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

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.

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

MODEL 13000 TFG, ITEM #165939 Triple Fuel Generator

M165939F

Owner's Manual

G;O*SCC

Please reference serial number when calling customer service.

Customer Service: 1.800-270-0810

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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

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Li uid petroleum gas and natural gas requirements 3 ftt Ma inWdirltrel-- - difi*.aifi'6"'`k : P..- : . .. : ,Wi7i1V7i7,517,4 CAfffe

Generator features 5-6 ,111471:- ,7 Intectiba fglegit&t, R q.v. ii-l_i_471-4-4-WattitVr=gfe

ANSI safety definitions 6 r„ , - .:A.,..tiie, brigolos761-ajiLerrim-,='2,- , -, • - . newt - pr- 6-eam.

Installation 7 Weig--*': ...,,,gv,,, et:—.4W- - .) MAL, `, -_,, 7.,.. • *-.1k,...

Pre-start up • re • aration ' to n 1-,, ,, , 4;',... VW ' l'', . -1 :•tAM4. : - M4V. .1'.

Sto. sin. 10 70

Engine care 10 ",-. '4;,GO-rialatorcardM, :,w,,,, 4 "At ..WWW1114,. r: ..„ II, _ tt ,',-,,, .

Troubleshooting 12

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- 7 ,, Item Number #165939 WlaxirA_LWtibtput***AR.e Continuous Output: Gasoline Liquid Petroleum Gas (LPG) Natural Gas (NG

MaIMML_85601.Wgitt M _

10500 Watts (W) 9600 Watts (W) 8400 Watts (N)

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20 HP Honda Engine En076T_ S'':gb -- s"-IA.4- Fuel Type _

Are. ,N7V-'W":3798 OPI\v-i--g4044._,. Unleaded gasoline/LPG/NG

.40-4.-.4-TTirctiang_e_APO, NG) : .'svgikatvAii0Vii.ColifififWV64014-1ei Min. Flow Range (LPG, NG), 2.2 Gal/Hr (LPG), 3.25 CFM NG F.-301r,g_-liffoitsf-41;,,,4-,i,-.2i,k fism,,Pa--,-10.0 Gallons (38`.-11.t),„ ..47gsg-_ -'-_, - Oil Capacity See Honda Manual Starting Method ...-:., - .: .. -''''!',4f9F`! Electric i'-7.1r,1 120V Receptacle 20 Amp (A) duplex (NEMA 5-20R)

30 Amp (A) locking device (NEMA L5-30R

120/24TIVWe-cepiecle - '

, . ,

-- . 30 Amp (A) locking devices .. ---,-:, f,„ (NEMA L14-30R) --!

4, . --::,-,

,50A_DRiagmight blade (NEM,A14-50R) _ Circuit Breaker (1) 50 Amp (A) thermal magnetic

(1) 30 Amp (A) thermal magnetic (1) 30 Amp (A) thermal, push to reset (2) 30 Amp (A) thermal, push to reset

Battery - ' - - - - ' - - - "- - -

Dimensions _ Length ,i7:91i,r:,W,_,i,77'"-:.,-:,'il'kkiii-L

Width

1-2V DC .

. Group Size: U1-7_______ _ s.:

ti- ,, . :.-.'biti:3527-5719018 cm) !-.. 7.4,-.nr_ 24.25" 61.6 cm)

k-Tafeight lit-il.gd-Mta z'''' ,-iftM. 6'.25"„- (6:MEn) ' -"Vi.-iigkit D Weight 4 340 lb. 155 kg1

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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

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 produ

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 ounces 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.

3

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

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.

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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.

A

6

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.

