Honda Gx350 Service Manual
If you have any questions about your engine, consult an authorized Honda servicing dealer. This manual should be considered a permanent part of the engine.
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. GX240 GX270 GX340 GX390 Serial number and engine type OWNER’S MANUAL 32ZH9611 00X32-ZH9-6111 HONDA EUROPE N.V.(EEC) 1 www.honda-engines-eu. Thank you for purchasing a Honda engine. This manual covers the operation and maintenance of your engine: GX240 GX270 GX340 GX390 All information in this publication is based on the latest product information available at the time of printing. Honda Motor Co., Ltd. Reserves the right to make changes at any time without notice and without incurring any obligation.
No part of this publication may be reproduced without written permission. SAFETY INSTRUCTIONS To ensure safe operation− Honda engine is designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the engine. Failure to do so could result in personal injury or equipment damage. Always make a pre-operation inspection (page 6 ) before you start the engine.
You may prevent an accident or equipment damage. Safety Instruction To ensure safe operation− Do not place anything on the engine, as it may create a fire hazard.
A spark arrester is available as an optional part for this engine. It is illegal in some areas to operate an engine without a spark arrester. Check local laws and regulations before operating. 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.
BATTERY CONNECTIONS (for electric starter) Use a 12 volt battery with an ampere-hour rating of at least 18 AH. Connect the battery positive (＋) cable to the starter solenoid terminal, as shown. Connect the battery negative (−) cable to an engine mounting bolt, frame bolt, or other good engine ground connection. Check the battery cable connections to be sure the cables are tightened and free of corrosion. Remove any corrosion, and coat the terminals and cable ends with grease. PRE-OPERATION CHECK 1. Engine oil level Running the engine with insufficient oil can cause serious engine damage.
Be sure to check the engine on a level surface with the engine stopped. Remove the oil filler cap and wipe the dipstick clean. Insert the dipstick into the oil filler neck, but do not screw it in. If the level is low, fill to the top of the oil filler neck with the recommended oil. Reduction gear oil (where equipped) Check reduction gear oil level. Fill with SG, SF rated engine oil, if necessary.
〈1/2 reduction with automatic centrifugal clutch〉 1. Remove the oil filler cap and wipe the dipstick clean. Insert the dipstick into the filler neck but do not screw it in.
If the level is low, fill to the upper level mark with the same oil recommended for the engine (see engine oil recommendations on page 6 ). Oil capacity: 0.30 (0.32 US qt, 0. Air cleaner Never run the engine without the air cleaner. Rapid engine wear will result.
〈Dual element type〉 1. Check the air cleaner elements to be sure they are clean and in good condition. Clean or replace the elements if necessary (page 21 ). ELEMENTS (Silent type only) 〈Cyclone type〉 1. Check cleaner for dirt or obstruction of elements. Check the cyclone housing for any dirt build-up, clean it, if necessary (page 22 ). 〈Semi-dry type〉 Check cleaner for dirt or obstruction of element (page 23 ).
ELEMENT 〈Oil bath type〉 1. Check the air cleaner element to be sure it is clean and in good condition. Clean or replace the element if necessary (page 23 ). Check oil level and condition. Never run the engine without the air cleaner. Rapid engine wear will result.
Fuel Use automotive gasoline (Unleaded or lowleaded is preferred to minimize combustion chamber deposits). FOR NEW SOUTH WALES ONLY: Use unleaded fuel only.
Never use an oil/gasoline mixture or dirty gasoline. Avoid getting dirt, dust or water in the fuel tank. Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored. GASOLINES CONTAINING ALCOHOL If you decide to use a gasoline containing alcohol (gasohol), be sure it’s octane rating is at least as high as that recommended by Honda. There are two types of ‘‘gasohol’’: one containing ethanol, and the other containing methanol.
Do not use gasohol that contains more than 10% ethanol. Do not use gasoline containing methanol (methyl or wood alcohol) that does not also contain cosolvents and corrosion inhibitors for methanol. STARTING THE ENGINE 1. Turn the fuel valve to the ON position. FUEL VALVE ON ON 2. Move the choke lever to the CLOSED position. Do not use the choke if the engine is warm or the air temperature is high.
