gx160 Ut2

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How to use this manual

A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an 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.
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.
0
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SPECIFICATIONS 1
SERVICE INFORMATION 2
MAINTENANCE 3
TROUBLESHOOTING 4
COVER 5
FUEL SYSTEM 6
GOVERNOR SYSTEM 7
CHARGING SYSTEM 8
IGNITION SYSTEM 9
STARTING SYSTEM 10
OTHER ELECTRICAL 11
MUFFLER 12
CYLINDER HEAD 13
CRANKCASE 14
REDUCTION UNIT 15
WIRING DIAGRAMS 16
INDEX
SUPPLEMENT Z GX120RT2/GX200RT2
SUPPLEMENT Y GX160RT2
SUPPLEMENT X GX120T2/GX160T2/GX200T2
SUPPLEMENT W GX160T2/GX200T2 QPW Types
SUPPLEMENT V GX160UT2/GX200UT2
CYCLONE AIR CLEANER
SUPPLEMENT T GX160UD/GX200UD
PSV61Z4H00E5.2022.02
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INTRODUCTION
This base manual covers the service and repair procedures for the Honda GX120UT2/160UT2/200UT2.
Supplements Z, Y, X, W, V, and T are located after the base manual and build upon it for the additional models shown below. UH2
models should be treated as UT2 models because the only difference is the country where the engine was manufactured.
This base manual and included supplements apply to the following models of engines shown below.
Supplement
Model Serial Number Range
Base Z Y X W V T
GX120UT2 GCBMT-1000001 ~ subsequent
•
GX160UT2 GCBPT-1000001 ~ 3999999
• •
GX200UT2 GCBTT-1000001 ~ subsequent
• •
GX160UH2 GCBCH-1000001 ~ subsequent
•
GX200UH2 GCBDH-1000001 ~ subsequent
•
GX120RT2 GCBMT-1000001 ~ subsequent
• •
GX160RT2 GCBPT-4000001 ~ subsequent
• •
GX200RT2 GCBTT-1000001 ~ subsequent
• •
GX120T2 GCBNT-1000001 ~ subsequent
• •
GX160T2 GCBRT-1000001 ~ subsequent
• • •
GX200T2 GCBUT-1000001 ~ subsequent
• • •
GX160UD GCAHD-1000001 ~ subsequent
• •
GX200UD GCAJD-1000001 ~ subsequent
• •
All information contained in this manual is based on the latest product information available at the time of printing. We reserve the
right to make changes at anytime without notice.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic,
mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and
tables.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to this Honda product, other property, or the environment.
SAFETY MESSAGES
Your safety and the safety of others are very important. To help you make informed decisions, we have provided safety messages
and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards
associated with servicing these products. You must use your own good judgment.
You will find important safety information in a variety of forms, including:
• Safety Labels – on the product.
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.

• Instructions – how to service these products correctly and safely.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS, AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda PRODUCTS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: February 2022
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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.
• Install new gaskets, O-rings, etc. when reassembling.
• When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless
a particular sequence is specified.
• Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
• After reassembly, check all parts for proper installation and operation.
• Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the
threads and ruin the hole.
Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. The
use of incorrect tools and fasteners will damage the unit.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it will be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommend engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use marine grease (water resistant urea based grease).
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use automatic transmission fluid.
( x )( ) Indicates the diameter, length, and quantity of metric bolts used.

page 1-1 Indicates the reference page.
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ABBREVIATIONS
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbreviated term Full term
ACG Alternator
API American Petroleum Institute
Approx. Approximately
Assy. Assembly
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
ATT Attachment
BAT Battery
BDC Bottom Dead Center
BTDC Before Top Dead Center
BARO Barometric Pressure
CKP Crankshaft Position
Comp. Complete
CMP Camshaft Position
CYL Cylinder
DLC Data Link Connector
EBT Engine Block Temperature
ECT Engine Coolant Temperature
ECM Engine Control Module
EMT Exhaust Manifold Temperature
EOP Engine Oil Pressure
EX Exhaust
F Front or Forward
GND Ground
HO2S Heated Oxygen sensor
IAB Intake Air Bypass
IAC Idle Air Control
IAT Intake Air Temperature
I.D. Inside diameter
IG or IGN Ignition
IN Intake
INJ Injection
L. Left
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
O.D. Outside Diameter
OP Optional Part
PGM-FI Programmed-Fuel Injection
P/N Part Number
Qty Quantity
R. Right
SAE Society of Automotive Engineers
SCS Service Check Signal
STD Standard
SW Switch
TDC Top Dead Center
TP Throttle Position
VTEC Variable Valve Timing & Valve Lift Electronic Control
Bl Black G Green Br Brown Lg Light green

Y Yellow R Red O Orange P Pink
Bu Blue W White Lb Light blue Gr Gray
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1. SPECIFICATIONS
SERIAL NUMBER LOCATION ·····················1-2 ENGINE SPECIFICATIONS ························ 1-11
P.T.O. TYPE VARIATION······························1-2 PERFORMANCE CURVES························· 1-12
DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS······················· 1-15

SPECIFICATIONS ·······································1-10
P.T.O. DIMENSIONAL DRAWINGS ··········· 1-21
1-1
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SPECIFICATIONS GX120•GX160•GX200UT2
SERIAL NUMBER LOCATION
SPECIFICATIONS
The model [1], type [2], and engine serial number [3] are stamped on the crankcase.
Refer to them when ordering parts or making technical inquiries.
[1]
[2]
[3]
P.T.O. TYPE VARIATION

GX120UT2
P.T.O. type H L P Q R
HH QH2 QH QX QX RH
Type HX2 HX4 LX4 PX2 QA2 QX2 QX4 QX9
Q4 6 Q4 C9 S2 Q4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Control base Manual Standard
Cyclone
standard
Remote Internal
EXP
Cyclone
Fixed throttle operation
Charge coil 1A
3A
7A
Lamp coil 12 V – 15 W
12 V – 25 W
12 V – 50 W
Starter motor/combination switch
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Reduction Gear
Chain Without clutch
With clutch
1-2
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GX120•GX160•GX200UT2 SPECIFICATIONS
P.T.O. type S T U V W
SH SM UX VEX WM
Type SX4 TX2
Q4 A7 U 9 A3
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Reduction Gear
With clutch
1-3
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GX160UT2
P.T.O. type H L P Q
HH2 HH HXE LH QA QB QH2 QH
Type HX2 HX4 LX2 LX4 PXU QA2
6 Q4 8 Q4 X4 C2 6 Q4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Reduction Gear
With clutch
1-4
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P.T.O. type Q R
QM QM QM QX QX QX QX QX RH
Type QX2 QX4 QX9 RH2 RX4
C6 C8 D6 C9 E2 E8 S2 U Q4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Reduction Gear
With clutch
1-5
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P.T.O. type R S T U V
RX SD1 SH SM SM TXC UX VSD
Type SX4 SX9 SXU TX2 TX4 VA2
U 6 Q4 C7 C9 9 U 9
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Reduction Gear
With clutch
1-6
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P.T.O. type V W
VXE VXU WK WK WM
Type VX2
9 1 S T2 BO
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Reduction Gear
With clutch
1-7
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GX200UT2
P.T.O. type H L P Q R
QH2 QH QX QX QX QX RH
Type HX2 LX4 PXU QX2 QX4 QX9 RH2
6 Q4 B2 C9 E2 E4 Q4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Reduction Gear
With clutch
1-8
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P.T.O. type R S T V
RX SH VSD VXU
Type RX4 SX4 SX9 SXU TX2 VXU
U Q4 9 1
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Reduction Gear
With clutch
1-9
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DIMENSIONS AND WEIGHTS SPECIFICATIONS
P.T.O. type GX120UT2 GX160UT2 GX200UT2
Overall length H* 370 mm (14.6 in) 377 mm (14.8 in) 386 mm (15.2 in)
L* 332 mm (13.1 in) 343 mm (13.5 in) 352 mm (13.9 in)
P, Q, T * 305.5 mm (12.03 in) 312.5 mm (12.30 in) 321.5 mm (12.66 in)
R* 384 mm (15.1 in) 391 mm (15.4 in) 400 mm (15.7 in)
S* 297 mm (11.7 in) 304 mm (12.0 in) 313 mm (12.3 in)
U* 309.8 mm (12.20 in) 316.8 mm (12.47 in) –
V* 315.5 mm (12.42 in) 322.5 mm (12.70 in) 331.5 mm (13.05 in)
W* 317.5 mm (12.50 in) 329.5 mm (12.97 in) –
Overall width H* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
L* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
P, Q, T * 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
R* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
S* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
U* 346 mm (13.6 in) 362 mm (14.3 in) –
V* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
W* 346 mm (13.6 in) 362 mm (14.3 in) –
Overall height H* 329 mm (13.0 in) 346 mm (13.6 in) 346 mm (13.6 in)
L* 329 mm (13.0 in) 346 mm (13.6 in) 346 mm (13.6 in)
P, Q, T * 329 mm (13.0 in) 346 mm (13.6 in) 346 mm (13.6 in)
R* 329 mm (13.0 in) 346 mm (13.6 in) 346 mm (13.6 in)
S* 329 mm (13.0 in) 346 mm (13.6 in) 346 mm (13.6 in)
U* 329 mm (13.0 in) 346 mm (13.6 in) –
V* 329 mm (13.0 in) 346 mm (13.6 in) 346 mm (13.6 in)
W* 329 mm (13.0 in) 346 mm (13.6 in) –
Dry weight H* 15.5 kg (34.2 lbs) 17.6 kg (38.8 lbs) 18.6 kg (41.0 lbs)
L* 14.0 kg (30.9 lbs) 16.1 kg (35.5 lbs) 17.1 kg (37.7 lbs)
P, Q, T * 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) 16.1 kg (35.5 lbs)
R* 18.0 kg (39.7 lbs) 20.0 kg (44.1 lbs) 21.0 kg (46.3 lbs)
S* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) 16.1 kg (35.5 lbs)
U* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) –
V* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) 16.1 kg (35.5 lbs)
W* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) –
Operating weight H* 18.0 kg (39.7 lbs) 21.1 kg (46.5 lbs) 22.1 kg (48.7 lbs)
P, Q, T * 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs) 19.6 kg (43.2 lbs)
R* 21.0 kg (46.3 lbs) 24.0 kg (52.9 lbs) 25.0 kg (55.1 lbs)
U* 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs) –
W* 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs) –
*: P. T. O. type. (page 1-2)
1-10
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ENGINE SPECIFICATIONS
Model GX120UT2 GX160UT2 GX200UT2
Description code GCBMT GCBPT GCBTT
Type 4 stroke, overhead valve, single cylinder, inclined by 25°
Displacement 118 cm3 (7.2 cu–in) 163 cm3 (9.9 cu–in) 196 cm3 (12.0 cu–in)
Bore x stroke 66.0 x 42.0 mm 68.0 x 45.0 mm 68.0 x 54.0 mm
(2.60 x 1.65 in) (2.68 x 1.77 in) (2.68 x 2.13 in)
Net power (SAE J1349) *1 2.6 kW (3.5 HP)/ 3.6 kW (4.9 HP)/ 4.1 kW (5.6 HP)/
3,600 min-1 (rpm) 3,600 min-1 (rpm) 3,600 min-1 (rpm)
Continuous rated power 2.1 kW (2.9 HP)/ 2.9 kW (3.9 HP)/ 3.7 kW (5.0 HP)/
Maximum net torque 7.3 N·m (0.7 kgf·m, 5.4 10.3 N·m (1.1 kgf·m, 7.6 12.4 N·m (1.3 kgf·m, 9
(SAE J1349) *1 lbf·ft)/2,500 min-1 (rpm) lbf·ft)/2,500 min-1 (rpm) lbf·ft)/2,500 min-1 (rpm)
Compression ratio 8.5 : 1 9.0 : 1 8.5 : 1
Fuel consumption (at 1.0 Liter (0.26 US gal, 0.22 1.4 Liters (0.37 US gal, 1.7 Liters (0.45 US gal,
continuous rated power) Imp gal)/h 0.31 Imp gal)/h 0.37 Imp gal)/h
Ignition system C.D.I. (Capacitor Discharge Ignition) type magneto ignition
Ignition timing B.T.D.C. 20°/ B.T.D.C. 18°/ B.T.D.C. 20°/
Recommended spark plug BPR6ES (NGK)/W20EPR-U (DENSO)
Lubrication system Forced splash
Oil capacity 0.56 Liter 0.58 Liter 0.60 Liter
(0.59 US qt, 0.49 Imp qt) (0.61 US qt, 0.51 Imp qt) (0.63 US qt, 0.53 Imp qt)
Recommended oil SAE 10W-30 API service category SJ or higher
Cooling system Forced air
Starting system Recoil or Recoil and Recoil or Recoil and
Recoil Starter
electric starter electric starter
Stopping system Ignition exciter coil circuit open
Carburetor Horizontal type, butterfly valve
Air cleaner Dual type, Dual silent type, Semi dry type, Dual silent type,
Oil bath type, Cyclone type Cyclone type
Governor Mechanical centrifugal
Breather system Reed valve type
Fuel used Unleaded gasoline with a pump octane rating 86 or higher
Fuel tank capacity 2.0 Liters
3.1 Liters (0.82 US gal, 0.68 Imp gal)
(0.53 US gal, 0.44 Imp gal)
Reduction Gear type 0.15 Liter (0.16 US qt, 0.13 Imp qt)
case oil Chain type
capacity (without Shared with engine oil
clutch)
Chain type
0.50 Liter (0.53 US qt, 0.44 Imp qt)
(with clutch)
Clutch Type Centrifugal
Engagement
1,800 min-1 (rpm)
start
Lock 2,200 min-1 (rpm)
*1: The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine
model and measured in accordance with SAE J1349 at 3,600 rpm (net power) and at 2,500 rpm (max net torque). Mass production
engines may vary from this value. Actual power output for the engine installed in the final machine will vary depending on numerous
factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables.
1-11
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PERFORMANCE CURVES
GX120
(N·m) (lbf·ft) (kgf·m)

7.5
5.5
0.75
TORQUE
NET TORQUE
7.0
5.0 0.70
6.5
(kW) (HP) (PS)

3 4 4
NET POWER
3 3
2
OUTPUT
2 2
1 1
RECOMMENDED OPERATING SPEED RANGE
0 0 0
2000 3000 3600
ENGINE SPEED (rpm)
1-12
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GX160

11
8.0 1.1
TORQUE
7.5
10
NET TORQUE 1.0
7.0
9
0.9
(kW)
4
(HP) (PS)
5 5
NET POWER
3 4 4
OUTPUT
3 3
2
2 2
1 1
0 0 0
2000 3000 3600
ENGINE SPEED (rpm)
1-13
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GX200

13
9.5 1.3
9.0
12
TORQUE
NET TORQUE 1.2

8.5
11
8.0 1.1
10
(kW)
5
(HP) (PS)
6 6
NET POWER 5 5
3 4 4
OUTPUT
3 3
2
2 2
1 1
0 0 0
2000 3000 3600
ENGINE SPEED (rpm)
1-14
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DIMENSIONAL DRAWINGS
*: P.T.O. type. (page 1-2)
GX120 (WITHOUT REDUCTION)
Unit: mm (in)
Dual/dual silent: 160 (6.3)

Cyclone: 166 (6.5)
Oil bath: 157 (6.2)
Semi dry: 156 (6.1) Dual/dual silent: 317 (12.5)
115 (4.5) 231 (9.1) Cyclone/Oil bath: 330 (13.0)
Semi dry: 314 (12.4)
Standard: 91 (3.6)
Silent: 104 (4.1)
346 (13.6)
UT2: 329
(13.0)
106 (4.2)
S type*: 75.5 (2.97)

162 (6.4) U, W type*: 75.2 (2.96)
5 (0.2)
96 (3.8)
39.5 (5.56)
P type*: 305.5 (12.03)
Q type*: 305.5 (12.03)
S type*: 297 (11.7)
80 (3.1)
T type*: 305.5 (12.03)
U type*: 309.8 (12.20)
V type*: 315.5 (12.42)
W type*: 317.5 (12.50)
1-15
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GX120 (WITH REDUCTION)
Unit: mm (in)
115 (4.5)
H type*: 45.1 (1.78)

L type*: 66.1 (2.60)
R type*: 89.7 (3.53) H type*: 185.9 (7.32)
L type*: 164.9 (6.49)
R type*: 141.3 (5.56)
346 (13.6) 91 (3.6) 160 (6.3)
317
(12.5)
UT2: 329
(13.0)
H, L type*: 106 (4.2)

R type*: 91.8 (3.61)
H type*: 151.2 (5.95)

162 (6.4) L type*: 110 (4.3)
5 (0.2) R type*: 162.8 (6.41)
96 (3.8)
39.5 (5.56)
H type*: 370 (14.6)

L type*: 332 (13.1)
80 (3.1) R type*: 384 (15.1)
1-16
dummyhead
Unit: mm (in)
121 (4.8)
70 (2.8)

Cyclone: 168 (6.6)
Oil bath: 159 (6.3)
123 (4.8) 239 (9.4) Semi dry: 156 (6.1) Dual/dual silent: 337 (13.3)
Cyclone/Oil bath/Semi dry:
333 (13.1)
419 (16.5) Standard: 93 (3.7)

Silent: 106 (4.2)
362 (14.3)
UT2: 346
(13.6)
106 (4.2)
S type*: 75.5 (2.97)

U, W type*: 75.2 (2.96)
162 (6.4)
5 (0.2)
96 (3.8)
39.5 (5.56)
P type*: 312.5 (12.30)
Q type*: 312.5 (12.30)
S type*: 304 (12.0)
80 (3.1) T type*: 312.5 (12.30)
U type*: 316.8 (12.47)
V type*: 322.5 (12.70)
W type*: 329.5 (12.97)
1-17
dummyhead
Unit: mm (in)
121 (4.8)
70 (2.8)
123 (4.8)
H type*: 45.1 (1.78)

L type*: 66.1 (2.60)
R type*: 89.7 (3.53) H type*: 193.9 (7.63)
L type*: 172.9 (6.81)
R type*: 149.3 (5.88)
419 (16.5)
362 (14.3) 93 (3.7) 160 (6.3)
UT2: 346
(13.6)
337
(13.3)
H, L type*: 106 (4.2)

R type*: 91.8 (3.61)
H type*: 151.2 (5.95)