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

• 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

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

7

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 Example: 120V X 5A = 600W

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 Split-Phase (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 Hp motor Running

Watts RI type Cap type SP type

ffilinifi 1/4 14.40a0.4 700

W3141 9-15

=OW gifMgM 22-32 12-23

WV (3, OL/LP:t"$e. 1175

jai 925* 2400

it41illell Er . 15-25

0424,440g1;

14,2_129k *20 5 NA

EaNAVO NA

g.INM. NA

% 20-40 ,3tuomAwl, 0,141440

1 % 30-50 40-80 R44,„21,%, 0...i.29.00g4

4075 iiti'5Z5Otidi

: -3v§1sof 51-85

a:4,af.,960, 68-136

,M127;22411g,NAZ 3

144.d.5-Ma AM:gal

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

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 seconds. If difficulties in starting a motor are 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.

rQurr7FrtllrowBZ .MairirnutiiiEictinsieri:Caditeriftra Amps

at 240V

Load (watts)

#10 Ga.

Cord

#12 Ga.

Cord

#14 Ga. Cord

#16 Ga.

Cord atm

20 40,0 50' fil''c150'"il fX.1.-6-0e t foz752,,,

4800 TrTfitgq

125' 75' 50' 25' ill'7,iia Imoj,d.4

30' 0:435K Kri.2514, PAI On

40 9600 15' 10' N:rfki....5;wit r,1' * rt, 50tE ti zoom w15wt tardrcil

*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. _, Device Running Watts Aiil:Gbriditicirier (12,000 Btu) , T',14,''' h.. ' 1-700 (g)

500

44-5X44.1000,.. _ Battery Charger (20 Amp) BSIt2§ahiderVigragift, Chain Saw 1200

Feittiiiiitsigmlx2i7P19.,&-WAION. Wkilrial9oo.4 1000 Coffee Maker

LCOTO es":11Pr )rafra,4V50-g414, Wij-ik:;:2000, (a) Compressor (3/4 HP) 1800 (a)

,.*r.,,.:: 1400; (a) fedifilirds-gdriT(1 HP)747' '4-,056'ith,A,',gg-

8

Curling Iron 700 V7.'::-7402-126-0147.20A Disfiwasheri: v-N, T ,*:X4W111,,,..7

Ed! e Trimmer 500 BF:, 1 all 0 c4J,47....tr&Z r---iNe ,i201 two EleCtric Range one element 1500 E :-.6...2111g- L., - ' 1, _24' fT,, .i'z' -": 2gfrie-4'.a, lar-r73- vureawi 1200 a

Hair D er 1200 - dmiligiiM%114g4SaajZt: rargaLitiligr:,-, "

875 mzikstLiyiv:aa2

250

Hand Drill 1/2" 0 , • ItPA:11-.74 M.--IT4 Hand Drill 1/4" U'L e li er .§..A.T.;,P0i.ki .',-fiv4:4,c-51- ,Zn Home Corn uter 150

LiraNYTA.,:, - -.4 m amcirL_7,1figivailm. .:- 800 a Jet Pum

• . 0 e z ' ,....,-..ti..:_.M503:407.., r. '-raiigitataWir Light Bulb

F--- • 100 ° °

—' kVISP A C°T

. iVAMP

,.,' ‘

s„. .0

44.-134- P. -eL.,t.. -tv." • ". 1 iniai

. 4̀ 000;•Wrig Milk Cooler ,iiiidirTFWE Mace 7.- ---M4- ..'''.:- - Oil Fired S ace Htr 140,000 Btu 400

red li•.'--r!.1-41120/0110:;Th-%:I4 &3-tit? -,461- --. Oil Fired S.ace Htr 30,000 Btu 150

Paint S. ra er Airless 1/3 HP 600 a Pal -■ra = an = h = d leg,

Lk.v.,Thm, cry. Radio 200

MEM.' it•Ir:- & ' 200

Rifn -1 • ..:,'''',:., .-, "'riff:Mile- Slow Cooker

y. ubmersi a = 46 ,e2 : M d'''' 80 ..eo",;%-i..,:. subrrrn. 1 HP 2000 a

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

500 Television gain er-l'AA'N''.-tR4.11r : Vs....(11-• [---'Wk ATell-' ! 3 1 Cit-Zi4 Vacuum Cleaner

- - U:,-IL:--iiirAMik&•. R

250 AIDME.,gi 3000 Water Heater

,f_ee , e rininiiik, 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.

