• File the brush so that the brush and commutator can
fit using an emery paper #500 or #600.
(3) (2)
MEMO
COMPONENT LOCATION··························11-2 OIL LEVEL SWITCH INSPECTION ············11-5

CONTROL BOX REMOVAL/ COMBINATION SWITCH INSPECTION·····11-6
INSTALLATION···········································11-3
INDICATOR INSPECTION··························11-6
CONTROL BOX DISASSEMBLY/
ASSEMBLY ·················································11-3 RECTIFIER INSPECTION···························11-6 11
OIL LEVEL SWITCH REMOVAL/ ENGINE WIRE HARNESS REMOVAL/
INSTALLATION···········································11-5 INSTALLATION ··········································11-7
OTHER ELECTRICAL
COMPONENT LOCATION
OTHER ELECTRICAL
CONTROL BOX
OIL LEVEL SWITCH

OTHER ELECTRICAL
CONTROL BOX REMOVAL/INSTALLATION
When installing the control box, refer to HARNESS AND TUBE ROUTING (page 2-3).
STARTER MOTOR NUT (8 mm)

8.8 N·m (0.90 kgf·m, 6.5 lbf·ft)
ENGINE WIRE HARNESS
CONTROL BOX
CORD GROMMET
COMBINATION SWITCH
HARNESS
CHARGE COIL CORD

BOLT (6 x 12 mm) (2)

OTHER ELECTRICAL
When assembling the control box, refer to HARNESS AND TUBE ROUTING (page 2-3).
CONTROL COVER
SCREW (6 x 8 mm) RECTIFIER
SCREW/WASHER SWITCH BOX BRACKET

(4 x 20 mm)
INDICATOR
GROUND TERMINAL
SCREW/WASHER
(4 x 10 mm)
SCREW/WASHER
(4 x 8 mm)
FUSE BOX COVER
MAIN FUSE 30 A
INSPECTION:
(page 11-7*)
CODE GROMMETS
COMBINATION SWITCH NUT (18 mm)
4.9 N·m (0.50 kgf·m, 3.6 lbf·ft)
COMBINATION SWITCH
TAPPING SCREWS (4 x 14 mm) (2)
CONTROL PANEL
OTHER ELECTRICAL
OIL LEVEL SWITCH REMOVAL/
INSTALLATION
(*) Refer to page of base shop manual (GX240/GX270/ (1)
GX340/GX390UT2, P/N 61Z5F00E3).
Drain the engine oil (page 3-4)*.
Disconnect the oil level switch connector (1).
Remove the two 6 x 16 mm flange bolts (2), oil level (4)
switch (3), and O-ring (4).
Replace the O-ring Installation is in the reverse order of removal.
with a new one.
• Install the oil level switch to the crankcase securely (3)

as shown.
• Wrong assembly can cause the engine trouble.
(2)
GX390: GX270: CUTOUT
CUTOUT
OIL LEVEL SWITCH INSPECTION
Remove the oil level switch (page 11-5).
Check for continuity between the oil level switch termi-
nals as follows:
1. Hold the oil level switch (1) in the direction as
shown. There should be continuity.
2. Hold the switch in the direction as shown. There
should be no continuity.
3. Hold the switch in the direction as shown and dip the (1)
float section of the switch into a container of oil.
If the correct continuity is not obtained, replace the oil
level switch (page 11-5). DIRECTION OF THE SWITCH INSPECTED IN
STEP 1 AND 3:
DIRECTION OF THE SWITCH INSPECTED IN

STEP 2:
OTHER ELECTRICAL
COMBINATION SWITCH INSPECTION
Check for continuity between the terminals at each BAT (W) ST (Bl/W)
switch position.
combination switch (page 11-3).
EXT (–) (Bl)
EXT (+) EXT (-) BAT ST
(R) (Bl) (W) (Bl/W)
OFF
ON
EXT(+) (R)
START
INDICATOR INSPECTION
Remove the indicator (page 11-3). (2)
Measure the resistance between the terminal and plate.
• Some testers have reverse polarity.
Unit: kȍ
(+) Tester probe
Terminal (1) Plate (2)
(–) Tester Terminal (1) – 200
probe Plate (2) –
(1)
RECTIFIER INSPECTION
Measure the resistance between the terminals and be (3) (2)
shown in the table.
• Some testers have reverse polarity.
Unit: kȍ
(+) Tester probe
W (1) Gr (2) G (3) Gr (4)
W (1) – –
(–) Tester Gr (2) 7 – –
probe G (3) – 7 –
Gr (4) 7 – 7 –
(4) (1)
OTHER ELECTRICAL
ENGINE WIRE HARNESS REMOVAL/
INSTALLATION
Release the engine wire harness (1) from the harness
clip (2). (3)
(5)
Remove the 6 x 12 mm flange bolt (3) and cord clamp
(4).
Disconnect the ignition coil connector (5) and remove (4)
the engine wire harness.
(1)
(2)
MEMO
12. CYLINDER HEAD/VALVES
CYLINDER HEAD REMOVAL/

INSTALLATION···········································12-2
12
CYLINDER HEAD REMOVAL/
INSTALLATION
(*) Refer to page of base shop manual (GX240/GX270/GX340/GX390UT2, P/N 61Z5F00E3).
Set the piston at top dead center of the cylinder compression stroke (page 3-3).
– Air cleaner (page 6-5)*
– Muffler (page 14-2)*
Check the valve clearance, and if necessary, adjust the clearance (page 3-3).
HEAD COVER PACKING

INSTALLATION:
UPPER SHROUD
BOLT (6 x 12 mm) (3)

HEAD
COVER
PACKING
HEAD COVER
INSULATOR (If equipped)
HEAD COVER WASHER
CYLINDER HEAD GASKET
CYLINDER HEAD
HEAD COVER BOLT (6 mm) INSTALLATION: CYLINDER HEAD
Before installing the cylinder head, remove any carbon
deposits from the combustion chamber, and inspect the
valve seats.
HEAD COVER After installing the cylinder head, measure the cylinder
compression.
(Apply to the threads
BOLT (10 x 80) (4) and seating surface)
Loosen and tighten the four 10 x 80 mm flange
bolts in a crisscross pattern in 2 – 3 steps.
13. CRANKCASE
CRANKCASE COVER REMOVAL/ CRANKSHAFT/BALANCER/PISTON

INSTALLATION···········································13-2 REMOVAL/INSTALLATION ·······················13-3
13
CRANKCASE
CRANKCASE COVER REMOVAL/INSTALLATION
CRANKCASE
(*) Refer to page of base shop manual (GX240/GX270/GX340/GX390UT2, P/N 61Z5F00E3).

