Honda WX15T Manual

Honda WX15T Manual

Self-priming, centrifugal pump
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How to use this manual
A Few Words About Safety
How to use this manual
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
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Summary of Contents for Honda WX15T

  • Page 1 Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 2: Table Of Contents

    dummyhead dummyhead CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING FUEL SYSTEM CONTROL SYSTEM IGNITION SYSTEM STARTING SYSTEM PUMP ENGINE REMOVAL/INSTALLATION CRANKCASE CYLINDER HEAD MUFFLER INDEX...
  • Page 3 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 4 How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product.
  • Page 5 dummyhead dummyhead How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated Full term term Alternator American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Auto Voltage Regulator...
  • Page 6: Specifications

    dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ·················· TOOLS ················································· SPECIFICATIONS··································· DIMENSIONAL DRAWINGS ····················· PERFORMANCE CURVES ·······················...
  • Page 7 The engine serial number [1] is located on the crank case side cover. The frame serial number [2] is located on the frame. Refer to these numbers when ordering parts and when making technical inquiries. SPECIFICATIONS DIMENSIONS AND WEIGHTS Model WX15T Description code WAHT Type A/CX Overall length 355 mm (14.0 in)
  • Page 8 Fuel used Unleaded gasoline with a pump octane rating 86 or higher Fuel tank capacity 0.77 Liters (0.203 US gal, 0.169 Imp gal) WATER PUMP Model WX15T Type Self-priming, centrifugal pump Drive system Direct coupled Suction port diameter 40 mm (1.5 in) Discharge port diameter 40 mm (1.5 in)
  • Page 9 dummyhead dummyhead SPECIFICATIONS PERFORMANCE CURVES (feet) (Liters/min) (US gal/min) (Imp gal/min) DISCHARGE CAPACITY...
  • Page 10 dummyhead dummyhead SPECIFICATIONS DIMENSIONAL DRAWINGS Unit: mm (in) 275 (10.8) 355 (14.0)
  • Page 11 dummyhead dummyhead MEMO...
  • Page 12: Service Information

    dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ·················· TOOLS ················································· TORQUE VALUES ·································· HARNESS AND TUBE ROUTING ·············· LUBRICATION & SEAL POINTS ···············...
  • Page 13 dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE Unit: mm (in) Part Item Standard Service limit Engine Maximum speed (at no load) 7,800±150 min (rpm) – Idle speed 2,500±200 min (rpm) – Cylinder compression 0.42 MPa (4.3 kgf/cm – 61 psi)/1.000 rpm Cylinder Sleeve I.D.
  • Page 14 dummyhead dummyhead SERVICE INFORMATION TORQUE VALUES Use standard torque values for the fasteners that are not listed in this table. ENGINE Torque values Item Thread Dia. (mm) Remark N·m kgf·m lbf·ft Spark plug M10×1.0 11.8 Crankcase cover bolt M5×0.8 (CT)(1) 0.75 Crankcase side cover bolt M5×0.8 (CT)(1)
  • Page 15 dummyhead dummyhead SERVICE INFORMATION FRAME Torque values Item Thread Dia. (mm) N·m kgf·m lbf·ft Screw 4 mm 0.21 5 mm 0.44 6 mm 0.92 Bolt and nut 5 mm 0.54 6 mm 8 mm 10 mm 12 mm Flange bolt and nut 5 mm 0.54 6 mm...
  • Page 16 dummyhead dummyhead SERVICE INFORMATION TOOLS Float level gauge Attachment, 24×26 mm Driver 07401-0010000 07746-0010700 07749-0010000 Attachment, 28×30 mm Oil seal driver attachment, 07946-1870100 27.5 x 44 mm 07948-9540000...
  • Page 17 dummyhead dummyhead SERVICE INFORMATION HARNESS AND TUBE ROUTING SPARK PLUG CAP FAN COVER 20° HIGH TENSION WIRE IGNITION COIL STOP SWITCH WIRE ENGINE STOP SWITCH To engine stop switch STOP SWITCH WIRE To oil alert unit To ignition coil To oil level switch OIL ALERT UNIT...
  • Page 18 dummyhead dummyhead SERVICE INFORMATION TUBE CLAMP (A type) FUEL TUBE...
  • Page 19 dummyhead dummyhead MEMO...
  • Page 20: Maintenance