EFEED)XV"0kftirrIiks,j1,,ITO

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.

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.

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

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 than when it is running with no load The slight 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.

MOM EIEMMZEOW Atla-T Percent of Generator

Output

Speed (RPM)

Frequency (Hz)

Generator Voltage at 120V

Receptacle W CIVIrta WNW

3600 KIWOM. ,M29Vardg

50 % 60.0 120V 7ATIV t'al:000.-= it 390.ffil ga',564.-ftt

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.

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.

ifkit STARTING_ 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.

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.

Mr—tiNITet-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.

' 1r4 =&G,IN"'"'Ett RE _ , vs"7111

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

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

30

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.

l [

TROUBLESHOOTING Problem

tigtittible Causes RossibleRemediesL, amw-vitcaft—qh.

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) Enaiii°6 speed too,sloiii-

b) Generator is overloaded

a) Defective load connected to generator. b) Defective receptacle. c) Generator overloaded.

a) Engine spew] 'tot,' high

a) Generator is overloaded.

b) Insufficient ventilation.

a) Defective loairConhected.to generator. 6) Broken or loose more

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,_16-e- 6- to to a qua ed

iciairfor adjustmen b) Re ce load ee oad Application section of this manual )_ a) Disconnect load. b) Replace receptacle. c) Reduce the load. (See Load Application section of this manual.)

BriFig generat to a qualified iteci i flitian fo actoknent a) Reduce the load. (See Load Application section of this manual.) b) Make sure there is at least 3 feet of clearance on all sides of generator. a) Discorihect load. b) Bring generator to a qualified technician fo repair c) Reaace,receptacle d) Biipibenerator to a quay ed techniCiadfOr repai e) Bring genera or to a qua ified technician for repair f) Bring generator to a qualified technician for repair a) Reduce the load. (See Load application section of this manual.) b) Clean or replace air filter. c) For LP, the hose should be on the left inlet, For NG, the hose should be on the right inlet, d) Clean or replace spark plug.

:a) Fill fuel tank 72* ALIT)) Fill crankcasel.Wproper oil level;,

Engine will not start.

oltaga too loW

Circuit breaker trips.

otage rob-Tif§11

Generator overheating.

N-o--61--itput voltage

Engine lacks power or sputters.

Engine shuts down during operation.

*IT

c) Defective receptacle d) Defective stator.

e) Defective rotor.

DefectiOe capacitor.

a) Generator is overloaded.

b) Dirty air filter. c) LP/NG hose is connected to the wrong Carburetor inlet.

cl) Fouled s ark plu . _ ap Out of Li IgtfWier

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#35310 Control Panel Wiring Diagram Part No. E35310A Date: 11/20/00

473

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Model No. 35310A Component List

Diag # Part # Description Qty 1 306422 Twist Lock Receptacle, NEMA L14-30R 1 2 306426 Receptacle, 120 Volt, 20 Amp, NEMA 5-20R 1 3 30643 Circuit Breaker, 20 Amp 2 4 306434 Circuit Breaker, 30 Amp 1 5 306423 Receptacle, 120 Volt, 30 Amp, NEMA L5-30R 1 6 31953 Receptacle, 120/240 Volt, 50 Amp, NEMA 14-50R 1 7 31211 Circuit Breaker Mounting Clip 8 8 35309 Panel Face Graphics 1 9 32805 Hour Meter 1

10 31824 Fuel Selector Switch 1 11 31005 Circuit Breaker, 30 Amp 1 12 31223 Circuit Breaker, 50 Amp 1 13 32816 Fuel Selector Switch Wiring Harness 1