L type*: 114.5 (4.51)
162 (6.4) R type*: 162.8 (6.41)
5 (0.2)
96 (3.8)
39.5 (5.56) H type*: 377 (14.8)
L type*: 343 (13.5)
R type*: 391 (15.4)
80 (3.1)
1-18
dummyhead
Unit: mm (in)
121 (4.8)
70 (2.8)

Cyclone: 168 (6.6)
Oil bath: 159 (6.3)
Semi dry: 156 (6.1) Dual/dual silent: 339 (13.3)
123 (4.8) 253 (10.0)
Cyclone/Oil bath/Semi dry:
335 (13.2)
433 (17.0)
376 (14.8) 106 (4.2)
UT2: 346
(13.6)
106 (4.2)
S type*: 75.5 (2.97)

U, W type*: 75.2 (2.96)
162 (6.4)
5 (0.2)
96 (3.8)
39.5 (5.56)
P type*: 321.5 (12.66)
Q type*: 321.5 (12.66)
S type*: 313 (12.3)
80 (3.1)
T type*: 321.5 (12.66)
V type*: 331.5 (13.05)
1-19
dummyhead
Unit: mm (in)
121 (4.8)
70 (2.8)
123 (4.8)
H type*: 45.1 (1.78)
L type*: 66.1 (2.60)
R type*: 89.7 (3.53) H type*: 207.9 (8.19)
L type*: 186.9 (7.36)
R type*: 163.3 (6.43)
433 (17.0)
376 (14.8) 106 (4.2) 160 (6.3)
UT2: 346
(13.6) 339
(13.3)
H, L type*: 106 (4.2)

R type*: 91.8 (3.61)
H type*: 151.2 (5.95)

L type*: 114.5 (4.51)
162 (6.4) R type*: 162.8 (6.41)
5 (0.2)
96 (3.8)
39.5 (5.56) H type*: 386 (15.2)
L type*: 352 (13.9)
R type*: 400 (15.7)
80 (3.1)
1-20
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P.T.O. DIMENSIONAL DRAWINGS
WITHOUT REDUCTION
Unit: mm (in)
45° 45°
M8 x 1.25
65.1 (2.56)
M8 x 1.25 (4 PLACES)
88 (3.5)
CRANKSHAFT (P.T.O.)
P type* Unit: mm (in) Q type* Unit: mm (in)
5/16-24UNF-2B 61.7 (2.43)

3/4-16UNF-2ARH
4.73 – 4.78 58.5 (2.30)
61.7 (2.43)
(0.186 – 0.188)
58.5 (2.30)
GX120: Φ 78 (3.1)
GX160/GX200:
Φ 74 (2.9)
16.26 – 16.36
22.5 (0.89) (0.640 – 0.644) 17 (0.7)
Φ 19.025 – 19.050 GX120: Φ 78 (3.1) GX120: Φ 19.000 – 19.050

(0.7490 – 0.4500) GX160/GX200: Φ 74 (2.9) (0.7480 – 0.7500)
GX160/GX200: Φ 19.025 – 19.050
(0.7490 – 0.7500)
1-21
dummyhead
S type* Unit: mm (in) T type* Unit: mm (in)

53.2 (2.09)
5.00 – 5.03 M8 X 1.25

50 (2.0) 61.7 (2.43)
(0.197 – 0.198) 5/8-18UNF-2ARH
58.5 (2.30)
GX120:
Φ 78 (3.1)
GX160/GX200:
Φ 74 (2.9)
GX120: 14.90 – 15.00 23 (0.9)

(0.587 – 0.591)
GX160/GX200: 16.90 – 17.00 GX120: Φ 17.957 – 17.984 (0.7070 – 0.7080) 22.5 (0.89)
(0.665 – 0.669) GX160/GX200: Φ 19.947 – 19.980 (0.7853 – 0.7866) Φ 15.852 – 15.870 (0.6241 – 0.6248)
GX120: Φ 78 (3.1)
GX160/GX200: Φ 74 (2.9)
U type* Unit: mm (in) V type* Unit: mm (in)
1/2-20UNF-2ARH 5/16-24UNF-2B
66 (2.6)
TAPER 2-1/4
9.90 – 10.00 (0.390 – 0.394) 56 (2.2) 71.7 (2.82)
33.5 (1.32)
3.954 – 3.984
(0.1557 – 0.1569) 8 (0.3)
Φ 14.225 – 14.275 (0.5600 – 0.5620)
Φ 18.927 – 19.177
Φ 19.000 – 19.050 (0.7480 – 0.7500) (0.7452 – 0.7550)
Φ 19.830 – 19.843 (0.7807 – 0.7812)

GX120: Φ 78 (3.1)
GX120: Φ 78 (3.1)
GX160/GX200: Φ 74 (2.9)
GX160/GX200: Φ 74 (2.9)
W type* Unit: mm (in)
GX120: M14 x 1.5 GX120: 73.7 (2.90)

GX160: M18 x 1.5 GX160: 78.7 (3.10)
58.7 (2.31)
GX120: Φ 78 (3.1)
GX160: Φ 74 (2.9)
GX120: 12.5 (0.49)

GX160: 15.9 (0.63)
GX120: Φ 17.976 – 17.994 GX120: 70 (2.8)
(0.7077 – 0.7084) GX160: 75 (3.0)
GX160: Φ 19.972 – 19.993
(0.7863 – 0.7871)
1-22
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WITH REDUCTION
H type* Unit: mm (in)
45.1 (1.78)
P.T.O. SHAFT
4.724 – 4.774
(0.1860 – 0.1880) 50 (2.0)
Φ 41.25
(1.624)
48 (1.9)
16.23 – 16.36
(0.639 – 0.644) Φ 19.037 – 19.050
(0.7495 – 0.7500)
REDUCTION UNIT
L type* Unit: mm (in)
P.T.O. SHAFT 45° 45°
M8 x 1.25
5.00 – 5.03 53.2 (2.09)
(0.197 – 0.198) 50 (2.0)
65.1
Φ 41.25
(2.56)
(1.624)
54 (2.1)
23 (0.9)
M8 x 1.25 (6 PLACES) GX120: Φ 17.957 – 17.984

(0.7070 – 0.7080)
66.1 (2.60)
GX160/GX200: Φ 19.947 – 19.980
(0.7853 – 0.7866)
GX120: Φ 14.90 – 15.00 (0.587 – 0.591)

93.5 (3.68)
GX160/GX200: Φ 16.90 – 17.00 (0.665 – 0.669)
REDUCTION UNIT
1-23
dummyhead
R type* Unit: mm (in)
45°
M8 x 1.25
45°
52.7 (2.07)
7.000 – 7.036
(0.2756 – 0.2770)
70
(2.8) Φ 50
(2.0)
50 (2.0)
70 17.90 – 18.00 25 (1.0)

(2.8) (0.705 – 0.709)
P.T.O. SHAFT
Φ 21.947 – 21.980 (0.8641 – 0.8654)
89.7 (3.53)
REDUCTION UNIT M8 x 1.25 (4 PLACES)
1-24
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1-25
dummytext
2. SERVICE INFORMATION
MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-8
TORQUE VALUES ········································2-6 HARNESS AND TUBE ROUTING ·············· 2-10
LUBRICATION & SEAL POINTS··················2-7
2-1
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SERVICE INFORMATION GX120•GX160•GX200UT2

MAINTENANCE STANDARDS
SERVICE INFORMATION
GX120
Unit: mm (in)
Part Item Standard Service limit
Engine Maximum speed (at no load) 3,900 ± 100 min-1 (rpm) –
Idle speed + 200
1,400 min-1 (rpm) –
– 150
Cylinder compression 0.49 – 0.69 MPa (5.0 – 7.0 kgf/cm2, 71 –
–
100 psi)/600 min-1 (rpm)
Cylinder head Warpage – 0.10 (0.004)
Cylinder Sleeve I.D. 60.000 – 60.015 (2.3622 – 2.3628) 60.165 (2.3687)
Piston Skirt O.D. 59.965 – 59.985 (2.3608 – 2.3616) 59.845 (2.3561)
Piston-to-cylinder clearance 0.015 – 0.050 (0.0006 – 0.0020) 0.12 (0.005)
Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.048 (0.5137)
Piston pin Pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.954 (0.5100)
Piston pin-to-piston pin bore
0.002 – 0.014 (0.0001 – 0.0006) 0.08 (0.003)
clearance
Piston rings Ring side clearance Top 0.035 – 0.070 (0.0014 – 0.0028) 0.15 (0.006)
Second 0.045 – 0.080 (0.0018 – 0.0032) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.500 (0.0138 – 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)
Ring width Top 0.950 – 0.970 (0.0374 – 0.0382) 0.93 (0.037)
Second 0.940 – 0.960 (0.0370 – 0.0378) 0.92 (0.036)
Connecting Small end I.D. 13.005 – 13.020 (0.5120 – 0.5126) 13.07 (0.515)
rod Big end side clearance 0.1 – 0.7 (0.004 – 0.028) 1.1 (0.04)
Big end I.D. 26.020 – 26.033 (1.0244 – 1.0249) 26.066 (1.026)
Big end oil clearance 0.040 – 0.063 (0.0016 – 0.0025) 0.12 (0.005)
Crankshaft Crankpin O.D. 25.970 – 25.980 (1.0224 – 1.0228) 25.92 (1.020)
Crankshaft runout – 0.10 (0.004)
Cylinder barrel Camshaft journal I.D. 14.000 – 14.018 (0.5512 – 0.5519) 14.048 (0.5531)
Crankcase Camshaft journal I.D.
14.000 – 14.018 (0.5512 – 0.5519) 14.048 (0.5531)
cover
Valves Valve clearance IN 0.15 ± 0.02 (0.006 ± 0.001) –
EX 0.20 ± 0.02 (0.008 ± 0.001) –
Valve stem O.D. IN 5.468 – 5.480 (0.2153 – 0.2157) 5.318 (0.2094)
EX 5.425 – 5.440 (0.2136 – 0.2142) 5.275 (0.2077)
Valve guide I.D. IN/EX 5.500 – 5.512 (0.2165 – 0.2170) 5.572 (0.2194)
Guide-to-stem IN 0.020 – 0.044 (0.0008 – 0.0017) 0.10 (0.004)
clearance EX 0.060 – 0.087 (0.0024 – 0.0034) 0.12 (0.005)
Valve guide
IN 4.8 – 5.2 (0.19 – 0.20) –
installation height
Valve seat width IN/EX 0.70 – 0.90 (0.028 – 0.035) 2.0 (0.08)
Valve spring free length 30.5 (1.20) 29.0 (1.14)
Valve spring perpendicularity – 1.5° max.
Camshaft Cam height IN 27.500 – 27.900 (1.0827 – 1.0984) 27.450 (1.0807)
EX 27.547 – 27.947 (1.0845 – 1.1003) 27.500 (1.0827)
Camshaft O.D. 13.966 – 13.984 (0.5498 – 0.5506) 13.916 (0.5479)
Carburetor Main jet BE60W A #62 –
BE99A A #60 –
BE61M A #62 –
BE99B A #62 –
Pilot screw opening BE60W A 2-1/8 turns out –
BE99A A 1-5/8 turns out –
BE61M A 2-1/8 turns out –
BE99B A 2-1/8 turns out –
Float height 13.7 (0.54) –
Spark plug Gap 0.70 – 0.80 (0.028 – 0.031) –
Spark plug cap Resistance (20°C/68°F) 7.5 – 12.5 kΩ –
Ignition coil Air gap 0.2 – 0.6 (0.01 – 0.02) –
Primary resistance 0.6 – 0.9 Ω –
Secondary resistance 5.6 – 6.9 kΩ –
2-2
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GX120•GX160•GX200UT2 SERVICE INFORMATION

Lamp coil Resistance 12 V – 50 W 0.18 – 0.23 Ω –
Reduction unit P.T.O. shaft journal O.D. 19.929 – 19.950 (0.7846 – 0.7854) –
(Chain type: P.T.O. shaft journal I.D.
without clutch) 20.000 – 20.021 (0.7874 – 0.7882) –
(Crankcase cover)
Reduction unit Clutch friction disc thickness 3.5 (0.14) 3.0 (0.12)
(Chain type: Clutch plate warpage – 0.10 (0.004)
with clutch)
GX160
Unit: mm (in)
Idle speed + 200
1,400 min-1 (rpm) –
– 150
Cylinder compression 0.49 – 0.69 MPa (5.0 – 7.0 kgf/cm2, 71 –
–
100 psi)/600 min-1 (rpm)
Piston Skirt O.D. 67.985 – 67.995 (2.6766 – 2.6770) 67.845 (2.6711)
Piston pin Pin O.D. 17.994 – 18.000 (0.7084 – 0.7087) 17.954 (0.7068)
0.002 – 0.014 (0.0001 – 0.0006) 0.08 (0.003)
clearance
Second 0.045 – 0.080 (0.0018 – 0.0032) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.500 (0.0138 – 0.0197) 1.0 (0.04)
Oil (side rail) 0.10 – 0.35 (0.004 – 0.014) 1.0 (0.04)
Ring width Top 0.925 – 0.945 (0.0364 – 0.0372) 0.905 (0.0356)
Second 0.940 – 0.960 (0.0370 – 0.0378) 0.92 (0.036)
Big end I.D. 30.020 – 30.033 (1.1819 – 1.1824) 30.066 (1.1837)
14.000 – 14.018 (0.5512 – 0.5519) 14.048 (0.5531)
cover
EX 0.10 ± 0.02 (0.004 ± 0.001) –
Valve stem O.D. IN 5.468 – 5.480 (0.2153 – 0.2157) 5.318 (0.2094)
EX 5.425 – 5.440 (0.2136 – 0.2142) 5.275 (0.2077)
Guide-to-stem IN 0.020 – 0.044 (0.0008 – 0.0017) 0.10 (0.004)
clearance EX 0.060 – 0.087 (0.0024 – 0.0034) 0.12 (0.005)
Valve guide
IN 4.8 – 5.2 (0.19 – 0.20) –
installation height
Valve seat width IN 0.70 – 0.90 (0.028 – 0.035) 2.0 (0.08)
EX 0.90 – 1.10 (0.035 – 0.043) 2.0 (0.08)
Camshaft Cam height IN/EX 27.503 – 27.903 (1.0828 – 1.0985) 27.450 (1.0807)
Camshaft O.D. 13.966 – 13.984 (0.5498 – 0.5506) 13.916 (0.5479)
2-3
dummyhead

Carburetor Main jet BE54C A #70 –
BE54D A #68 –
BE66U A #68 –
BE54P A #70 –
BE54J B #68 –
Pilot screw opening BE54C A 2-1/4 turns out –
BE54D A 1-7/8 turns out –
BE66U A 1-7/8 turns out –
BE54P A 2-1/2 turns out –
BE54J B 1-7/8 turns out –
Spark plug Gap 0.70 – 0.80 (0.028 – 0.031) –
Starter motor Brush length 11.0 (0.43) 6.0 (0.24)
Mica depth 1.6 (0.06) 1.1 (0.04)
Charge coil Resistance 1A 3.15 – 3.85 Ω –
7A 0.22 - 0.30 Ω –
Lamp coil Resistance 12 V – 25 W 0.36 - 0.46 Ω –
12 V – 50 W 0.18 - 0.23 Ω –
without clutch) 20.000 – 20.021 (0.7874 – 0.7882) –
(Crankcase cover)
with clutch)
GX200
Unit: mm (in)
Idle speed + 200
1,400 min-1 (rpm) –
– 150
Cylinder compression 0.35 MPa (3.6 kgf/cm2, 51 psi)/600 min-1 –
(rpm)
Piston Skirt O.D. 67.965 – 67.985 (2.6758 – 2.6766) 67.845 (2.6711)
Piston pin Pin O.D. 17.994 – 18.000 (0.7084 – 0.7087) 17.954 (0.7068)
0.002 – 0.014 (0.0001 – 0.0006) 0.08 (0.003)
clearance
Second 0.045 – 0.080 (0.0018 – 0.0032) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.500 (0.0138 – 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)
Ring width Top 0.950 – 0.970 (0.0374 – 0.0382) 0.93 (0.037)
Second 0.940 – 0.960 (0.0370 – 0.0378) 0.92 (0.036)
Big end I.D. 30.020 – 30.033 (1.1819 – 1.1824) 30.066 (1.1837)
14.000 – 14.018 (0.5512 – 0.5519) 14.048 (0.5531)
cover
2-4
dummyhead

EX 0.20 ± 0.02 (0.008 ± 0.001) –
Valve stem O.D. IN 5.468 – 5.480 (0.2153 – 0.2157) 5.318 (0.2094)
EX 5.425 – 5.440 (0.2136 – 0.2142) 5.275 (0.2077)
Guide-to-stem IN 0.020 – 0.044 (0.0008 – 0.0017) 0.10 (0.004)
clearance EX 0.060 – 0.087 (0.0024 – 0.0034) 0.12 (0.005)
Valve guide
IN 4.8 – 5.2 (0.19 – 0.20) –
installation height
Valve seat width IN/EX 0.70 – 0.90 (0.028 – 0.035) 2.0 (0.08)
EX 27.547 – 27.947 (1.0845 – 1.1003) 27.500 (1.0827)
Camshaft O.D. 13.966 – 13.984 (0.5498 – 0.5506) 13.916 (0.5479)
Carburetor Main jet BE59L A #75 –
BE59N A #75 –
BE59U A #75 –
BE74Y A #78 –
Pilot screw opening BE59L A 1-7/8 turns out –
BE59N A 1-7/8 turns out –
BE74Y A 2-3/4 turns out –
Spark plug Gap 0.70 – 0.80 (0.028 – 0.031) –
Starter motor Brush length 11.0 (0.43) 6.0 (0.24)
Mica depth 1.6 (0.06) 1.1 (0.04)
Charge coil Resistance 1A 3.15 – 3.85 Ω –
without clutch) 20.000 – 20.021 (0.7874 – 0.7882) –
(Crankcase cover)
with clutch)
2-5
dummyhead