    dummytext 3. MAINTENANCE TOOL···················································· VALVE CLEARANCE CHECK/ADJUSTMENT···························· MAINTENANCE SCHEDULE ···················· COMBUSTION CHAMBER CLEANING······· ENGINE OIL LEVEL CHECK/CHANGE······· FUEL TANK AND FILTER CLEANING/ FUEL TUBE CHECK ······························· AIR CLEANER CHECK/CLEANING ··········· IMPELLER CHECK ······························· 3-10 SPARK PLUG CHECK/ADJUSTMENT/REPLACEMENT ···· IMPELLER CLEARANCE CHECK ··········· 3-10 SPARK ARRESTER CLEANING (Optional part) ·······································...
  • Page 21: Tool

    dummyhead dummyhead MAINTENANCE TOOL MAINTENANCE Vacuum tester 07APJ-YB3A100...
  • Page 22: Maintenance Schedule

    dummyhead dummyhead MAINTENANCE MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (2) Perform at every indicated month or operating hour interval, whichever comes first. Refer to Item page First Every Every Every Every Each use month or 3 months or 6 months or year or two years or 10 hrs.
  • Page 23: Engine Oil Level Check/Change

    dummyhead dummyhead MAINTENANCE ENGINE OIL LEVEL CHECK/CHANGE SERVICE BULLETIN #9 CHECK Place the engine on a level surface. Remove the oil filler cap [1], and wipe the oil level gauge [2] clean. Insert the oil filler cap without screwing it into the oil filler neck.
  • Page 24: Air Cleaner Check/Cleaning

    dummyhead dummyhead MAINTENANCE Add the specified amount of recommended oil into the SAE 10W - 30 is engine. SAE VISCOSITY GRADES recommended for general use. Other ENGINE OIL CAPACITY: viscosities shown in 0.25 liter (0.26 US qt, 0.22 Imp qt) the chart may be used when the RECOMMENDED OIL:...
  • Page 25: Spark Plug

    dummyhead dummyhead MAINTENANCE SPARK PLUG CHECK/ADJUSTMENT/ REPLACEMENT CHECK/ADJUSTMENT Remove the spark plug (page 3-6). Clean the spark plug [1] electrodes with a wire brush [2] or special plug cleaner. Check the following and replace if necessary. – Insulator [3] and sealing washer [4] for damage –...
  • Page 26: Spark Arrester Cleaning (Optional Part)

    dummyhead dummyhead MAINTENANCE SPARK ARRESTER CLEANING (Optional part) The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Touching a hot muffler will severely burn you. Allow the muffler to cool before proceeding. Remove the muffler protector (page 13-2).
  • Page 27: Valve Clearance Check/Adjustment

    dummyhead dummyhead MAINTENANCE VALVE CLEARANCE CHECK/ ADJUSTMENT Valve clearance inspection and adjustment must be performed with the engine cold. Remove the following: – Fuel tank (page 5-3) – Flange bolt (5 x 22 mm) [1] (4) – Fuel tank mount stay [2] –...
  • Page 28: Combustion Chamber Cleaning

    dummyhead dummyhead MAINTENANCE COMBUSTION CHAMBER CLEANING Prepare a protective lining of thick paper or equivalent material with a diameter large enough to fit against the cylinder inner bore, and insert it into the cylinder. Attach a commercially available cleaning brush [1] to an electric drill and clean the combustion chamber.
  • Page 29: Impeller Check

    dummyhead dummyhead MAINTENANCE IMPELLER CHECK Remove the volute case [1]. Check the impeller [1] and volute [2] for damage or excessive wear and replace if necessary. IMPELLER CLEARANCE CHECK Remove the volute case [1] (page 9-4). Measure the depth [2] of the volute case by using the depth gauge or vernier caliper.
  • Page 30 dummyhead dummyhead MAINTENANCE Measure the height of the impeller vanes [1] from the casing cover [2]. Subtract the height of the impeller [1] from the depth of the volute case [2] to obtain the impeller clearance [3]. IMPELLER CLEARANCE: 0.70 - 1.00 mm (0.028 - 0.39 in) If the clearance is not within specification, adjust the clearance by adding or removing adjuster shims [4] (page...
  • Page 31: Pump Inlet Valve Check