B15 305608 Lead Wire, B15 1 B45 305609 Lead Wire, B45 1

G5,G6 305588 Lead Wire Assembly, G5, G6 1 B14 306477 Lead Wire, B14 1 B43 306478 Lead Wire, B43 1 B12 306479 Lead Wire, B12 1 B42 306488 Lead Wire, B42 1 B11 31214 Lead Wire, B11 1 B41 31215 Lead Wire, B41 1 B18 306608 Lead Wire, B18 1 B13 306609 Lead Wire, B13 1 B16 307500 Lead Wire, B16 1 B46 307501 Lead Wire, B46 1 W2 31217 Lead wire, W2 1

W3-W7 31216 Lead Wire Assembly, W3, W4, W5, W6, W7 1 G4 307503 Lead Wire, G4 1 G3 307504 Lead Wire, G3 1 01 307505 Lead Wire, G1 1 B1 307506 Lead Wire, B1 1 B4 307507 Lead Wire, B4 1

W44 35324 Lead Wire, W44 1 B44 306498 Lead Wire, B44 1

sal 419

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#30990 MR2-200 Generator Head Parts Explosion Part No. E30990C Date: 6/2/04

Part No E:10990C Component List Date: 3/3/05

Diag # Part # Description Qty

1 30991 Drive End- Bracket 1 2 30994 Protection Screen 2 3 31013 Phillips Screw 10 4 30995 Fan 1 5 307489 Grommet 1 6 305605 Terminal Box Cover 1 7 31014 M5 X .8, 16mm Long 2 8 31018 M5 X .8, 10mm Long, Green 2 9 31015 M5 X .8, 10mrh Long 4 10 307484 Rubber Cup 2 11 306403 Rear Bearing 1 12 306416 Nylock Nut and Star Washer 1 13 30997 Grill 1 14 31065 Securing Stud Cap 1 15 30999 Fixing Ring 1 16 30992 Rotor Assembly 1 17 307479 Diode 2 18 307481 Varistor 2 19 9910303129 Capacitor, 35uF 1 20 39256 Frame and Stator Assembly 1 21 31017 M5 X .8, Nut 8 22 31011 Brass Jumper 2 23 307478 Terminal Board . 1 24 31022 Securing Stud (333mm) 1

#E35490E Fuel System Explosion Model No. 165939E

In

Model No. E35490E Component List

Diag # Part # Description Qty 1 82187 M6-1.0 X 65mm Socket Head Cap Screw, w/ thread locking patch 2 2 35846 Venturi 1 3 35847 Adapter 1 4 32808 Elbow 1 5 777119 Hose Clamp 2 6 37748 Regulator Wire Harness 1 7 35488 Oil Pressure Switch Wire Harness 1 8 777239 Protective Sleeve 13.2" 9 32811 Gas Hose 16.6"

10 36297 Load Block 1 11 38183 Street Elbow, 3/8" MPT x 1/4" FPT 1 12 38625 Gas Regulator 1 13 32822 1/8" NPT Plug 1 14 32798 Pipe Nipple, 1-5/16" 1 15 777148 LP/NG Fuel Lock Solenoid 1 16 35330 Pipe Nipple, 12" • 1 17 777237 Pipe Hanger 1 18 777238 Hex Nut Coupler 1 19 32821 Lanyard 1 20 32817 Triple Fuel Hang Tag 1 21 35325 Oil Pressure Switch 1 22 35008 0-Ring 1 23 35037 Air Cleaner Riser 1

#E165939H 13000 TFG Parts Explosion Model No. 165939H

Model No. 165939H Component List

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

I

These signal words mean:

A DANGER

A WARNING

A CAUTION

The engine engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects

or other reproductive harm.

