MODEL 13000 TFG, ITEM #165939 Triple Fuel Generator

M165939F

Owner's Manual

A WARNING
Read this manual. Serious injury or death can result if safety instructions are not followed.

A DANGER
Fire hazard.
Do not operate in an enclosure or building. Fire or explosion will result. Never place this product near combustible materials.

DANGER
Breathing hazard. Poisonous fumes from engine will kill you. Do not operate the generator in enclosed areas. Do not operate generator near building or inside of buildings.

G;O*SCC

Please reference serial number when calling customer service. Customer Service: 1.800-270-0810

wit
44
gettUti

ourmAgondayggajogy zlocrAmatslogRmx-.4.-- t-A.

"M" ' 4.1

rare 6 7 . 6 23 0 lad r efo lr ai M V;*.1 4 _ Vag -'4:44Alat il.W .4 1. gfii: 51 P4*

r
Thank you for purchasing a NorthStar Triple Fuel Generator. Your machine is designed for long life, dependability, and the top performance you demand. Please take time now to read through this manual so you can better understand machine operation, maintenance and safety precautions. Everyone who operates this generator must read and understand this manual The time you take now will prolong your generator's life and prepare you for its safe operation. Enjoy the exceptional performance of your NorthStar Triple Fuel Generator.

Make certain the operator: - Reads and understands the manuals pertaining to this machine. - Is instructed in safe and proper operation of this machine

K-BAR Industries Incorporated reserves the right to make improvements in design and/or changes in specifications at any time without incurring any obligation to install them on units previously sold

_...... sto:Kvap",4,..,s,fiRt.4.43.eat...4
Thank Lc1 .1

'`,,,rt-s-r

'.

Li uid petroleum gas and natural gas requirements 3 ftt Ma inWdirltrel-- - difi* .aifi'6"'`k : P..- : . .. : ,Wi7i1V7i7 , 51 7,4 CAfffe Generator features 5-6 1 ,1 1 47 1 : - ,7 Intectiba f glegit&t, 7 R 1-4-4-WattitVr=gfe q.v. ii-l_i_4 ANSI safety definitions 6

r ,A.,..tiie, - .: brigolos 761 jiL -a errim-,='2, Installation Pre-start up re aration

, -, - . newt - pr- 6-eam.

.) .1 k, ... MAL, `, -_,, 7.,.. *- M4V. .1'.

W- .4 ': ..,,,gv,,, et: Weig--*

'
70

to n

1,, ,, ,

',... 4;

'', . VW ' l

tAM 4. : -1 :

Sto. sin. Engine care rialatorcardM, ",-. '4;,GO Troubleshooting

w,,,, 4 :,

10

4,. r: .. II, _ tt .,',-, , "At ..WWW111

12

10

0 0 0 0

-7

r,

#165939 Item Number _ 85601.Wgitt M MaIMML_ WlaxirA_LWtibtput***AR.e Continuous Output: 10500 Watts (W) Gasoline 9600 Watts (W) Liquid Petroleum Gas (LPG) 8400 Watts (N) Natural Gas (NG ,t1Zettae -,, , .- .. , **;1,,fp , _ . , , '''' --47', 74 -2 ,,,.....g12-4:Pol ,1,& -Y -MIK:Wi` Single hase 4-wire Phase :.7 i' -,"4 .R -,.. d ta;oliski --F ftf itei 218 - 258 V Volta se Regulation -, , , _ ,.., z_mtm re-zw i f- i --; ,,,,,,, -71 5w6f Figt.._4:05 20 HP Honda Engine -- 4En076T _ S'':gbs"-IA. Are. ,N7V-'W" :3798 OPI\v-i --g40 4 4._,. Unleaded gasoline/LPG/NG _ Fuel Type .' NG) :svgikatvAii0Vii.ColifififWV64014-1ei .40-4. -TTirctiang_e_APO, .- 4 2.2 Gal/Hr (LPG), 3.25 CFM NG Min. Flow Range (LPG, NG), Pa--,-10.0 Gallons (38`.-11.t), ..47gsg-_ -' _,- .2i,k fism,, -301r,g_-liffoitsf-41;,,,4-,i,F. See Honda Manual Oil Capacity Electric -''''!' , 4f9F`! i'-7.1r,1 Starting Method ...-:., - .: .. 20 Amp (A) duplex (NEMA 5-20R) 120V Receptacle 30 Amp (A) locking device (NEMA L5-30R . 30 Amp (A) locking devices 120/24TIVWe cepiecle - ' -.. ---,-:,4,f, --! . --::,-, (NEMA L14-30R) _DRiagmight blade (NEM,A14-50R) , . , _ ,50A (1) 50 Amp (A) thermal magnetic Circuit Breaker (1) 30 Amp (A) thermal magnetic (1) 30 Amp (A) thermal, push to reset (2) 30 Amp (A) thermal, push to reset . -2V DC 1 Battery - ' - - - - ' - - - "- - _ s.: . Group Size: U1-7_______ Dimensions ti- ,, . :.-.'biti:3527-5719018 cm) !-.. 7.4, -.nr_ _ Length ,7 i:91i, : r,W, _,i,77'": .:,-il'kkiii-L , ' 24.25" 61.6 cm) Width k , -iftM. 6'.25"- (6 :MEn) ' -"Vi. Tafeight lit-il.gd-Mta z'''' -iigkit 340 lb. 155 kg1 D 4 Weight 7 -77416Tb.- 180 ) 7-''' :,;-G rtis6Weitit7:'--7':'-''"`-"';,7- 777.77

ic Ass .-r-feesirp - .i7

- VZ

'1

Liquid Petroleum Gas (LPG) and Natural Gas (NG) F;;Zequiremer-k Liquid Petroleum Gas (LPG)
This generator will not work with 20-lbs gas cylinders used in gas grit Is and recreational equipment, or 40-lbs gas cylinders used in forklifts and trictors. A 100-lbs LPG gas cylinder is the minimum fuel tank size for this produ c t. Some installations may require tanks larger than 100-lbs as a result of low su varrounding air temperature and other appliances drawing fuel from the same tank. LPG Fuel Inlet Requirements: This product is designed to operate oni LPG within al specific gas pressure range_ The LPG gas pressure range is 7" to 11" 4=4 water colurr-ii This product does not include a pressure-reducing regulator for LPG. gas cylinders produce gas pressure in excess of 11" water column. Introduc=tion of gas price into the generator in excess of 11" water column Will permanently dames ge this prod u void the warranty. Minimum LPG gas flow requirement: 9.33 lb/hr, 2.2 Gal/hr, or 201,718 BTU/hr. Always use a certified gas technician for installation of the fuel system.

Natural Gas (NG)

NG Fuel Inlet Requirements: This product is designed to operate on NG within specific gas pressure range. The gas pressure range is 4 to 6 ounce s per square E. I-) This product does not include a pressure-reducing regulator for NG _ Your system pressure may be exceed the generator's pressure rating of 4 to 6 ou inces, and will permanently damage this product and void the warranty. Minimum NG gas flow requirement: 3.25 CFM. Always use a certified gas technician for installation of the fuel system.

WARNING
Poisonous gas.
This machine gives off carbon monoxide, a poisonous gas that can kill yc..)u. You CANNOT smell it, see it, or taste it. -This machine produces carbon monoxide, while operating on Liquid Petroleum Gas (LPG). Natural Gas (NG) or Gasoline. -ONLY run machine outdoors and away from air intakes. -NEVER run machine inside homes, garages, sheds, or other semi-enclosed spaces. These spaces can trap poisonous gases, EVEN IF you run a fan or open doors and windows. If you start to feel sick, dizzy. or weak while using this machine, shut it off and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

Risk of fire and explosion.

Hookup must comply with the Federal and Local jurisdictions for Liquid Petroleum Gas (LPG) and Natural Gas (NG), ALWAYS have a qualified technician complete the LPG/NG hookup. Improper Installation can cause injury or death. LPG/NG are lethal and explosive gases. -If you smell gas, exit the area immediately -DO NOT start engine. -DO NOT light a match. -DO NOT flip on an electrical switch.
,0-7' 4076

Switching from LP or NG to gasoline: 1. Disconnect all loads to generator. 2. Turn the gas line valve to ON position. 3. Flip the fuel selection switch to the GASOLINE position. Switching from gasoline to LP or NG: 1. Disconnect all loads to generator. 2. Make sure LP or NG fuel is being supplied. 3. Flip the fuel selection switch to the LP/NG position. 4. Momentary sputtering is common. 5. Turn gasoline line valve to OFF position. Reference 16 - Hour Meter. The control panel includes an hour meter to monitor engine run time. The hour meter will not work if the 120 volt, 20 amp circuit breaker is OFF (Reference 13). Reference 17 - Oil Drain Area. This product was designed with a large window in the base directly below the engine oil drain plug (Reference 19). The large window facilitates a quick and clean process to change engine oil. Reference 18 - Demand Regulator Assembly. Controls the flow of LP or NG gas into the engine carburetor. Reference 19 - Oil Drain Plug. Refer to your Honda engine manual for oil change recommendations. Reference 20 - Oil level Dip Stick. Refer to your Honda engine manual for proper oil level recommendations. Low Oil Shutdown. The Honda engine is protected against damage resulting from low oil level. As the oil falls below the safe level, the engine automatically shuts off (the engine stop switch remains in the on position). The engine will not start until the oil is refilled to above the safe level. Reference 21 - Starting/ Stopping instructions. Reference 22 - Engine Oil Fill Port. Remove the oil fill cap to add engine oil Reference 23 - Engine Start/Stop Key Switch. The engine key switch is located on the front of the engine. Always locate this switch and be familiar with its location before operating the generator. Reference 24 - Engine Choke Lever. Used during cold starts. Refer to the starting/stopping instructions and the Honda engine manual for usage. Reference 25 - Vibration Isolation Mounts. The engine and generator head is mounted on rubber cylinders that absorb most of the engine vibration. This feature eliminates the tendency of the machine to "walk" which is common with engine powered equipment. Reference 26 - Engine Exhaust Muffler. The muffler is designed to reduce engine noise. Keep debris and combustible materials away from the muffler. The muffler contains a spark arrester. Refer to the Honda engine owner's manual for spark arrester maintenance. Reference 27 - Engine Oil Filter. Replace the oil filter at each oil change. Replace with Honda genuine replacement parts
6

Reference 28 - Generator Head. The electricity producing part of the generator. The neutral line of the generator is mechanically grounded to the frame. Reference 29 - Gas Line Valve. The fuel tank has an ON-OFF valve mounted underneath Always keep this valve closed (OFF) when the generator is not in use.
lzo 4;kr4-" , as

Before starting your generator, thoroughly study the instructions and cautions in this manual to assure you are fully acquainted with the operation of all components of this generator. Proper preparation, operation and maintenance will result in operator safety, best performance and long life of the generator. For detailed engine operation and maintenance always refer to the Honda engine owner's manual furnished with the generator (Honda refers to the 20 HP engine as a GX620). NorthStar is constantly improving its products. The specifications outlined herein are subject to change without prior notice or obligation. The purchaser and/or user shall assume liability of any modification and/or alterations on this equipment from original design and manufacture. Before using, the user shall determine the suitability of this product for its intended use and assumes liability therein.