Move the throttle control lever slightly to the left. HIGH LOW THROTTLE CONTROL LEVER 4. Start the engine. With recoil starter: Turn the engine switch to the ON position. Pull the starter grip lightly until resistance is felt, then pull briskly.
Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter. STARTER GRIP With electric starter (where equipped): Turn the engine switch to the START position and hold it there until the engine starts.
Do not use the electric starter for more than 5 seconds at a time. If the engine fails to start, release the key and wait 10 seconds before operating the starter again. High altitude operation At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase.
High altitude performance can be improved by specific modifications to the carburetor. If you always operate the engine at altitudes higher than 1,830 m (6,000 feet) above sea level, have your authorized Honda dealer perform these carburetor modifications.
OPERATION 1. As the engine warms up, gradually move the choke lever to the OPEN position. CHOKE LEVER OPEN OPEN 2. Position the throttle control lever for the desired engine speed.
Oil alert system (where equipped) The Oil Alert System is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert System will automatically stop the engine (the engine switch will remain in the ON position).
If the engine stops and will not restart, check the engine oil level (page 6 ) before troubleshooting in other areas. STOPPING THE ENGINE To stop the engine in an emergency, turn the engine switch to the OFF position.
Under normal conditions, use the following procedure: 1. Move the throttle control lever fully to the right.
THROTTLE LEVER LOW 2. Turn the engine switch to the OFF position.
ENGINE SWITCH OFF OFF OFF 3. Turn the fuel valve to the OFF position.
MAINTENANCE Shut off the engine before performing any maintenance. To prevent accidental start-up, turn OFF the engine switch and disconnect the spark plug cap.
The engine should be serviced by an authorized Honda dealer unless the owner has proper tools and service data and feels he is mechanically qualified. Use only genuine Honda parts or their equivalent. The use of replacement parts which are not of equivalent quality may damage the engine.
Oil change Drain the oil while the engine is still warm to assure rapid and complete draining. Remove the oil filler cap and drain plug to drain the oil. Install the drain plug, and tighten it securely. Refill with the recommended oil (see page 6 ) and check the oil level. Install the oil filler cap. ENGINE OIL CAPACITY: 1.10 (1.16 US qt, 0.97 Imp qt) 1/2 REDUCTION GEAR OIL CAPACITY: 0.30 (0.32 US qt, 0. Air cleaner service A dirty air cleaner will restrict air flow to the carburetor.
To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the engine in extremely dusty areas. Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result.
Never run the engine without the air cleaner. Rapid engine wear will result. 〈Dual element type〉 1. 〈Cyclone type〉 1.
Remove the wing nut and the air cleaner cover. Remove the elements and separate them. Carefully check both elements for holes or tears and replace if damaged. Foam element: Clean in warm soapy water, rince and allow to dry thoroughly. Or clean in high flash-point solvent and allow to dry. Dip the element in clean engine oil and squeeze out all the excess.
The engine will smoke during initial start-up if too much oil is felt in the foam. 〈Semi-dry type〉 1. Unscrew the wing nut, remove the air cleaner cover and remove the element. Wash the element in a nonflammable or high flash point solvent and dry it thoroughly. Soak the element in clean engine oil and squeeze out the excess oil. Reinstall the air cleaner element and the cover. AIR CLEANER COVER ELEMENT 〈Oil bath type〉 1.
Unscrew the wing nut, remove the air cleaner cover and remove the element. Sediment cup cleaning Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area.
After installing the sediment cup, check for leaks, and make sure the area is dry before starting the engine. Turn the fuel valve to OFF.
Remove the sediment cup and O-ring, and wash them in nonflammable or high flash point solvent. Dry them thoroughly and reinstall securely. Turn the fuel valve ON and check for leaks. O-RING SEDIMENT CUP 4. Visually inspect the spark plug. Discard the spark plug if there is apparent wear, or if the insulator is cracked or chipped. Clean the spark plug with a wire brush if it is to be reused.