    dummyhead dummyhead MAINTENANCE PUMP INLET VALVE CHECK Remove the inlet pipe [1] (page 9-3). Check the pump inlet valve [2] for damage or excessive wear and replace if necessary. PUMP VACUUM TEST Test Procedure Install thread tape or sealant to the vacuum gauge and install in the base plate.
  • Page 32: Troubleshooting

    dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING ················ WATER PUMP TROUBLESHOOTING ········ ENGINE TROUBLESHOOTING ·················...
  • Page 33 dummyhead dummyhead TROUBLESHOOTING BEFORE TROUBLESHOOTING TROUBLESHOOTING • Check that the connectors are connected securely. • Check for sufficient fresh fuel in the fuel tank. • Read the circuit tester's operation instructions carefully, and observe the instructions during inspection. ENGINE TROUBLESHOOTING ENGINE LOCKED UP Remove the pump case and volute case, and (page 9-4)
  • Page 34 dummyhead dummyhead TROUBLESHOOTING ENGINE WON’T START • Check the oil level before troubleshooting (page 3-4). Loosen the carburetor drain screw and check the Check for clogged fuel tank joint or fuel tube fuel flow from the fuel tank (page 5-6) (page 5-3) No fuel Fuel...
  • Page 35 dummyhead dummyhead TROUBLESHOOTING ENGINE SURGES Clean or replace the air cleaner element Check the air cleaner element (page 3-5) Clogged or saturated (page 3-5) Clean Check the valve clearance (page 3-8) Adjust the valve clearance (page 3-8) Abnormal Normal Inspect the spark plug and adjust the spark plug Check the spark plug (page 3-6) Abnormal...
  • Page 36 dummyhead dummyhead TROUBLESHOOTING ENGINE DOES NOT STOP WHEN ENGINE STOP SWITCH IS TURNED OFF (page 7-8) (page 7-5) Check the engine stop switch Replace the engine stop switch Abnormal Normal Check the wire harness connecting the engine Replace the engine wire harness. No continuity stop switch and the ignition coil for open or short circuit.
  • Page 37 dummyhead dummyhead TROUBLESHOOTING WATER PUMP TROUBLESHOOTING Priming water too low. Fill pump housing with water. Won‘t prime Mechanical seal damaged. (page 9-6) Replace Inlet valve damaged. Replace (page 9-3) Suction hose damaged. Replace. Check coupling for proper Air leak. gasket. Tighten parts.
  • Page 38 dummyhead dummyhead TROUBLESHOOTING Check coupling for proper Suction hose air leak. Discharge volume or gasket. pressure too low Tighten parts. Strainer clogged. Clean out. Suction hose damaged. Replace. (page 9-6) Replace Mechanical seal damaged. Replace worn or damaged Impeller clearance excessive. parts.
  • Page 39 dummyhead dummyhead MEMO...
  • Page 40: Fuel System

    dummytext 5. FUEL SYSTEM TOOL···················································· CARBURETOR DISASSEMBLY/ASSEMBLY····················· FUEL TANK REMOVAL/INSTALLATION ···· CARBURETOR INSPECTION ··················· AIR CLEANER REMOVAL/INSTALLATION ······················ PILOT SCREW REPLACEMENT ··············· CARBURETOR REMOVAL/INSTALLATION ······················...
  • Page 41: Tool

    dummyhead dummyhead FUEL SYSTEM TOOL FUEL SYSTEM Float level gauge 07401-0010000...
  • Page 42: Fuel Tank Removal/Installation

    dummyhead dummyhead FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Place a suitable container under the carburetor.
  • Page 43: Air Cleaner Removal/Installation

    dummyhead dummyhead FUEL SYSTEM AIR CLEANER REMOVAL/INSTALLATION Remove the fuel tank and fuel tank tube (page 5-3). AIR CLEANER GASKET AIR CLEANER CASE AIR CLEANER SEAL BOLT (5 x 75 mm) (2) 4.4 N·m (0.45 kgf·m, 3.3 lbf·ft) AIR FILTER AIR CLEANER COVER...
  • Page 44: Carburetor Removal/Installation