ANsLsaFEVIOffigiitibbacA
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. WARNING indicates a potentially hazardous situation which, if not avoided, could result in a death or serious injury CAUTION indicates a potentially hazardous situation, which if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

ikuLEgr-

EE,OPERATIONS

Safety precautions are essential when operating this generator. Respectful and cautious operation will considerably lessen the possibilities of a personal injury. This manual will warn of specific personal injury potential, and these will be designated by the symbol.

WARNING This generator is equipped

with a grounding post, located on the control panel for your protection. Always complete the grounding path from the generator to a copper pipe/rod that is driven into moist earth, to prevent electrical shock. ALWAYS use electrical cords that are in good condition. Worn, bare, frayed or otherwise damaged cords can cause electric shock. NEVER operate the generator, or handle any electrical equipment while standing in water, while barefoot, while hands are wet or while in the rain or snow. Electric shock may result. ALWAYS use a ground fault circuit interrupter (GFCI) in damp or highly electrical conductive areas and on construction job-sites to prevent electric shock. ALWAYS remove the spark plug or spark plug wire before working on the engine or generator, to prevent accidental starting. ALWAYS provide adequate ventilation. Do ' not operate generator in any enclosed or narrow space. Engines consume oxygen and give off deadly carbon monoxide poisonous gas. Improper ventilation will cause damage to generator and possible injury to people. NEVER touch hot muffler, hot exhaust manifold or engine cooling fins. ALWAYS remove all oil or gasoline deposits and accumulated dirt from generator and immediate area. Keep generator head and engine clean. NEVER operate the generator under the following conditions: A. Excessive change in engine speed, slow or fast. B. Overheating in load connecting devices. C. Sparking or arcs from generator. D. Loss of electrical output E. Damaged receptacles F. Engine misfire G. Excessive vibration. H. Enclosed compartments, or confined areas. I. Flame or smoke. J. Rain, snow or wet conditions. K. Operator non-attendance.

DO NOT light a match. DO NOT flip on an electrical switch Exit area immediately and call gas supplier or fire department. Minimum flow range required: NG - 3.25 CFM, LPG - 9.33 LB/hr. Pressure Range: 4-6 ounces, OR 7-11 inches of water column. NEVER over pressurize.

WARNING Check fuel system on a regular basis. Look for signs of leaks, deterioration, chafed or spongy fuel hose, loose or missing fuel hose clamps, damaged fuel tank or a defective fuel shut-off valve. Correct any defects before operation. WARNING Keep the fire extinguisher close by your generator and be familiar on how to use it. Consult your local fire department for correct extinguisher type.

INsii-ALgolON
OUTDOORS: Choose an location where the generator will not be exposed to rain, snow or direct sunlight. Position the generator on secure, level ground so it will not tip or slide down a hill. Place the generator so that the exhaust fumes will not be directed towards people The installation site must be free from water, moisture, or dust. All electrical components should be protected from excessive moisture or the insulation system will deteriorate and result in grounding or shorting out the generating system. Foreign matters, such as dust, dirt, sand, lint, or abrasive materials can cause damage to the generator head and engine if allowed into its cooling system. NEVER install your generator inside confined areas. Inside installation can cause health hazards or death. Gasoline, Liquid Petroleum, and Natural Gas will produce varying amounts of carbon monoxide

DANGER Remember, exhaust fumes are deadly carbon monoxide gas, and must be vented to the outside where there are no people. Cooling air of sufficient amounts must be allowed to flow in and exhausted out to ensure proper cooling of the engine and generator head

WARNING Hookup must comply with the Federal and Local jurisdiction of Liquid Petroleum (LP) and Natural Gas (NG). ALWAYS have a qualified technician complete the LP/NG hookup. Improper installation can cause injury or death. LP/NG are lethal and explosive gases. If you smell gas, exit area immediately, if possible shut off the LP/NG supply Before you start engine, smell next to floor for gas, if you do smell gas: DO NOT start engine
7

It is important to determine the total electrical load before it is connected to the generator. The two major factors in determining the life of a generator head are heat build-up, caused by overloading the generator and corrosive contaminants that attack the wiring insulation. If the generator is overloaded, the wires become excessively hot and cause the insulation to break down, reducing its ability to resist corrosive

contaminants. Over time the effectiveness of the insulation is eliminated and a dead short can result Always compare the generator nameplate data with that of the equipment to be used to ensure that watts, volts, amperage, and frequency requirements are suitable for operating equipment. The wattage listed on the equipment nameplate is its rated output. However, some equipment may require three to ten times more wattage than its rating on the nameplate, as the wattage is influenced by the equipment efficiency, power factor and starting system. NOTE: If wattage is not given on equipment nameplate, approximate wattage may be determined by multiplying nameplate voltage by nameplate amperage. VOLTS X AMPS = WATTS = 600W Example: 120V X 5A When connecting a resistive load such as incandescent lights, heaters or common electric power tools, a capacity of up to the generator full rated wattage output can be used. When connecting a resistive-inductive load such as a fluorescent or mercury light, transformers or inductive coils, a capacity of up to 0.6 times the generators full rated output can be used. Always allow the generator to reach operating speed before a load is applied. STARTING ELECTRIC MOTORS Electric motors require much more current (amps) to start than to run. Some motors, particularly low cost split-phase motors, are very hard to start and require 5 to 7 times more current to start than to run. Capacitor motors are easier to start and usually require 2 to 4 times as much current to start than to run. Repulsion Induction motors are the easiest to start and require 1 5 to 2.5 times as much to start than to run. Most fractional motors take about the same amount of current to run them whether they are of Repulsion-Induction (RI), Capacitor (Cap), or SplitPhase (SP) type. The following chart shows the approximate current required to start and run various types and sizes of 120 volt 60 cycle electric motors under various conditions gliti.M.01K00161 0 - WATEntlairfOrrAMPea RI type Cap type SP type Hp motor Running Watts =OW gifMgM 40a0.4 fi 14. ffilini 1/4 22-32 700 9-15 12-23 *20 5 l Er . ,2_129k 14 WV (3,L/LP O :t"$e. it41illel % 20-40 NA 1175 15-25 uomAwl , EaNAVO 0, 141440 jai 925* 0424,440g1; ,3t 40-80 1% 2400 30-50 NA R44, 21,%, 0...i.29.00g4 : a:4 ,af.,960, g.INM. v1sof -3 68-136 NA 3 4075 51-85 '5Z5Otidi AM:gal , M127;22411g,NAZ 144.d.5-Ma iiti

connected to a hard starting load such as an air compressor, it will require more starting current If it is connected to a light load or no load such as a power saw, it will require less starting current The exact requirement will also vary with the brand or design of the motor. Generators respond to severe overloading differently than the power line. When overloaded, the engine is not able to supply enough power to bring the electric motor up to operating speed. The generator responds to the high initial starting current, but the engine speed drops sharply. The overload may stall the engine. If allowed. to operate at very low speeds, the electric motor starting winding will burn out in a short time. The generator head winding might also be damaged. Running the generator under these conditions may result in damage to the generator stator as well as the motor windings. Because the heavy surge of current is required for only an instant, the generator will not be damaged if it can bring the motor up to speed in a few If difficulties in starting a motor are seconds. experienced, turn off all other electrical loads and if possible reduce the load on the electric motor. EXTENSION CORDS When electric power is to be provided to various loads at some distance from the generator, extension cords can be used. These cords should be sized to allow for distance in length and amperage so that the voltage drop between the set and point of use is held to a minimum. rQurr 7FrtllrowBZ .MairirnutiiiEictinsieri:Caditeriftra #10 #12 Amps Load #14 #16 Ga. Ga. Ga. (watts) Ga. at Cord Cord Cord Cord 240V 50' fil''c150'"il fX. 1 .-60 - e foz752,,, t atm 40,0 125' 75' 50' 4800 25' 20 ill'7 ,iiaTrTfitgq Imoj,d.4 0:435K Kri.2514, PAI On 30' 15' 10' 40 9600 ,1' * rt, 50tE tizoom w15wt tardrcil N:rfki....5;wit r *Not recommended CAUTION: Equipment damage can result from the low voltage caused by using an extension cord with a small wire size. Use this chart to estimate the total load on your enerator. Eor Determining GeneratorLoad Requirements. _, Running Watts Device 4, ''' h.. ' 1-700 (g) Aiil:Gbriditicirier (12,000 Btu) , T',1 Battery Charger (20 Amp) 500 , 44 -5X44.1000,.. _ BSIt 2ahiderVigragift 1200 Chain Saw