Drain the engine oil (page 3-4)*
Remove the key (6.3 x 6.3 x 43 mm) (If equipped).
KEY (6.3 x 6.3 x 43 mm)

(If equipped)
(Oil seal lip)
OIL FILLER CAP
OIL FILLER CAP PACKING (2)
OIL FILLER CAP BOLT (8 x 40 mm) (7)

(With oil level gauge) (Bearing) 24 N·m (2.4 kgf·m, 17 lbf·ft)
CRANKCASE COVER
REMOVAL: INSTALLATION:
Insert a screwdriver into the recess as shown and remove the crankcase Clean the mating surfaces of the crankcase cover and
cover from the cylinder barrel by gentry prying the screwdriver. the cylinder barrel with a degreasing cleaning agent
or a clean shop towel.
Apply liquid sealant (Hondabond HT, Hondabond 4,
or equivalent) to the mating surface on the crankcase
cover as shown.
Wait for 30 minutes after assembly. Do not add oil or
start the engine during this period.
Apply a bread about
ĭ 1.0 – 1.5 mm (0.04 – 0.06 in)
CRANKCASE
CRANKSHAFT/BALANCER/PISTON
– Cylinder head (page 12-2)
– Flywheel (page 8-7)*
– Crankcase cover (page 13-2)
PISTON
INSTALLATION:
Install the piston to the cylinder barrel
with the mark on the piston head
toward the push rod hole of the
cylinder head.
MARK
Viewed from cylinder head side

(Oil seal lip)
VALVE LIFTER
REMOVAL:
When removing the
valve lifters, mark so
that the intake and
exhaust sides can be
distinguished.
INSTALLATION:
Install the valve lifters
in the cylinder barrel
immediately before
installing the camshaft.
DRAIN PLUG WASHER

WASHER (12 mm) (2) (16 mm)
CAMSHAFT
See BALANCER
WEIGHT/CAMSHAFT
INSTALLATION on
page 13-6
DRAIN PLUG BOLT (12 x 15 mm) (2)
22.5 N·m (2.25 kgf·m, 17 lbf·ft)
CRANKSHAFT
INSTALLATION:
BALANCER WEIGHT Before installing the crankshaft,
(GX390T2/UT2) check the oil seal of the cylinder
barrel for damage or hardening.
Be careful not to damage the oil
seal when installing the crankshaft.
CONNECTING ROD LOWER
CONNECTING ROD BOLT (8 x 40.5 mm) (2) INSTALLATION:
14 N·m (1.4 kgf·m, 10 lbf·ft) Set the connecting rod lower with
(Apply to the threads and seating surface) the oil dipper toward the camshaft.
MEMO
15. WIRING DIAGRAMS
WIRING DIAGRAMS ···································15-2
15
WIRING DIAGRAMS
INTERFACE
RECTIFIER
C10 C11 C12 C13
INDICATOR
C6 C7
C5 C8
1
WIRING DIAGRAMS
COM_12V Lg P Y/Bl G C9
1
COM_TX
5
COM_RX Gr G Gr W Bu
6
WIRING DIAGRAMS
S_GND Lg
3
OUTPUT P
4
GND1
SW1 C3
Y/Bl
8 Gr Gr
SW2 G Gr Gr
7 C4
2
W W
2 1
MAIN FUSE (30A)
PWR1 W 2
Bu Bu
1 1
Bl Bl
PWR2 Bl 3
2 R R
ECM
(ENGINE CONTROL MODULE)
Bl W Gr Gr
POWER
COIL W Bl/W
Bu Y Bl R Y T1 C2 Bl/W R Bl W
3
C1
T2
3 4 1 2
ST
LO
BAT
LED
EXT ( - )
EXT ( + )
OIL_ALT
EXT ( + )
EXT ( - )
CHARGE
COIL
COMBINATION
SWITCH
T3
CONTROL BOX
SPARK IGNITION OIL LEVEL BATTERY STARTER MOTOR

PLUG COIL SWITCH
COMBINATION SWITCH
EXT ( + ) EXT ( - ) BAT ST
(R) (Bl) (W) (Bl/W) Bl Black Br Brown
Y Yellow O Orange
OFF Bu Blue Lb Light blue
ON R Red P Pink
W White Gr Gray
START
Printed on
Recycled Paper
SUPPLEMENT W
To:
• GX240/270/340/390 SHOP MANUAL
• SUPPLEMENT Y
Includes:
• iGX240/iGX340
SHOP MANUAL
iGX240•iGX340
61Z5F00WE1
AHM.25.2012.04
PRINTED IN U.S.A.
©2010-2012 American Honda Motor Co., Inc.—All Rights Reserved FIRST EDITION

SERVICE INFORMATION
require the use of 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.
Improper service or repairs can create an unsafe

condition that can cause your customer or others to
be seriously hurt or killed.
ual and other service materials carefully.
For Your Safety
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Failure to properly follow instructions and precau-

tions can cause you to be seriously hurt or killed.
ual carefully.
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
0-1