    dummyhead dummyhead FUEL SYSTEM CARBURETOR REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the air cleaner (page 5-4).
  • Page 45: Carburetor Disassembly/Assembly

    dummyhead dummyhead FUEL SYSTEM CARBURETOR DISASSEMBLY/ASSEMBLY Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Tampering is a violation of Federal and California law. Remove the carburetor (page 5-5).
  • Page 46: Carburetor Inspection

    dummyhead dummyhead FUEL SYSTEM FLOAT CHAMBER ASSEMBLY Install the float chamber to the carburetor body at an angle as shown. ENGINE SIDE 10° CARBURETOR INSPECTION FLOAT LEVEL HEIGHT Place the carburetor in the position shown, and push in the float with a finger. Measure the distance (float height) between the float top and carburetor body when the leg of the float just starts to push the float valve.
  • Page 47: Pilot Screw Replacement

    dummyhead dummyhead FUEL SYSTEM PILOT SCREW REPLACEMENT Leave the pilot screw [1] and limiter cap [2] in place during carburetor cleaning. Remove only if necessary for carburetor repair. Removal of the limiter cap requires breaking the pilot screw. A new pilot screw and limiter cap must be installed.
  • Page 48: Control System

    dummytext 6. CONTROL SYSTEM CONTROL BASE/GOVERNOR ARM GOVERNOR ADJUSTMENT ····················· REMOVAL/INSTALLATION ······················...
  • Page 49 dummyhead dummyhead CONTROL SYSTEM CONTROL BASE/GOVERNOR ARM CONTROL SYSTEM REMOVAL/INSTALLATION Remove the following: – Fan cover (page 8-2) – Carburetor (page 5-5) THROTTLE RETURN SPRING INSTALLATION: Hook the ends through the big holes in the governor arm GOVERNOR ROD and throttle. Install the spring with the short end in the carburetor.
  • Page 50 dummyhead dummyhead CONTROL SYSTEM GOVERNOR ROD/ THROTTLE RETURN SPRING REMOVAL Remove the air cleaner cover (page 5-4). Disconnect the throttle return spring [1] from the throttle valve. Twist the carburetor and remove the governor rod [2] from the throttle valve. INSTALLATION First, install the governor rod on the throttle valve.
  • Page 51 dummyhead dummyhead MEMO...
  • Page 52: Ignition System

    dummytext 7. IGNITION SYSTEM SYSTEM DIAGRAM ································ OIL LEVEL SWITCH REMOVAL/INSTALLATION ······················ IGNITION SYSTEM TROUBLESHOOTING ····························· OIL LEVEL SWITCH INSPECTION ············ FLYWHEEL/IGNITION COIL IGNITION COIL AIR GAP REMOVAL/INSTALLATION ······················ CHECK/ADJUSTMENT···························· ENGINE STOP SWITCH/OIL ALERT UNIT SPARK TEST········································· REMOVAL/INSTALLATION ······················ IGNITION COIL INSPECTION ··················· ENGINE STOP SWITCH REMOVAL/INSTALLATION ······················...
  • Page 53: System Diagram

    dummyhead dummyhead IGNITION SYSTEM SYSTEM DIAGRAM IGNITION SYSTEM IGNITION COIL ENGINE STOP SWITCH SPARK PLUG ENGINE ALERT LEVEL STOP UNIT SWITCH SWITCH Black Brown Yellow Orange Blue Light blue Green Light green Pink White Gray IGNITION SYSTEM TROUBLESHOOTING NO OR WEAK SPARK AT SPARK PLUG Check the following before troubleshooting: –...
  • Page 54: Flywheel/Ignition Coil Removal/Installation

    dummyhead dummyhead IGNITION SYSTEM FLYWHEEL/IGNITION COIL REMOVAL/INSTALLATION Remove the following: – Fan cover (page 8-2) – Stop switch bracket (page 7-5) – Carburetor (page 5-5) – Control base (page 6-2) • Route the engine wire harness and high-tension wire properly(page 2-6) •...
  • Page 55 dummyhead dummyhead IGNITION SYSTEM FLYWHEEL REMOVAL/INSTALLATION REMOVAL Remove the ignition coil (page 7-3). Holding the flywheel with a commercially available strap wrench [1], remove the nut (10 mm) [2]. Do not loosen the nut holding the flywheel by setting a screw driver or equivalent tool on the fan blade or projection.
  • Page 56: Engine Stop Switch/Oil Alert Unit Removal/Installation