W3 141

Feittiiiiitsigmlx2i7P19. -WAION. Wkilrial9oo.4 , &

The figures given above are for an average load such as a blower or fan. If the electric motor is 8

1000 Coffee Maker ik:;:2000, (a) LCOTO res":11P)rafra,4V50-g414, WijCompressor (3/4 HP) 1800 (a) -gdriT(1 HP)747' '4,-056'ith,A,' ,gg - ,.*r.,,.:: 1400; (a) fedifilirds

700 Curling Iron -7402-126-0147.20A 11,,,..7 V7.':: Disfiwasheri: v-N, T ,*:X4W1 500 Ed! e Trimmer .tr&Z r---iNe ,i201 two all 0 c4J,47... BF:, 1 1500 EleCtric Range one element E :-.6...211 1g - L., - '1, _24' fT,, .i'z' -": 2gfrie4'.a , 1200 a lar-r73 - vureawi

Hair D er
0

875 Hand Drill 1/2" .74 M. -IT4 mzik stLiyiv:aa2 , ItPA:11 250 Hand Drill 1/4" U'L e li er ...A.T.;, P0i.ki .',fiv4:4,c -51 - ,Zn 150 Home Corn uter amcirL_ 71 , figivailm. .:.4 m LiraNYTA., :, - 800 a Jet Pum . 0 ez' , ....,-..ti..:_.M503: 407.., r. '-raiigitataWir 100 Light Bulb F--- . ,., s . . 44.-14L., .. tv -." " t . iVAMP ' 0 3 P. -e ' kVISP A CT 1 iniai Milk Cooler ,iiiidirTFWE Mace 7 .- -M4-- ..'''.:- - . 4`000;Wrig 400 Oil Fired S ace Htr 140,000 Btu 461 -, - --. red li.'--r!.141120/0110:;Th-%:I4 &3-tit? 150 Oil Fired S.ace Htr 30,000 Btu 600 a Paint S. ra er Airless 1/3 HP Pal -I ra = an = h = d leg, Lk.v.,Thm, cry. 200 Radio Rifn -1 ..:, '''' ,:., .-, "'r iff:Mi l e- MEM. ' itIr:- & ' 200 Slow Cooker y. ubmersi a = 46 ,e2 : M d'''' 80 ..eo",;%-i..,:. 2000 a subrrrn. 1 HP

1 - dmiligiiM%1 4g4SaajZt:

rargaLitiligr:,- , "

1200

Figure 3. Load Block Adjustment - All Triple Fuel generators are factory pre-set to operate on LP vapor fuel. If the engine experiences difficulty starting on LP or Natural Gas, the load block may need adjustment. To adjust the load block, loosen the lock nut, then turn the adjustment screw clockwise until resistance is felt. At this point the load block in completely shut-off. While LP gas or Natural Gas is being supplied to the generator, turn the ignition key to the start position and slowly turn the adjustment screw counterclockwise until the engine starts. Once the engine is running turn the adjustment screw very slowly to smooth out engine performance. Once the proper setting is achieved turn the brass lock nut to secure the adjustment screw. Depress the primer button when cold starting the engine. GROUNDING - All units must be grounded. Drive a 3/4" or 1" copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth. Connect an approved ground clamp to the pipe. Run a 10 Ga. wire from the clamp to the generator grounding post located on the rear of the generator head Do not connect to a water pipe or a ground used by a radio system. CAUTION: The engine has been shipped without oil. Fill the crankcase with oil before trying to start. Low oil shut down prevents your generator from starting without sufficient oil.

500 Television ..(11. -'Wk -- [ ATell-' ! 3 1 CitZ - i4 gain er-l'AA 'N'' .t - R4.11r : Vs. 250 Vacuum Cleaner - - U:,-IL:-iiirAMik&. R AIDME.,gi Water Heater 3000
,f_ee , e r

. .WMT -Mr!ii.4'. EM1116151bOVINFOIST 60-Wrir _'''-3.-, ' WL 600 a Sum' Pum. Table: il eTPKVilf- 7...T likrfailia`iWil

ininiiik, i-,,,,,,_ ., ., - Ilon,r.-

,A-4:q wouggits

(a) Hard-starting motors require 3 to 5 times the rated running watts. (b) These loads may require up to 15 minutes to restart due to its normal build up of compressor head pressure. NOTE For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer to determine the maximum wattage.

OPERATING SPEED
The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency. The speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency. The output voltage should be checked to ensure the generator is working properly before connecting a load to the generator. Failure to do so could result in damage to equipment plugged into the unit and possible injury to the individual. All engines have a tendency to slow down when a load is applied. When the electrical load is connected to the generator, the engine is more heavily loaded, and as a result the speed drops slightly. This slight 9

,j1,, ITO "0kftirrIiks EFEED)XV

Your generator has been thoroughly tested prior to shipment from the factory. A factory test report has been included with this manual. However, damage can occur during shipping, so be sure to check for damaged parts or loose or missing nuts and bolts. If the aforementioned problems occur, call Customer Service at 1-800-270-0810.

decrease in speed, together with the voltage drop within the generator itself, results in a slightly lower voltage when the generator is loaded to its full capacity The slight than when it is running with no load variation has no appreciable effect in the operation of motors, lights and most appliances. Electronic equipment and clocks will be affected if correct RPM is not maintained. See Load vs. Output chart. MOMEIEMMZEOW Atla-T Frequency Generator Percent of Speed Voltage at 120V (Hz) Generator (RPM) Receptacle Output

5. Turn the key to the START position. 6. When engine starts, move choke lever to RUN position. 7. Loads may now be connected to generator.

1.Disconnect all loads to generator. 2. Turn engine key to OFF position 3. Turn fuel line valve to OFF position. 4. The fuel kick-off solenoid automatically stops the flow of LP or NG to the engine.

W CIVIrta WNW KIWOM. ,M29Vardg

3600 60.0 120V 50 % 390.ffil ga',564. -ftt =it t'al:000.Output voltage should periodically be checked to ensure continued proper operation of the generating plant and appliafices. It can be checked with a portable meter. Check frequency by using an electric clock with a sweep second hand. Timed against a wristwatch or a stopwatch, the clock should be correct within +1- 2 seconds per minute. Speed adjustments should be accomplished by qualified engine technicians.

7ATIV

MrtiNITet-TINWATLEE .
Switching from LP or NG to gasoline: 1.Disconnect all loads to generator. 2. Turn the gas line valve to ON position. 3 Flip the fuel selection switch to the GASOLINE position Switching from gasoline to LP or NG: 1. Disconnect all loads to generator. 2. Make sure LP or NG fuel is being supplied. 3. Flip the fuel selection switch to the "None" position. The fuel conversion should take 1-2 seconds. See the STARTING section of this manual for further details. 4. Wait for the engine to begin sputtering. This indicates the engine is being starved of gasoline. 5. Flip the fuel selection switch to the LP/NG position. Turn gasoline line valve to OFF position.

BEFORE STARTING
1. Make sure the generator is positioned on firm level surface. 2. Check the crankcase for oil and maintain at a proper level. 3. Check fuel level and fill tank with fresh unleaded gasoline if necessary. Allow for gasoline expansion by never filling fuel tank completely to the top. Always wipe up and remove any spilled gasoline. 4. Make sure that the exhaust fumes are directed away from people.

=&G,IN "'"' Ett RE _ , "7111 vs 1r 4 '

ifkit

STARTING_

Refer to your Honda Owner's Manual for proper care and maintenance.

Operating Instructions- LP/NG: NOTE: Do not choke engine. 1 Supply LP or NG to 3/4" NPT inlet on generator base. 2. Disconnect all loads to generator. 3. Flip fuel selector switch to LP/NG. 4. Turn the key to the START position 5. It may be necessary to momentarily depress the primer button while starting the engine. 6 When engine starts, loads may be connected to the generator. Operating Instructions- Gasoline: 1. Disconnect all loads to generator. 2. Flip the fuel selector switch to GASOLINE position. 3. Turn gas line valve to ON position. 4. For cold engine, move choke lever to full choke position. For a warm engine, move choke lever to half choke or to RUN position. 30

CAUTION NEVER change oil in a hot engine, the hot oil could cause severe burns

The generator head is two pole, 3600 RPM, 60 Hz, brushless, revolving field with one sealed radial roller bearing. The rotor of the generator head is directly connected to the engine crankshaft and the stator is rigidly coupled to the engine casting via the generator head casting. Exercising the Generator - The generator should be operated every four weeks. Warm unit up by starting the engine and letting it run for 10 to 15 minutes. This will dry out any moisture that has accumulated in the windings. If left, this moisture can cause corrosion in the winding. Frequent operation of the engine generator will also ensure that the set is operating properly should it be needed in an emergency. Generator Maintenance - The generator head is brushless and maintenance free. Major service, including installation or replacement of parts should be performed only by a qualified electrical service technician. USE ONLY FACTORY APPROVED REPAIR PARTS. Obtain all factory parts from Customer Service at 1-800-270-0810. A. Bearing - The bearing used in these generators is a heavy duty sealed ball bearing. They require no maintenance or lubrication. B. Receptacles - Quality receptacles have been utilized. if a receptacle should become cracked or otherwise damaged, replace it. Using cracked or damaged receptacles can be both dangerous to the operator and destructive to the equipment. Stand-by Operation If your generator is to be used as a standby electric power source in case of utility failure, it must be installed by a licensed electrician and in compliance with all applicable state and local electrical codes. Also, local Fire Departments must be consulted concerning proper and safe handling procedures for gasoline. NEVER connect any generator to any existing electrical system without an isolating, UL approved transfer switch, installed by a licensed electrician.