TORQUE VALUES
Torque values
Item Tread Dia. (mm)
N·m kgf·m lbf·ft
Crankcase cover bolt (GX120) M6 x 1.0 12 1.2 9
Crankcase cover bolt (GX160/GX200) M8 x 1.25 24 2.4 18
Cylinder head bolt M8 x 1.25 24 2.4 18
Engine oil drain bolt M10 x 1.25 18 1.8 13
Connecting rod bolt (GX120/GX200) M7 x 1.0 12 1.2 9
Connecting rod bolt (GX160) M6 x 1.0 10 1.0 7
Rocker arm pivot bolt M8 x 1.25 (Special bolt) 24 2.4 18
Rocker arm pivot adjusting nut M6 x 0.5 (Special nut) 10 1.0 7
Spark plug M14 x 1.25 (Special) 18 1.8 13
Oil level switch joint nut M10 x 1.25 10 1.0 7
Flywheel nut M14 x 1.5 (Special nut) 75 7.6 55
Fuel tank nut/bolt M6 x 1.0 10 1.0 7
Fuel tank joint M10 x 1.25 2 0.2 1.5
Air cleaner elbow nut M6 x 1.0 9 0.9 6.6
Muffler nut M8 x 1.25 24 2.4 18
Drive sprocket bolt (Reduction unit: chain type (without M8 x 1.25 24 2.4 18
clutch))
Reduction case oil level bolt (Reduction unit: gear type) M12 x 1.5 23 2.3 17
Reduction case oil drain bolt (Reduction unit: chain type M12 x 1.5 23 2.3 17
(with clutch))
Recoil starter center screw M6 x 1.0 (Special bolt) 5.4 0.6 4.0
Fuel strainer cup M24 x 1.0 3.9 0.4 2.9
STANDARD TORQUE VALUES

Torque values
N·m kgf·m lbf·ft
Screw 4 mm 2.1 0.2 1.5
5 mm 4.3 0.4 3.2
6 mm 9 0.9 6.6
Bolt and nut 5 mm 5.3 0.5 3.9
6 mm 10 1.0 7
8 mm 22 2.2 16
10 mm 34 3.5 25
12 mm 54 5.5 40
Flange bolt and nut 5 mm 5.3 0.5 3.9
6 mm 12 1.2 9
8 mm 23 2.3 17
10 mm 40 4.1 30
SH (Small head) flange bolt 6 mm 9 0.9 6.6
CT (Cutting threads) flange bolt (Retightening) 5 mm 5.4 0.6 4.0
6 mm 12 1.2 9
2-6
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LUBRICATION & SEAL POINTS
Material Location Remarks
Engine oil Crankshaft pin and gear teeth
Piston outer surface, ring groove, and piston pin hole
Piston pin outer surface
Piston ring entire surface
Cylinder inner surface
Connecting rod big and small end bearing
Connecting rod bolt threads and seating surface
Camshaft cam lobes and journal
Valve lifter pivot, pivot end, and slipper surface
Valve stem sliding surface and stem end
Valve rocker arm tappet surface and pivot
Rocker arm pivot threads and pivot
Flywheel nut threads and seating surface
Governor weight holder gear and sliding surface
Governor holder shaft journal
Governor arm shaft journal
Cylinder head bolt threads and seating surface
P.T.O. shaft gear teeth and journal Reduction unit (gear type)
Drive sprocket, P.T.O. shaft gear teeth, and journal Reduction unit (chain type:
without clutch)
Drive sprocket, P.T.O. shaft, clutch center gear teeth, Reduction unit (chain type:
and journal with clutch)
Clutch disc, clutch plate entire surface
Multi-purpose grease Oil seal lips
Control lever sliding surface
Recoil starter case pulley sliding surface
Recoil starter ratchet sliding surface
Recoil starter spring retainer inside
Use molybdenum oil solution Camshaft cam profile When installing a new
(mixture of the engine oil and camshaft
molybdenum grease in a ratio
of 1:1)
Hondalock 1, Threebond® Recoil starter center screw threads
2430, or equivalent
Hondalock 3, LOCTITE® 638, Limiter cap inside
or equivalent
2-7
dummyhead

TOOLS
SPECIAL TOOLS
Special tools used in this manual can be ordered using normal American Honda parts ordering procedures.
Float level gauge Remover weight Valve guide driver, 5.5 mm
07401-0010000 07936-371020A 07742-0010100
Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 40 x 42 mm

07746-0010100 07746-0010200 07746-0010900
Attachment, 42 x 47 mm Attachment, 52 x 55 mm Pilot, 20 mm

07746-0010300 07746-0010400 07746-0040500
Pilot, 22 mm Pilot, 25 mm Pilot, 30 mm

07746-0041000 07746-0040600 07746-0040700
2-8
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Driver Puller collar set Bearing remover, 20 mm
07749-0010000 07APC-ZY1A100 07936-3710600
Remover handle Bearing remover, 25 mm Valve guide reamer, 5.5 mm

07936-3710100 07936-ZV10100 07984-200000D
Attachment, 45 x 50 mm Attachment, 62 x 64 mm
07946-6920100 07947-6340400
COMMERCIALLY AVAILABLE TOOLS

Tool name Tool number Application
Steering wheel puller OTC7403 Flywheel removal
Use with 07APC-ZY1A100
Fuel line clip pliers HCP6A Carburetor removal
Steering wheel puller OTC7403 Flywheel removal with starter motor
Use with 07APC-ZY1A100
Two-jaw puller OTC1035 Flywheel removal without starter motor
Valve seat cutter, 31° NWYCU115 Valve seat reconditioning
Valve seat cutter, 45° NWYCU122
Valve seat cutter, 60° MWYCU111
Solid pilot (short) 5.5 mm NWYPM10055SH
Accessory kit NWYKACC246
T-wrench NWYTW505
Adapter, 1/2"-3/8" NWYTW503-1
There are two convenient ways to order: online or by toll-free phone.
• To order online, go to the iN: SERVICE>Tools>Tool and Equipment Program>Online Catalog, and then search by model
number.
• To order by phone, call 1-888-424-6857.
Customer service representatives are available from 7:30 AM until 7:00 PM CT, Monday through Friday.
2-9
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HARNESS AND TUBE ROUTING
Connection of regulator/rectifier, charge/lamp coil, and sub wire harness depend on the application of the engine; therefore, the
routing of these parts is not indicated in this manual.
IGNITION COIL WIRE CYLINDER BARREL RIBS
CARBURETOR INSULATOR
GX120:
HIGH-TENSION CORD
CYLINDER BARREL RIBS
GX160/GX200:
HIGH-TENSION CORD
IGNITION COIL WIRE
CORD HOOK
IGNITION COIL CONNECTOR
2-10
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GX120: GX160/GX200:
FUEL TUBE
BREATHER TUBE
HIGH-TENSION CORD
2-11
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ENGINE STOP SWITCH TYPE
ENGINE STOP SWITCH ONLY:
GX120: GX160/GX200:
CLAMP
IGNITION COIL WIRE
IGNITION COIL WIRE
IGNITION COIL WIRE CONNECTOR IGNITION COIL WIRE

ENGINE STOP SWITCH WIRE ENGINE STOP SWITCH WIRE CONNECTOR
WITH OIL LEVEL SWITCH:

HARNESS CLIP
ENGINE STOP SWITCH WIRES
IGNITION COIL WIRE
To ignition coil
ENGINE STOP SWITCH CONNECTOR
Bl
Bl
Y Y
To oil level switch
HARNESS CLIP
To engine stop switch
IGNITION COIL WIRE CONNECTOR

ENGINE STOP SWITCH WIRE OIL LEVEL SWITCH WIRE
2-12
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WITH OIL LEVEL SWITCH AND OIL ALERT UNIT:
IGNITION COIL WIRE

GX160/GX200:
HARNESS CLIP
CLAMP
IGNITION COIL WIRE
ENGINE STOP OIL ALERT UNIT CONNECTOR To ignition coil To oil alert unit
SWITCH WIRES
OIL ALERT
UNIT WIRES
Y Bl
Bl
Bl
Y
Y
To engine stop switch To oil level switch

ENGINE STOP
SWITCH WIRE
HARNESS CLIP
IGNITION COIL WIRE CONNECTOR OIL LEVEL SWITCH WIRE

2-13
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COMBINATION SWITCH (CONTROL BOX) TYPE
IGNITION COIL WIRE
CHARGE COIL CORD

STARTER SOLENOID WIRE
IGNITION COIL WIRE
CONNECTOR
OIL LEVEL
SWITCH WIRE
TERMINAL
WIRE
OIL ALERT
UNIT WIRE
45 ± 5°
CHARGE COIL
CONNECTOR
TERMINAL WIRE
FASTENER TUBE
CHARGE COIL CORD
HARNESS CLIP
HARNESS CLIP PURSE STARTER MOTOR WIRE
OIL LEVEL SWITCH WIRE
LOCK CLIP
TERMINAL WIRE
STARTER MOTOR OIL LEVEL SWITCH

CONNECTOR CONNECTOR
PURSE LOCK CLIP
TERMINAL WIRE
FASTENER TUBE To ignition coil

HARNESS CLIP
PURSE LOCK CLIP
Bl/R
Gr W To charge coil
To starter motor/
To control box Bl/W Bl/W
starter solenoid
Y To oil level switch
To starter motor/
(W)
starter solenoid
2-14
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WITH CHARGE COIL/LAMP COIL
1 A/3 A CHARGE COIL, 12 V – 15 W/12 V – 25 W LAMP COIL TYPE:
COIL CORD
CORD GROMMET
CORD CLAMPER
7 A CHARGE COIL TYPE:
COIL CORD
CORD GROMMET
CORD CLAMPER
12 V – 50 W LAMP COIL TYPE:
COIL CORD
CORD GROMMET
CORD CLAMPER
2-15
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3. MAINTENANCE
MAINTENANCE SCHEDULE························3-2 SPARK PLUG REPLACEMENT ················· 3-11
ENGINE OIL LEVEL CHECK/CHANGE ·······3-3 SPARK ARRESTER CLEANING················ 3-12
REDUCTION CASE OIL LEVEL CHECK/ IDLE SPEED CHECK/ADJUSTMENT ········ 3-13
CHANGE························································3-4
VALVE CLEARANCE CHECK/
AIR CLEANER CHECK/CLEANING/ ADJUSTMENT ············································ 3-13
REPLACEMENT············································3-7
COMBUSTION CHAMBER CLEANING ····· 3-15
SEDIMENT CUP CLEANING ······················3-10
FUEL TANK AND FILTER CLEANING ······ 3-15
SPARK PLUG CHECK/ADJUSTMENT ······3-11
FUEL TUBE CHECK ··································· 3-16
3-1
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MAINTENANCE GX120•GX160•GX200UT2
MAINTENANCE SCHEDULE
MAINTENANCE
ITEM Perform at every indicated month REGULAR SERVICE PERIOD (2)

or operating hour interval, Every Every Every Refer
whichever comes first. First
Each 3 months 6 months year to
month or
use or or or page
20 hrs.
50 hrs. 100 hrs. 300 hrs.
Engine oil Check level 3-3
Change 3-3
Reduction case oil Check level 3-4
(applicable types) Change 3-5
Air cleaner Check 3-7
(1) (*)(1) 3-7
Clean
(Cyclone type) Every 6 months or 150 hours 3-7
(**) 3-7
Replace
(Cyclone type) Every 2 years or 600 hours 3-7
Sediment cup Clean 3-10
Spark plug Check–adjust 3-11
Replace 3-11
Spark arrester
Clean 3-12
(applicable types)
Idle speed Check–adjust 3-13
Valve clearance Check–adjust 3-13
Combustion chamber Clean After every 500 hours 3-15
Fuel tank and filter Clean 3-15
Fuel tube Check Every 2 years (Replace if necessary) 3-16
(1) Service more frequently when used in dusty areas.

(2) For commercial use, log hours of operation to determine proper maintenance intervals.
(*) Internal vent carburetor with dual element type only.
(**) Replace paper element type only.
3-2
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GX120•GX160•GX200UT2 MAINTENANCE
ENGINE OIL LEVEL CHECK/CHANGE
CHECK
Place the engine on a level surface.
[1]
Remove the oil filler cap [1] and check the oil level
shown into the oil filler neck [2]. [2]
If the oil level is low, fill with recommended oil to the
upper level of the oil filler neck (page 3-3).
Check that the oil filler packing [3] is in good condition;
replace it if necessary.
Install and tighten the oil filler cap securely.
[3]
CHANGE
Place the engine on a level surface and place a suitable
[2] [4]
container under the drain plug bolt [1].
Remove the oil filler cap [2], drain bolt, and drain bolt
washer [3], and drain the oil into a suitable container.
Please dispose of used oil in a manner that is
compatible with the environment. We suggest you take
used oil in a sealed container to your local recycling
center or service station for reclamation. Do not throw it
in the trash, pour it on the ground, or pour it down a
drain.
Used engine oil contains substances that have

been identified as carcinogenic. If repeatedly left in [1] [3]
contact with the skin for prolonged periods, it may
cause skin cancer. Wash your hands thoroughly
with soap and water as soon as possible after SAE VISCOSITY GRADES
contact with used engine oil.
Install the drain bolt with a new drain bolt washer, and
tighten the bolt to the specified torque.
TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft)
SAE 10W - 30 is Add the specified amount of recommended oil into the
recommended for engine.
general use. Other
viscosities shown in
RECOMMENDED OIL:
the chart may be SAE 10W-30
AMBIENT TEMPERATURE
used when the API service category: SJ or higher
average
temperature in your OIL CAPACITY:
area is within the GX120: 0.56 Liter (0.59 US qt, 0.49 Imp qt)
recommended GX160: 0.58 Liter (0.61 US qt, 0.51 Imp qt)
range. GX200: 0.60 Liter (0.63 US qt, 0.53 Imp qt)
After adding the oil, check the oil level.
Check that the oil filler packing [4] is in good condition;
replace it if necessary.
Install and tighten the oil filler cap securely.
Make sure there are no oil leaks.
3-3
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REDUCTION CASE OIL LEVEL CHECK/
CHANGE
• For the chain type (without clutch), refer to the
ENGINE OIL LEVEL CHECK/CHANGE because it
shares the reduction oil with the engine oil
(page 3-3).
CHECK
GEAR TYPE
[1]/[2]
Remove the oil level bolt [1] and oil level bolt washer
[2], and check whether oil flows out.
Fill with recommended oil if it does not flow (page 3-5).
Install the oil level bolt with a new oil level bolt washer,
and tighten it to the specified torque.
CHAIN TYPE (with clutch)

[1]
Remove the oil filler cap/oil level gauge [1], and wipe
the oil level gauge clean.
Insert the oil level gauge without screwing it into the oil
filler neck.
Remove the oil level gauge and check oil level shown [2]
on the oil level gauge.
If the oil level is low, fill with recommended oil to the
[3]
upper level [2] of the oil level gauge (page 3-6).
Check that the O-ring [3] is in good condition; replace it
if necessary.
Install and tighten the oil filler cap/oil level gauge
securely.
3-4
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CHANGE
GEAR TYPE
Remove the oil fill/breather bolt [1].
[2]/[3] [1]
Remove the oil level bolt [2] and oil level bolt washer
[3], tilt the engine, and drain the oil into a suitable
container.
drain.
Used engine oil contains substances that have

been identified as carcinogenic. If repeatedly left in
with soap and water as soon as possible after
contact with used engine oil. SAE VISCOSITY GRADES
SAE 10W - 30 is Fill with the recommended engine oil through the oil fill/
recommended for breather bolt hole until oil begins to run out of the oil
general use. Other level bolt hole.
the chart may be
RECOMMENDED OIL:
used when the SAE 10W-30
average API service category SJ or higher
temperature in your
area is within the OIL CAPACITY: 0.15 Liter (0.16 US qt, 0.13 Imp qt)
recommended AMBIENT TEMPERATURE
Install the oil level bolt with a new oil level bolt washer,
range.
and tighten the bolt to the specified torque.
Install and tighten the oil fill/breather bolt securely.
3-5
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Place the engine on a level surface and place a suitable
[2]
container under the drain plug bolt [1].
Remove the oil filler cap/oil level gauge [2], drain bolt,
and drain bolt washer [3], and drain the oil into a
suitable container.
[4] [1]
drain.
Used engine oil contains substances that have [3]

been identified as carcinogenic. If repeatedly left in
SAE VISCOSITY GRADES
with soap and water as soon as possible after
contact with used engine oil.
Install the drain bolt with a new drain bolt washer, and
tighten the bolt to the specified torque.
SAE 10W - 30 is Add the specified amount of recommended oil into the
recommended for reduction case.
general use. Other
RECOMMENDED OIL:
the chart may be SAE 10W-30 AMBIENT TEMPERATURE
used when the API service category: SJ or higher
average
temperature in your OIL CAPACITY: 0.50 Liter (0.53 US qt, 0.44 Imp qt)
area is within the
After adding the oil, check the oil level.
recommended
range. Check that the O-ring [4] is in good condition; replace it
if necessary.
Install and tighten the oil filler cap/oil level gauge
securely.
3-6
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AIR CLEANER CHECK/CLEANING/
REPLACEMENT
A dirty air filter will restrict air flow to the carburetor,
reducing engine performance. If the engine is operated
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE.
• Operating the engine without the air filters or with the

filter installed loosely will allow dirt to enter the
engine, causing rapid engine wear. Install the air
filters securely.
DUAL, DUAL SILENT TYPE
Remove the following:
[1] [2]
– Nut [1]
– Air cleaner cover [2]
– Wing nut [3]
– Element Assy.
– Grommet [4]
– Inner filter (Paper) [5]
– Outer filter (Foam) [6]
Carefully check both filters for holes or tears and
replace if damaged.
Clean the filters if they are to be reused (page 3-9).
[7] [4]
Installation is in the reverse order of removal.
[3]
• Install the air cleaner cover with its long skirt portion
[7] facing forward.
[5] [6]
3-7
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CYCLONE TYPE
[4]
– Bolt (4 x 6 mm) [1] (3) [5]
– Pre air cleaner case [2] [1]
– Air cleaner guide [3]
– Wing nut [4]
– Air cleaner cover Assy. [5]
– Wing nut [6]
– Element Assy.
– Grommet [7]
– Inner filter (Paper) [8] [3]
– Outer filter (Foam) [9] [6]
replace if damaged. [10]
[7]
Clean the filters if they are to be reused (page 3-9).
[12]
Clean the pre air cleaner case and air cleaner guide.
Check that the air cleaner cover packing [10] is in good
condition; replace it if necessary.
Installation is in the reverse order of removal. [8]
[11]
• Install the pre air cleaner case by align it the groove
[11] and tab [12] of the air cleaner cover Assy. [2]
[9]
LOW PROFILE TYPE

Remove the air cleaner case lid spring [1] and air
[2] [1]
cleaner cover [2].
Remove the pre air cleaner element [3].
Carefully check the air cleaner element and replace if
damaged.
Clean the filter if it is to be reused (page 3-9).
[3]
3-8
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OIL BATH TYPE
[3] [2] [1]
– Wing nut [1]
– Air cleaner cap [2]
– Air cleaner element [4]
Carefully check the element for holes or tears and
replace if damaged. [4]
Clean the element if it is to be reused (page 3-9).
Check the oil contamination and oil level of the cleaner
oil pan [5].
If the oil level is low, fill with the recommended oil
(page 3-3) to the upper level [6] of the cleaner oil pan.
If the oil is dirty, clean the cleaner oil pan and add the
recommended oil to the upper level of the cleaner oil
pan.
OIL CAPACITY: 60 cc
[5] [6]
SEMI DRY TYPE
[3] [2] [1]
– Wing nut [1]
– Air cleaner cap [2]
– Air cleaner element [4]
Carefully check the element for holes or tears and
replace if damaged.
Clean the element if it is to be reused (page 3-9).
[4]
ELEMENT CLEANING
FOAM
Clean the filter [1] in warm soapy water, rinse, and allow
[1] Wash Dip
to dry thoroughly, or clean with a non-flammable
solvent and allow to dry thoroughly.
Dip the filter in clean engine oil, and squeeze out all the Squeeze
excess oil. and dry
Excess oil will restrict air flow through the foam element
and may cause the engine to smoke at startup.
Squeeze thoroughly
3-9
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PAPER
Tap the inner filter [1] lightly several times on a hard
[1]
surface to remove excess dirt, or blow compressed air
lightly (206 kPa [2.11 kgf/cm2, 30 psi] or less) through
the paper filter from the inside out. Never try to brush
the dirt off; brushing will force dirt into the fibers.
SEDIMENT CUP CLEANING ENGINE SERVICE BULLETIN #40
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.
Turn the fuel valve lever [1] to the OFF position.