INTRODUCTION OUTLINE OF CHANGES
This supplement covers the construction, function, and
servicing procedures of the Honda
SPECIFICATIONS 1
iGX240UT2·iGX340UT2 Engines. SERVICE INFORMATION 2
For service information that is not covered in this
supplement, please refer to the GX240R2/RT2/U2/
UT2, GX270R2/RT2/U2/UT2, GX340R2/RT2/T2/U2/
MAINTENANCE 3
UT2, and GX390RT2/T2/UT2 base shop manual and
supplement Y.
TROUBLESHOOTING 4
All information contained in this manual is based on the
COVER 5
latest product information available at the time of
printing. We reserve the right to make changes at
FUEL SYSTEM 6
anytime without notice. GOVERNOR SYSTEM 7
No part of this publication may be reproduced, stored in
a retrieval system, or transmitted, in any form, by any
CHARGING SYSTEM 8
means, electronic, mechanical, photocopying,
recording, or otherwise, without prior written permission IGNITION SYSTEM 9
of the publisher. This includes text, figures, and tables. STARTING SYSTEM 10
As you read this manual, you will find information that is OTHER ELECTRICAL
preceded by a symbol. The purpose of this
11
message is to help prevent damage to this Honda
product, other property, or the environment.
CYLINDER HEAD/VALVES 12
CRANKCASE 13
SAFETY MESSAGES
Your safety and the safety of others are very important. MUFFLER 14
To help you make informed decisions, we have
provided safety messages and other safety information WIRING DIAGRAMS 15
throughout this manual. Of course, it is not practical or
possible to warn you about all the hazards associated INDEX
with servicing these products. You must use your own
good judgement. The marked sections contain no changes.
They are not covered in this supplement.
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
You CAN be KILLED or SERIOUSLY
You CAN be HURT if you don’t follow
instructions.
· Instructions – how to service these products correctly

and safely.
© Honda Motor Co., Ltd.
Date of Issue: April 2012
0-2i

SYMBOLS
these symbols, it will be explained specifically in the text without the use of the symbols.
Use the recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use marine grease (water resistant urea based grease).
Apply sealant.

ii0-3
OUTLINE OFHowCHANGES
to use this manual
ITEM MODEL
iGX270UT2·iGX390UT2/T2 iGX240UT2·iGX340UT2
Charge/power iGX240UT2 QZX4, QZA2, QZAV types/
coil iGX340UT2 QZX4, QZA2, QZAV types:
POWER COIL
POWER COIL
iGX240UT2 QZX4 type/iGX340UT2 QZX4

type: 0.9 A CHARGE COIL
iGX240UT2 QZA2, QZAV types/iGX340UT2
QZA2, QZAV types: 2.9 A CHARGE COIL
iGX340UT2 QZN2 type:
0.9 A CHARGE COIL
12 A CHARGE COIL
Regulator/ iGX340UT2 QZN2 type:

rectifier
0-4
iii
How
OUTLINE
to useOFthis
CHANGES
manual
ITEM MODEL
iGX270UT2·iGX390UT2/T2 iGX240UT2·iGX340UT2
Engine wire iGX240UT2 QZX4, QZA2 types/
harness iGX340UT2 QZX4, QZA2, QZN2 types:
/ / /
/ / /
iGX240UT2 QZAV type/iGX340UT2 QZAV type:

/ / / /
Control box iGX240UT2 QZX4, QZA2, QZAV types/

iGX340UT2 QZX4, QZA2, QZAV types:
iGX340UT2 QZN2 type:
0-5
iv
dummytext gx240ut2_gx270ut2_gx340ut2_gx390ut2
1. SPECIFICATIONS
1
SERIAL NUMBER LOCATION ·····················1-2 ENGINE SPECIFICATIONS··························1-3

TYPE CODE ··················································1-2 DIMENSIONAL DRAWINGS·························1-4
DIMENSION AND WEIGHT P.T.O. DIMENSIONAL DRAWINGS ·············1-5
SPECIFICATIONS·········································1-3
1-1
SPECIFICATIONS
SERIAL NUMBER LOCATION
SPECIFICATIONS
The engine serial number (1), description code (2), and type (3) are stamped on the crankcase.
Refer to them when ordering parts or making technical inquiries.
(1)
(2)
(3)
TYPE CODE
Model iGX240UT2
Type QZX4 QZA2 QZAV
P. T. O. Q type
Model iGX340UT2
Type QZX4 QZA2 QZAV QZN2
P. T. O. Q type
1-2
SPECIFICATIONS
DIMENSION AND WEIGHT SPECIFICATIONS
Model iGX240UT2 iGX340UT2
Overall length 384 mm (15.1 in) 409 mm (16.1 in)
Overall width 462 mm (18.2 in) 484 mm (19.1 in)
Overall height 422 mm (16.6 in) 448 mm (17.6 in)
Dry weight 30.3 kg (66.8 lbs) 36.4 kg (80.2 lbs)
Operating weight 35.1 kg (77.4 lbs) 41.7 kg (91.9 lbs)
Model iGX240UT2 iGX340UT2
Description code GCBJT GCBET
Displacement 270 cm3 (16.5 cu-in) 389 cm3 (23.7 cu-in)
Bore x stroke 77.0 x 58.0 mm (3.0 x 2.3 in) 88.0 x 64.0 mm (3.5 x 2.5 in)
Net power (SAE J1349)*1 5.9 kW (7.9 HP)/3,600 min-1 (rpm) 8.0 kW (10.7 HP)/3,600 min-1 (rpm)
Continuous rated power 4.6 kW (6.1 HP)/3,600 min (rpm)
-1 6.3 kW (8.4 HP)/3,600 min-1 (rpm)
Maximum net torque 18.3 N·m (1.86 kgf·m, 13.4 lbf·ft)/ 26.4 N·m (2.6 kgf·m, 19.4 lbf·ft)/
(SAE J1349)*1 2,500 min-1 (rpm) 2,500 min-1 (rpm)
Compression ratio 8.5 : 1 8.2 : 1
Fuel consumption 2.2 Liters (0.58 US gal, 0.48 Imp gal)/h 3.1 Liters (0.82 US gal, 0.68 Imp gal)/h
Ignition timing B.T.D.C. 10°/1,400 min-1 (rpm)
Spark advancer performance B.T.D.C. 10° – 17° B.T.D.C. 10° – 22°
Spark plug BPR6ES (NGK)/W20EPR-U (DENSO)
Recommended oil SAE 10W-30, API service classification SJ or later
Starting system Recoil starter and Starter motor
Air cleaner Dual element type
Governor STR (Self Tuning Regulator) governor
Breather system Flat valve type
model and measured in accordance with SAE J1349 at 3,600 min-1 (rpm) (net power) and at 2,500 min-1 (rpm) (maximum 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, mainte-
nance, and other variables.
1-3
SPECIFICATIONS
Unit: mm (in)
iGX240UT2: 84 (3.3) iGX240UT2: 137 (5.4)
iGX340UT2: 76 (3.0) iGX340UT2: 135 (5.3)
184 (7.2) iGX240UT2: 278 (10.9)