TROUBLESHOOTING
Problem
Engine will not start.

igtittible Causes t
a) Low oil level. b) Fouled spark plug. c) Out of fuel. d) Stop switch in OFF position. e) Battery disconnected or dead. f) Fuel selector switch is set to the incorrect fuel. a) Enaiii6 speed too,sloiii-

RossibleRemediesL,
amw-vitcaftqh.

a) Fill crankcase to proper oil level. b) Clean or replace spark plug. c) Fill fuel tank. d) Place switch in ON position. e) Charge or replace battery. f) Place switch in desired location (Gasoline or LP/NG). a) Btirg,_ 16e - 6- to to a qua ed oltaga too loW iciairfor adjustmen b) Re ce load ee oad b) Generator is overloaded Application section of this manual )_ a) Disconnect load. a) Defective load connected to generator. Circuit breaker trips. b) Replace receptacle. b) Defective receptacle. c) Reduce the load. (See Load c) Generator overloaded. Application section of this manual.) BriFig generat to a qualified a) Engine spew] 'tot,' high otage rob-Tif11 itecifl iitian fo actoknent *IT a) Reduce the load. (See Load Generator overheating. a) Generator is overloaded. Application section of this manual.) b) Make sure there is at least 3 feet of b) Insufficient ventilation. clearance on all sides of generator. a) Discorihect load. a) Defective loairConhected.to generator. N o -61 -itput voltage b) Bring generator to a qualified 6) Broken or loose more technician fo repair c) Reaace,receptacle c) Defective receptacle d) Biipibenerator to a quay ed d) Defective stator. techniCiadfOr repai e) Bring genera or to a qua ified e) Defective rotor. technician for repair f) Bring generator to a qualified DefectiOe capacitor. technician for repair a) Reduce the load. (See Load Engine lacks power or a) Generator is overloaded. application section of this manual.) sputters. b) Clean or replace air filter. b) Dirty air filter. c) For LP, the hose should be on the left c) LP/NG hose is connected to the wrong inlet, For NG, the hose should be on the Carburetor inlet. right inlet, d) Clean or replace spark plug. cl) Fouled s ark plu . _ 72* IgtfWier :a) Fill fuel tank ap Out of Li Engine shuts down 47.,"" ALIT)) Fill crankcasel.Wproper oil level;, during operation. (elS)1410W oil level.

12

#35310 Control Panel

Wiring Diagram

Part No. E35310A Date: 11/20/00

473

0 0 /

0
(9)

-r
r)

C O

< o 0

CONTROLBOX

LO

jr1

TO")\I I ef CO
O O O

o E
C L Ky 0 0 Okti (NI C.) .0

tN

0 o OZ

Lc)

a_ o

0 0

Model No. 35310A Component List

Diag #
1 2 3 4 5 6 7 8 9 10 11 12 13 B15 B45 G5,G6 B14 B43 B12 B42 B11 B41 B18 B13 B16 B46 W2 W3-W7 G4 G3 01 B1 B4 W44 B44

Part #
306422 306426 30643 306434 306423 31953 31211 35309 32805 31824 31005 31223 32816 305608 305609 305588 306477 306478 306479 306488 31214 31215 306608 306609 307500 307501 31217 31216 307503 307504 307505 307506 307507 35324 306498

Description
Twist Lock Receptacle, NEMA L14-30R Receptacle, 120 Volt, 20 Amp, NEMA 5-20R Circuit Breaker, 20 Amp Circuit Breaker, 30 Amp Receptacle, 120 Volt, 30 Amp, NEMA L5-30R Receptacle, 120/240 Volt, 50 Amp, NEMA 14-50R Circuit Breaker Mounting Clip Panel Face Graphics Hour Meter Fuel Selector Switch Circuit Breaker, 30 Amp Circuit Breaker, 50 Amp Fuel Selector Switch Wiring Harness Lead Wire, B15 Lead Wire, B45 Lead Wire Assembly, G5, G6 Lead Wire, B14 Lead Wire, B43 Lead Wire, B12 Lead Wire, B42 Lead Wire, B11 Lead Wire, B41 Lead Wire, B18 Lead Wire, B13 Lead Wire, B16 Lead Wire, B46 Lead wire, W2 Lead Wire Assembly, W3, W4, W5, W6, W7 Lead Wire, G4 Lead Wire, G3 Lead Wire, G1 Lead Wire, B1 Lead Wire, B4 Lead Wire, W44 Lead Wire, B44

Qty
1 1 2 1 1 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

LEI

#30990 MR2-200 Generator Head

Parts Explosion

Part No. E30990C Date: 6/2/04

419

sal

Generator Hea d

/
e

Part No E:10990C Component List

Date: 3/3/05 Diag # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Part # 30991 30994 31013 30995 307489 305605 31014 31018 31015 307484 306403 306416 30997 31065 30999 30992 307479 307481
9910303129

Description Drive End- Bracket Protection Screen Phillips Screw Fan Grommet Terminal Box Cover M5 X .8, 16mm Long M5 X .8, 10mm Long, Green M5 X .8, 10mrh Long Rubber Cup Rear Bearing Nylock Nut and Star Washer Grill Securing Stud Cap Fixing Ring Rotor Assembly Diode Varistor Capacitor, 35uF Frame and Stator Assembly M5 X .8, Nut Brass Jumper Terminal Board . Securing Stud (333mm)

Qty 1 2 10 1 1 1 2 2 4 2 1 1 1 1 1 1 2 2 1 1 8 2 1 1

39256 31017 31011 307478 31022

#E35490E Fuel System Explosion Model No. 165939E

Model No. E35490E Component List

Diag #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Part #
82187 35846 35847 32808 777119 37748 35488 777239 32811 36297 38183 38625 32822 32798 777148 35330 777237 777238 32821 32817 35325 35008 35037

Description
M6-1.0 X 65mm Socket Head Cap Screw, w/ thread locking patch Venturi Adapter Elbow Hose Clamp Regulator Wire Harness Oil Pressure Switch Wire Harness Protective Sleeve Gas Hose Load Block Street Elbow, 3/8" MPT x 1/4" FPT Gas Regulator 1/8" NPT Plug Pipe Nipple, 1-5/16" LP/NG Fuel Lock Solenoid Pipe Nipple, 12" Pipe Hanger Hex Nut Coupler Lanyard Triple Fuel Hang Tag Oil Pressure Switch 0-Ring Air Cleaner Riser

Qty
2 1 1 1 2 1 1 13.2" 16.6" 1 1 1 1 1 1 1 1 1 1 1 1 1 1

In

#E165939H 13000 TFG Parts Explosion Model No. 165939H

Model No. 165939H Component List

Diag # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Part # 777149 38760 171410 30754 38566 38564 35298 35844 6022 31007 E30990 34857 31210 34172 32844 32848 35300 . 82018 E35490E 33277 32797 E35310B 35304 306579 35296 32840 777345 32551 777352 32839 777108 Description Fuel Cap, With Gauge Fuel Tank Assembly Fuel Clamp, 1/4" Leather Washer, 1/4" Decal, Control Panel Side Decal, Gas Valve Side Cradle Weldment Nameplate CO Decal Spark Arrester Generator Head Generator Bracket Lead Wire Isolation Mounts Lower Bracket Upper Bracket Generator Base 5/16-18 X 2" Button Head Socket Cap Screw Fuel System Components 10-32 Clip Nut 10-32 X .75" Socket Head Cap Screw Electrical Diagram Receptacle Box Weldment Grommet Engine Mount Plate Engine, 20 HP Honda Fuel Line, 1/4" Battery Decal Battery Box Battery Cable, Positive Battery Cable, Negative Qty 1 1 2 4 1 1 1 1 1 - 1 1 1 1 4 4 4 1 4 1 4 4 1 1 1 1 1 18" 1 1 1 1

INTRODUCTION
Thank you for purchasing a Honda engine. We want to help you to get the best results from your new engine and to operate it safely. This manual contains information on how to do that; please read it carefully before operating the engine. If a problem should arise, or if you have any questions about your engine, consult an authorized Honda servicing dealer. 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. This manual should be considered a permanent part of the engine and should remain with the engine if resold. Review the instructions provided with the equipment powered by this engine for any additional information regarding engine startup, shutdown, operation, adjustments or any special maintenance instructions. United States, Puerto Rico, and U.S. Virgin Islands: We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership. The warranty policy is a separate document that should have been given to you by your dealer.

1-101%,113.2%.
OWNER'S MANUAL IVIANUEL DE L'UTILISATEUR MANUAL DEL PROPIETARIO

GX670 GX620 GX670

Iffd

CE
ra

SAFETY MESSAGES
Your safety and the safety of others is very important. We have provided important safety messages in this manual and on the engine. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol and one of three words, DANGER, WARNING, or CAUTION. These signal words mean:

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

o_ Le)

LLi

CONTENTS
INTRODUCTION SAFETY MESSAGES SAFETY INFORMATION SAFETY LABEL LOCATION COMPONENT & CONTROL LOCATION FEATURES BEFORE OPERATION CHECKS OPERATION SAFE OPERATING PRECAUTIONS STARTING THE ENGINE STOPPING THE ENGINE SETTING ENGINE SPEED SERVICING YOUR ENGINE THE IMPORTANCE OF MAINTENANCE MAINTENANCE SAFETY SAFETY PRECAUTIONS MAINTENANCE SCHEDULE REFUELING ENGINE OIL Recommended Oil Oil Level Check Oil Change OIL FILTER AIR CLEANER Inspection Cleaning FUEL FILTER 1 SPARK PLUG 10 1 SPARK ARRESTER 11 2 HELPFUL TIPS & 2 SUGGESTIONS 11 STORING YOUR ENGINE 11 2 TRANSPORTING 12 3 TAKING CARE OF UNEXPECTED PROBLEMS 13 3 FUSE REPLACEMENT 13 4 TECHNICAL & CONSUMER INFORMATION 14 4 Serial Number Location 14 4 Battery Connections for 5 Electric Starter 14 5 Remote Control Linkage 15 6 Carburetor Modifications for High Altitude Operation 15 6 Oxygenated Fuels 16 6 Emission Control System 6 Information 16 Air Index 17 6 Specifications 17 7 Tuneup Specifications 18 7 Quick Reference 7 Information 18 7 Wiring Diagrams 18 8 CONSUMER INFORMATION 19 8 Distributor/Dealer Locator 9 Information 19 9 Customer Service 9 Information 19 10

A DANGER A WARNING A CAUTION

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.