1-101%,113.2%. OWNER'S MANUAL

IVIANUEL DE L'UTILISATEUR MANUAL DEL PROPIETARIO

GX670 GX620 • GX670

L

CONTENTS

CE

Iff

d

ra

o_ Le) LLi

INTRODUCTION 1 SAFETY MESSAGES 1 SAFETY INFORMATION 2 SAFETY LABEL LOCATION 2 COMPONENT & CONTROL LOCATION 2 FEATURES 3 BEFORE OPERATION CHECKS 3 OPERATION 4

SAFE OPERATING PRECAUTIONS 4 STARTING THE ENGINE 4 STOPPING THE ENGINE 5 SETTING ENGINE SPEED 5

SERVICING YOUR ENGINE 6 THE IMPORTANCE OF MAINTENANCE 6 MAINTENANCE SAFETY 6 SAFETY PRECAUTIONS 6 MAINTENANCE SCHEDULE 6 REFUELING 7 ENGINE OIL 7

Recommended Oil 7 Oil Level Check 7 Oil Change 8

OIL FILTER 8 AIR CLEANER 9

Inspection 9 Cleaning 9

FUEL FILTER 10

SPARK PLUG 10 SPARK ARRESTER 11

HELPFUL TIPS & SUGGESTIONS 11

STORING YOUR ENGINE 11 TRANSPORTING 12

TAKING CARE OF UNEXPECTED PROBLEMS 13

FUSE REPLACEMENT 13 TECHNICAL & CONSUMER INFORMATION 14

Serial Number Location 14 Battery Connections for Electric Starter 14 Remote Control Linkage 15 Carburetor Modifications for High Altitude Operation 15 Oxygenated Fuels 16 Emission Control System Information 16 Air Index 17 Specifications 17 Tuneup Specifications 18 Quick Reference Information 18 Wiring Diagrams 18

CONSUMER INFORMATION 19 Distributor/Dealer Locator Information 19 Customer Service Information 19

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.

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.

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

4 Q ® C) 10000.2005 06 00X37 Z6C 6001 (Ea Printed in Japan

ENGUSH 1

COMPONENT & CONTROL LOCATION

AIR CLEANER (Snorkel type)

FUEL FILTER

AIR CLEANER

CHOKE KNOB

SPARK PLUG

THROTTLE LEVER

OIL FILTER ENGINE SWITCH

SCREEN GRID (optional parts) FLYWHEEL PTO TYPE

FLYWHEEL PTO TYPE

PROTECTOR TYPE (S.T.D)

RECOIL STARTER EQUIPPED TYPE

STARTER GRIP

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

A ATTENTION T4otooluttlsolben411 of apish. O a skmetaeb VsombollkaolblOokOotama

ofereporMs oonnosirtshomon*Ncokse peollsobo onloolads. h0000digoopthisonetheubt

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

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.

SAFETY LABEL LOCATION

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.

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

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

Read Owner's Manual before operation.

2 ENGLISH

OIL FILLER CAP HIGH-MOUNT MUFFLER (B type)

SPARK PLUG

OIL DRAIN BOLT

SIDE-MOUNT MUFFLER

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.

Always perform a preoperation inspection before each operation, and correct any problem.

BEFORE OPERATION CHECKS

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).

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

Fuel-cut Solenoid

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 fuel-cut 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.

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.

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.

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

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.

ENGLISH 3

• WARMING

STARTER GRIP •

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 .

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

4 Turn the engine switch to the ON position.

ON

O ON 8

START

5 Operate the starter.

ELECTRIC STARTER

Turn the key to the START position, and hold it there until the engine starts

0 OFF

ENGINE SWITCH

START

OFF OH START

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

OPEN

CLOSED

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

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

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.

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.

NOTICE

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

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

OPEN

CLOSED

— MIN

II

4 ENGLISH

ENGINE SWITCH

STOPPING THE ENGINE

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.

2. Turn the engine switch to the OFF position.

SETTING ENGINE SPEED

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.

ENGINE SWITCH OFF

ON 8 OFF START

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

L,

ENGLISH 5

SERVICING YOUR ENGINE

THE IMPORTANCE OF MAINTENANCE

Good maintenance is essential for safe, economical and trouble-free operation. It will also help reduce pollution.

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.

The maintenance schedule applies to normal operating conditions. If you operate your engine under severe conditions, such as sustained high-load or high-temperature operation, or use in unusually wet or dusty conditions, consultyour servicing dealer for recommendations applicable to your individual needs and use.

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

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.

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.

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.