[1]
– Sediment cup [2]
– O-ring [3]
– Cup filter [4] [6]
Clean the sediment cup and the cup filter with non-
flammable solvent and allow them to dry thoroughly.
Install the cup filter while aligning the tip with the groove
of the carburetor and cup filter tab [5] with the mark [6]
of the carburetor.
Install a new O-ring and sediment cup.
Tighten the sediment cup to the specified torque.
TORQUE: 3.9 N·m (0.4 kgf·m, 2.9 lbf·ft)
[5]
Check the installation part of the sediment cup for any
sign of fuel leakage. Align
[4]
[3] [2]
3-10
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SPARK PLUG CHECK/ADJUSTMENT
Remove the spark plug (page 3-11).
[2] [3]
Visually inspect the spark plug. Replace the plug if it is
heavily fouled or the insulator [1] is cracked or chipped.
Check the following and replace if necessary.
– Insulator and sealing washer [2] for damage
– Center electrode [3] and side electrode [4] for wear
– Burning condition, coloration
RECOMMENDED SPARK PLUG:
BPR6ES (NGK)
W20EPR-U (DENSO)
Measure the plug gap with a wire-type feeler gauge.
PLUG GAP: 0.70 – 0.80 mm (0.028 – 0.031 in)
[1]
If the measurement is out of the specification, adjust by
bending the side electrode. [4]
Install the spark plug (page 3-11).
SPARK PLUG REPLACEMENT

REMOVAL
The engine and the muffler becomes very hot

during operation and remain hot for a while after
stopping the engine. Be careful not to touch the
muffler while it is hot. Allow it to cool before
proceeding.
Disconnect the spark plug cap [1] and remove the spark
[2]
plug [2].
• Clean around the spark plug base with compressed

air before removing the spark plug, and be sure that
no debris is allowed to enter into the combustion
chamber.
INSTALLATION
Install the spark plug finger tight to seat the washer.
RECOMMENDED SPARK PLUG:
BPR6ES (NGK)
W20EPR-U (DENSO) [1]
Tighten the spark plug to the specified torque.
Connect the spark plug cap.
3-11
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SPARK ARRESTER CLEANING
GENERAL INFO #6
The engine and the muffler comes very hot during

operation and remain hot for a while after stopping
the engine. Be careful not to touch the muffler while
it is hot. Allow it to cool before proceeding.
STANDARD, SILENT TYPE

Remove the air cleaner (page 6-5).
[3] [2]
Disconnect the spark plug cap [1].
Remove the four screws (5 x 8 mm) [2] and muffler
protector [3].
Remove the screw (4 x 6 mm) [4] and spark arrester [5].
[4]
• Be careful to avoid damaging the screen.

Clean the carbon deposits from the spark arrester
screen [6] with a wire brush.
[5]
Check the spark arrester screen for damage. If the
screen is damaged, replace the spark arrester.
Install the spark arrester in the reverse order of
removal.
[1]
[6]
LOW PROFILE TYPE

Remove the two bolts (8 x 20 mm) [1], muffler [2] and
[1]
muffler gasket [3].
Remove the spark arrester [4].
• Be careful to avoid damaging the screen.

Clean the carbon deposits from the spark arrester
screen with a wire brush.
Check the spark arrester screen for damage. If the
[3]
screen is damaged, replace the spark arrester.
Replace the muffler gasket with a new one and install [4]
the spark arrester in the reverse order of removal.
[2]
3-12
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IDLE SPEED CHECK/ADJUSTMENT
Ensure the governor arm and governor arm shaft are
installed correctly (page 7-5).
Use a tachometer with graduations of 50 min-1 (rpm) or
smaller that will accurately indicate 50 min-1 (rpm)
change.
Start the engine and allow it to warm up to normal
operating temperature.
Turn the throttle stop screw [1] to obtain the specified
idle speed.
+ 200
IDLE SPEED: 1,400 min-1 (rpm)
– 150
[1]
VALVE CLEARANCE CHECK/

ADJUSTMENT
• Inspect and adjust the valve clearance while the

engine is cold.
CHECK
Disconnect the spark plug cap [1] and remove the
[4] [1] [2]
following:
– Breather tube [2]
– Head cover bolt (6 x 12 mm) [3] (4)
– Head cover [4]
– Head cover packing [5]
[3] [5]
Set the piston near top dead center of the cylinder

[1] [3]
compression stroke (both valves fully closed) by pulling
the recoil starter slowly. When the piston is near top
dead center of the compression stroke, the triangle
mark [1] on the starter pulley [2] will align with the top
hole [3] on the recoil starter case [4]. Pull slowly.
If the exhaust valve is open, use the recoil starter to turn

the crankshaft one additional turn and align the triangle
mark on the starter pulley with the top hole on the recoil
starter case again.
[4] [2]
3-13
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Insert a thickness gauge [1] between the valve rocker
arm [2] and valve stem [3] to measure the valve [1] [3] [2]
clearance.
VALVE CLEARANCE:
GX120/GX200:
IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in)
EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in)
GX160:
IN: 0.08 ± 0.02 mm (0.003 ± 0.001 in)
EX: 0.10 ± 0.02 mm (0.004 ± 0.001 in)
If adjustment is necessary, proceed as follows.
[2]
[3]
ADJUSTMENT
Hold the rocker arm pivot [1] and loosen the pivot
[3] [1]
adjusting nut [2].
Insert a thickness gauge [3] between the valve rocker
arm and the valve stem.
Adjust by turning the adjusting screw until there is a
slight drag on the feeler gauge.
VALVE CLEARANCE:
GX120/GX200:
IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in)
EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in)
GX160:
IN: 0.08 ± 0.02 mm (0.003 ± 0.001 in)
EX: 0.10 ± 0.02 mm (0.004 ± 0.001 in) [2]
Hold the rocker arm pivot and retighten the pivot

adjusting nut to the specified torque.
Recheck the valve clearance, and if necessary, readjust
the clearance.
Replace the head cover packing with a new one and
install the removed parts in the reverse order of
removal.
• Route the high-tension cord and breather tube

properly (page 2-10).
3-14
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COMBUSTION CHAMBER CLEANING
Remove the cylinder head (page 13-3).
[1]
Clean any carbon deposits from the combustion
chamber [1].
FUEL TANK AND FILTER CLEANING ENGINE SERVICE BULLETIN #40

fuel.
Remove the fuel tank (page 6-3).

[3]
Remove the fuel tank joint [1] and O-ring [2] from the
fuel tank [3].
Clean the fuel tank joint and fuel tank with non-
flammable solvent, and allow them to dry thoroughly. [2]
Check the screen of the fuel tank joint for clogs or
damage.
Replace if necessary.
Install a new O-ring on the fuel tank joint and install the
fuel tank joint to the fuel tank.
Tighten the fuel tank joint to the specified torque.
TORQUE: 2 N·m (0.2 kgf·m, 1.5 lbf·ft) [1]
Install the fuel tank (page 6-3).

After installation, check for any signs of fuel leakage.
3-15
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FUEL TUBE CHECK

fuel.
Check the fuel tube [1] for deterioration, cracks, or signs

[1]
of leakage.
• When checking, GX160/GX200 remove the fan

cover (page 5-2).
3-16
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4. TROUBLESHOOTING
BEFORE TROUBLESHOOTING···················4-2 TROUBLESHOOTING ·································· 4-2
4-1
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TROUBLESHOOTING GX120•GX160•GX200UT2
BEFORE TROUBLESHOOTING
TROUBLESHOOTING
• Use a known-good battery for 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.
TROUBLESHOOTING ENGINE SERVICE BULLETIN #40

ENGINE DOES NOT CRANK
Remove the recoil starter (page 10-3) and check Cannot be cranked Disassemble the engine and replace the faulty
whether the engine cranks. part(s) (page 14-4).
Cranks
Inspect the recoil starter (page 10-6). Abnormal Replace the faulty part(s).
Normal
Perform the STARTING SYSTEM

TROUBLESHOOTING (page 10-2).
4-2
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GX120•GX160•GX200UT2 TROUBLESHOOTING
ENGINE CRANKS BUT WON’T START
ENGINE SERVICE BULLETIN #40
• Check the oil level before troubleshooting (page 3-3).
Loosen the carburetor drain screw and check the Check for clogged fuel filter, fuel tank joint, fuel
fuel flow from the fuel tank (page 6-11). No fuel tube or, cup filter (page 6-4, 6-11).
Fuel
Perform the spark test (page 9-5). Perform the IGNITION SYSTEM
No spark TROUBLESHOOTING (page 9-3).
Spark
Check the cylinder compression (page 13-5). Compression Check the valve clearance (page 3-13), and then
is too high perform the cylinder compression test. If the
cylinder compression is too high, remove carbon
deposits in the combustion chamber (page 3-15).
Check the decompressor operation of the
camshaft (page 14-12)
Check the valve clearance (page 3-13), and then

perform the cylinder compression test.
If the cylinder compression is too low, perform a
leak down test.
If there is no air leakage in the engine, check the
following.
Compression - Valve spring free length (page 13-8)
is too low - Valve seat width (page 13-6)
- Valve face irregularly worn (page 13-7)
- Decompressor operation (page 14-12)
- Piston ring side clearance (page 14-8)
- Piston ring width (page 14-9)
- Piston ring end gap (page 14-9)
- Piston skirt O.D. (page 14-7)
- Cylinder sleeve I.D. (page 14-6)
If spark plug is correct, clean and dry the

Check the spark plug (page 3-11). electrodes and then restart the engine, taking
Wet
care that the choke valve is not closed too much.
If the engine does not start and the electrodes are
wet again, check the carburetor float valve
Dry
(page 6-13).
Disassemble the carburetor to clean the

carburetor ports, jets and nozzles (page 6-11,
6-12).
Check for a restricted spark arrester (applicable
types) (page 3-12))
4-3
dummyhead
TROUBLESHOOTING GX120•GX160•GX200UT2
ENGINE SPEED DOES NOT INCREASE OR
STABILIZE
Check the air cleaner elements (page 3-7). Clogged Clean or replace the air cleaner elements (page 3-
9).
Clean
Check the valve clearance (page 3-13). Abnormal Adjust the valve clearance (page 3-14).
Normal
Inspect the spark plug and adjust the spark plug

Check the spark plug (page 3-11). Abnormal
gap (page 3-11). Replace if necessary (page 3-
11).
Normal
Check the carburetor for any blockage Clogged Disassemble and clean the carburetor (page 6-11,
(page 6-11). 6-12).
Clean
Check for secondary air leak. Air leaking Check around the air intake joint and carburetor;
replace the insulator and/or gasket if necessary.
No air leaking
Compression
Check the cylinder compression(page 13-5). is too high Check for carbon deposits in the combustion
chamber (page 3-15).
Check that the cylinder head bolts are correctly

tightened (page 13-3)
Compression
Check for defective cylinder head gasket, valves,
is too low
or valve seats (page 13-3, 13-5).
Normal Check for worn piston, piston rings, or cylinder
(page 14-6).
Check the governor system is installed correctly Abnormal Adjust or replace the faulty part(s).
(page 7-3).
Normal
Check the ignition coil air gap (page 9-5). Abnormal Adjust the ignition coil air gap (page 9-5).
Normal
Check the ignition coil (page 9-6)

Replace the ignition coil if abnormalities are found,
and recheck.
4-4
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GX120•GX160•GX200UT2 TROUBLESHOOTING
ENGINE DOES NOT STOP WHEN COMBINATION/
ENGINE STOP SWITCH IS TURNED OFF
Check the engine stop switch (If equipped) Replace the engine stop switch (page 11-5)/
Abnormal
(page 11-5)/combination switch (If equipped) combination switch (page 11-6).
(page 11-6).
Normal
Check the wire harness connecting the Replace the ignition coil wire.
No continuity
combination/engine stop switch and the ignition
coil for open or short circuit.
Continuity
Check the ignition coil primary side (page 9-6).

and recheck.
ENGINE DOES NOT STOP WHEN ENGINE OIL

LEVEL IS LOW
Check the oil level switch (page 11-7). Replace the oil level switch (page 11-5).
Abnormal
Normal
Check the oil alert unit (If equipped) (page 11-8). Replace the oil alert unit (page 11-6).
Abnormal
Normal
Check the wire harness connecting the oil level Replace the ignition coil wire.
No continuity
switch and ignition coil for open or short circuit.
Continuity
Check the ignition coil primary side (page 9-6).

and recheck.
4-5
dummyhead
MEMO
dummytext
5. COVER
FAN COVER REMOVAL/INSTALLATION····5-2
5-1
dummyhead
COVER GX120•GX160•GX200UT2
FAN COVER REMOVAL/INSTALLATION
COVER
GX120: Remove the fuel tube from the clamp.

Starter motor type: Remove the control box (page 11-3).
When disassembling the fan cover, remove the
following:
– Recoil starter Assy. (page 10-3)
– Engine stop switch (page 11-5)
(with engine stop switch type)
– Grommet
(without engine stop switch type)
• Route the tube and wires properly (page 2-10).
FUEL TUBE CLAMP

(With oil level switch and oil alert unit)
GX120:
ENGINE STOP SWITCH ONLY:

(With oil level switch and oil alert unit)
FAN COVER Assy.

INSTALLATION:
Be careful not to clip the fuel tube.
BOLT (6 x 14 mm) (4)

5-2
dummytext
6. FUEL SYSTEM
TOOLS···························································6-2 CARBURETOR BODY CLEANING ············ 6-12
FUEL TANK REMOVAL/INSTALLATION ····6-3 CARBURETOR INSPECTION ···················· 6-12
AIR CLEANER REMOVAL/ PILOT SCREW REPLACEMENT ··············· 6-13

INSTALLATION·············································6-5
CHOKE REPLACEMENT ··························· 6-14
CARBURETOR REMOVAL/
INSTALLATION···········································6-10 CARBURETOR STUD BOLT
REPLACEMENT ········································· 6-14
CARBURETOR DISASSEMBLY/
ASSEMBLY ·················································6-11
6-1
dummyhead
FUEL SYSTEM GX120•GX160•GX200UT2

TOOLS
FUEL SYSTEM
Float level gauge Jet cleaner set

07401-0010000 07JPZ-001010B
or 07JPZ-001010A
6-2
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GX120•GX160•GX200UT2 FUEL SYSTEM

FUEL TANK REMOVAL/INSTALLATION

fuel.
GX160/GX200: Remove the fan cover (page 5-2).