    dummyhead dummyhead IGNITION SYSTEM ENGINE STOP SWITCH/OIL ALERT UNIT REMOVAL/INSTALLATION IGNITION COIL LEAD STOP SWITCH BRACKET OIL ALERT UNIT BOLT (6 x 8 mm) OIL LEVEL SWITCH LEAD HARNESS CLIP ENGINE STOP SWITCH ENGINE STOP SWITCH REMOVAL/INSTALLATION • Remove the engine stop switch only if necessary for engine stop switch...
  • Page 57: Oil Level Switch Removal/Installation

    dummyhead dummyhead IGNITION SYSTEM OIL LEVEL SWITCH REMOVAL/INSTALLATION Remove the following: – Fan cover (page 8-2) – Ignition coil (page 7-3) O-RING OIL LEVEL SWITCH BOLT (5 x 14 mm) (3) OIL LEVEL SWITCH INSPECTION Remove the oil level switch (page 7-6).
  • Page 58: Ignition Coil Air Gap Check/Adjustment

    dummyhead dummyhead IGNITION SYSTEM IGNITION COIL AIR GAP CHECK/ADJUSTMENT Remove the fan cover (page 8-2). Insert a feeler gauge [1] of the proper thickness between the ignition coil [2] and the flywheel [3]. IGNITION COIL AIR GAP: 0.3 – 0.5 mm (0.01 – 0.02 in) •...
  • Page 59: Ignition Coil Inspection

    dummyhead dummyhead IGNITION SYSTEM IGNITION COIL INSPECTION PRIMARY SIDE Attach one lead of the tester to the lead terminal and another tester lead to the iron core, and measure the primary resistance of the ignition coil. RESISTANCE: 0.99 – 1.21 Ω SECONDARY SIDE Attach one lead of the tester to the terminal inside the spark plug cap and another lead to the iron core, and...
  • Page 60: Oil Alert Unit Inspection

    dummyhead dummyhead IGNITION SYSTEM OIL ALERT UNIT INSPECTION Remove the oil alert unit (page 7-5). Check the continuity between the terminals, and oil alert unit body. Use a following range of recommended tester. • TH-5H (KOWA): R x 100 range •...
  • Page 61 dummyhead dummyhead MEMO...
  • Page 62: Starting System

    dummytext 8. STARTING SYSTEM RECOIL STARTER/FAN COVER RECOIL STARTER REMOVAL/INSTALLATION ······················ DISASSEMBLY/ASSEMBLY·····················...
  • Page 63 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER/FAN COVER STARTING SYSTEM REMOVAL/INSTALLATION FAN COVER NUT (5 mm) (3) RECOIL STARTER FAN COVER COLLAR (3)
  • Page 64 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER DISASSEMBLY/ASSEMBLY The recoil spring is wound under high tension and when released from the groove will cause sudden unwinding. Sudden unwinding can cause severe lacerations. Wear gloves and eye protection during this procedure and take care not to allow the spring to come out.
  • Page 65 dummyhead dummyhead STARTING SYSTEM ASSEMBLY The recoil spring is wound under high tension and when released from the groove will cause sudden unwinding. Sudden unwinding can cause severe lacerations. Wear gloves and eye protection during this procedure and take care not to allow the spring to come out.
  • Page 66 dummyhead dummyhead STARTING SYSTEM Hold the starter case and rotate the starter reel three turns in the direction of the arrow for preliminary winding. Pass the starter rope end through the case and pull it outwards [1]. Pass the starter rope through the starter knob and tie the rope so that it can be untied easily [2] by pulling it as shown.
  • Page 67 dummyhead dummyhead MEMO...
  • Page 68: Pump