— 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 Honda parts or their equivalents for repair and replacement.

MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD (3)

Perform at every

indicated month or

operating hour interval,

whichever comes first.

Each

Use

First

Month

or

20 Hrs

Every 3

Months

or

50 Hrs

Every 6

Months

or

100 Hrs

Every

Year

or

300 Hrs

Refer

to

Page

ITEM

Engine oil Check level 0 7

Change 0 o 8

Engine oil filter Replace Every

200 Hrs

8

Air filter Check o 9

Clean 0 (1) 9

Replace 0 * Spark plug Check-adjust 0 10

Replace 0

Spark arrester Clean

(applicable types)

0 11

Idle speed Check-adjust 0 (2) * * Valve clearance Check-adjust 0 (2) * * Combustion Clean

chamber

After every 500 Hrs. (2) * *

Fuel filter Check 0 10

Replace 0 (2) * *

Fuel tank Clean Every year (2) * *

Fuel tube Check Every 2 years (Replace if necessary) (2) * *

* 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 non-warrantable failures.

6 ENGLISH

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.

eimms.o.

.20 0 1) 40 e4 10 100.1

ao -/0 -10 0 1'0 m ao 4111.0

AMBIENT TEMPERATURE

REFUELING

Recommended Fuel Unleaded gasoline

U.S. Pump octane rating 86 or higher Except U S. Research octane rating 91 or higher

Pump octane rating 86 or higher

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

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 .

ENGINE OIL

Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil.

Recommended Oil SAE Viscosity Grades

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 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

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 7

FILLER CAP SEALING WASHER

DIPSTICK

-UPPER LIMIT

LOWER LIMIT

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.

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.

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

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 Ibf•ft)

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.

8 ENGLISH

AIR CLEANER COVER AIR CLEANER CASE

j WING NUTS

AIR CLEANER CASE

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

Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered by the Distributor's Limited Warranty.

Inspection

Remove the air cleaner cover and inspect the filter elements. Clean or replace dirty filter elements. Always replace damaged filter elements.

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.

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.

Snorkel Type:

1. Remove the wing nut from the air cleaner cover, and remove the cover.

2. Remove the wing nut from the paper filter element.

3. Remove the paper filter element from the air cleaner case.

PAPER FILTER ELEMENT

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.

AIR CLEANER COVER

FOAM FILTER ELEMENT PAPER FILTER ELEMENT

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.

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.

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.

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

ENGLISH 9

FUEL FILTER

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

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.

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)

SEALING WASHER

0.70 —0.80 mm (0.028 0.031 In)

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

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

5. Install the spark plug carefully, by hand, to avoid cross-threading.

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

SPECIAL SCREW

SPARK ARRESTER

6 mm FLANGE BOLTS

MUFFLER

SPARK ARRESTER 6 mm FLANGE BOLT

MUFFLER PROTECTOR

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.

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

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

SPARK ARRESTER SCREEN

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

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

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

MUFFLER

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.

DRAIN SCREW

CARBURETOR

Engine Oil

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.

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

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

SWITCH BOX COVER

6 X 12 ram SPECIAL SCREW

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START

Possible Cause Correction

1. Electric starting: Check battery and fuse.

Battery discharged.

Recharge battery.

Fuse burnt out. Replace fuse. 2. Check control

positions. Fuel valve CLOSED or OFF. (If equipped)

Move lever to OPEN or ON position.

Choke open. Move lever to CLOSED position unless the engine is warm.

Engine switch OFF.

Turn engine switch to ON position.

3. Check engine oil level.

Engine oil level low (Oil Alert!' stops engine).

Fill with the recommended oil to the proper level (p. 7).

4. Check fuel. Out of fuel. Refuel (p. 7). Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline.

Drain fuel tank and carburetor (p. 12). Refuel with fresh gasoline(p. 7).

5 Remove and inspect spark plugs.

Spark plugs faulty, fouled, or improperly gapped.

Gap, or replace spark plugs (p. 10)

Spark plugs wet with fuel (flooded engine).