[1]
Starter motor type: Remove the starter motor (page 10-7).
Place a suitable container under the carburetor.
Turn the fuel valve lever [1] to the ON position.
Loosen the drain screw [2] and drain the fuel.
• Route the fuel tube properly (page 2-10).
[2]
FUEL FILTER (If equipped) FUEL FILLER CAP

CHECK:
Check the fuel filter for clogs or
damage.
FUEL FILTER HOLDER FUEL FILLER CAP PACKING

CHECK:
Check for deterioration or cracks.
O-RING
FUEL TANK JOINT

2 N·m (0.2 kgf·m, 1.5 lbf·ft)
FUEL TANK
CHECK:
Check the screen of the fuel tank
joint for clogs or damage.
FUEL TANK NUT (6 mm) (2)

10 N·m (1.0 kgf·m, 7 lbf·ft)
FUEL TANK BOLT (6 x 29 mm)
10 N·m (1.0 kgf·m, 7 lbf·ft)
FUEL TUBE
CHECK:
6-3
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FUEL FILLER CAP/FUEL FILTER
HOLDER REMOVAL/INSTALLATION
Remove the fuel filler cap [1].
[5] [1]
Turn the fuel filter holder [2] to align it the tether hole [3]
with the cutout [4] of the fuel filler neck, and then
remove the fuel filler cap.
Before installing, check the air vent hole of the fuel filler
cap for clogs. If necessary, clean it using low-pressure
compressed air.
Install the fuel filter holder into the fuel filler neck and
align the cutouts.
[3] [2]
Set the fuel filler cap to the fuel filler neck by aligning
the projections [5] of the cap with the cutouts of the fuel
filler neck and fuel filter holder and then turn the fuel
filler cap.
[4]
FUEL FILTER REMOVAL/

INSTALLATION
Remove the fuel filler cap [1].
Remove or install the fuel filter by aligning the cutout [2]
of the fuel filter with the fuel filler cap tether [3] as
shown.
[2]
Before installing, check the screen of the fuel filter [4]
for clogs or damage.
[1] [4]
[3]
6-4
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AIR CLEANER REMOVAL/
INSTALLATION
DUAL, DUAL SILENT TYPE
• Route the breather tube properly (page 2-10).
AIR CLEANER COVER NUT

INSTALLATION:
Install the air cleaner cover with the long
skirt portion facing toward the front.
WING NUT
GROMMET
INNER FILTER (PAPER)
OUTER FILTER (FOAM)
BOLT (6 x 20 mm) NOISE SILENCER

(Dual silent type only)
COLLAR
AIR CLEANER
ELBOW SEAL
AIR CLEANER ELBOW

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

Viewed from air cleaner side 9 N·m (0.9 kgf·m, 6.6 lbf·ft)
6-5
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CYCLONE TYPE
CARBURETOR SPACER
INSTALLATION:
Before installing, check for damage. WING NUT
Note the installation direction.
AIR CLEANER COVER

PRE AIR CLEANER CAP
SCREW (4 x 6 mm) (5)

Viewed from air cleaner side
AIR CLEANER GUIDE
AIR CLEANER PLATE
WING NUT
TAB
GROMMET
AIR CLEANER
COVER PACKING
CHECK: GROOVE
Replace if necessary. INNER FILTER
(PAPER)
BREATHER TUBE
BOLT (6 x 20 mm) AIR CLEANER OUTER FILTER

ELBOW SEAL (FOAM)
COLLAR
PRE AIR CLEANER CASE

ASSEMBLY:
Align the pre air cleaner cap tab
with the groove in the pre air
cleaner case.
AIR CLEANER ELBOW
Remove and install the air cleaner elbow AIR CLEANER ELBOW NUT (6 mm) (2)
with the fuel valve lever in the OFF position 9 N·m (0.9 kgf·m, 6.6 lbf·ft)
and the choke lever in the CLOSE position.
Before installation, clean the inside of the
air cleaner elbow.
6-6
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LOW PROFILE TYPE
AIR CLEANER SEPARATOR BREATHER TUBE
AIR CLEANER PACKING
AIR CLEANER ELEMENT

NUT (6 mm) (2)
BOLT (6 x 10 mm)
AIR CLEANER STAY
BOLT (5 x 13.4 mm) (4)

AIR CLEANER CASE
AIR CLEANER COVER
AIR CLEANER SEAL
6-7
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OIL BATH TYPE
CARBURETOR SPACER
INSTALLATION:
Before installing, check for damage. AIR CLEANER CAP
Note the installation direction. WING NUT
AIR CLEANER COVER
BOLT (6 x 20 mm)
AIR CLEANER ELEMENT
AIR CLEANER
ELBOW SEAL
COLLAR
AIR CLEANER GRID
UPPER LEVEL
BREATHER TUBE
CLEANER OIL PAN

INSTALLATION:
If the oil level is low, fill with the
recommended engine oil (page 3-
3) to the upper level.
If the oil is dirty, clean the cleaner
oil pan and replace the oil.
AIR CLEANER ELBOW
Remove and install the air cleaner elbow
with the fuel valve lever in the OFF position
and the choke lever in the CLOSE position. 9 N·m (0.9 kgf·m, 6.6 lbf·ft)
air cleaner elbow.
6-8
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SEMI DRY TYPE
CARBURETOR SPACER
INSTALLATION:
Before installing, check for damage. WING NUT
AIR CLEANER CAP

AIR CLEANER COVER
BOLT (6 x 20 mm)
COLLAR
AIR CLEANER
ELEMENT
AIR CLEANER GRID
BREATHER TUBE
AIR CLEANER ELBOW

Remove and install the air cleaner elbow
AIR CLEANER COLLAR (2) with the fuel valve lever in the OFF position
and the choke lever in the CLOSE position.
air cleaner elbow.

9 N·m (0.9 kgf·m, 6.6 lbf·ft)
6-9
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CARBURETOR REMOVAL/
INSTALLATION

fuel.

Set a commercially available tube clamp HCP6A on the
fuel tube.
Loosen the drain screw of the carburetor to drain the
fuel completely (page 6-3).
GOVERNOR ROD/
FUEL TUBE THROTTLE RETURN SPRING
Pull the carburetor to a point where the
groove [1] of the throttle arm lines up with the
governor rod [2], and then lift the governor
rod out of the hole of the throttle arm and
unhook the throttle return spring [3].
[2]
[3] [1]
HCP6A
(Commercially
available)
CARBURETOR PACKING
TUBE CLIP
INSULATOR
CARBURETOR INSULATOR PACKING
INSTALLATION:
Before installing, clean the passage [1] thoroughly with
compressed air.
Install the carburetor insulator with the vent groove facing
toward the carburetor.
After installing, clamp the high-tension cord [2] and fuel tube
[3] to the carburetor insulator.
GX120: [2] GX160/GX200: [3]
CARBURETOR DRAIN SCREW
[2]
[1] [1]
6-10
dummyhead

ASSEMBLY

fuel.
To prevent serious eye injury, always wear safety

goggles or other eye protection when using
compressed air.
Remove the carburetor (page 6-10).

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

ASSEMBLY: (3 x 6 mm) (2)
Before installing, clean VALVE LEVER
thoroughly with the jet SPRING
cleaning special tool and
low-pressure compressed CHOKE LEVER
air. O-RING FUEL VALVE LEVER
Lightly lubricate the O-ring [1]
[1] to ensure easy installation THROTTLE STOP SCREW
into the carburetor body. ADJUSTMENT: (page 3-13) FUEL VALVE
PILOT SCREW PACKING
REPLACEMENT: (page 6-13) CHECK:
MAIN NOZZLE
ASSEMBLY: UPPER SPRING PIN
Before installing, clean SIDE
thoroughly with the jet CARBURETOR BODY
cleaning special tool and CLEANING: (page 6-12)
low-pressure compressed
CUP FILTER
air. LIMITER CAP
REMOVAL/
INSTALLATION:
MAIN JET
(page 3-10)
NOTICE:
Tampering is a violation of Federal and California Law.
O-RING
ASSEMBLY: UPPER
Before installing, clean thoroughly with the SIDE
jet cleaning special tool and low-pressure FLOAT SEDIMENT CUP
compressed air. 3.9 N·m (0.4 kgf·m, 2.9 lbf·ft)
FLOAT PIN FLOAT VALVE

FLOAT CHAMBER
INSPECTION: (page 6-13)
ASSEMBLY: O-RING
Install the float chamber to the
carburetor body at an angle as shown.
FLOAT VALVE SPRING
0 – 30°
SET BOLT GASKET
DRAIN SCREW GASKET
SET BOLT DRAIN SCREW
6-11
dummyhead

CARBURETOR BODY CLEANING

goggles or other eye protection when using
compressed air.
• Some commercially available chemical cleaners are

very caustic. These cleaners may damage plastic
parts such as the O-ring, the float, and the float seat
of the carburetor. Check the container for
instructions. If you are in doubt, do not use these
products to clean Honda carburetors.
• High air pressure may damage the carburetor body.
Use low air pressure (206 kPa [2.11 kgf/cm2, 30 psi]
or less) when cleaning passages and ports.
Clean the carburetor body with non-flammable solvent.
[8]
Clean thoroughly the following passages and ports with
the jet cleaning special tool and low-pressure
compressed air.
– Pilot screw hole [1]
– Pilot jet hole [2]
– Pilot air jet [3]
– Main air jet [4]
– Transition ports [5]
– Pilot outlet [6] [5]
– Main nozzle holder [7]
– External vent port [8]
– Internal vent port [9]
[6]
[9]
[3]
[1]
[2] [4]
[7]
CARBURETOR INSPECTION
FLOAT LEVEL HEIGHT
Place the carburetor in the position as shown. Measure
the distance between the float top and carburetor body
when the float just contacts the seat without
compressing the valve spring.
TOOL:
Float level gauge [1] 07401-0010000
FLOAT HEIGHT: 13.7 mm (0.54 in)

If the measured float height is out of specification,
check the float valve and float valve spring (page 6-13).
If the float valve and float valve spring are normal,
replace the float (page 6-11).
[1]
6-12
dummyhead

FLOAT VALVE
Check the float valve and its seat [1] for wear or
contamination.
Check the valve seat [2] for clogs.
Before installation, check for wear or a weak float valve
spring [3]. [1]
[2]
Check the operation of the float valve.
[3]
OK CLEAN REPLACE
PILOT SCREW REPLACEMENT
• Tampering is violation of Federal and California

Pilot screw will break at narrow point.
Law.
Only remove the pilot screw [1] and limiter cap [2] when
necessary for repair or to clean stubborn deposits from
the pilot circuit passages.
Removal of the limiter cap requires breaking the pilot
screw. A new pilot screw and limiter cap must be
installed.
[2]
When the limiter cap has been broken off, remove the
broken pilot screw.
[1]
Place the spring on the replacement pilot screw, and
install it on the carburetor.
Turn the pilot screw in until it is lightly seated, and then
turn the screw out the required number of turns. [4]
Carburetor
Pilot screw
Model identification Number
opening
[3] + [4]
BE60W A 2-1/8
BE99A A 1-5/8
GX120
BE61M A 2-1/8
BE99B A 2-1/8
BE54C A 2-1/4
BE54D A 1-7/8
GX160 BE66U A 1-7/8
BE54P A 2-1/2
BE54J B 1-7/8 [3]
BE59L A 1-7/8
BE59N A 1-7/8
GX200
BE59U A 2-1/4
BE74Y A 2-3/4 STOP [1]
Refer to the table above for carburetor pilot screw initial

opening setting.
Apply Hondalock 3, LOCTITE 638, or equivalent to the
inside of the limiter cap, and then install the cap so the
stop prevents the pilot screw from being turned
counterclockwise.
Be careful to avoid turning the pilot screw while [2]
installing the limiter cap. The pilot screw must stay at its
required setting.
6-13
dummyhead

CHOKE REPLACEMENT
Pull out the choke valve plate [1]. [2]
Remove the choke shaft [2] and install a new choke
[3]
shaft.
Insert a new choke valve plate into the slit [3] of the
choke shaft.
Be sure the choke shaft is in the position between the
projections [4] of the choke valve plate.
[1]
[2]
[4]
[4]
[2]
[1]
CARBURETOR STUD BOLT

REPLACEMENT
[1]
Thread two nuts onto the carburetor stud bolt [1] and
tighten them together, then use a wrench to turn the
stud bolt out.
Install and tighten new stud bolts until they are fully
seated.
6-14
dummytext
7. GOVERNOR SYSTEM
GOVERNOR MECHANISM ···························7-2 GOVERNOR ADJUSTMENT ························ 7-5
GOVERNOR ARM/CONTROL BASE Assy. GOVERNOR DISASSEMBLY/

REMOVAL/INSTALLATION··························7-3 ASSEMBLY ··················································· 7-6
CONTROL BASE Assy. DISASSEMBLY/ MAXIMUM SPEED ADJUSTMENT ·············· 7-7

ASSEMBLY ···················································7-4
7-1
dummyhead
GOVERNOR SYSTEM GX120•GX160•GX200UT2

GOVERNOR MECHANISM
GOVERNOR SYSTEM
FUNCTION OF THE COMPONENTS

The free end of the governor arm [1] is linked by the governor rod [2] to the carburetor throttle valve [3]. The governor arm moves to
open and close the throttle.
The middle of the governor arm is connected by the governor spring [4] to the throttle lever [5]. The pivot end of the governor arm is
connected by the governor arm shaft [6] to the governor slider [7]. During operation, the governor arm is pulled left or right by the
action of the governor spring and the governor arm shaft.
Centrifugal weights [8] apply outward pressure against the governor slider in proportion to the engine speed. As engine speed
increases, the governor slider is forced outward against the governor arm shaft, which rises to move the free end of the governor
arm to the right. This force is opposed by the governor spring. When the engine speed matches the speed set by the throttle lever,
the force of the governor spring and the force of the governor arm shaft are equal, and the engine speed is stable.
If engine speed increases beyond the speed set by the throttle lever, the force of the governor mechanism will be stronger than the
governor spring, and the free end of the governor arm will move right to reduce the throttle valve opening. If the engine speed falls
below the speed set by the throttle lever, the force of the spring will be stronger than the governor mechanism, and the free end of
the governor arm will move left to increase the throttle valve opening.
[3] [2] [4] [6]
[7]
[8]
[5]
[1]
MAX. MIN.
7-2
dummyhead
GX120•GX160•GX200UT2 GOVERNOR SYSTEM

GOVERNOR ARM/CONTROL BASE
Assy. REMOVAL/INSTALLATION
Remove the following parts.
– Air cleaner (page 6-5)
– Fuel tank (page 6-3)
• After installation, adjust the following:

– Governor (page 7-5)
– Idle speed (page 3-13)
– Maximum speed (page 7-7)
GOVERNOR ROD/THROTTLE RETURN SPRING GOVERNOR SPRING

REMOVAL/INSTALLATION: INSTALLATION:
Pull the carburetor to a point where the groove [1] of Hook the governor spring to the
the throttle arm lines up with the governor rod [2], and appropriate hole on the control lever
then lift the governor rod out of the hole of the throttle as shown.
arm and unhook the throttle return spring [3].
[3] [2] NUT (6 mm)
GOVERNOR
ARM BOLT
[1] GOVERNOR
ARM
GX160 GX120/GX200
BOLT SCREW (5 x 16 mm)

GX120: (6 x 20 mm) (If equipped)
GX160/GX200: (6 x 12 mm) SCREW (4 x 6 mm)
(If equipped)
CABLE HOLDER
(If equipped)
GX200:
REMOTE CABLE
(Commercially available)
(If equipped)
BOLT (6 x 12 mm)
CONTROL BASE Assy.

(MANUAL/REMOTE TYPE)
CONTROL BASE Assy.

(FIXED THROTTLE OPERATION TYPE)
7-3
dummyhead

CONTROL BASE Assy. DISASSEMBLY/
ASSEMBLY
MANUAL/REMOTE TYPE
Remove the control base Assy (page 7-3).
LOCK NUT (6 mm) CONTROL LEVER WASHER

INSTALLATION: INSTALLATION:
After installation the control base Assy., Install the control lever washer by aligning the cutout of the control
measure force at 10 mm (0.4 in) from lever washer with the claw of the control base.
the tip of the control lever [1] by pulling.
Adjust by turning the lock nut [2] so that
the gauge shows 19.6 ± 4.9 N (2.0 ±
0.5 kgf) when the control lever starts to
move.
[2]
CONTROL RETURN SPRING
WIRE HOLDER (If equipped)
10 mm
[1] (0.4 in)
CONTROL LEVER
CONTROL ADJUST SPRING

LEVER SPRING
INSTALLATION:
Note the installation
direction. CIRCLIP
(If equipped)
CLAW SCREW (5 x 25 mm)
SCREW (5 x 25 mm) (If equipped)
CONTROL LEVER SPACER

CONTROL BASE
(Control lever sliding surface)
STOPPER COLLAR (If equipped)
7-4
dummyhead

FIXED THROTTLE OPERATION TYPE
Remove the control base Assy. (page 7-3).
CONTROL BASE
SCREW (5 x 35 mm)
CONTROL ADJUST SPRING
GOVERNOR ADJUSTMENT
Loosen the nut (6 mm) [1] of the governor arm.
Turn the governor arm [2] clockwise to fully open the
carburetor throttle valve [3].
Rotate the governor arm shaft [4] as far as it will go in
the same direction the governor arm moved to open the
throttle valve.
Make sure the carburetor throttle valve is fully open.
Tighten the nut (6 mm) securely.
[2]
[4] [1]
[3]
7-5
dummyhead

GOVERNOR DISASSEMBLY/
ASSEMBLY
Remove the crankshaft (page 14-4).
GOVERNOR WEIGHT
CHECK: WASHER (6 mm)
After installing the governor weights,
check to be sure they move freely.
GOVERNOR WEIGHT PIN GOVERNOR HOLDER CLIP

INSTALLATION:
Install firmly into the
groove of the
GOVERNOR WEIGHT HOLDER governor holder shaft.
(Gear and sliding surface)
GROOVE
LOCK PIN
INSTALLATION:
Install firmly into the
groove of the governor
arm shaft.
WASHER (6 mm) GOVERNOR ARM SHAFT

WASHER (6 mm)
(GX120/GX200)
(Journal)
GOVERNOR HOLDER SHAFT

(Journal)
GOVERNOR SLIDER
INSTALLATION:
Spread the governor weights to install
the governor slider.
CHECK:
After installing the governor slider,
check to be sure it moves smoothly.
7-6
dummyhead

MAXIMUM SPEED ADJUSTMENT
Use a tachometer with graduations of 50 min-1 (rpm) or
changes.
Start the engine and allow it to warm up to normal
operating temperature.
Move the control lever [1] to run the engine at the
specified maximum speed, and hold the control lever.
Make sure the carburetor throttle valve [2] is fully open. [3]
Turn the screw [3] of the control base to obtain the

specified maximum speed.
MAXIMUM SPEED:
GX120: 3,900 ± 100 min-1 (rpm) [1]
GX160: 3,900 ± 100 min-1 (rpm)
GX200: 3,850 ± 150 min-1 (rpm)
[2]
7-7
dummyhead
MEMO
dummytext
8. CHARGING SYSTEM
TOOL ·····························································8-2 COOLING FAN/FLYWHEEL REMOVAL/

INSTALLATION ············································ 8-5
SYSTEM DIAGRAM ······································8-3
CHARGE/LAMP COIL REMOVAL/
CHARGING SYSTEM INSTALLATION ············································ 8-7
TROUBLESHOOTING···································8-4
CHARGE/LAMP COIL INSPECTION ··········· 8-8
8-1
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CHARGING SYSTEM GX120•GX160•GX200UT2

TOOL
CHARGING SYSTEM
Puller collar set

07APC-ZY1A100
8-2
dummyhead
GX120•GX160•GX200UT2 CHARGING SYSTEM

SYSTEM DIAGRAM
1 A/3 A CHARGE COIL TYPE:
Gr
(W)
(W)
(Gr)
(W)
(W)
(W)
(W)
(W)
MAIN FUSE (5 A) CIRCUIT SILICON
CHARGE COIL PROTECTOR RECTIFIER
BATTERY
CONTROL BOX
7 A CHARGE COIL TYPE:

Gr
Gr
Gr
Gr
W
Bl
CHARGE COIL REGULATOR/RECTIFIER BATTERY
8-3
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CHARGING SYSTEM TROUBLESHOOTING
Check the following before troubleshooting:
– Faulty battery
– Loose connectors
1 A/3 A charge coil type: Abnormal Replace the main fuse (5 A) (page 11-4).
Check the main fuse (5 A) (page 11-7).
Normal
Check the charge/lamp coil (page 8-8). Replace the charge/lamp coil (page 8-7)
Abnormal
Normal
Check the following: Replace the faulty part(s).