Each message tells you what the hazard is, what can happen, and what you can do to avoid or reduce injury. DAMAGE PREVENTION MESSAGES You will also see other important messages that are preceded by the word NOTICE This word means: NOTICE j Your engine or other property can be damaged if you don't follow instructions. The purpose of these messages is to help prevent damage to your engine, other property, or the environment. 2005 Honda Motor Co , Ltd All Rights Reserved
GX610U1 GX620U1 GX670U

37Z6C600 00X37 Z6C 6001

Q C) 10000.2005 06
(Ea Printed in Japan
ENGUSH 1

SAFETY INFORMATION
Understand the operation of all controls and learn how to stop the engine quickly in case of emergency. Make sure the operator receives adequate instruction before operating the equipment Do not allow children to operate the engine. Keep children and pets away from the area of operation. Your engine's exhaust contains poisonous carbon monoxide Do not run the engine without adequate ventilation, and never run the engine indoors. The engine and exhaust become very hotduring operation. Keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Keep flammable materials away, and do not place anything on the engine while it is running.

COMPONENT & CONTROL LOCATION

AIR CLEANER (Snorkel type)

FUEL FILTER AIR CLEANER

SAFETY LABEL LOCATION

CHOKE KNOB

This label warns you of potential hazards that can cause serious injury. Read it carefully. If the label comes off or becomes hard to read, contact your Honda dealer for replacement.

SPARK PLUG THROTTLE LEVER OIL FILTER

A ATTENTION
GawUm 4 hie* flammable and el ploolvo.
Tom engim oil ind IN tool beim naluelloo.

ENGINE SWITCH

T4otooluttlsolben411 of apish.
O a skmetaeb VsombollkaolblOokOotama

ofereporMs oonnosirtshomon*Ncokse
peollsobo onloolads.

h0000digoopthisonetheubt

STARTER GRIP

(optional parts)
FLYWHEEL PTO TYPE

SCREEN GRID

For Canadian types only: French label comes with the engine.

FLYWHEEL PTO TYPE

PROTECTOR TYPE (S.T.D)

Gasoline is highly flammable and explosive. Turn engine off and let cool before refueling.

RECOIL STARTER EQUIPPED TYPE

The engine emits toxic poisonous carbon monoxide gas Do not run in an enclosed area.

Read Owner's Manual before operation.

ENGLISH

BEFORE OPERATION CHECKS

OIL FILLER CAP HIGH-MOUNT MUFFLER (B type)

IS YOUR ENGINE READY TO GO? For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the engine to check its condition. Be sure to take care of any problem you find, or have your servicing dealer correct it, before you operate the engine.

SPARK PLUG

WARNING
Improperly maintaining this engine, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.
OIL DRAIN BOLT SIDE-MOUNT MUFFLER

Always perform a preoperation inspection before each operation, and correct any problem. Before beginning your preoperation checks, be sure the engine is level and the engine switch is in the OFF position. Always check the following items before you start the engine.
Check the General Condition of the Engine

1.Look around and underneath the engine for signs of oil or gasoline leaks.

FEATURES
OIL ALERT SYSTEM (applicable types) 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).

2.Remove any excessive dirt or debris, especially around the muffler and recoil starter. 3.Look for signs of damage. 4.Check that all shields and covers are in place, and all nuts, bolts, and screws are tightened.
Check the Engine

If the engine stops and will not restart, check the engine oil level (see page 7 ) before troubleshooting in other areas.
Fuel-cut Solenoid

1.Check the fuel level. Starting with a full tank will help to eliminate or reduce operating interruptions for refueling. 2.Check the engine oil level (see page 7 ). Running the engine with a low oil level can cause engine damage. The Oil Alert system (applicable types) will automatically stop the engine before the oil level falls below safe limits. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup. 3. Check the air filter element (see page 9 ). A dirty air filter element will restrict air flow to the carburetor, reducing engine performance. 4.Check the equipment powered by this engine. Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine startup.

The engine is equipped with a fuel-cut solenoid that allows fuel to flow to the carburetor main jet when the engine switch is in the ON or START position and stops the flow of fuel to the main jet when the engine switch is in the OFF position. The engine must be connected to the battery to energize the fuelcut solenoid, allowing the engine to run. If the battery is disconnected, fuel flow to the carburetor main jet will stop.
Oil Cooler (GX670)

The GX670 engine is equipped with an oil cooler to maintain the correct temperature.

ENGLISH

OPERATION
SAFE OPERATING PRECAUTIONS Before operating the engine for the first line, please review the SAFETY INFORMATION section on page and the BEFORE OPERATION CHECKS on page 3 .

4 Turn the engine switch to the ON position.

ON ENGINE SWITCH 0 OFF

WARMING

O
ON

START

Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you. Avoid any areas or actions that expse you to carbon monoxide - - - Review the instructions provided with the equipment powered by this engine for any safety precautions that should be observed with engine startup, shutdown or operatn STARTING THE ENGINE 1.If the fuel tank is equipped with a valve be sure the fuel valve is in the OPEN or ON position before attempting to start the engine 2 To start a cold engine, pull the choke k ob out to the CLOSED position.
CHOKE KNOB

5 Operate the starter.

START

ELECTRIC STARTER Turn the key to the START position, and hold it there until the engine starts If the engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again. NOTICE Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.
ENGINE SWITCH OFF OH START

OPEN CLOSED

When the engine starts, release the key, allowing it to return to the ON position. RECOIL STARTER (applicable types) Pull the starter grip lightly until you feel resistance, then pull briskly. Return the starter grip gently.

To restart a warm engine, leave the choke lever in the OPEN position. Some engine applications use a remote-mounted choke control rather than the engine mounted chokeever shown here. Refer to the instructions provided by the equipment manufacturer 3. Move the throttle lever away from the MIN position, about 1/3 of the way toward the MAX position
STARTER GRIP

NOTICE Do not allow the starter grip to snap back against the engine. Return it gently to prel.ent damage to the starter.

MIN
6 If the choke knob has been pulled to the CLOSED position to start the engine, gradually push it to the OPEN position as the engine warms up.
CHOKE KNOB

Some engine applications use a remote mounted throttle control rather than the engine mounted throttle lever shown here Refer to the instructions provided by the equipment manufacturer

II

OPEN CLOSED

ENGLISH

STOPPING THE ENGINE

SETTING ENGINE SPEED

To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. Refer to the instructions provided by the equipment manufacturer. 1.Move the throttle lever to the MIN. position. Some engine applications use a remote-mounted throttle control rather than the engine-mounted throttle lever shown here.

Position the throttle lever for the desired engine speed. Some engine applications use a remote-mounted throttle control rather than the engine-mounted throttle lever shown here. Refer to the instructions provided by the equipment manufacturer. For engine speed recommendations, refer to the instructions provided with the equipment powered by this engine.

MAX.

MIN.

MIN.

2.Turn the engine switch to the OFF position.

ENGINE SWITCH

OFF

OFF

ON

START

3 If the fuel tank is equipped with a valve, turn the fuel valve to the CLOSED or OFF position.

L,

ENGLISH

SERVICING YOUR ENGINE

THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical and troublefree operation. It will also help reduce pollution.

SAFETY PRECAUTIONS

Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate

the engine.

A WARNING
Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner's manual. To help you properly care for your engine, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic.

Burns from hot parts.

Let the engine and exhaust system cool before touching.

Injury from moving parts.

Do not run the engine unless instructed to do so. Read the instructions before you begin, and make sure you have the tools and skills required. To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and flames away from all fuel related parts. Remember that an authorized Honda servicing dealer knows your engine best and is fully equipped to maintain and repair it

To ensure the best quality and reliability, use only new genuine The maintenance schedule applies to normal operating conditions. Honda parts or their equivalents for repair and replacement. If you operate your engine under severe conditions, such as sustained high-load or high-temperature operation, or use in MAINTENANCE SCHEDULE unusually wet or dusty conditions, consultyour servicing dealer for recommendations applicable to your individual needs and use. REGULAR SERVICE PERIOD (3) Each First Every 3 Every 6 Every Refer
Perform at every Use Month Months Months Year or or or or 20 Hrs 50 Hrs 100 Hrs 300 Hrs to Page

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are "certified" to EPA standards. MAINTENANCE SAFETY

indicated month or operating hour interval, whichever comes first. ITEM Engine oil Engine oil filter Check level Change Replace Check Clean Replace Spark plug Check-adjust Replace Spark arrester Clean Check-adjust Check-adjust Clean Check Replace Fuel tank Fuel tube Clean Check o 0

7 0

o
Every 200 Hrs

8 8 9

Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

Air filter

(1)
0

*
10

0 0 0 0 (2) 0 (2) After every 500 Hrs. (2) 0 0 (2) Every year (2) Every 2 years (Replace if necessary) (2)

L~~WARNING
Failure to properly follow maintenance instructions
and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in this owner's manual.
(applicable types) Idle speed Valve clearance Combustion chamber Fuel filter

11

* * * * * * 10 * * * * * *

* Replace the paper air filter element only. * * Refer to the Shop Manual. (1) Service more frequently when used in dusty areas. (2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to Honda shop manual for service procedures. (3) For commercial use, log hours of operation to determine proper maintenance intervals. Failure to follow this maintenance schedule could result in nonwarrantable failures. 6
ENGLISH

REFUELING Recommended Fuel Unleaded gasoline U.S. Except U S.

ENGINE OIL Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. Pump octane rating 86 or higher Research octane rating 91 or higher Pump octane rating 86 or higher Recommended Oil Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SJ, SL, or equivalent. Always check the API service label on the oil container to be sure it includes the letters SJ, SL, or equivalent. SAE Viscosity Grades

eimms.o.