Dry and reinstall spark plugs. Start engine with throttle lever in FAST position.

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

Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc.

Replace or repair faulty components as necessary.

ENGINE LACKS • POWER

Possible Cause Correction

1. Check air filter. Filter element(s) restricted.

Clean or replace filter element(s) (P. 9).

2. Check fuel. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline.

Drain fuel tank and carburetor (p. 12). Refuel with fresh gasoline (p. 7).

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

Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc.

Replace or repair faulty components as necessary.

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

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.

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.

ENGLISH 13

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.

NEGATIVE ( — ) BATTERY CABLE

STARTER SOLENOID

POSITIVE ( + ) BATTERY CABLE

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.

SERIAL NUMBER & ENGINE TYPE LOCATION

Engine serial number:

Engine type:

Date Purchased: / /

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.

1. Connect the battery positive (+) cable to the starter solenoid terminal as shown.

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.

14 ENGLISH

ENGLISH 15

CABLE HOLDER CHOKE KNOB ROD 5 X 16 mm

CHOKE LEVER

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

SOLID WIRE CABLE TYPE

LEFT SIDE CONTROL RIGHT SIDE CONTROL

5 X 16 mm (2)

NstCABLE HOLDER (2) CHOKE

CH KE CABLE CABLE

5 X 16 mm (2)

CABLE HOLDER (2)

THROTTLE CABLE

THROTTLE CABLE

CONTROL LEVER

REMOTE THROTTLE AND MANUAL CHOKE

ROD JOINT LINKAGE BUSH CONTROL LEVER

MANUAL THROTTLE AND MANUAL CHOKE LOCK PIN

CHOKE KNOB ROD

ROD JOINT UNKAGE BUSH CONTROL LEVER

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

CHOKE LEVER THROTTLE ROD

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.

NOTICE When the carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use. Operation 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 dealer return the carburetor to original factory specifications.

r •

5 X 16 mm (2)

CABLE HOLDER (2) CHOKE

C OKE CABLE CABLE (2)

5 X 16 mm (2)

CABLE HOLDER (2)

WIRE HOLDER (2)

4 X 6 mm (2)

THROTTLE CABLE

WIRE 4 x 6 mm (2)

HOLDER (2)

LEFT SIDE CONTROL

CONTROL LEVER

RIGHT SIDE CONTROL

THROTTLE CABLE

Oxygenated Fuels

Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions.

If you use oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirements.

Before using an oxygenated fuel, try to confirm the fuel's contents. Some states/provinces require this information to be posted on the pump.

The following are the EPA approved percentages of oxygenates:

ETHANOL — (ethyl or grain alcohol) 10% by volume You may use gasoline containing up to 10% ethanol by volume. Gasoline containing ethanol may be marketed under the name Gasohol.

MTBE

(methyl tertiary butyl ether) 15% by volume You may use gasoline containing up to 15% MTBE by volume.

METHANOL (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.

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

Emission Control System Information

Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.

The U.S., California Clean Air Acts and Environment Canada EPA, California and Canadian regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems.

The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards.

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.

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 Applicable to Emissions Durability Period

Moderate 50 hours [0-65 cm3 (0-65 cc)] 125 hours [greater than 65 cm3 (65 cc)]

Intermediate 125 hours [0-65 cm3 (0-65 cc)) 250 hours [greater than 65 cm3 (65 cc))

Extended 300 hours [0-65 cm3 (0-65 cc)) 500 hours [greater than 65 cm3 (65 cc)]

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

Specifications

GX610 (QAF-T e) Length X Width X

Height 388 X 457 X 452 mm (15.3 X 18.0 X 17.8 in)

Dry weight 42 kg (93 Ibs) Engine type 4-stroke, overhead valve, 2 cylinders (90° V-Twin) Displacement [Bore X Stroke)

615 cm3 (37.5 cu-in) [77 X 66 mm (3.03 X 2.60 in)]