– Circuit protector (page 11-7) Abnormal – Circuit protector (page 11-4)
– Silicon rectifier (page 11-6) – Silicon rectifier (page 11-4)
– Regulator/rectifier (page 11-8) – Regulator/rectifier
Normal
Check the harness connecting the charge coil for

open or short circuit and for proper connection.
If necessary, replace the harness.
8-4
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COOLING FAN/FLYWHEEL REMOVAL/
INSTALLATION
REMOVAL
Remove the ignition coil (page 9-4).
SIDE PLATE
WOODRUFF KEY REMOVAL:
Before removal, remove the 7 A charge coil
MAGNET PART (7 A charge coil type only) (page 8-7).
BOLT (6 × 22 mm)
STARTER PULLEY
(Without screen)
With starter motor:
COOLING FAN
FLYWHEEL NUT (14 mm)

(Threads and seating surface)
FLYWHEEL 75 N·m (7.6 kgf·m, 55 lbf·ft)
REMOVAL: REMOVAL:
Hold the flywheel [1] with a commercially available strap wrench [2], being careful not Hold the flywheel [1] with a commercially
to damage the magnet part. available strap wrench [2], being careful not
Use the special tool [3] and/or commercially available tool [4] to remove the flywheel. to damage the magnet part.
Remove the flywheel nut (14 mm) [3].
With starter motor: Without starter motor:
[2]
[1] [1]
[2]
[1]
[3] /[4]
PULLER COLLAR SET [4]
TWO-JAW PULLER [3]
07APC-ZY1A100
STEERING WHEEL PULLER OTC1035
OTC7403
8-5
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INSTALLATION
• Clean the tapered parts [1] of dirt, oil, grease, and

[4] [3] [6]
other foreign material before installation.
• Be sure there are no metal parts or other foreign
material on the magnet part [2] of the flywheel.
Set the woodruff key [3] in the key groove [4] of the [2]
crankshaft securely.
Set the flywheel [5] by aligning the key slot [6] with the
the woodruff key on the crankshaft.
[1] [5]
Attach the cooling fan [1] to the flywheel [2] by aligning

Align [1] Align [3]
the four projections of the cooling fan with the holes of
the flywheel.
Attach the starter pulley [3] by aligning the following:
– Holes of the pulley and tabs of the cooling fan
– Tab of the pulley and hole of the flywheel
[2] Align
Apply a light coat of oil to the threads and the seating

[3]
surface of the flywheel nut [1] and loosely tighten the
nut.
Hold the flywheel [2] with a commercially available strap
wrench [3], being careful not to damage the magnet
part.
Tighten the flywheel nut to the specified torque.
[2]
[1]
8-6
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CHARGE/LAMP COIL REMOVAL/
INSTALLATION
Disconnect the charge/lamp coil connectors.
Remove the flywheel (page 8-5).
• When installation, route the wire harness properly

(page 2-10).
12 V-50 W LAMP COIL TYPE:
12 V - 50 W LAMP COIL
BOLT (6 x 28 mm) (4)
CORD CLAMP
BOLT (5 x 10 mm)
7 A CHARGE COIL TYPE: 1 A/3 A CHARGE COIL TYPE: 12 V - 15 W/12 V - 25 W LAMP COIL TYPE:
7 A CHARGE COIL 1 A/3 A CHARGE COIL 12 V - 15 W/12 V - 25 W LAMP COIL

INSPECTION: (page 8-8) INSPECTION: (page 8-8) INSPECTION: (page 8-8)
BOLT (6 x 28 mm) (2) BOLT (6 x 28 mm) (2)
BOLT (6 x 28 mm) (4)
8-7
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CHARGE/LAMP COIL INSPECTION
7 A CHARGE COIL/12 V - 25 W LAMP
COIL TYPE
Disconnect the charge/lamp coil connectors [1].
[1]
Measure the resistance between the terminals of the
charge/lamp coil connectors.
Resistance:
7 A charge coil: 0.22 – 0.30 Ω
12 V - 25 W lamp coil: 0.36 – 0.46 Ω
Check for continuity between each terminal and engine
ground.
There should be no continuity.
If the measured resistance is not within the specified
range or if any wire has continuity to engine ground,
replace the charge/lamp coil (page 8-7).
If the resistance is good and the flywheel is ok, replace
the charge/lamp coil and retest.
1 A/3 A CHARGE COIL/12 V - 50 W

LAMP COIL TYPE
Disconnect the charge/lamp coil connector [1].
[1]
Measure the resistance between the terminal and
engine ground.
Resistance:
12 V - 50 W lamp coil: 0.18 – 0.23 Ω
If the measured resistance is not within the specified
range, replace the charge/lamp coil (page 8-7).
8-8
dummytext
9. IGNITION SYSTEM
SYSTEM DIAGRAM ······································9-2 IGNITION COIL AIR GAP CHECK/

ADJUSTMENT ·············································· 9-5
IGNITION SYSTEM
TROUBLESHOOTING···································9-3 SPARK TEST ················································ 9-5
IGNITION COIL REMOVAL/ SPARK PLUG CAP INSPECTION················ 9-6

INSTALLATION·············································9-4
IGNITION COIL INSPECTION ······················ 9-6
9-1
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IGNITION SYSTEM GX120•GX160•GX200UT2

SYSTEM DIAGRAM
IGNITION SYSTEM
ENGINE STOP SWITCH TYPE:
Bl
Bl
Y
Bl
Y
SPARK PLUG IGNITION COIL ENGINE STOP OIL ALERT UNIT OIL LEVEL SWITCH
SWITCH
CONTROL BOX TYPE:
Bl/R
(W)
Bl
Y
(Bl/Y)
(W)
(W)
(W)
(Bl)
(Y)
COMBINATION MAIN FUSE (5 A)

OIL LEVEL SPARK IGNITION COIL SWITCH OIL ALERT UNIT
BATTERY
SWITCH PLUG
CONTROL BOX
9-2
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GX120•GX160•GX200UT2 IGNITION SYSTEM

IGNITION SYSTEM TROUBLESHOOTING
NO OR WEAK SPARK AT SPARK PLUG
– Spark plug (page 3-11)
– Engine oil level (page 3-3)
Check the oil level switch (If equipped) (page 11-7)/ Replace the oil level switch (page 11-5).
Abnormal
oil alert unit (If equipped) (page 11-8). Replace the oil alert unit.
– Without control box (page 11-6)
– With control box (page 11-4)
Normal
Check for continuity between the ignition coil wire Replace the ignition coil wire.
Abnormal
connectors.
Normal
Check the engine stop switch (If equipped) Abnormal Replace the engine stop switch (page 11-5)/
(page 11-8)/combination switch (If equipped) combination switch (page 11-4).
(page 11-6).
Normal
Check the ignition coil (page 9-6). Abnormal Replace the ignition coil (page 9-4).
Normal
Check the spark plug cap (page 9-6).

If necessary, replace the spark plug cap.
9-3
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IGNITION COIL REMOVAL/
INSTALLATION
– Fan cover (page 5-2)
– Carburetor (page 6-10)
• Route the ignition coil wire and high-tension code

• After installation, check the ignition coil air gap
(page 9-5).
IGNITION COIL WIRE
BOLT (6 x 25 mm) (2)
HIGH-TENSION CORD IGNITION COIL

SPARK PLUG CAP INSPECTION: (page 9-6)
9-4
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GX120•GX160•GX200UT2 IGNITION SYSTEM

IGNITION COIL AIR GAP CHECK/
ADJUSTMENT
Remove the fan cover (page 5-2).
[2] 0.2 – 0.6 mm (0.01 – 0.02 in)
Insert the thickness gauge [1] of proper thickness
between the ignition coil [2] and the flywheel [3].
IGNITION COIL AIR GAP:
0.2 – 0.6 mm (0.01 – 0.02 in)
• Avoid the magnet part of the flywheel when

adjusting.
• Adjust the ignition coil air gap equally on both sides.
If measured clearance is out of specification, adjust the
air gap. 0.2 – 0.6 mm
Loosen the two bolts (6 x 25 mm) [4]. [3] (0.01 – 0.02 in)
[1]
Insert the thickness gauge of proper thickness between
the ignition coil and flywheel.
Push the ignition coil firmly against the flywheel and
tighten the ignition coil bolts securely.
Remove the thickness gauge.
[4]
SPARK TEST
[2]
Never hold the high-tension cord with wet hands

while performing this test.
Check for the following before conducting the spark

test. [4]
– Faulty spark plug
– Loose spark plug cap
– Water in the spark plug cap (leaking the ignition coil
secondary voltage) [3]
– Loose ignition coil connector
Disconnect the spark plug cap [1] from the spark plug [1]
[2].
Connect a known-good spark plug to the spark plug cap
and ground the spark plug to the cylinder head cover
bolt.
With engine stop Turn the engine stop switch/combination switch to "ON"
switch/combination position.
switch type:
Crank the engine by pulling the recoil starter or crank
the engine with the starter motor and check whether
sparks jump across the electrodes.
• To avoid discharging the battery, do not operate the

starter motor for more than 5 seconds at a time. Wait
for approximately 10 seconds before operating it
again.
9-5
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SPARK PLUG CAP INSPECTION
Measure the resistance of the spark plug cap [1] by
attaching one ohmmeter probe to the terminal in the
spark plug cap and the other to the high-tension cord
terminal.
RESISTANCE: 7.5 – 12.5 kΩ (20°C/68°F)

If measured resistance is out of specification, replace
the spark plug cap.
IGNITION COIL INSPECTION

PRIMARY SIDE
Disconnect the ignition coil connector [1].
[3]
Measure the resistance of the primary coil by attaching
one ohmmeter probe to the ignition coil wire terminal [2]
and the other at the iron core [3].
RESISTANCE: 0.6 – 0.9 Ω
the ignition coil.
[1] [2]
SECONDARY SIDE
Disconnect the spark plug cap from the high-tension
[1] [2]
cord [1].
Measure the resistance of the secondary coil by
attaching one ohmmeter probe to the high-tension cord
and the other at the iron core [2].
RESISTANCE: 5.6 – 6.9 kΩ
the ignition coil.
9-6
dummytext
10. STARTING SYSTEM
SYSTEM DIAGRAM ····································10-2 RECOIL STARTER INSPECTION ·············· 10-6
STARTING SYSTEM STARTER MOTOR REMOVAL/

TROUBLESHOOTING·································10-2 INSTALLATION ·········································· 10-7
RECOIL STARTER Assy. REMOVAL/ STARTER MOTOR DISASSEMBLY/

INSTALLATION···········································10-3 ASSEMBLY ················································· 10-8
RECOIL STARTER Assy. DISASSEMBLY/ STARTER MOTOR INSPECTION ·············· 10-9

ASSEMBLY ·················································10-4
10-1
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STARTING SYSTEM GX120•GX160•GX200UT2

SYSTEM DIAGRAM
STARTING SYSTEM
STARTER MOTOR TYPE:
(W)
Bl/W
Bl/W
(Bl/W)
(W)
(W)
(W)
STARTER
SOLENOID
COMBINATION MAIN FUSE (5 A)

STARTER MOTOR SWITCH
BATTERY
CONTROL BOX
STARTING SYSTEM TROUBLESHOOTING

STARTER MOTOR DOES NOT OPERATE
Check the battery condition. Abnormal Replace with a known-good battery.
If the battery runs down again, perform
the CHARGING SYSTEM
TROUBLESHOOTING (page 8-4).
Normal
Check the fuse. Replace the fuse.

Abnormal
Normal
Check the combination switch Abnormal Replace the combination switch

(page 11-6). (page 11-4).
Normal
Check the starter solenoid (page 10-9). Abnormal Replace the starter solenoid (page 10-8)
Normal
Check the wire harness for shorts or Abnormal Replace the wire harness.
open circuits.
Normal
Disassemble the starter motor

(page 10-8) and check each part
(page 10-9).
10-2
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GX120•GX160•GX200UT2 STARTING SYSTEM

RECOIL STARTER Assy. REMOVAL/
INSTALLATION
RECOIL STARTER Assy.
RECOIL STARTER SPACER

(GX200 only)
BOLT (3)
GX120/GX160: (6 x 10 mm)
GX200: (6 x 18 mm)
10-3
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RECOIL STARTER Assy.
DISASSEMBLY/ASSEMBLY
• Wear gloves and eye protection.

• During disassembly/assembly, take care not to
allow the return spring to come out.
DISASSEMBLY
Remove the recoil starter Assy. (page 10-3).
SPRING RETAINER RECOIL STARTER CENTER SCREW

(Inside) 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
(Threads)
FRICTION PLATE
FRICTION SPRING
RATCHET RATCHET SPRING

(Sliding surface)
RECOIL STARTER PULLEY
REINFORCEMENT GRIP
STARTER RETURN SPRING
STARTER GRIP
RECOIL STARTER CASE

(Pulley sliding surface)
10-4
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ASSEMBLY
Pass the recoil starter rope [1] through the hole [2] of
[2]
the recoil starter pulley [3], and then tie the rope as
shown.
Wind the recoil starter rope onto the recoil starter pulley
counterclockwise as shown.
[3] [1]
Hook the outer hook [1] of the starter return spring [2] to
[2] [3] [1]
the groove [3] of the recoil starter pulley [4], and then
install the starter return spring by winding it.
[4]
Apply grease to the starter pulley sliding surface [1] of

[3]
the recoil starter case [2].
Set the recoil starter pulley [3] to the recoil starter case
by aligning the inner hook [4] of the starter return spring
[1]
with the boss [5] of the recoil starter case as shown.
[4]
[2] [5]
Apply grease to the ratchets [1].

[1] [1] [2]
Install the ratchet springs [2] and ratchets to the recoil
starter pulley as shown.
[2]
10-5
dummyhead

Apply grease to the inside of the spring retainer [1].
[2]
Apply locking agent (Hondalock 1, Threebond 2430, or
[1]
equivalent) to the threads of the center screw [2].
Set the friction spring [3], friction plate [4], and spring [4]
retainer to the recoil starter pulley in the direction as
shown.
Hold the spring retainer and tighten the center screw to
the specified torque.
TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
[3]
Turn the recoil starter pulley [1] 2 turns

[1]
counterclockwise to preload the starter return spring.
Be sure to hold the recoil starter pulley.
Pass the recoil starter rope [1] through hole [2] of the
[5] [2] [4]
recoil starter case, starter grip [3], and reinforcement
grip [4], and then tie the rope as shown. Be sure to hold
the recoil starter pulley [5].
Check the recoil starter operation (page 10-6).
[3] [1]
RECOIL STARTER INSPECTION

RECOIL STARTER OPERATION
[2] [1]
Pull the starter grip [1] several times to inspect that the
ratchets [2] are operated properly (the ratchet ends
come out from the spring retainer [3]).
[3]
10-6
dummyhead

STARTER PULLEY
[2]
Inspect the square holes [1] of the starter pulley [2] for
deformation.
[1]
STARTER MOTOR REMOVAL/

INSTALLATION
– Control box (page 11-3)
– Flywheel (page 8-5)
STARTER MOTOR
BOLT (6 x 34 mm)
BOLT (6 x 26 mm)
DOWEL PIN
SIDE PLATE
10-7
dummyhead

STARTER MOTOR DISASSEMBLY/
ASSEMBLY
Remove the starter motor (page 10-7).
SCREW (5 x 14 mm) (2)

WASHER
SPRING COVER
STARTER SOLENOID
PINION GEAR INSPECTION: (page 10-9)
RETURN SPRING
STOPPER PIECE B
CIRCLIP
PINION GEAR SHAFT GEAR COVER
OVERRUNNING CLUTCH
SCREW (5 x 30 mm)
STARTER MOTOR
TERMINAL COVER
STOPPER PIECE A
BOLT (5 x 70 mm) (2)
NUT (6 mm)
SPRING WASHER
SCREW SCREW
HARNESS HOLDER
(5 x 8 mm) (5 x 20 mm) (2)
STARTER
SOLENOID COVER
GROOVE SCREW (5 x 14 mm)
STARTER SOLENOID WIRE

SCREW (3 x 5 mm)
SPECIAL WASHER
INDEX MARK
O-RING
ARMATURE
YOKE
INSTALLATION:
Install the yoke to the front bracket,
aligning its groove with index mark O-RING
on the front bracket.
POSITIVE (+) BRUSH

FRONT BRACKET
10-8
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STARTER MOTOR INSPECTION
STARTER SOLENOID
Disconnect the starter motor connector [1].
[1] [3]
Connect the positive (+) lead of a 12 V battery to the
starter motor connector and the negative (–) lead to the
solenoid body [2].
Check the continuity between the starter motor terminal
[3] and battery terminal [4] as shown.
Continuity should exist when the battery is connected
and not exist when the battery is disconnected.
[2] [4]
BRUSH
BRUSH LENGTH
Measure the brush length.
STANDARD: 11.0 mm (0.43 in)

SERVICE LIMIT: 6.5 mm (0.26 in)
If the brush length is less than the service limit, replace
the front bracket.
BRUSH CONTINUITY CHECK

Check the continuity as follows:
[2] [1]
– There should be no continuity between the positive
(+) brush [1] and negative (–) brush [2].
– There should be continuity between the positive (+)
brush and terminal [3].
– There should be no continuity between the positive
(+) brush and front bracket [4].
– There should be continuity between the negative (–)
brush [2] and front bracket.
If the correct continuity is not obtained, replace the front
bracket.
[4] [3]
10-9
dummyhead

ARMATURE
Visually inspect the commutator [1] surface for dust,
[3] [2]
rust, or other damage.
If necessary, wipe it with a clean lint-free cloth.
If rusted or damaged, dress with a fine emery cloth.
[1]
Measure the mica depth.
If the mica depth is less than the service limit, replace
the armature.
Check the continuity as follows:
– There should be continuity between each segment [4]
[2].
– There should be no continuity between each
segment and armature core [3].
– There should be no continuity between each
segment and armature shaft [4].
OVERRUNNING CLUTCH
Check the pinion gear shaft [1] for smooth axial
[2] [3]
movement.
Replace the overrunning clutch [2] if necessary.
Check the pinion gear [3] operation by holding the
pinion gear shaft and turning the pinion gear. The pinion
gear should turn counterclockwise freely and should not
turn clockwise.
Check the pinion gear for wear or damage and replace
the overrunning clutch if necessary.
If the pinion gear is worn or damaged, the flywheel ring
gear must be inspected.
[1]
10-10
dummytext
11. OTHER ELECTRICAL
COMPONENT LOCATION ··························11-2 COMBINATION SWITCH INSPECTION ····· 11-6
CONTROL BOX REMOVAL/ SILICON RECTIFIER INSPECTION ··········· 11-6

INSTALLATION···········································11-3
CIRCUIT PROTECTOR INSPECTION········ 11-7
CONTROL BOX DISASSEMBLY/
ASSEMBLY ·················································11-4 MAIN FUSE INSPECTION ·························· 11-7
OIL LEVEL SWITCH REMOVAL/ OIL LEVEL SWITCH INSPECTION ············ 11-7
INSTALLATION···········································11-5
ENGINE STOP SWITCH INSPECTION ······ 11-8
ENGINE STOP SWITCH REMOVAL/
INSTALLATION···········································11-5
OIL ALERT UNIT INSPECTION ················· 11-8
OIL ALERT UNIT REMOVAL/
INSTALLATION···········································11-6 REGULATOR/RECTIFIER INSPECTION ··· 11-8
11-1
dummyhead
OTHER ELECTRICAL GX120•GX160•GX200UT2

COMPONENT LOCATION
OTHER ELECTRICAL
WITHOUT CONTROL BOX:
ENGINE STOP SWITCH

(If equipped)
OIL ALERT UNIT (If equipped) OIL LEVEL SWITCH (If equipped)
WITH CONTROL BOX:
OIL ALERT UNIT
CONTROL BOX
11-2
dummyhead
GX120•GX160•GX200UT2 OTHER ELECTRICAL

CONTROL BOX REMOVAL/
INSTALLATION
Disconnect the control box wires.
• Route the wire harness properly (page 2-10).
IGNITION COIL WIRE
NUT (6 mm)
TERMINAL WIRE
STARTER MOTOR WIRE
OIL LEVEL SWITCH WIRE

CHARGE COIL CORD
BOLT (6 x 14 mm)
BOLT (6 x 10 mm)
CONTROL BOX
11-3
dummyhead

CONTROL BOX DISASSEMBLY/
ASSEMBLY
Remove the control box (page 11-3).
SPECIAL SCREW
SILICON RECTIFIER
(6 x 12 mm)
CONTROL BOX CASE

MAIN FUSE (5 A)
CASE MOUNTING BRACKET
OIL ALERT UNIT

CONTROL PANEL
CUTOUT
COMBINATION
SWITCH WASHER
COMBINATION SWITCH
INSTALLATION:
Align the tab [1] with the cutout
CIRCUIT PROTECTOR
in the case mounting bracket
(If equipped)
and the control panel.
INSTALLATION: PROTECTOR LENS
Note the installation direction. (If equipped)
SCREW (3 x 12 mm) (2)

SHORT
COMBINATION
LONG SWITCH NUT
[1]
CONTROL PANEL
11-4
dummyhead

OIL LEVEL SWITCH REMOVAL/
INSTALLATION
Except control box Disconnect the Oil Alert® unit connectors.
type:
Control box type: Disconnect the oil level switch connector.