This engine is certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life.

A WARNING
Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling. Stop engine and keep heat, sparks, and flame away. Refuel only outdoors. Wipe up spills immediately.

.20 0 1) 40

e4 m

10 100. 1 ao 4111.0

ao

-/0 -10 0 1 '0

AMBIENT TEMPERATURE

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 indicated range. Oil Level Check

NOTICE Fuel can damage paint and some types of plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under the Distributor's Limited Warranty. Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid getting dirt or water in the fuel tank. Occasionally you may hear a light "spark knock" or "pinging" (metallic rapping noise) while operating under heavy loads. This is no cause for concern. If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda servicing dealer. NOTICE Running the engine with persistent spark knock or pinging can cause engine damage. Running the engine with persistent spark knock or pinging is considered misuse, and the Distributor's Limited Warranty does not cover parts damaged by misuse. 1. With the engine stopped and on a level surface, remove the fuel tank cap and check the fuel level. Refill the tank if the fuel level is low. Refer to the instructions provided with the equipment powered by this engine for refuelling. Refuel in a well ventilated area before starting the engine. If the engine has been running, allow it to cool. Refuel carefully to avoid spilling fuel It may be necessary to lower the fuel level depending on operating conditions After refueling, tighten the fuel tank cap securely. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc. Spilled fuel is not only a fire hazard, it causes environmental damage. Wipe up spills immediately. For information regarding oxygenated fuels, please refer to page 16 .

Check the engine oil level with the engine stopped and in a level position. 1.GX670 ONLY: Start the engine and let it idle for 1 or 2 minutes. Stop the engine and wait for 2 or 3 minutes. 2.Remove the dipstick and wipe it clean. 3.Fully insert the dipstick, then remove it to check the oil level. 4.If the oil level is low, remove the oil filler cap, and fill to the upper limit mark on the dipstick with the recommended oil. 5.Reinstall the dipstick and filler cap.

NOTICE Running the engine with a low oil level can cause engine damage The Oil Alerts system (applicable types) will automatically stop the engine before the oil level falls below the safe limit. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup.

ENGUSH

Oil Change Drain the used oil when the engine is warm. Warm oil drains quickly and completely 1. Place a suitable container below the engine to catch the used oil, then remove the filler cap, drain bolt and washer. 2.Allow the used oil to drain completely, then reinstall the drain bolt and new washer, and tighten the drain bolt securely. 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 down a drain.
FILLER CAP SEALING WASHER DIPSTICK

OIL FILTER Change 1.Drain the engine oil, and retighten the drain bolt securely. 2.Remove the oil filter, and drain the oil into a suitable container. Dispose the used oil and filter in a manner compatible with the environment. NOTICE Use an oil filter socket, rather than a strap wrench, to avoid striking and damaging the oil pressure switch.
SEAL

- UPPER

LIMIT LOWER LIMIT

3.Clean the filter mounting base, and coat the seal of the new oil filter with clean engine oil. NOTICE Use only a genuine Honda oil filter or a filter of equivalent quality specified for your model. Using the wrong filter, or a non-Honda filter which is not of equivalent quality, may cause engine damage. 4.Screw on the new oil filter by hand until the seal contacts the filter mounting base, then use an oil filter socket tool to tighten the filter an additional 7/8 turn. Oil filter tightening torque: 22 N-m (2.2 kgf-rn , 16 Ibfft) 5.Refill the crankcase with the specified amount of the recommended oil (see page 7 ) Reinstall the oil filler cap and dipstick. 6.Start the engine, and check for leaks. 7.Stop the engine, and check the oil level as described on page 7 . If necessary, add oil to bring the oil level to the upper limit mark on the dipstick.

3.With the engine in a level position, fill to the upper limit mark on the dipstick with the recommended oil. NOTICE Running the engine with a low oil level can cause engine damage. The Oil Alert system (applicable types) will automatically stop the engine before the oil level falls belowthe safe limit. However, to avoid the inconvenience of an unexpected shutdown, fill to the upper limit, and check the oil level regularly. 4.Reinstall the filler cap and dipstick securely.

ENGLISH

r I

r AIR CLEANER A dirty air cleaner will restrict air flow to the carburetor, reducing engine performance. If you operate the engine in very dusty areas, clean the air filter more often than specified in the MAINTENANCE SCHEDULE. NOTICE

6. Wipe dirt from the inside of the air cleaner body and cover, using a moist rag. Be careful to prevent dirt from entering the air chamber that leads to the carburetor. 7. Place the foam air filter element in the air cleaner cover, then reinstall the paper air filter element and cover to the air cleaner case. Hook the four latch tabs securely.

Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear. Snorkel Type: This type of damage is not covered by the Distributor's Limited 1.Remove the wing nut from the air cleaner cover, and remove the Warranty. cover. Inspection 2. Remove the wing nut from the paper filter element. Remove the air cleaner cover and inspect the filter elements. 3. Remove the paper filter element from the air cleaner case. Clean or replace dirty filter elements. Always replace damaged filter elements.
PAPER FILTER ELEMENT

Cleaning Standard Type: 1.Release four latch tabs from the air cleaner cover, and remove the cover. 2. Remove the foam filter from the cover. 3.Remove the paper filter from the air cleaner case.

AIR CLEANER COVER AIR CLEANER CASE

WING NUTS

AIR CLEANER COVER

4.Inspect the paper air filter element, and replace it if it is damaged. Always replace the paper air filter element at the scheduled interval (see page 6 ). 5. Clean the paper air filter element if it is to be reused.

FOAM FILTER ELEMENT

PAPER FILTER ELEMENT

Tap the filter element several times on a hard surface to remove dirt, or blow compressed air [not exceeding 207 kPa (2 1 kg/cm2, 30 psi)] through the filter element from the inside. Never try to brush off dirt; brushing will force dirt into the fibers.
AIR CLEANER CASE

6. Wipe dirt from the inside of the air cleaner case and cover, using a moist rag. Be careful to prevent dirt from entering the air duct that leads to the carburetor. 7. Reinstall the paper air filter element. Tighten the air filter wing nut securely.

4 Inspect both air filter elements, and replace them if they are damaged. Always replace the paper air filter element at the scheduled interval (see page 6 ). 5. Clean the air filter elements if they are to be reused. Paper air filter element Tap the filter element several times on a hard surface to remove dirt, or blow compressed air [not exceeding 207 kPa (2 1 kgf/cm2, 30 psi)] through the filter element from the air cleaner case side. Never try to brush off dirt, brushing will force dirt into the fibers. Replace the paper element if it is excessively dirty. Foam air filter element: Clean in warm soapy water, rinse, and allow to dry thoroughly. Or clean in nonflammable solvent and allow to dry. Do not put oil on the foam element.

8. Reinstall the air cleaner cover, and tighten the cover wing nut securely.

ENGLISH

FUEL FILTER Inspection 1. Check the fuel filter for water accumulation or sediment. If no water or sediment is found, reinstall the fuel filter and the air cleaner case

SPARK PLUG Recommended Spark Plugs: ZGR5A (NGK) J16CR U (DENSO) The recommended spark plugs are the correct heat range for normal engine operating temperatures. NOTICE

FUEL FILTER

Incorrect spark plugs can cause engine damage. For good performance, the spark plugs must be properly gapped and free of deposits. 1.Disconnect the spark plug caps, and remove any dirt from around the spark plug area.

2. If the fuel filter is found with excessive water accumulation or sediment, take the engine to your authorized Honda servicing dealer.

2.Remove the spark plugs with a 13/16-inch spark plug wrench.

SPARK PLUG WRENCH

3.Inspect the spark plugs. Replace them if damaged, badly fouled, if the sealing washer is in poor condition, or if the electrode is worn.

0.70 0.80 mm (0.028 0.031 In)

4. Measure the spark plug electrode gaps with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode. The gap should be: 0.70 0 80 mm (0.028-0.031 in) 5.Install the spark plug carefully, by hand, to avoid crossthreading.

SEALING WASHER

6. After the spark plug is seated, tighten with a 13/16 inch spark plug wrench to compress the sealing washer. When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. When reinstalling the original spark plug, tighten 1/8 1/4 turn after the spark plug seats to compress the washer . NOTICE A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head. 7.Attach the spark plug caps to the spark plugs.

10

ENGLISH

SPARK ARRESTER (applicable types) Your engine is not factory-equipped with a spark arrester. The spark arrester is optional part. In some areas, it is illegal to operate an engine without a spark arrester. Check local laws and regulations. A spark arrester is available from authorized Honda servicing dealers. The spark arrester must be serviced every 100 hours to keep it functioning as designed If the engine has been running, the muffler will be hot. Allow it to cool before servicing the spark arrester. Spark Arrester Cleaning & Inspection 1. Remove the spark arrester: HIGH-MOUNT MUFFLER TYPE: Remove the special screw from the muffler and remove the spark arrester. SPECIAL SCREW

HELPFUL TIPS & SUGGESTIONS

STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your engine's function and appearance, and will make the engine easier to start when you use it again. Cleaning If the engine has been running, allow it to cool for at least half an hour before cleaning. Clean all exterior surfaces, touch up any damaged paint, and coat other areas that may rust with a light film of oil. NOTICE Using a garden hose or pressure washing equipment can force water into the air cleaner or muffler opening. Water in the air cleaner will soak the air filter, and water that passes through the air filter or muffler can enter the cylinder, causing damage. Fuel Gasoline will oxidize and deteriorate in storage. Deteriorated gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your engine deteriorates during storage, you may need to have the carburetor, and other fuel system components, serviced or replaced. The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled. The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel problems may occur within a few months, or even less if the gasoline was not fresh when you filled the fuel tank. Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under the Distributor's Limited Warranty. You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor. Adding a Gasoline Stabilizer to Extend Fuel Storage Life