    dummytext 9. PUMP TOOLS ················································· IMPELLER/CASING COVER REMOVAL/INSTALLATION ······················ INLET PIPE/OUTLET PIPE REMOVAL/INSTALLATION ······················ MECHANICAL SEAL REPLACEMENT ······· CASING/VOLUTE CASE REMOVAL/INSTALLATION ······················...
  • Page 69 dummyhead dummyhead PUMP TOOLS PUMP Driver handle Bearing driver attachment, Oil seal driver attachment, 07749-0010000 28 x 30 mm 27.5 x 44 mm 07946-1870100 07948-9540000...
  • Page 70 dummyhead dummyhead PUMP INLET PIPE/OUTLET PIPE REMOVAL/INSTALLATION SERVICE BULLETIN #9 FILLER CAP O-RING BOLT (6 x 20 mm) (4) OUTLET PIPE OUTLET PACKING INSTALLATION: Install in desired position. Three options to choose from. BOLT (6 x 25 mm) (3) INLET VALVE INLET PIPE INSTALLATION: Check the inlet valve for breakage,...
  • Page 71 dummyhead dummyhead PUMP CASING/VOLUTE CASE REMOVAL/INSTALLATION VOLUTE CASE INSTALLATION: Check the mating surface for damage and nicks. INSPECTION: Inspect the inside for excessive wear or damage. O-RING (174 x 3.5 mm) O-RING (41.5 x 5.7 mm) O-RING SERVICE BULLETIN #9 DRAIN CAP CASING BOLT (8 x 28 mm) (4)
  • Page 72 dummyhead dummyhead PUMP IMPELLER/CASING COVER REMOVAL/INSTALLATION Remove the volute case (page 9-4). CASING COVER RUBBER RING /CERAMIC RING ADJUSTER SHIM WASHER (6 mm) (4) BOLT (6 x 28 mm) (4) IMPELLER INSTALLATION: REMOVAL: Hold the flywheel [1] with a commercially Hold the flywheel [1] with a available strap wrench [2], being careful not to commercially available strap wrench...
  • Page 73 dummyhead dummyhead PUMP MECHANICAL SEAL REPLACEMENT Drive out the mechanical seal [1] from the inside using the special tools. TOOLS: Driver handle [2] 07749-0010000 Bearing driver attachment, 07946-1870100 28 x 30 mm [3] Drive the mechanical seal [1] until it is fully seated on the end using the special tools.
  • Page 74: Engine Removal/Installation

    dummytext 10. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION ·········10-2 10-1...
  • Page 75 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION HANDLE BOLT (6 x 14 mm) (2) FRAME BED NUT (6 mm) (4) BOTTOM RUBBER (4) BOLT (6 x 14 mm) (4) INSTALLATION: Check for cracking, deformation or other damage before installation. Install by aligning with the hole in SCREW (6 x 10 mm) (4) the frame.
  • Page 76: Crankcase

    dummytext 11. CRANKCASE TOOLS CAMSHAFT ·····················································11-2 DISASSEMBLY/ASSEMBLY ····················· 11-9 CRANKCASE COVER REMOVAL/INSTALLATION CRANKCASE COVER/CYLINDER BARREL/ ······················11-3 PISTON/CONNECTING ROD/CRANKSHAFT/ CAMSHAFT INSPECTION ······················ 11-10 PISTON DISASSEMBLY/ASSEMBLY ·····················11-6 OIL SEAL REPLACEMENT ····················· 11-16 GOVERNOR DISASSEMBLY/ASSEMBLY ·····················11-7 11-1...
  • Page 77: Tools

    dummyhead dummyhead CRANKCASE TOOLS CRANKCASE Attachment, 24 x 26 mm Driver 07746-0010700 07749-0010000 11-2...
  • Page 78: Crankcase Cover Removal/Installation

    dummyhead dummyhead CRANKCASE CRANKCASE COVER REMOVAL/INSTALLATION Drain the engine oil (page 3-4). Remove the flywheel (page 7-3). Remove the crankcase side cover (page 11-7). BOLT (5 x 23 mm) (8) OIL FILLER CAP OIL SEAL 7.3 N·m (0.75 kgf·m, 5.4 lbf·ft) INSTALLATION: Be careful not to damage the lip of the oil seal when installing the crankcase cover with the...
  • Page 79 dummyhead dummyhead CRANKCASE CRANKCASE COVER REMOVAL/INSTALLATION REMOVAL Insert a screwdriver or equivalent tool into the recess [1] as shown, and remove the crankcase cover from the cylinder barrel. INSTALLATION Clean the mating surfaces of the cylinder barrel [1] and the crankcase cover using a degreasing cleaning agent or a clean shop towel.
  • Page 80 dummyhead dummyhead CRANKCASE OIL OUTLET VALVE INSTALLATION Align the two projections of the oil outlet valve [1] with the two grooves in the cylinder barrel [2], and install the oil outlet valve. Align the cutout in the stopper plate [3] with the "A" part [4] of the cylinder barrel and set the stopper plate on the oil outlet valve.
  • Page 81: Piston