Max. output 13.4 kW (18 PS, 18 bhp) at 3,600 rpm Max. torque 43.1 N-m (4.39 kgf.m, 31.8 lbf-ft) at

2,500 rpm Engine oil capacity 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) Fuel consumption 313 g/kWh (230 g/PSh, 0.51 lb/hph) Cooling system Forced air Ignition system Transistorized magneto PTO shaft rotation Counterclockwise

GX620 (12AF-T e) Length X Width X Height

388 X 457 X 452 mm (15.3 X 18.0 X 17.8 in)

Dry weight 42 kg (93 Ibs) Engine type 4-stroke, overhead valve, 2 cylinders (90° V-Twin) Displacement [Bore X Stroke)

615 cm3 (37.5 cu-in) [77 X 66 mm (3.03 X 2.60 in))

Max. output 14.9 kW (20 PS, 20 bhp) at 3,600 rpm Max. torque 44.1 N-m (4.50 kgf-m, 32.5 Ibf•ft) at

2,500 rpm Engine oil capacity 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) Fuel consumption 313 g/kWh (230 g/PSh, 0.51 lb/hph) Cooling system Forced air Ignition system Transistorized magneto PTO shaft rotation Counterclockwise

GX670 (TAF-T e) Length X Width X Height

412 X 471 X 457 mm (16.2 X 18.5 X 18.0 in)

Dry weight 43 kg (95 Ibs) Engine type 4-stroke, overhead valve, 2 cylinders (90° V Twin) Displacement [Bore X Stroke)

671 cm3 (40.9 cu-in) [77 X 72 mm (3.03 X 2.83 in)]

Max. output 17.9 kW (24 PS, 24 bhp) at 3,600 rpm Max. torque 50.81\1-rn (5.18 kgf-rn, 37.5 Ibf•ft) at

2,500 rpm Engine oil capacity 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) Fuel consumption 360 g/kWh (265 g/PSh, 0.59 lb/hph) Cooling system Forced air Ignition system Transistorized magneto PTO shaft rotation Counterclockwise

ENGUSH 17

Tuneup Specifications GX610/620/670 ITEM SPECIFICATION MAINTENANCE

Spark plug gap

0.70 0.80 mm

(0.028 0.031 in) Refer to page 10

Idle speed 1,400 ± 150 rpm See your authorized Honda dealer

Valve clearance (cold)

IN: 0.15 ± 0.02 mm EX: 0.20 ± 0.02 mm

See your authorized Honda dealer

Other specifications No other adjustments needed.

Quick Reference Information Fuel Unleaded gasoline (Refer to page 7 ).

U. S. Pump octane rating 86 or higher Except U. S.

Research octane rating 91 or higher 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.

Wiring Diagrams

3A Charge Coil and Switch Box Type

9/11

(0)

(N)

-4-0TVIP

EIESESHEIGI MM.

IMMIZ■0111.1r4r-a• mumnamrs.'m

(J)

(I)

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

(A) MAIN FUSE (B) ENGINE SWITCH (C) CONTROL BOX (D) OIL ALERT UNIT

(E) OIL LEVEL SWITCH (F) 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

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

20 A Charge Coil and Switch Box Type

I (A) w

STMT

Off

ON

0-0 MT

0-0 0-0-0

Lc

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)

oE) 1- —1

.=-1J

— - ► (G)

L +141 0431> _►

(A) MAIN FUSE (B) ENGINE SWITCH (C) CONTROL BOX (D) OIL ALERT UNIT (E) OIL LEVEL SWITCH (F) FUEL CUT

SOLENOID (G) STARTER MOTOR (H) BATTERY (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

ENGLISH 18

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

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.

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

Canada: Honda Canada, Inc. 715 Milner Avenue Toronto, ON M1B 2K8

Telephone: (888) 9HONDA9 Toll free (888) 946-6329

English: (416) 299-3400

Local Toronto dialing area

French: (416) 287-4776

Local Toronto dialing area

Facsimile: (877) 939-0909

Toll free

(416) 287-4776

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

http://www.honda-engines-eu.com

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