SPARK ARRESTER

MUFFLER

SIDE-MOUNT MUFFLER TYPE: Remove the 6 mm flange bolts from the muffler protector and remove the muffler protector. Remove the special screws from the spark arrester and remove the spark arrester from the muffler.
SPECIAL SCREWS 6 mm FLANGE BOLTS

MUFFLER SPARK ARRESTER 6 mm FLANGE BOLT MUFFLER PROTECTOR

2 Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen. The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged.
HIGH-MOUNT MUFFLER TYPE SIDE-MOUNT MUFFLER TYPE

When adding a gasoline stabilizer, fill the fuel tank with fresh gasoline. If only partially filled, air in the tank will promote fuel deterioration during storage. If you keep a container of gasoline for refueling, be sure that it contains only fresh gasoline. 1.Add gasoline stabilizer following the manufacturer's instructions. 2. After adding a gasoline stabilizer, run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor. 3. Stop the engine, and if the fuel tank is equipped with a fuel valve, move the fuel valve to the CLOSED or OFF position

SPARK ARRESTER SCREEN

3 Install the spark arrester and muffler protector in the reverse order of disassembly

ENGLISH

11

Draining the Fuel Tank and Carburetor

A WARNING
Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel. Stop engine and keep heat, sparks, and flame away. Refuel only outdoors. Wipe up spills immediately ----1.Disconnect the fuel line to the engine, and drain the fuel tank into an approved gasoline container. If the fuel tank is equipped with a valve, turn the fuel valve to the OPEN or ON position to enable draining. After draining is completed, reconnect the fuel line. 2.Loosen the carburetor drain screw, and drain the carburetor into an approved gasoline container. After draining is completed, tighten the carburetor drain screw.

Storage Precautions If your engine will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a spark producing electric motor, or where power tools are operated. If possible, avoid storage areas with high humidity, because that promotes rust and corrosion. Keep the engine level in storage. Tilting can cause fuel or oil leakage. Unless all fuel has been drained from the fuel tank, leave the fuel valve in the CLOSED or OFF position to reduce the possibility of fuel leakage. With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials. Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture around the engine, promoting rust and corrosion. If installed, remove the battery and store it in a cool, dry place. Recharge the battery once a month while the engine is in storage. This will help to extend the service life of the battery. Removal from Storage Check your engine as described in the BEFORE OPERATION CHECKS section of this manual (see page 3 ). If the fuel was drained during storage preparation, fill the tank with fresh gasoline. If you keep a container of gasoline for refueling, be sure it contains only fresh gasoline. Gasoline oxidizes and deteriorates over time, causing hard starting. If the cylinders were coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal. TRANSPORTING

DRAIN SCREW Engine Oil

CARBURETOR

1.Change the engine oil (see page 8). 2.Remove the spark plugs (see page10). 3.Pour a tablespoon 5 10 cm3 (5 10 cc) of clean engine oil into each cylinder. 4.Turn the engine for a few seconds by turning the engine switch to the START position to distribute the oil in the cylinders. 5.Reinstall the spark plugs.

If the engine has been running, allow it to cool for at least 15 minutes before loading the engine-powered equipment on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials. Keep the engine level when transporting to reduce the possibility of fuel leakage. If the fuel tank is equipped with a fuel valve, move the fuel valve lever to OFF.

12

ENGLISH

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START 1.Electric starting: Check battery and fuse. 2.Check control positions. Possible Cause Battery discharged. Fuse burnt out. Fuel valve CLOSED or OFF. (If equipped) Choke open. Correction Recharge battery.

FUSE REPLACEMENT The electric starter relay circuit and battery charging circuit are protected by a 25-ampere fuse. If the fuse burns out, the electric starter will not operate. The engine can be started manually if the fuse burns out, but running the engine will not charge the battery. 1.Remove the 6 X 12 mm screw from the rear cover of the engine switch box. 2.Remove the fuse cover, and inspect the fuse. If the fuse is burnt out, remove the fuse cover, then pull out and discard the burnt-out fuse. Install a new 25-ampere fuse, and reinstall the fuse cover. NOTICE

3.Check engine oil level.

Engine switch OFF. Engine oil level low (Oil Alert!' stops engine). Out of fuel. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline. Spark plugs faulty, fouled, or improperly gapped. Spark plugs wet with fuel (flooded engine).

4.Check fuel.

Replace fuse. Move lever to OPEN or ON position. Move lever to CLOSED position unless the engine is warm. Turn engine switch to ON position. Fill with the recommended oil to the proper level (p. 7). Refuel (p. 7). Drain fuel tank and carburetor (p. 12). Refuel with fresh gasoline(p. 7).

Never use a fuse with a rating greater than 25 amperes. Serious

damage to the electrical system or a fire could result. 3.Reinstall the rear cover. Install the 6 X 12 mm screw and tighten it securely.
SWITCH BOX COVER

5 Remove and inspect spark plugs.

Gap, or replace spark plugs (p. 10)

6 X 12 ram SPECIAL SCREW

6 Take engine to an authorized Honda servicing dealer, or refer to shop manual. ENGINE LACKS POWER 1.Check air filter.

Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc. Possible Cause Filter element(s) restricted. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline. Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc.

Dry and reinstall spark plugs. Start engine with throttle lever in FAST position. Replace or repair faulty components as necessary.

Frequent fuse failure usually indicates a short circuit or an overload in the electrical system. If the fuse burns out frequently, take the engine to a servicing Honda dealer for repair.

Correction Clean or replace filter element(s) (P. 9). Drain fuel tank and carburetor (p. 12). Refuel with fresh gasoline (p. 7).

2.Check fuel.

3.Take engine to an authorized Honda servicing dealer, or refer to shop manual.

Replace or repair faulty components as necessary.

ENGLISH

13

TECHNICAL & CONSUMER INFORMATION

TECHNICAL INFORMATION Serial Number Location Record the engine serial number, type and purchase date in the space below. You will need this information when ordering parts and when making technical or warranty inquiries.

Battery Connections for Electric Starter Use a 12-volt battery with an ampere-hour rating of at least 45 Ah. Be careful not to connect the battery in reverse polarity, as this will short circuit the battery charging system. Always connect the positive (+) battery cable to the battery terminal before connecting the negative ( ) battery cable, so your tools cannot cause a short circuit if they touch a grounded part while tightening the positive (+) battery cable end.

WARNING
A battery can explode if you do not follow the correct procedure, seriously injuring anyone nearby. Keep all sparks, open flames, and smoking materials away from the battery. 1. Connect the battery positive (+) cable to the starter solenoid terminal as shown. SERIAL NUMBER & ENGINE TYPE LOCATION 2. Connect the battery negative () cable to an engine mounting bolt, frame bolt, or other good engine ground connection. 3. Connect the battery positive (+) cable to the battery positive (+) terminal as shown. 4. Connect the battery negative () cable to the battery negative () terminal as shown. 5. Coat the terminals and cable ends with grease. NEGATIVE ( ) BATTERY CABLE

Engine serial number: Engine type: Date Purchased: / /

STARTER SOLENOID POSITIVE ( + ) BATTERY CABLE

14

ENGLISH

Remote Control Linkage 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 flexible, braided wire cable.
REMOTE THROTTLE AND REMOTE CHOKE BRAIDED WIRE CABLE TYPE 5 X 16 mm (2) CABLE HOLDER (2) C OKE CABLE 5 X 16 mm (2) CHOKE CABLE (2) CABLE HOLDER (2) WIRE HOLDER (2) 4 X 6 mm (2)

Carburetor Modifications for High Altitude Operation At high altitude,

the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions. High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above 1,500 meters (5,000 feet), have your servicing dealer perform this carburetor modification This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life. Even with carburetor modification, engine horsepower will decrease about 3.5% for each 300-meter (1,000-foot) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.

THROTTLE CABLE 4 x 6 mm (2) WIRE THROTTLE HOLDER (2) CABLE LEFT SIDE CONTROL

SOLID WIRE CABLE TYPE 5 X 16 mm (2) CABLE HOLDER (2)

NOTICE When the carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use. Operation RIGHT SIDE CONTROL at altitudes below 1,500 meters (5,000 feet) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have your servicing 5 X 16 mm (2) dealer return the carburetor to original factory specifications.
CABLE HOLDER (2)

CONTROL LEVER

Nst

CH KE CABLE

CHOKE CABLE

THROTTLE CABLE LEFT SIDE CONTROL

THROTTLE CABLE

CONTROL LEVER

RIGHT SIDE CONTROL

REMOTE THROTTLE AND MANUAL CHOKE CHOKE KNOB ROD CHOKE LEVER 5 X 16 mm CABLE HOLDER

ROD JOINT LINKAGE BUSH

CONTROL LEVER

MANUAL THROTTLE AND MANUAL CHOKE

CHOKE LEVER

THROTTLE ROD

LOCK PIN REASSEMBLY: Install the lock pin in the direction as shown.