    dummyhead dummyhead CRANKCASE PISTON DISASSEMBLY/ASSEMBLY Remove the piston (page 11-3). PISTON RINGS ASSEMBLY: Install with the maker mark facing upward as shown. Do not interchange the top ring and the second ring. TOP RING After assembly, check for smooth movement of the piston ring.
  • Page 82: Governor Disassembly/Assembly

    dummyhead dummyhead CRANKCASE GOVERNOR DISASSEMBLY/ASSEMBLY Remove the casing cover (page 9-5). OIL SEAL BOLT (5 x 23 mm) (6) CRANKCASE SIDE COVER 7.3 N·m (0.75 kgf·m, 5.4 lbf·ft) GOVERNOR WEIGHT HOLDER ASSEMBLY: Before installing, check for wear and damage of the gear. Check that the weights move freely.
  • Page 83 dummyhead dummyhead CRANKCASE CRANKCASE SIDE COVER INSTALLATION Wipe out oil from the crankcase side cover/cylinder barrel [1] mating surface with a clean shop towel or a degreasing cleaning agent. Apply a liquid gasket (ThreeBond® 1206/1216E/1207B, Hondabond 4, Hondabond HT or equivalent) [2] as an even bead (1.5 –...
  • Page 84: Camshaft

    dummyhead dummyhead CRANKCASE CAMSHAFT DISASSEMBLY/ASSEMBLY VALVE LIFTER COLLAR CAMSHAFT ROLLER (5 x 29.8 mm) ( Journal and slipper surface ) VALVE LIFTER (2) ( Whole surface ) VALVE LIFTER ROLLER ( Gear teeth, journal, cam profile, and decomper shaft ) CAMSHAFT ASSEMBLY: Be careful not to drop...
  • Page 85: Crankcase Cover/Cylinder Barrel

    dummyhead dummyhead CRANKCASE CRANKCASE COVER/CYLINDER BARREL/PISTON/CONNECTING ROD/ CRANKSHAFT/CAMSHAFT INSPECTION CYLINDER SLEEVE I.D. Measure and record the cylinder I.D. at three levels in both the "X" axis (perpendicular to crankshaft) and the "Y" axis (parallel to crankshaft). Take the maximum reading to determine cylinder wear and taper. STANDARD: 41.800 –...
  • Page 86 dummyhead dummyhead CRANKCASE PISTON PIN O.D. Measure and record the piston pin O.D. at three points (both ends and middle). Take the minimum reading to determine piston pin O.D. STANDARD: 9.994 – 10.000 mm (0.3935 – 0.3937 in) SERVICE LIMIT: 9.950 mm (0.3917 in) If the measurement is less than the service limit, replace the piston pin (page...
  • Page 87 dummyhead dummyhead CRANKCASE PISTON RING END GAP Before inspection, check whether the cylinder sleeve I.D. is within the specification (page 11-10). Measure each piston ring [1] end gap using a feeler gauge. STANDARD: Top/Second: 0.150 – 0.300 mm (0.0059 – 0.0118 in) 0.20 –...
  • Page 88 dummyhead dummyhead CRANKCASE CONNECTING ROD BIG END I.D. Apply engine oil to the connecting rod bolt threads and seating surface. Set the connecting rod lower to the connecting rod upper and tighten the connecting rod bolts to the specified torque. TORQUE: 5.9 N·m (0.6 kgf·m, 4.3 lbf·ft) Measure the connecting rod big end I.D.
  • Page 89 dummyhead dummyhead CRANKCASE CAMSHAFT CAM HEIGHT Measure the cam height. STANDARD: IN/EX: 27.972 mm (1.1013 in) SERVICE LIMIT: IN/EX: 26.972 mm (1.0619 in) If the measurement is less than the service limit, replace the camshaft (page 11-9). CAMSHAFT ROLLER/ VALVE LIFTER ROLLER O.D.
  • Page 90 dummyhead dummyhead CRANKCASE VALVE LIFTER I.D. Measure and record the valve lifter I.D. STANDARD: 5.005 – 5.025 mm (0.1970 – 0.1978 in) SERVICE LIMIT: 5.050 mm (0.1988 in) If the measurement is more than the service limit, replace the valve lifter (page 11-9).
  • Page 91: Oil Seal Replacement