iGX340UT2: 300 (11.8)
iGX240UT2: 462 (18.2)

iGX340UT2: 484 (19.1)
iGX240UT2: 116 (4.6) iGX240UT2: 192 (7.6)
CONTROL iGX340UT2: 142 (5.6) iGX340UT2: 201 (7.9)
BOX
iGX240UT2: 422 (16.6)
iGX340UT2: 447 (17.6)
iGX240UT2: 418 (16.5)

iGX340UT2: 448 (17.6)
CRANKSHAFT
(P. T. O.)
70 (2.8)
133.5 (5.26)
iGX240UT2: 34.5 (1.36)
103 (4.1)
iGX340UT2: 27 (1.1)
STARTER MOTOR
iGX240UT2: 92 (3.6)
iGX340UT2: 100 (3.9)
iGX240UT2: 13 (0.5)
iGX340UT2: 17 (0.7)
iGX240UT2: 384 (15.1)

iGX340UT2: 409 (16.1)
iGX340UT2: 103 (4.1)
iGX240UT2: 96 (3.8)
105 (4.1)
195.5 (7.70)
1-4
SPECIFICATIONS
Q TYPE
Unit: mm (in)
45° 45°
30° 30°
(6 .50)
165.1 5/16-24UNF-2B TAP
. (2 PLACES)
P.D 6.3 – 6.35 88.5 (3.48)
(0.2480 – 0.2500)
56 (2.2)
70 (2.8)
(ĭ 0.9990 – 1.0000)
28 (1.1)
ĭ 25.375 – 25.400
(0.8539 – 0.8591)
21.69 – 21.82
72.2 (2.84)
5/16-24UNF-2B TAP
(4 PLACES)
iGX240: 7/16-20UNF 2B TAP

.33 .05
iGX340: 3/8-24UNF 2B TAP

3)
– 4 10
31 – 1
3/8-16UNC-2B TAP
(4 PLACES)
4.3 .00
)
(5.00
(ĭ 110
103 (4.1)
ĭ
127
P.D.
1-5
MAINTENANCE STANDARDS·····················2-2 LUBRICATION & SEAL POINTS ·················2-4

TORQUE VALUES ········································2-4 HARNESS AND TUBE ROUTING ················2-5
2-1
SERVICE INFORMATION
SERVICE INFORMATION
iGX240UT2
Unit: mm (in)
Engine Maximum speed (at no load) 3,600 ± 150 min-1 (rpm)* –
Cylinder compression 1.31 MPa (13.4 kgf/cm2, 190 psi)/ –
1,400 min-1 (rpm)
Cylinder Sleeve I.D. 77.000 – 77.017 (3.0315 – 3.0322) 77.17 (3.038)
Piston Skirt O.D. 76.975 – 76.985 (3.0305 – 3.0309) 76.85 (3.026)
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 (0.7872 – 0.7874) 17.95 (0.707)
Second 0.030 – 0.060 (0.0012 – 0.0024) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.500 (0.0138 – 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)
Ring width Top 1.160 – 1.175 (0.0457 – 0.0463) 1.140 (0.0449)
Second 1.160 – 1.175 (0.0457 – 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 I.D. 33.025 – 33.039 (1.3002 – 1.3007) 33.07 (1.302)
Crankshaft Crankpin O.D. 32.975 – 32.985 (1.2982 – 1.2986) 32.92 (1.296)
Cylinder barrel Camshaft bearing I.D. 16.000 – 16.018 (0.6299 – 0.6306) 16.05 (0.632)
(Crankcase)
Crankcase cover Camshaft bearing I.D. 16.000 – 16.018 (0.6299 – 0.6306) 16.05 (0.632)
Valves Valve clearance IN 0.15 ± 0.02 (0.006 ± 0.001) –
EX 0.20 ± 0.02 (0.008 ± 0.001) –
Valve stem O.D. IN 6.575 – 6.590 (0.2588 – 0.2594) 6.44 (0.254)
EX 6.535 – 6.550 (0.2572 – 0.2578) 6.40 (0.252)
ance EX 0.050 – 0.080 (0.0020 – 0.0032) 0.12 (0.005)
Valve seat width 1.0 – 1.2 (0.04 – 0.05) 2.0 (0.08)
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 BE93B A: #82 –
Pilot screw opening BE93B A: 1 turn out –
Spark plug Gap 0.7 – 0.8 (0.028 – 0.031) –
Starter motor Brush length 10 (0.4) 6 (0.2)
Mica depth – 0.2 (0.01)
Charge coil Resistance QZX4 type 5.1 – 7.7 ȍ –
(0.9 A)
QZA2, QZAV 0.4 – 0.8 ȍ –
types (2.9 A)
Power coil Resistance 2.9 – 4.5 ȍ –
2-2
SERVICE INFORMATION
iGX340UT2
Unit: mm (in)
Engine Maximum speed (at no load) 3,600 ± 150 min-1 (rpm)* –
Cylinder compression 1.29 MPa (13.2 kgf/cm2, 187 psi)/ –
1,400 min-1 (rpm)
Cylinder Sleeve I.D. 88.000 – 88.017 (3.4646 – 3.4652) 88.17 (3.471)
Piston Skirt O.D. 87.975 – 87.985 (3.4635 – 3.4640) 87.85 (3.459)
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)
Second 0.030 – 0.060 (0.0012 – 0.0024) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.500 (0.0138 – 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)
Ring width Top 1.160 – 1.175 (0.0457 – 0.0463) 1.140 (0.0449)
Second 1.160 – 1.175 (0.0457 – 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 I.D. 36.025 – 36.039 (1.4183 – 1.4189) 36.07 (1.420)
Crankshaft Crankpin O.D. 35.975 – 35.985 (1.4163 – 1.4167) 35.93 (1.415)
Cylinder barrel Camshaft bearing I.D. 16.000 – 16.018 (0.6299 – 0.6306) 16.05 (0.632)
(Crankcase)
Crankcase cover Camshaft bearing I.D. 16.000 – 16.018 (0.6299 – 0.6306) 16.05 (0.632)
Valves Valve clearance IN 0.15 ± 0.02 (0.006 ± 0.001) –
EX 0.20 ± 0.02 (0.008 ± 0.001) –
Valve stem O.D. IN 6.575 – 6.590 (0.2588 – 0.2594) 6.44 (0.254)
EX 6.535 – 6.550 (0.2572 – 0.2578) 6.40 (0.252)
ance EX 0.050 – 0.080 (0.0020 – 0.0032) 0.12 (0.005)
Valve seat width 1.0 – 1.2 (0.04 – 0.05) 2.0 (0.08)
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 BE91A A: #95 –
Pilot screw opening BE91A A: 1 turn out –
Spark plug Gap 0.7 – 0.8 (0.028 – 0.031) –
Starter motor Brush length 10 (0.4) 6 (0.2)
Mica depth – 0.2 (0.01)
Charge coil Resistance QZX4 type 5.1 – 7.7 ȍ –
(0.9 A)
QZA2, QZAV 0.4 – 0.8 ȍ –
type (2.9 A)
QZN2 type 0.22 – 0.34 ȍ –
(12 A)
Power coil Resistance QZX4, QZA2, 2.9 – 4.5 ȍ –
QZAV types
QZN2 type 2.8 – 4.4 ȍ –
2-3
SERVICE INFORMATION
TORQUE VALUES
Item Tread Dia. (mm) Torque values
N·m kgf·m lbf·ft
Crankcase cover bolt M8 x 1.25 24 2.4 17
Cylinder head bolt M10 x 1.25 35 3.5 26
Oil drain bolt M12 x 1.5 22.5 2.25 17
Connecting rod bolt M8 x 1.25 (Special bolt) 14 1.4 10
Rocker arm pivot bolt M8 x 1.25 (Special bolt) 24 2.4 17
Rocker arm pivot adjusting nut M6 x 0.5 10 1.0 7
Spark plug M14 x 1.25 18 1.8 13
Flywheel nut (iGX240UT2) M16 x 1.5 (Special nut) 128 13.1 94
Flywheel nut (iGX340UT2) M16 x 1.5 (Special nut) 170 17.3 125
Fuel tank nut/bolt M8 x 1.25 24 2.4 17
Fuel tank joint M10 x 1.25 2 0.2 1.5
Air cleaner elbow nut M6 x 1.0 9 0.9 6.6
Muffler nut M8 x 1.25 24 2.4 17
Exhaust pipe nut M8 x 1.25 24 2.4 17
Starter motor stud bolt M10 x 1.25 40 4.1 30
Fan cover stud bolt M8 x 1.25 23 2.3 17
Combination switch nut M18 x 1.0 4.9 0.50 3.6
Fuel strainer cup M24 x 1.0 3.9 0.40 2.9
ECM screw/washer M4 x 0.7 2.1 0.21 1.5
Motor case set screw A/B M4 x 0.7 2.1 0.21 1.5
Starter motor nut M8 x 1.25 8.8 0.90 6.5
Jet set screw M5 x 0.8 0.3 0.03 0.22
LUBRICATION & SEAL POINTS