Measure the plug gap with a feeler gauge. Correct as necessary by bending the side electrode. The gap should be: 0.70−0.80 mm (0.028−0.031 in) 0.70−0.80 mm (0.028−0.031 in) 4. Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross-threading.
Spark arrester maintenance (optional part) If the engine has been running, the muffler will be very hot. Allow it to cool before proceeding. The spark arrester must be serviced every 100 hours to maintain its efficiency. Remove the two 8 mm nuts and remove the muffler from the cylinder. Remove the three 4 mm screws from the exhaust deflector, and remove the deflector. Remove the four 5 mm screws from the muffler protector, and remove the muffler protector. Carburetor idle speed adjustment 1.
Start the engine and allow it to warm up to normal operating temperature. With the engine idling, turn the throttle stop screw to obtain the standard idle speed. Standard idle speed: 1,400±150rpm. THROTTLE AND CHOKE CONTROL CABLE (optional part) The throttle and choke control levers are provided with holes for optional cable attachment.
The following illustrations show installation examples for a solid wire cable and for a braided wire cable. If using a braided wire cable, add a return spring as shown.
It is necessary to loosen the throttle lever friction nut when operating the throttle with a remote cable. TRANSPORTING/STORAGE When transporting the engine, turn the fuel valve OFF and keep the engine level to prevent fuel spillage.
Fuel vapor or spilled fuel may ignite. Before storing the unit for an extended period; 1. Be sure the storage area is free of excessive humidity and dust. Drain the fuel. Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area. With the fuel valve in the OFF position, remove and empty the sediment cup.
TROUBLESHOOTING Engine will not start using recoil starter: 1. Is the engine switch in the ON position? Is there enough oil in the engine? Is the fuel valve ON?
Is there fuel in the fuel tank? Is gasoline reaching the carburetor? To check, loosen the drain screw with the fuel valve ON. If any fuel is spilled, make sure the area is dry before testing the spark plug or starting the engine. Fuel vapor or spilled fuel may ignite.
Honda Gx240 Shop Manual
DRAIN SCREW 6. Is there a spark at the spark plug?. SPECIFICATIONS Dimensions Power equipment description code Length Width Height Dry weight Engine Engine type Displacement Bore×Stroke Max. Torque Fuel consumption Cooling system Ignition system PTO shaft rotation GX240 GC04 GX270 GCAB 360 mm (14.2 in) 420 mm (16.5 in) 410 mm (16.1 in) 23.5 kg (51.8 lbs) 4-stroke, over head valve, 1 cylinder 270 cm (16.5 cu-in) 242 cm (14.8 cu-in) 73 x 58 mm (2.9 x 2.3 in) 77 x 58 mm (3.0 x 2.3 in) 8.0 HP/3,600 rpm 9.0 HP/3,600 rpm 1.7 kg-m (12. Dimensions Power equipment description code Length Width Height Dry weight Engine Engine type Displacement Bore×Stroke Max.
Torque Fuel consumption Cooling system Ignition system PTO shaft rotation GX340 GC05 GX390 GCAA 390 mm (15.4 in) 450 mm (17.7 in) 435 mm (17.1 in) 31 kg (68 lbs) 4-stroke, over head valve, 1 cylinder 337 cm (20.6 cu-in) 389 cm (23.7 cu-in) 82 x 64 mm (3.2 x 2.5 in) 88 x 64 mm (3.5 x 2.5 in) 11.0 HP/3,600 rpm 13.0 HP/3,600 rpm 2.4 kg-m (17.36 ft-lb) /2,500 rpm 2. MEMO Head office: HONDA EUROPE N.V. European Engine Center Langerbruggestraat 104, B-9000 GENT TEL. +32(0)9 250 12 11 FAX +32(0)9 250 14 24 VAT: BE 418.250.835 - HRG 125.024 Fortis Bank: BE33 2900 0170 0046 BIC GEBABEBB www.honda-engines-eu.com 33 United Kingdom selling agent: HONDA ENGINES Honda Logistic Centre( UK)Ltd. Unit 3210, Wellington Parkway Magna Park Lutterworth Leicestershire LE 17 4JQ United Kingdom TEL.