CHOKE KNOB ROD

ROD JOINT UNKAGE BUSH

CONTROL LEVER
ENGLISH

15

Oxygenated Fuels

Emission Control System Information

Some conventional gasolines are being blended with alcohol or an Source of Emissions ether compound. These gasolines are collectively referred to as The combustion process produces carbon monoxide, oxides of oxygenated fuels. To meet clean air standards, some areas of the nitrogen, and hydrocarbons. Control of hydrocarbons and oxides United States and Canada use oxygenated fuels to help reduce of nitrogen is very important because, under certain conditions, emissions. they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it If you use oxygenated fuel, be sure it is unleaded and meets the is toxic. minimum octane rating requirements. Honda utilizes lean carburetor settings and other systems to Before using an oxygenated fuel, try to confirm the fuel's contents. reduce the emissions of carbon monoxide, oxides of nitrogen, and Some states/provinces require this information to be posted on hydrocarbons. the pump. The U.S., California Clean Air Acts and Environment Canada The following are the EPA approved percentages of oxygenates: EPA, California and Canadian regulations require all manufacturers to furnish written instructions describing the ETHANOL (ethyl or grain alcohol) 10% by volume operation and maintenance of emission control systems. You may use gasoline containing up to 10% ethanol by volume. Gasoline containing The following instructions and procedures must be followed in ethanol may be marketed under the name order to keep the emissions from your Honda engine within the Gasohol. emission standards. MTBE (methyl tertiary butyl ether) 15% by volume You may use gasoline containing up to 15% MTBE by volume. (methyl or wood alcohol) 5% by volume You may use gasoline containing up to 5% methanol by volumeas long as it also contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of your fuel system. Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. Among those acts that constitute tampering are: Removal or alteration of any part of the intake, fuel, or exhaust systems. Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters. Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption. Replacement Parts The emission control systems on your Honda engine were designed, built, and certified to conform with EPA, California and Canadian emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system. A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations. Maintenance Follow the maintenance schedule on page 7 . Remember that this schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load or high temperature operation, or use in unusually wet or dusty conditions, will require more frequent service.

METHANOL

If you notice any undesirable operating symptoms, try another service station or switch to another brand of gasoline. Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing morethan the percentages of oxygenates mentioned above are not covered under the Distributor's Limited Warranty

16

ENGLISH

Air Index An Air Index Information hang tag/label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution. The durability description is intended to provide you with information relating the engine's emission durability period. The descriptive term indicates the useful life period for the engine's emission control system. See your Emission Control System Warranty for additional information. Descriptive Term Moderate Intermediate Extended Applicable to Emissions Durability Period 50 hours [0-65 cm3 (0-65 cc)] 125 hours [greater than 65 cm3 (65 cc)] 125 hours [0-65 cm3 (0-65 cc)) 250 hours [greater than 65 cm3 (65 cc)) 300 hours [0-65 cm3 (0-65 cc)) 500 hours [greater than 65 cm3 (65 cc)]

Specifications GX610 (QAF-T e) Length X Width X Height Dry weight Engine type Displacement [Bore X Stroke) Max. output Max. torque Engine oil capacity

Fuel consumption Cooling system Ignition system PTO shaft rotation GX620 (12AF-T e) Length X Width X Height Dry weight Engine type Displacement [Bore X Stroke) Max. output Max. torque Engine oil capacity

388 X 457 X 452 mm (15.3 X 18.0 X 17.8 in) 42 kg (93 Ibs) 4-stroke, overhead valve, 2 cylinders (90 V-Twin) 615 cm3 (37.5 cu-in) [77 X 66 mm (3.03 X 2.60 in)] 13.4 kW (18 PS, 18 bhp) at 3,600 rpm 43.1 N-m (4.39 kgf.m, 31.8 lbf-ft) at 2,500 rpm Without oil filter replacement: approximatly 1.1 4 (1.2 US qt , 1.0 Imp qt) With oil filter replacement: approximatly 1.4 4 (1.5 US qt, 1.2 Imp qt) 313 g/kWh (230 g/PSh, 0.51 lb/hph) Forced air Transistorized magneto Counterclockwise

The Air Index Information hang tag/label must remain on the engine until it is sold. Remove the hang tag before operating the engine.

Fuel consumption Cooling system Ignition system PTO shaft rotation GX670 (TAF-T e) Length X Width X Height Dry weight Engine type Displacement [Bore X Stroke) Max. output Max. torque Engine oil capacity

388 X 457 X 452 mm (15.3 X 18.0 X 17.8 in) 42 kg (93 Ibs) 4-stroke, overhead valve, 2 cylinders (90 V-Twin) 615 cm3 (37.5 cu-in) [77 X 66 mm (3.03 X 2.60 in)) 14.9 kW (20 PS, 20 bhp) at 3,600 rpm 44.1 N-m (4.50 kgf-m, 32.5 Ibfft) at 2,500 rpm Without oil filter replacement: approximatly 1.1 4 (1.2 US qt, 1.0 Imp qt) With oil filter replacement: approximatly 1.4 2 (1.5 US qt , 1.2 Imp qt) 313 g/kWh (230 g/PSh, 0.51 lb/hph) Forced air Transistorized magneto Counterclockwise

Fuel consumption Cooling system Ignition system PTO shaft rotation

412 X 471 X 457 mm (16.2 X 18.5 X 18.0 in) 43 kg (95 Ibs) 4-stroke, overhead valve, 2 cylinders (90 V Twin) 671 cm3 (40.9 cu-in) [77 X 72 mm (3.03 X 2.83 in)] 17.9 kW (24 PS, 24 bhp) at 3,600 rpm 50.81\1-rn (5.18 kgf-rn, 37.5 Ibfft) at 2,500 rpm Without oil filter replacement approximatly 1.1 4(1.2 US qt , 1.0 Imp qt) With oil filter replacement: approximatly 1.4 4 (1.5 US qt, 1.2 Imp qt) 360 g/kWh (265 g/PSh, 0.59 lb/hph) Forced air Transistorized magneto Counterclockwise

ENGUSH

17

Tuneup Specifications GX610/620/670 SPECIFICATION ITEM 0.70 0.80 mm Spark plug gap (0.028 0.031 in) 1,400 150 rpm Idle speed Valve clearance (cold) Other specifications

Wiring Diagrams MAINTENANCE Refer to page 10

3A Charge Coil and Switch Box Type
9/11

See your authorized Honda dealer IN: 0.15 0.02 mm See your authorized EX: 0.20 0.02 mm Honda dealer No other adjustments needed.

'm mumnamrs.
BI Black Y Yellow Bu Blue G Green R Red W White (0) (A) (B) (C) (D) (E) (F)

EIESESHEIGI MM. IMMIZI0111.1r4ra

Quick Reference Information Unleaded gasoline (Refer to page 7 ). Fuel U. S. Pump octane rating 86 or higher Except Research octane rating 91 or higher U. S. Pump octane rating 86 or higher Engine oil SAE 10W-30, API SJ or SL, for general use. Refer to page 8. Spark plug ZGR5A (NGK) J16CR-U (DENSO) Maintenance Before each use: Check engine oil level. Refer to page 7. Check air filter. Refer to page 9. First 20 hours: Change engine oil. Refer to page 8. Subsequent: Refer to the maintenance schedule on page 6.

Br Brown O Orange Lb Light blue Lg Light green P Pink Gr Gray

-4-0TVIP
(I) (N) (J)

MAIN FUSE ENGINE SWITCH CONTROL BOX OIL ALERT UNIT OIL LEVEL SWITCH FUEL CUT SOLENOID (G) STARTER MOTOR (H) BATTERY (I) CHARGE COIL (3A) (J) LEFT IGNITION COIL (K) LEFT SPARK PLUG IL) RIGHT IGNITION COIL (M) RIGHT SPARK PLUG (N) ENGINE STOP DIODE (0) RECTIFIER

20 A Charge Coil and Switch Box Type

MT Off ON STMT

(A) w

Lc

0-0

00

0-0-0

BI Black Y Yellow Bu Blue G Green R Red W White

Br Brown O Orange Lb Light blue Lg Light green P Pink Gr Gray

(N)

MAIN FUSE ENGINE SWITCH CONTROL BOX OIL ALERT UNIT ~~ (E) OIL LEVEL SWITCH (F) FUEL CUT (G) SOLENOID (G) STARTER MOTOR (H) BATTERY +14 1 04 31 >_ ~~ (I) CHARGE COIL (3A) (J) LEFT IGNITION COIL (I) (K) LEFT SPARK PLUG IL) RIGHT IGNITION COIL (M) RIGHT SPARK PLUG (N) ENGINE STOP DIODE (0) REGULATOR/ RECTIFIER (A) (B) (C) (D)

oE) 1- 1 . =1J

18

ENGLISH

CONSUMER INFORMATION Distributor/Dealer Locator Information United States, Puerto Rico, and U.S. Virgin Islands: Call (800) 426-7701 or visit our website: www.honda-engines.com Canada: Call (888) 9HONDA9 or visit our website: www honda.ca For European Area: visit our website: http://www honda-engines-eu.com

Canada: Honda Canada, Inc. 715 Milner Avenue Toronto, ON M1B 2K8 Telephone: (888) 9HONDA9 (888) 946-6329 English: (416) 299-3400 French: (416) 287-4776 Facsimile: (877) 939-0909 (416) 287-4776 Toll free Local Toronto dialing area Local Toronto dialing area Toll free Local Toronto dialing area

Australia: Honda Australia Motorcycle and Power Equipment Pty. Ltd. 1954 1956 Hume Highway Campbellfield Victoria 3061 Telephone: (03) 9270 1111 Facsimile: (03) 9270 1133 For European Area: Honda Europe NV. European Engine Center

Customer Service Information Servicing dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership's management. The Service Manager, General Manager, or Owner can help. Almost all problems are solved in this way.

http://www.honda -engines-eu.com United States, Puerto Rico, and U.S. Virgin Islands:
If you are dissatisfied with the decision made by the dealership's management, contact the Honda Regional Engine Distributor for your area. If you are still dissatisfied after speaking with the Regional Engine Distributor, you may contact the Honda's Office as shown. All Other Areas: If you are dissatisfied with the decision made by the dealership's management, contact the Honda's Office as shown. (Honda's Office) When you write or call, please provide this information: Equipment manufacturer's name and model number that the engine is mounted on Engine model, serial number, and type (see page 14 ) Name of dealer who sold the engine to you Name, address, and contact person of the dealer who services your engine Date of purchase Your name, address and telephone number A detailed description of the problem United States, Puerto Rico, and U.S. Virgin Islands: American Honda Motor Co., Inc. Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta, GA 30005 8847 Or telephone: (770) 497-6400, 8:30 am - 8:00 pm EST All Other Areas: Please contact the Honda distributor in your area for assistance.

HONDA.
The Power of Dreams
ENGLISH

19

HONDA
The Power of Dreams