Crankshaft crankpin and gear Engine oil
Piston outer surface
Piston pin outer surface
Piston rings
Cylinder inner surface
Connecting rod big and small end bearings
Connecting rod bolt threads and seating surface
Camshaft cam profiles and bearings
Valve lifter stem and slipper
Valve stem sliding surface and stem end
Rocker arm tappet surfaces and pivot
Rocker arm pivot threads and pivot
Flywheel nut threads and seating surface
Cylinder head bolt threads and seating surface
Balancer shaft bearings and gear
Each oil seal lip Multi-purpose grease
Each O-ring
Recoil starter case cutout
Recoil starter ratchet sliding surface
Recoil starter spring retainer inside
Camshaft cam profile Use molybdenum solution (mixture When installing a new cam-
of the engine oil and molybdenum shaft
grease with the ratio 100 g grease:
70 cc oil)
Recoil starter center screw threads Threebond® 2430 or equivalent
Crankcase cover mating surface Liquid sealant
(Hondabond HT, Hondabond 4, or
equivalent)
2-4
SERVICE INFORMATION
HARNESS AND TUBE ROUTING
QZX4, QZA2, QZAV types:
CORD GROMMET
POWER COIL CORD
CORD CLAMP
POWER COIL
CORD CLAMP
CORD GROMMET
QZX4 type: 0.9 A CHARGE COIL CHARGE COIL CORD

QZA2, QZAV types: 2.9 A CHARGE COIL
2-5
SERVICE INFORMATION
QZN2 type:
CORD GROMMET
POWER COIL CORD
CORD CLAMP
CORD CLAMP
CORD GROMMET
12 A CHARGE COIL CHARGE COIL CORD
2-6
SERVICE INFORMATION
QXX4, QZA2, QZN2 types:
COMBINATION
Y/Bl Lg (ENGINE CONTROL MODULE)
G P
Y/Bl
Lg
G

STARTER MOTOR
Bu
Bl
R
3P
COUPLER
TO OIL LEVEL SWITCH
TO CONTROL BOX /
Gr
Gr TO CHARGE COIL
GROUND TERMINAL
STARTER
MOTOR
2-7
SERVICE INFORMATION
QZAV type:
COMBINATION
Lg (ENGINE CONTROL MODULE)
W/Bl
Y/Bl
W/Bl
Y/Bl
Lb
Lb
Lg
P
P

STARTER MOTOR
Bu
Bl
R
3P
COUPLER
TO OIL LEVEL SWITCH
TO CONTROL BOX /
Gr
Gr TO CHARGE COIL
GROUND TERMINAL
STARTER
MOTOR
2-8
4. TROUBLESHOOTING
BEFORE TROUBLESHOOTING···················4-2 TROUBLESHOOTING ··································4-2
4-1
TROUBLESHOOTING
TROUBLESHOOTING