Remove the camshaft (page 14-4).
• Take care not to drop the valve lifter.
OIL LEVEL SWITCH
OIL LEVEL SWITCH JOINT NUT (10 mm)

10 N·m (1.0 kgf·m, 7.4 lbf·ft)
BOLT (6 x 12 mm) (2)

O-RING
ENGINE STOP SWITCH REMOVAL/

INSTALLATION
• Remove the engine stop switch only if necessary for
Align
engine stop switch or fan cover replacement.
Straighten the tab [1] of the engine stop switch [2] and
remove the engine stop switch.
Install the engine stop switch to the fan cover, aligning
its groove with the boss of the fan cover.
Bend the tab until it is fully seated on the fan cover so
the engine stop switch is held.
• The tab is used for ground terminal.

Install the fan cover (page 5-2). [1] [2]
11-5
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OIL ALERT UNIT REMOVAL/
INSTALLATION
With control box: Disassemble the control box (page 11-4).
[4] [2] [3]
Without control box: Disconnect the Oil Alert unit connectors [1].
Remove the bolt (6 x 12 mm) [2] and oil alert unit [3].
Install the Oil Alert unit and bolt.
Hold the Oil Alert unit against the boss [4] of the stay,
and then tighten the bolt.
• Route the wire harness properly (page 2-10).
[1]
COMBINATION SWITCH INSPECTION

Disconnect the combination switch connectors.
[1] [3] [2]
Check the continuity between the terminals at each
switch position.
Bl/R [1] Ground W [2] Bl/W [3]
OFF
ON
START
If the correct continuity is not obtained, replace the

combination switch (page 11-4).
SILICON RECTIFIER INSPECTION

Remove the silicon rectifier (page 11-4).
Check the continuity between the terminals. There
should be continuity in one direction only. Replace the
rectifier if there is continuity in both directions or in
neither direction.
11-6
dummyhead

CIRCUIT PROTECTOR INSPECTION
Remove the circuit protector (page 11-4).
Check the continuity between the terminals.
Switch position Continuity
ON Yes
OFF No

circuit protector. ON
OFF
MAIN FUSE INSPECTION

Remove the main fuse (5 A) (page 11-4).
BLOWN
Visually inspect the fuse to see if it is blown.
Check the continuity across the two blades.
Replace the fuse if it is blown or there is no continuity
across the blades.
OIL LEVEL SWITCH INSPECTION

Check the oil level (page 3-3).
Without control box: Disconnect the Oil Alert unit connector [1].
With control box: Disconnect the oil level switch connector [1].
Check the continuity between the switch terminal and
engine ground.
There should be no continuity when the engine is full of
oil.
Drain the engine oil completely (page 3-3).
Check the continuity between the switch terminal and
engine ground.
There should be continuity.
Check the continuity between the switch terminals while [1]
filling the engine with oil.
The ohmmeter reading should go from continuity to no
continuity as the oil is filled.
If the correct continuity is not obtained, replace the oil
level switch (page 11-5).
11-7
dummyhead

ENGINE STOP SWITCH INSPECTION
Remove the engine stop switch connector [1].
Check the continuity between the terminals at each
switch position.
Switch position Continuity
ON No
OFF Yes
engine stop switch (page 11-5).
[1]
OIL ALERT UNIT INSPECTION

Remove the Oil Alert unit.
[2] [3]
– Without control box (page 11-6)
– With control box (page 11-4)
Check the continuity between the terminals, and Oil
Alert unit body.
Unit: kΩ
(+)
Bl [1] Y [2] Body [3]
Bl [1] – 0.5 – 10
(–) Y [2] 0.5 – 10 –
Body [3] –
[1]
REGULATOR/RECTIFIER INSPECTION
Disconnect the regulator/rectifier connector.
Measure the resistance between the terminals and be
sure that the measurements conform to the ranges
shown in the table.
Unit: kΩ
4 6 1 3
4 –
6 –
1 1 – 200 1 – 200 – 0.5 – 100 Not used
3 0.1 – 50 0.1 – 50 –
Use a tester that has an internal resistance equal to or
greater than: 20 kΩ/VDC, 9 kΩ/VAC 1 3
Be careful not to touch the metallic part of the tester 4 6
probe with your fingers; otherwise, the correct
resistance value cannot be obtained.
Read the tester manufacturer's operation instructions
carefully before operating the tester. Follow the
instructions of the service manual. Be sure the tester‘s
battery is fully charged, and check the meter before
using the tester.
11-8
dummytext
12. MUFFLER
MUFFLER REMOVAL/INSTALLATION······12-2 EXHAUST PIPE STUD BOLT

REPLACEMENT ········································· 12-3
12-1
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MUFFLER GX120•GX160•GX200UT2
MUFFLER REMOVAL/INSTALLATION
MUFFLER
GENERAL INFO #6
The muffler becomes very hot during operation and
remains hot for a while after stopping the engine.
Be careful not to touch the muffler while it is hot.
Allow it to cool before proceeding.
MUFFLER PROTECTOR
SCREW (4 x 6 mm)
MUFFLER
SPARK ARRESTER (If equipped)
MUFFLER NUT (8 mm) (2)

24 N·m (2.4 kgf·m, 18 lbf·ft)
EXHAUST PIPE GASKET If equipped:
BOLT (6 x 14 mm)
12-2
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GX120•GX160•GX200UT2 MUFFLER
LOW PROFILE TYPE
EXHAUST PIPE
MUFFLER NUT (8 mm) (2) EXHAUST PIPE GASKET
24 N·m (2.4 kgf·m, 18 lbf·ft)
BOLT (8 x 20 mm) (2)
MUFFLER GASKET
SPARK ARRESTER
MUFFLER
EXHAUST PIPE STUD BOLT

REPLACEMENT
Remove the muffler (page 12-2).
Thread two nuts onto the exhaust pipe stud bolt [1] and
tighten them together; then use a wrench to turn the SPECIFIED LENGTH
[1]
stud bolt out.
Install and tighten the new stud bolts until they are the
specified length.
SPECIFIED LENGTH: 15 mm (0.6 in)
12-3
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MEMO
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13. CYLINDER HEAD
TOOLS·························································13-2 CYLINDER HEAD/VALVES

INSPECTION··············································· 13-5
CYLINDER HEAD REMOVAL/
INSTALLATION···········································13-3 VALVE GUIDE REPLACEMENT ················ 13-8
CYLINDER HEAD DISASSEMBLY/ VALVE GUIDE REAMING ·························· 13-9

ASSEMBLY ·················································13-4
VALVE SEAT RECONDITIONING············ 13-10
13-1
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CYLINDER HEAD GX120•GX160•GX200UT2

TOOLS
CYLINDER HEAD
Valve guide driver, 5.5 mm Valve guide reamer, 5.5 mm

07742-0010100 07984-200000D
13-2
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GX120•GX160•GX200UT2 CYLINDER HEAD

CYLINDER HEAD REMOVAL/
INSTALLATION
Set the piston at top dead center of the cylinder
compression stroke (page 3-13).
– Fan cover (page 5-2)
– Carburetor (page 6-10)
– Control base Assy (page 7-3)
– Muffler (page 12-2)
After installation, inspect following:
– Valve clearance (page 3-13)
– Cylinder compression (page 13-5)
CYLINDER HEAD BOLT (Threads and seating surface)

GX120: (8 x 55 mm) (4)
GX160/GX200: (8 x 60 mm) (4)
Loosen and tighten the bolts in a crisscross pattern in
CYLINDER HEAD COVER PACKING 2 – 3 steps.
CYLINDER HEAD COVER
PUSH ROD
HEAD COVER BOLT

(6 x 12 mm) (4)
CYLINDER HEAD
BOLT (6 x 12 mm) (2)
SHROUD
CYLINDER HEAD GASKET
DOWEL PIN
13-3
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CYLINDER HEAD DISASSEMBLY/
ASSEMBLY
Remove the cylinder head (page 13-3).
INTAKE/EXHAUST VALVE SPRING RETAINER

REMOVAL: [1] [2]
Push down and slide the valve spring retainer [1] to
the side so that the valve stem [2] slips through the
hole at the side of the valve spring retainer.
Do not remove the valve spring retainer while the
cylinder head is installed to the cylinder barrel, or the
valve will drop into the cylinder.
INSTALLATION: (Sliding surface and stem end)
Do not interchange the intake and exhaust retainers EXHAUST VALVE
(GX200 only). INSPECTION: (page 13-7)
INSTALLATION:
Do not interchange with the
IN EX intake valve.
The exhaust valve is smaller
than the intake valve.
EXHAUST VALVE GUIDE SPARK PLUG
INTAKE VALVE
VALVE GUIDE
GUIDE
CLIP
CYLINDER HEAD
ROTATOR
(GX200 only)
(Sliding surface and
stem end)
INTAKE VALVE
INSTALLATION:
VALVE SPRING Do not interchange with the
INSPECTION: (page 13-8) exhaust valve.
VALVE STEM SEAL The intake valve is larger
than the exhaust valve.
PUSH ROD GUIDE PLATE
ROCKER ARM PIVOT BOLT (2)

24 N·m (2.4 kgf·m, 17 lbf·ft)
VALVE ROCKER ARM (Tappet surface and pivot)

INSTALLATION:
Before installing the rocker arm, check for wear on the surfaces of
the rocker arm that contact the pivot bolt, push rod, and valve stem.
ROCKER ARM PIVOT (Threads and pivot)
PIVOT ADJUSTING NUT (2)

10 N·m (1.0 kgf·m, 7 lbf·ft)
13-4
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CYLINDER HEAD/VALVES
INSPECTION
CYLINDER COMPRESSION CHECK
Start the engine and warm up to normal operating
[1]
temperature.
Turn off the engine stop switch/combination switch to
stop the engine.
Turn the fuel valve lever to the OFF position, and then
loosen the drain screw of the carburetor to drain the fuel
completely (page 6-3).
Remove the spark plug (page 3-11).
Pull the recoil starter several times to expel unburned
gas.
Attach a commercially available compression gauge [1]
to the spark plug hole.
Pull the recoil starter forcefully to measure stable
cylinder compression.
CYLINDER COMPRESSION:
GX120/GX160:
0.49 - 0.69 MPa (5.0 - 7.0 kgf/cm2, 71 - 100 psi)/
600 min-1 (rpm)
GX200:
0.35 MPa (3.6 kgf/cm2, 51 psi)/600 min-1 (rpm)
CYLINDER HEAD WARPAGE

Check the spark plug hole and valve areas for cracks.
[2] [1]
Clean any gasket material from the cylinder head
mating surface and check the cylinder head warpage
using a straightedge [1] and thickness gauge [2].
• Be careful not the damage the mating surface.

If the measurement is more than the service limit,
replace the cylinder head.
13-5
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VALVE SEAT WIDTH
Remove the carbon deposits from the combustion
VALVE LAPPER
chamber (page 3-15).
Inspect each valve face for irregularities.
If necessary, replace the valve.
Apply a light coat of Prussian Blue or erasable felt-
tipped marker ink to each valve seat.
Insert the valve, and snap it closed against its seat
several times. Be sure the valve does not rotate on the
seat.
The transferred marking compound will show any area
of the valve face that is not concentric.
Measure the valve seat width of the cylinder head.
STANDARD:
GX120/GX200:
IN/EX: 0.70 – 0.90 mm (0.028 – 0.035 in)
GX160:
IN: 0.70 – 0.90 mm (0.028 – 0.035 in)
EX: 0.90 – 1.10 mm (0.035 – 0.043 in)
SERVICE LIMIT: TOO LOW

GX120/GX200:
IN/EX: 2.0 mm (0.08 in)
GX160: VALVE SEAT
IN: 2.0 mm (0.08 in) WIDTH
EX: 2.0 mm (0.08 in)
TOO HIGH
recondition the valve seat (page 13-10).
Check whether the valve seat contact area of the valve
is too high.
If the valve seat is too high or too low, recondition the
valve seat (page 13-10).
VALVE GUIDE I.D.

Ream the valve guide to remove any carbon deposits
[2] HANDLE
before measuring the guide I.D. [1].
(Commercially
TOOL: available)
Valve guide reamer 5.5 mm [2] 07984-200000D
• Turn the valve guide reamer (special tool) clockwise,

never counterclockwise.
• Continue to rotate the special tool while removing it
[1]
from the valve guide.
13-6
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Measure and record each valve guide I.D.
STANDARD: 5.500 – 5.512 mm (0.2165 – 0.2170 in)

If the measured valve guide I.D. is more than the
service limit, replace the valve guide (page 13-8).
VALVE FACE/VALVE STEM O.D.

Inspect each valve face [1] for irregularities.
[2]
Inspect each valve [2] for bending or abnormal stem
wear.
Measure and record each valve stem O.D.
STANDARD:
IN: 5.468 – 5.480 mm (0.2153 – 0.2157 in)
EX: 5.425 – 5.440 mm (0.2136 – 0.2142 in)
SERVICE LIMIT:
IN: 5.318 mm (0.2094 in) [1]
EX: 5.275 mm (0.2077 in)
If the measurement is less than the service limit,
replace the valve.
GUIDE-TO-STEM CLEARANCE
Subtract each valve stem O.D. from the corresponding
guide I.D. to obtain the guide-to-stem clearance.
STANDARD:
IN: 0.020 – 0.044 mm (0.0008 – 0.0017 in)
EX: 0.060 – 0.087 mm (0.0024 – 0.0034 in)
SERVICE LIMIT:
IN: 0.10 mm (0.004 in)
EX: 0.12 mm (0.005 in)
If the calculated clearance is more than the service limit,
replace the valve and valve guide as a set (page 13-8).
13-7
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VALVE SPRING FREE LENGTH/
PERPENDICULARITY
Measure the valve spring free length.

If the measured length is less than the service limit,
replace the valve spring.
Measure the valve spring perpendicularity.
SERVICE LIMIT: 1.5° max.
If the measured perpendicularity is more than the
service limit, replace the valve spring.
PUSH ROD RUNOUT

Check both ends of the push rod for wear.
Check the push rod for straightness.
If necessary, replace the push rod.
VALVE GUIDE REPLACEMENT

Chill the replacement valve guides in the freezer
section of a refrigerator for about an hour.
Use a hot plate or oven to heat the cylinder head evenly
to 150°C (302°F).
To avoid burns, use heavy gloves when handling

the heated cylinder head.
• Do not use a torch to heat the cylinder head;

warpage of the cylinder head may result.
• Do not get the cylinder head hotter than 150°C
(302°F); excessive heat may loosen the valve seat.
13-8
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Remove the heated cylinder head from the hot plate
[2]
and support it with wooden blocks.
Drive the valve guides [1] out of the cylinder head from
the combustion chamber side.
TOOL:
Valve guide driver 5.5 mm [2] 07742-0010100
• When driving the valve guides out, be careful not to

damage the cylinder head.
[1]
Remove the new valve guides [1] from the refrigerator

IN: [2] EX:
one at a time as needed.
Install the valve guides from the valve spring side of the
cylinder head.
TOOL:
Valve guide driver 5.5 mm [2] 07742-0010100
EX: Drive the exhaust valve guide until new valve guide clip [3]
[3] is fully seated as shown.
IN: Drive the intake valve guide to the specified height
(measured from the end of the valve guide to the
cylinder head as shown).
IN VALVE INSTALLATION HEIGHT: [1]
4.8 – 5.2 mm (0.19 – 0.20 in)
After installing the valve guide, check the guide for
damage.
Replace the valve guide if damaged.
Let the cylinder head cool to room temperature.
Ream the valve guide (page 13-9).
VALVE GUIDE REAMING

For best results, be sure the cylinder head is at room
HANDLE
temperature before reaming valve guides.
(Commercially
Coat the reamer and valve guide with cutting oil. available)
TOOL:
Valve guide reamer 5.5 mm [1] 07984-200000D
Rotate the reamer clockwise through the valve guide COMBUSTION
the full length of the reamer. CHAMBER SIDE [1]
• Turn the valve guide reamer (special tool) clockwise,

never counterclockwise.
• Continue to rotate the special tool while removing it VALVE SPRING SIDE
from the valve guide.
Thoroughly clean the cylinder head to remove any
cutting residue.
13-9
dummyhead

Check the valve guide bore; it should be straight, round
and centered in the valve guide. Insert the valve and
check operation. If the valve does not operate
smoothly, the guide may have been bent during
installation.
Replace the valve guide if it is bent or damaged
(page 13-8).
Check the valve guide-to-stem clearance (page 13-7).
VALVE SEAT RECONDITIONING

Inspect the valve seat contact area (page 13-6).
Using a 45° seat cutter, remove any roughness or
irregularities from the seat. 45°
If the contact area is too low on the valve, the seat must
be raised using a 60° interior cutter. TOO LOW
If the contact area is too high on the valve, the seat 60°
must be lowered using a 31° flat cutter.
TOO HIGH
31°
Valve seat cutters [1]/grinder or equivalent valve seat

refacing equipment is recommended to correct a worn
valve seat.
• Turn the cutter clockwise, never counterclockwise.