    dummyhead dummyhead CRANKCASE OIL SEAL REPLACEMENT CRANKCASE COVER Clean the mating surface of the oil seal and the 0.7 - 1.7 mm crankcase cover using a clean shop towel or an (0.03 - 0.07 in) equivalent material. Install the oil seal in the crankcase cover in the specified position, using the special tools as shown.
  • Page 92: Cylinder Head

    dummytext 12. CYLINDER HEAD CYLINDER HEAD COVER/VALVE CYLINDER HEAD/VALVE REMOVAL/INSTALLATION ····················· INSPECTION ········································ 12-2 12-4 CYLINDER COMPRESSION CHECK········· 12-3 12-1...
  • Page 93 dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD COVER/VALVE CYLINDER HEAD REMOVAL/INSTALLATION Set the piston at top dead center of the compression stroke. • After installation, inspect the following: – Valve clearance (page 3-8). – Cylinder compression (page 12-3). CYLINDER HEAD COVER BOLT (5 x 12 mm) (4) 5.9 N·m (0.6 kgf·m, 4.3lbf·ft) page 12-3...
  • Page 94 dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD COVER INSTALLATION Wipe out oil from the cylinder head cover/cylinder barrel [1] mating surface with a clean shop towel or a degreasing cleaning agent. Apply a liquid gasket (ThreeBond® 1206/1216E/1207B, Hondabond 4, Hondabond HT or equivalent) [2] as an even bead (1.5 –...
  • Page 95 dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD/VALVE INSPECTION VALVE STEM O.D. Inspect each valve face for pitting or wear irregularities. Inspect each valve stem [1] for bending or abnormal stem wear. Replace the valve if necessary. Measure and record each valve stem O.D. STANDARD: IN: 3.970 –...
  • Page 96 dummyhead dummyhead CYLINDER HEAD PUSH ROD RUNOUT Check both ends of the push rod for wear. Check the push rod for straightness. If necessary, replace the push rod (page 12-2). VALVE ROCKER ARM SHAFT JOURNAL I.D. Measure and record each valve rocker arm shaft journal I.D.
  • Page 97 dummyhead dummyhead MEMO...
  • Page 98: Muffler

    dummytext 13. MUFFLER MUFFLER REMOVAL/INSTALLATION ······················13-2 13-1...
  • Page 99 dummyhead dummyhead MUFFLER MUFFLER MUFFLER REMOVAL/INSTALLATION The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Touching a hot muffler will severely burn you. Allow the muffler to cool before proceeding. MUFFLER INSTALLATION: After removing any carbon deposits from the muffler, install using a plastic hammer.
  • Page 100: Index

    INDEX dummytext INDEX AIR CLEANER CHECK/CLEANING ··························3-5 IMPELLER CLEARANCE CHECK ·························· 3-10 AIR CLEANER REMOVAL/INSTALLATION ················5-4 IMPELLER/CASING COVER BEFORE TROUBLESHOOTING ······························4-2 REMOVAL/INSTALLATION·····································9-5 CAMSHAFT DISASSEMBLY/ASSEMBLY ················ 11-9 INLET PIPE/OUTLET PIPE CARBURETOR DISASSEMBLY/ASSEMBLY··············5-6 REMOVAL/INSTALLATION·····································9-3 CARBURETOR INSPECTION ·································5-7 LUBRICATION & SEAL POINTS ······························2-4 CARBURETOR REMOVAL/INSTALLATION ···············5-5 MAINTENANCE SCHEDULE···································3-3 CASING/VOLUTE CASE REMOVAL/INSTALLATION···9-4...

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