TROUBLESHOOTING
(*) Refer to page of base shop manual (GX240·GX270·GX340·GX390)
(**) Refer to page of base shop manual (iGX270UT2·iGX390T2/UT2 Supplement Y)
ENGINE SPEED DOES NOT INCREASE OR STABILIZE (QZAV type)
ON
Check whether the oil level indicator is ON. Add the recommended engine oil (page 3-3*).
OFF
Check the external connected control and wire harness Abnormal

for failure or open circuit. Replace the external control and/or wire harness.
Normal
Check the engine wire harness connecting the ECM No continuity
and each control for continuity. Replace the engine wire harness (page 11-7**).
P Lg Lb W/Bl Y/Bl
ENGINE WIRE HARNESS

Continuity
Check whether the engine retains 1,400 min-1 (rpm) Constant
constantly when the external connected control is Replace the ECM (page 6-4**).
operated.
Not constant
Remove the air cleaner elbow (page 6-5*) and check Abnormal
whether the choke valve is closed when turning on Check the control gear box (page 6-5**).
the starter motor or pulling the recoil starter.
4-2
8. CHARGING SYSTEM
CHARGING SYSTEM DIAGRAM··················8-2 CHARGE/POWER COIL REMOVAL/

INSTALLATION ············································8-4
BEFORE TROUBLESHOOTING···················8-2 8
CHARGE/POWER COIL INSPECTION ········8-6
CHARGING SYSTEM
TROUBLESHOOTING···································8-3
8-1
CHARGING SYSTEM
CHARGING SYSTEM DIAGRAM
CHARGING SYSTEM
QZX4, QXA2, QZAV types:

RECTIFIER
(W)
Gr
Gr
G
( Gr ) ( Gr )
( Gr ) ( Gr )
W
W (W)
Bl
MAIN FUSE 30A
ECM
(W)
( Bl )
Gr
Gr
( Bl/W )
(W)
POWER
Bl/W
W
COIL
CHARGE
COIL COMBINATION
Black Brown SWITCH
Yellow Orange
Blue Light blue CONTROL BOX
Green Light green
Red Pink
White Gray BATTERY STARTER MOTOR
QZN2 type:
REGULATOR/
RECTIFIER
COM_12V
1
COM_TX
W/Bu
Bl/Y
5
Gr
Gr
W
Bl
COM_RX
6
S_GND 5 1 6 4 3 2
3 2
OUTPUT
4
SW1
W/Bu
8
Gr
Gr
W
W
Bl
SW2
7 GND2
2
C19
(W) (W)
2 C20
C3
PWR1 W ( Gr ) ( Gr ) W (W)
1 ( Gr ) ( Gr ) MAIN FUSE 30A
PWR2 Bl C4
2
( Bl/W )
(W)
ECM
( Bl )
(W)
Gr
Gr
Bl/W
T1 C2
W
POWER T2
COIL
ST
BAT
EXT ( + )
EXT ( - )
LO
Bl Black Br Brown COMBINATION

Y Yellow O Orange SWITCH
CHARGE Bu Blue Lb Light blue T3
COIL G Green Lg Light green CONTROL BOX
R Red P Pink
W White Gr Gray BATTERY STARTER MOTER
8-2
CHARGING SYSTEM
CHARGING SYSTEM TROUBLESHOOTING

(*) Refer to page of base shop manual (GX240·GX270·GX340·GX390)
(**) Refer to page of base shop manual (iGX270UT2·iGX390T2/UT2 Supplement Y)
Abnormal
Check the main fuse 30 A (page 11-7*). Replace the main fuse 30 A (page 11-2).
Normal
Abnormal
Check the charge coil (page 8-6). Replace the charge coil (page 8-4).
Normal
QZX4, QZA2, QZAV types: Check the rectifier (page Abnormal

Replace the rectifier (page 11-2).
11-6**).
Normal
QZN2 type: Check the regulator/rectifier (page 11-4). Abnormal

Replace the regulator/rectifier (page 11-3).
Normal
Check the wire harness connecting to the charge coil
and battery for open or short circuit and for proper
connection.
If necessary, replace or repair the wire harness.
8-3
CHARGING SYSTEM
CHARGE/POWER COIL REMOVAL/INSTALLATION
(*) Refer to page of base shop manual (iGX270UT2·iGX390T2/UT2 Supplement Y)
(**) Refer to page of base shop manual (GX240·GX270·GX340·GX390)
– Fan cover (page 5-2*)
– Ignition coil (page 9-3*)
– Starter motor (page 10-8*)
– Flywheel (page 8-7**)
When installing the cord clamp, refer to HARNESS AND TUBE ROUTING (page 2-5).
CORD GROMMET
CORD CLAMP
BOLT (6 x 12 mm)
iGX240UT2:
BOLT (6 x 28 mm) (2)
iGX340UT2:
BOLT (6 x 40 mm) (2)
POWER COIL
iGX240UT2 QZX4 type:

BOLT (6 x 25 mm) (2)
iGX240UT2 QZA2, QZAV types:
BOLT (6 x 32 mm) (2)
iGX340UT2 QZX4 type: BOLT (6 x 12 mm)
BOLT (6 x 35 mm) (2)
iGX340UT2 QZA2, QZAV types:
BOLT (6 x 40 mm) (2) CORD CLAMP
QZX4 type:
0.9 A CHARGE COIL CORD GROMMET
QZA2, QZAV types:
2.9 A CHARGE COIL
8-4
CHARGING SYSTEM
QZN2 type:
CORD GROMMET
CORD CLAMP
BOLT (6 x 12 mm)
BOLT (6 x 40 mm) (4)
BOLT (6 x 12 mm)
12 A CHARGE COIL
CORD CLAMP
CORD GROMMET
8-5
CHARGING SYSTEM
CHARGE/POWER COIL INSPECTION
CHARGE COIL
(*) Refer to page of base shop manual (iGX270UT2·
iGX390T2/UT2 Supplement Y).
Remove the control box (page 11-3*).
charge coil.
Resistance:
QZX4 type (0.9 A): 5.1 – 7.7 ȍ
QZA2, QZAV types (2.9 A): 0.4 – 0.8 ȍ
QZN2 type (12 A): 0.22 – 0.34 ȍ
ground.
• If the resistance is good and the flywheel is OK,
replace the rectifier (QZX4, QZA2, QZAV types) or
regulator/rectifier (QZN2 type), and recheck.
POWER COIL
(*) Refer to page of base shop manual
(GX240·GX270·GX340·GX390).
Remove the air cleaner element (page 6-5*).
Disconnect the power coil connector [1].
[1]
Check for continuity between the terminals of the power
coil connector. (Engine wire harness side)
Resistance:
QZX4, QZA2, QZAV types: 2.9 – 4.5 ȍ
QZN2 type: 2.8 – 4.4 ȍ
ground.
ground, replace the power coil (page 8-4).
replace the ECM and recheck.
8-6
CONTROL BOX DISASSEMBLY/ OIL LEVEL SWITCH REMOVAL/

ASSEMBLY ·················································11-2 INSTALLATION ··········································11-4
REGULATOR/RECTIFIER INSPECTION ···11-4
11
11-1
OTHER ELECTRICAL
OTHER ELECTRICAL
(*) Refer to page of base shop manual (iGX270UT2·iGX390T2/UT2 Supplement Y)

(**) Refer to page of base shop manual (GX240·GX270·GX340·GX390)
Remove the control box (page 11-3*).
When assembling the control box, refer to HARNESS AND TUBE ROUTING (page 2-5).
CONTROL COVER
RECTIFIER
INSPECTION:
SCREW (6 x 8 mm) (page 11-6*)
SCREW/WASHER
(4 x 20 mm)
SWITCH BOX BRACKET
INDICATOR
INSPECTION:
(page 11-6*) GROUND TERMINAL
SCREW/
WASHER
(4 x 10 mm) SCREW/WASHER
(4 x 8 mm)
FUSE BOX COVER
MAIN FUSE 30 A
INSPECTION:
(page 11-7**)
GROMMETS
4.9 N·m (0.50 kgf·m, 3.6 lbf·ft)
COMBINATION SWITCH
CONTROL PANEL
11-2
OTHER ELECTRICAL
QZN2 type:
SUB-WIRE HARNESS
REGULATOR/RECTIFIER
INSPECTION: (page 11-4)
CONTROL COVER
SCREW (6 x 8 mm)
SWITCH BOX BRACKET
SCREW/WASHER INDICATOR
(4 x 10 mm) INSPECTION:
(page 11-6*)

4.9 N·m (0.50 kgf·m, 3.6 lbf·ft)
FUSE BOX COVER
MAIN FUSE 30 A
INSPECTION:
(page 11-7**)
GROMMETS
COMBINATION SWITCH
CONTROL PANEL
11-3
OTHER ELECTRICAL
OIL LEVEL SWITCH REMOVAL/
INSTALLATION
(*) Refer to page of base shop manual (1)
(GX240·GX270·GX340·GX390).
Drain the engine oil (page 3-3*).
Disconnect the oil level switch connector (1).
Remove the two 6 x 16 mm flange bolts (2), oil level (4)
switch (3), and O-ring (4).
Replace the O-ring Installation is in the reverse order of removal.
with a new one.
• Install the oil level switch to the crankcase securely (3)

as shown.
• Wrong assembly can cause engine trouble.
(2)
iGX340: iGX240: CUTOUT
CUTOUT
REGULATOR/RECTIFIER INSPECTION
shown in the table.
Use a tester that has an internal resistance equal to or 1 2 3
greater than 20 kȍ/VDC, 9 kȍ/VAC.
resistance value cannot be obtained.
carefully before operating the tester. Follow the 4 6
battery is fully charged, and check that the meter 5
display is working before using the tester.
Unit: kȍ
Tester (+) probe
1 2 3 4 5 6
1 —
2 — 1 – 600 2 – 230 2 – 600 2 - 230
Tester (–) 3 — 0.09 – 40 2 – 400 0.09 - 40
probe 4 2 – 230 — 10 – 1,000 4 - 400
5 —
6 2 – 230 4 – 400 10 – 1,000 —
11-4
15. WIRING DIAGRAMS
WIRING DIAGRAMS ···································15-2
15
15-1
WIRING DIAGRAMS
WIRING DIAGRAMS
WIRING DIAGRAMS

INTERFACE
RECTIFIER
C10 C11 C12 C13
INDICATOR
C6 C7
C5 C8
1
( Y/Bl )
( Lg )
(G)
(P)
COM_12V C9
1
COM_TX
5
(W)
Bu
Gr
Gr
COM_RX
G
6
S_GND Lg
3
OUTPUT P
4
C3 GND1
SW1 Y/Bl
8 ( Gr ) ( Gr )
SW2 G ( Gr ) ( Gr )
7 C4
2
W (W)
2 1
MAIN FUSE 30A
PWR1 W ( Bu ) 2 ( Bu )
1 1
PWR2 Bl ( Bl ) ( Bl )
3
2 (R) (R)
ECM
(W)
( Bl )
Gr
Gr
( Bl/W )
(W)
POWER
(Y)
Bl/W
Bu
Bl
T1 C2
R
Y
W
Bl
R
COIL
3
C1
T2
3 4 1 2
ST
BAT
EXT ( + )
EXT ( - )
LO
OIL_ALT
LED
EXT ( + )
EXT ( - )
CHARGE
COIL COMBINATION
SWITCH
T3
CONTROL BOX
SPARK IGNITION OIL LEVEL BATTERY STARTER MOTER

PLUG COIL SWITCH
QZAV type: INTERFACE

C14 C15 C16 C17 C18
4 COMBINATION
SWITCH
( W/Bl )
( Y/Bl )
( Lg )
( Lb )
(P)
COM_12V Bl Black Br Brown

1 EXT ( + ) EXT ( - ) BAT ST
Y Yellow O Orange
COM_TX OFF Bu Blue Lb Light blue
5 G Green Lg Light green
COM_RX ON R Red P Pink
6 W White Gr Gray
START TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
S_GND Lg
3
OUTPUT P
4
SW1 Y/Bl
8
DC5V W/Bl
7
SET_NE Lb
2
2
PWR1 W TO
1
PWR2 Bl POWER COIL
2
ECM
15-2
WIRING DIAGRAMS
QZN2 type:
REGULATOR/
RECTIFIER
INTERFACE
C10 C11 C12 C13
INDICATOR
W/Bu
Bl/Y
Gr
Gr
W
Bl
1
5 1 6 4 3 2
( Y/Bl )
2
( Lg )
(G)
(P)
COM_12V
1 C9
COM_TX
5
W/Bu
Bu
COM_RX
Gr
Gr
W
W
Bl
6
GND2
S_GND Lg
3
OUTPUT P
4 C19
SW1 Y/Bl C3 (W) (W)
8 ( Gr ) ( Gr ) C20
SW2 G ( Gr ) ( Gr )
7 C4
2
W (W)
2 1
MAIN FUSE 30A
PWR1 W ( Bu ) 2 ( Bu )
1 1
PWR2 Bl ( Bl ) ( Bl )
3
2 (R) (R)
ECM
(W)
( Bl )
Gr
Gr
( Bl/W )
(W)
POWER
(Y)
Bl/W
Bu
Bl
T1 C2
R
Y
W
Bl
R
COIL
3
C1
T2
3 4 1 2
ST
BAT
EXT ( + )
EXT ( - )
LO
OIL_ALT
LED
EXT ( + )
EXT ( - )
CHARGE
COIL COMBINATION
SWITCH
T3
CONTROL BOX
SPARK IGNITION OIL LEVEL BATTERY STARTER MOTER

PLUG COIL SWITCH
COMBINATION
SWITCH
EXT ( + ) EXT ( - ) BAT ST Bl Black Br Brown
Y Yellow O Orange
OFF Bu Blue Lb Light blue
ON R Red P Pink
W White Gr Gray
START TWO COLORED WIRE (EXAMPLE:YELLOW/RED)
15-3
INDEX
B
INTRODUCTION ·································································i
CHARGING SYSTEM ················································8-2 LUBRICATION & SEAL POINT······································ 2-4
L
TROUBLESHOOTING ···············································4-2 MAINTENANCE STANDARDS ······································ 2-2

M
CHARGE / POWER COIL REMOVAL/ OIL LEVEL SWITCH REMOVAL/INSTALLATION ······· 11-4
O
INSTALLATION·······························································8-4 OUTLINE OF CHANGES ·················································· iii

P
CHARGE/POWER COIL INSPECTION··························8-6 P.T.O. DIMENSIONAL DRAWINGS······························· 1-5

R
CHARGING SYSTEM DIAGRAM ···································8-2 REGULATOR/RECTIFIER INSPECTION ···················· 11-4

R
CHARGING SYSTEM TROUBLESHOOTING················8-3 SERIAL NUMBER LOCATION······································· 1-2

S
CONTROL BOX DISASSEMBLY/ASSEMBLY ·············11-2 SYMBOLS ··········································································ii

DIMENSIONAL DRAWINGS···········································1-4
D
TORQUE VALUES ························································· 2-4
DIMENSIONS AND WEIGHTS SPECIFICATIONS ········1-3 TROUBLESHOOTING···················································· 4-2
ENGINE SPECIFICATIONS ···········································1-3
E
TYPE CODE··································································· 1-2
HARNESS AND TUBE ROUTING ··································2-5
H
WIRING DIAGRAMS ···················································· 15-2
16
16-1

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gx240ut2_gx270ut2_gx340ut2_gx390ut2

How to use this manual

Improper service or repairs can create an un-

For Your Safety

Failure to properly follow instructions and pre-

Important Safety Precautions

How to use this manual

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.

© American Honda Motor Co., Inc.

How to use this manual

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

Use the recommended engine oil, unless otherwise specified.

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

Use marine grease (water resistant urea based grease).

Use automatic transmission fluid.

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

How to use this manual

BI Black G Green Br Brown Lg Light

SERIAL NUMBER LOCATION . . . . . . . . . . 1-2 PERFORMANCE CURVES

TYPE CODE GX240. . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

GX240 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 GX270. . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

GX270 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 GX340. . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

GX340 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 GX390. . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

GX390 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 DIMENSIONAL DRAWINGS

DIMENSIONS AND WEIGHTS GX240. . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

GX240 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 GX270. . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

GX270 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 GX340. . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

GX340 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 GX390. . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

GX390 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 P.T.O. DIMENSIONAL DRAWINGS

ENGINE SPECIFICATIONS GX240. . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

GX240 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 GX240•GX270 . . . . . . . . . . . . . . . . . . . 1-26

GX270 . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 GX340•GX390 . . . . . . . . . . . . . . . . . . . 1-30

Model GX240UT2 GX240UT2 GX240UT2 GX240UT2 GX240UT2

Model GX240UT2 GX240UT2 GX240UT2 GX240UT2 GX240UT2

Model GX340U2 GX340UT2 GX340UT2 GX340UT2 GX340UT2

Model GX340UT2 GX340UT2 GX340UT2 GX340UT2 GX340UT2

Model GX340UT2 GX340UT2 GX340UT2 GX340UT2

Model P.T.O.* GX240R2 GX240RT2 GX240U2 GX240UT2

Model P.T.O.* GX340R2 GX340RT2 GX340U2 GX340UT2

Model GX340R2 GX340RT2 GX340U2 GX340UT2

(N·m) (lbf·ft) (kgf·m)

RECOMMENDED OPERATING SPEED RANGE

2000 3000 3600

ENGINE SPEED (rpm)

(N·m) (lbf·ft) (kgf·m)

RECOMMENDED OPERATING SPEED RANGE

2000 3000 3600

ENGINE SPEED (rpm)

24 NET TORQUE 18 2.5

RECOMMENDED OPERATING SPEED RANGE 6

150 (5.9) 278 (10.9)

116 (4.6) 192 (7.6)

STARTER MOTOR 195.5 (7.70) 92 (3.6)

GX240UT2 * V:400 (15.7)

STARTER REDUCTION UNIT * L/H:140.3 (5.52)

150 (5.9) 278 (10.9)

CONTROL BOX With control box type: 462 (18.2)