• Continue to turn the cutter as you lift it from the valve
seat.
TOOLS (Commercially available):

Valve seat cutter, 60° MWYCU111
Solid pilot (short) 5.5 mm NWYPM10055SH [1]
Accessory kit NWYKACC246
T-wrench NWYTW505
Adapter, 1/2"-3/8" NWYTW503-1
Make a light pass with the 45° cutter to remove any
possible burrs at the edge of the seat.
Be sure that the width of the finished valve seat is within
specification.
STANDARD:
GX120/GX200:
IN/EX: 0.70 – 0.90 mm (0.028 – 0.035 in)
GX160:
IN: 0.70 – 0.90 mm (0.028 – 0.035 in)
EX: 0.90 – 1.10 mm (0.035 – 0.043 in)
45°
13-10
dummyhead

Lap the valves into their seats, using a commercially
VALVE LAPPER
available valve lapper and lapping compound.
After lapping, wash all residual compound off the
cylinder head and valve.
• Do not push the valve against the seat with force

during lapping. Apply a light pass with the valve
lapper.
• Avoid lapping the valve in the same position as it
causes uneven wear. Lap the valve by turning the
lapper slowly.
• Take care not to allow the lapping compound to
enter the gap between the stem and guide.
13-11
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MEMO
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14. CRANKCASE
TOOLS·························································14-2 PISTON Assy. DISASSEMBLY/

ASSEMBLY ················································· 14-5
CRANKCASE COVER REMOVAL/
INSTALLATION···········································14-3 CRANKCASE COVER/CYLINDER BARREL/
PISTON/CONNECTING ROD/CRANKSHAFT/
CRANKSHAFT/PISTON REMOVAL/ CAMSHAFT INSPECTION·························· 14-6
INSTALLATION···········································14-4
CRANKSHAFT BEARING/OIL SEAL
REPLACEMENT ······································· 14-13
14-1
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CRANKCASE GX120•GX160•GX200UT2
TOOLS
CRANKCASE
Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 52 x 55 mm

07746-0010100 07746-0010200 07746-0010400
Pilot, 22 mm Pilot, 25 mm Driver

07746-0041000 07746-0040600 07749-0010000
14-2
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GX120•GX160•GX200UT2 CRANKCASE
INSTALLATION
Drain the engine oil (page 3-3).
Reduction type: Remove the reduction unit (page 15-4).
CRANKSHAFT BEARING
GX120: (62/22)
GX160/GX200: (6205)
CRANKCASE COVER
(Reduction unit: chain type (Without clutch))
Crankshaft bearing replacement (page 15-10).
WASHER (If equipped)
KEY
OIL FILLER CAP
DOWEL PIN
CASE COVER PACKING
OIL FILLER CAP

(With oil level gauge)
OIL SEAL
(Lips)
OIL FILLER CAP PACKING
CHECK:
CRANKCASE COVER BOLT
CRANKCASE COVER GX120:
INSTALLATION: (6 x 28 mm) (7)
Be careful not to damage the oil seal lips. 12 N·m (1.2 kgf·m, 9 lbf·ft)
GX160/GX200:
(8 x 32 mm) (6)
24 N·m (2.4 kgf·m, 18 lbf·ft)
14-3
dummyhead
CRANKSHAFT/PISTON REMOVAL/
INSTALLATION
– Flywheel (page 8-5)
– Cylinder head (page 13-3)
– Crankcase cover (page 14-3)
PISTON Assy.
(Outer surface and big end bearing)
INSTALLATION:
Install the piston Assy. to the cylinder barrel with
the mark [1] on the piston head toward the push
rod hole [2] of the cylinder head.
VALVE LIFTER
[1] REMOVAL:
Mark the valve lifters so that the
[2] intake and exhaust sides can be
distinguished.
INSTALLATION:
Attach the valve lifters to the
cylinder barrel immediately before
installing the camshaft.
CYLINDER BARREL
(Cylinder inner surface)
OIL SEAL
(Lips)
(Pivot, pivot end and

slipper surface)
CRANKSHAFT BEARING
GX120: (62/22)
GX160/GX200: (6205)
CONNECTING ROD LOWER CAMSHAFT

(Big end bearing) (Cam lobes and journal)
INSTALLATION: INSPECTION: (page 14-6)
Set the connecting rod INSTALLATION:
lower with the oil dipper Install the timing gear [1] of the
toward the camshaft. crankshaft and camshaft [2] by
aligning the punch marks [3].
[3]
CONNECTINGCOVER
CRANKCASE ROD BOLTBOLT (2)
GX120/GX200: CRANKSHAFT
(7 x 34 mm) (Pin and gear teeth)
12 N·m (1.2 kgf·m, 9 lbf·ft) INSPECTION: (page 14-6)
GX160: INSTALLATION: [1]
(6 x 34 mm) Be careful not to damage the oil seal lips. [2]
10 N·m (1.0 kgf·m, 7 lbf·ft)
14-4
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PISTON Assy. DISASSEMBLY/
ASSEMBLY
Remove the piston Assy. (page 14-4).
MAKER MARK
PISTON RING SET (Entire surface)
INSPECTION: (page 14-6) TOP RING
INSTALLATION:
To install the oil ring, install the spacer [1] first,
and then install the side rails [2].
Be sure that the top ring [3] and second ring [4]
are not interchanged.
Install the top ring and second ring on the piston
with the maker mark side facing up.
Check that the piston rings rotate smoothly after 120° SECOND RING
installing them. 120°
Space the piston ring end gaps 120° apart, and 120°
do not align the ring end gaps with the piston pin
bore. SIDE RAIL
[3]
OIL RING
[4] 10 mm (0.4 in)
(COMBINATION RING)
[2]
SPACER
[1]
10 mm (0.4 in) SIDE RAIL
[2]
PISTON PIN
(Outer surface)
MARK
PISTON
(Ring groove and piston pin hole)
PISTON PIN CLIP INSPECTION: (page 14-6)
INSTALLATION:
Install by setting one end of the piston pin
clip in the groove of the piston pin bore,
holding the other end with long needle pliers, CONNECTING ROD UPPER
and rotating the clip in. (Small end bearing)
Do not align the end gap [1] of the piston pin
clip with the cutout [2] of the piston pin bore.
INSTALLATION:
[1] Set the connecting rod upper with
the long end toward the mark on
the piston head.
LONG END
[2]
14-5
dummyhead
CRANKCASE COVER/CYLINDER
BARREL/PISTON/CONNECTING ROD/
CRANKSHAFT/CAMSHAFT
INSPECTION
CAMSHAFT HOLDER I.D.
CRANKCASE COVER SIDE
Measure the camshaft holder I.D. of the crankcase
cover.
STANDARD: 14.000 – 14.018 mm (0.5512 – 0.5519 in)

replace the crankcase cover.
Inspect the camshaft O.D. (page 14-12).
CYLINDER BARREL SIDE

Measure the camshaft holder I.D. of the cylinder barrel
assembly.
STANDARD: 14.000 – 14.018 mm (0.5512 – 0.5519 in)

replace the cylinder barrel.
Inspect the camshaft O.D. (page 14-12).
CYLINDER SLEEVE I.D.

Measure and record the cylinder I.D. at three levels in
both the "X" axis (perpendicular to crankshaft) and the
"Y" axis (parallel to crankshaft). Take the maximum X
reading to determine cylinder wear and taper.
GX120: Y TOP
STANDARD: 60.000 – 60.015 mm
(2.3622 – 2.3628 in)
SERVICE LIMIT: 60.165 mm (2.3561 in) MIDDLE
GX160/GX200:
STANDARD: 68.000 – 68.015 mm BOTTOM
(2.6772 – 2.6778 in)
replace the cylinder barrel.
Inspect the piston skirt O.D. (page 14-7).
14-6
dummyhead
PISTON SKIRT O.D.
Measure and record the piston O.D. at a point 10 mm
(0.4 in) from the bottom of the skirt and 90° to the piston
90°
pin bore.
GX120:
STANDARD: 59.965 – 59.985 mm
(2.3608 – 2.3616 in)
GX160:
STANDARD: 67.985 – 67.995 mm
(2.6766 – 2.6770 in)
10 mm
GX200: (0.4 in)
STANDARD: 67.965 – 67.985 mm
(2.6758 – 2.6766 in)
replace the piston.
Inspect the cylinder sleeve I.D. (page 14-6).
PISTON-TO-CYLINDER CLEARANCE
Subtract the piston skirt O.D. from the cylinder sleeve
I.D. to obtain the piston-to-cylinder clearance.
GX120/GX200:
STANDARD: 0.015 – 0.050 mm
(0.0006 – 0.0020 in)
GX160:
STANDARD: 0.005 – 0.030 mm
(0.0002 – 0.0012 in)
If the calculated clearance is more than the service
limit, replace the piston and recheck the clearance.
If the clearance is still more than the service limit with
the new piston, replace the cylinder barrel.
PISTON PIN BORE I.D.

Measure and record the piston pin bore I.D. of the
piston.
GX120:
STANDARD: 13.002 – 13.008 mm
(0.5119 – 0.5121 in)
GX160/GX200:
STANDARD: 18.002 – 18.008 mm
(0.7087 – 0.7090 in)
replace the piston.
Inspect the piston pin O.D. (page 14-8).
14-7
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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.
GX120:
STANDARD: 12.994 – 13.000 mm
(0.5116 – 0.5118 in)
GX160/GX200:
STANDARD: 17.994 – 18.000 mm
(0.7084 – 0.7087 in)
replace the piston pin.
Inspect the piston pin bore I.D. (page 14-7).
Inspect the connecting rod small end I. D. (page 14-10).
PISTON PIN-TO-PISTON PIN BORE

CLEARANCE
Subtract the piston pin O.D. from the piston pin bore
I.D. to obtain the piston pin-to-piston pin bore
clearance.
STANDARD: 0.002 – 0.014 mm (0.0001 – 0.0006 in)

If the calculated clearance is more than the service limit,
replace the piston pin and recheck the clearance.
the new piston pin, replace the piston.
PISTON RING SIDE CLEARANCE

Measure the clearance between each piston ring and
ring groove of the piston using a feeler gauge.
GX120/GX200:
STANDARD:
Top: 0.035 – 0.070 mm (0.0014 – 0.0028 in)
Second: 0.045 – 0.080 mm (0.0018 – 0.0032 in)
SERVICE LIMIT:
Top: 0.15 mm (0.006 in)
Second: 0.15 mm (0.006 in)
GX160:
STANDARD:
Top: 0.060 – 0.095 mm (0.0024 – 0.0037 in)
Second: 0.045 – 0.080 mm (0.0018 – 0.0032 in)
SERVICE LIMIT:
Top: 0.15 mm (0.006 in)
Second: 0.15 mm (0.006 in)
If any of the measurements is more than the service
limit, inspect the piston ring width.
If the piston ring width is normal, replace the piston and
reinspect the clearance.
If necessary, replace the piston rings (top, second, oil)
as a set and reinspect the clearance.
If any of the measurements is still more than the service
limit with the new piston rings, replace the piston.
14-8
dummyhead
PISTON RING WIDTH
Measure each piston ring width.
GX120/GX200:
STANDARD:
Top: 0.950 – 0.970 mm (0.0374 – 0.0382 in)
Second: 0.940 – 0.960 mm (0.0370 – 0.0378 in)
SERVICE LIMIT:
Top: 0.93 mm (0.037 in)
Second: 0.92 mm (0.036 in)
GX160:
STANDARD:
Top: 0.925 – 0.945 mm (0.0364 – 0.0372 in)
Second: 0.940 – 0.960 mm (0.0370 – 0.0378 in)
SERVICE LIMIT:
Top: 0.905 mm (0.0356 in)
Second: 0.92 mm (0.036 in)
If any of the measurements is less than the service limit,
replace the piston rings (top, second, oil) as a set.
PISTON RING END GAP

Before inspection, check whether the cylinder sleeve
I.D. is within the specification (page 14-6).
Measure each piston ring end gap using a feeler gauge.
GX120/GX200:
STANDARD:
Top: 0.200 – 0.350 mm
(0.0079 – 0.0138 in)
Second: 0.350 – 0.500 mm
(0.0138 – 0.0197 in)
Oil (side rail): 0.2 – 0.7 mm
(0.01 – 0.03 in)
SERVICE LIMIT:
Top: 1.0 mm (0.04 in) [1]
Second: 1.0 mm (0.04 in)
Oil (side rail): 1.0 mm (0.04 in)
GX160:
STANDARD:
Top: 0.200 – 0.350 mm
(0.0079 – 0.0138 in)
Second: 0.350 – 0.500 mm
(0.0138 – 0.0197 in)
Oil (side rail): 0.10 – 0.35 mm
(0.004 – 0.014 in)
SERVICE LIMIT:
Top: 1.0 mm (0.04 in)
Second: 1.0 mm (0.04 in)
Oil (side rail): 1.0 mm (0.04 in)
If any of the measurements is more than the service
limit, replace the piston rings (top, second, oil) as a set.
14-9
dummyhead
CONNECTING ROD BIG END SIDE
CLEARANCE
Measure the clearance between the connecting rod big
end and crankshaft using a feeler gauge.
STANDARD: 0.1 – 0.7 mm (0.004 – 0.028 in)

replace the connecting rod (page 14-5) and recheck the
clearance.
the new connecting rod, replace the crankshaft.
CONNECTING ROD SMALL END I.D.

Measure the connecting rod small end I.D.
GX120:
STANDARD: 13.005 – 13.020 mm
(0.5120 – 0.5126 in)
GX160/GX200:
STANDARD: 18.005 – 18.020 mm
(0.7089 – 0.7094 in)
replace the connecting rod.
Inspect the piston pin O.D. (page 14-8).
CONNECTING ROD BIG END I.D.

Set the connecting rod lower to the connecting rod
upper and tighten the connecting rod bolts to the
specified torque.
TORQUE:
GX120/GX200: 12 N·m (1.2 kgf·m, 9 lbf·ft)
GX160: 10 N·m (1.0 kgf·m, 7 lbf·ft)
Measure the connecting rod big end I.D.
GX120:
STANDARD: 26.020 – 26.033 mm
(1.0244 – 1.0249 in)
GX160/GX200:
STANDARD: 30.020 – 30.033 mm
(1.1819 – 1.1824 in)
replace the connecting rod (page 14-5).
14-10
dummyhead
CRANKPIN O.D.
Measure the crankpin O.D. of the crankshaft.
GX120:
STANDARD: 25.970 – 25.980 mm
(1.0224 – 1.0228 in)
GX160/GX200:
STANDARD: 29.970 – 29.980 mm
(1.1799 – 1.1803 in)
replace the crankshaft.
CONNECTING ROD BIG END OIL

CLEARANCE
Clean all oil from the crankpin and connecting rod big
end surface.
Place a piece of plastigauge on the crankpin, install the
connecting rod upper and the connecting rod lower, and
tighten the connecting rod bolts to the specified torque.
TORQUE:
GX120/GX200: 12 N·m (1.2 kgf·m, 9 lbf·ft)
GX160: 10 N·m (1.0 kgf·m, 7 lbf·ft)
• Do not rotate the crankshaft while the plastigauge is

in place.
Remove the connecting rod and measure the

plastigauge.
STANDARD: 0.040 – 0.063 mm (0.0016 – 0.0025 in)

If the clearance is more than the service limit, inspect
the connecting rod big end I.D. and the crankpin O.D.
If necessary replace the part that is not within the
service limit and reinspect the clearance.
CRANKSHAFT RUNOUT
Set the crankshaft on V-blocks and measure the runout
using a dial indicator.

If the measured runout is more than the service limit,
15.0 mm (0.59 in) 14.0 mm (0.55 in)
14-11
dummyhead
CAMSHAFT CAM HEIGHT
Measure the cam height of the camshaft.
GX120/GX200:
STANDARD:
IN: 27.500 – 27.900 mm (1.0827 – 1.0984 in)
EX: 27.547 – 27.947 mm (1.0845 – 1.1003 in)
SERVICE LIMIT:
IN: 27.450 mm (1.0807 in)
EX: 27.500 mm (1.0827 in)
GX160:
STANDARD:
IN/EX: 27.503 – 27.903 mm (1.0828 – 1.0985 in)
SERVICE LIMIT:
IN/EX: 27.450 mm (1.0807 in)
replace the camshaft.
CAMSHAFT O.D.
Measure the O.D. of the camshaft.
STANDARD: 13.966 – 13.984 mm (0.5498 – 0.5506 in)

DECOMPRESSOR WEIGHT
Check for worn and weakened spring.
If the return spring [1] is worn or weakened, replace the
weight return spring.
Check that the decompressor weight moves smoothly.
If the decompressor weight does not move correctly,
[1]
14-12
dummyhead
CRANKSHAFT BEARING
Turn the inner race of the bearing with your finger and
check for play.
Replace the bearing if it is noisy or has excessive play.
CRANKSHAFT BEARING/OIL SEAL

REPLACEMENT
CRANKSHAFT BEARING
CRANKCASE SIDE/CYLINDER BARREL SIDE
Remove the oil seal and drive out the crankshaft
[4]
bearing.
Drive a new crankshaft bearing [1] until it is fully seated
on the end using the special tools.
TOOLS: GX120 (62/22):
Attachment, 52 x 55 mm [2] 07746-0010400 [1]
Pilot, 22 mm [3] 07746-0041000
Driver [4] 07749-0010000 [2]
TOOLS: GX160/GX200 (6205):

Attachment, 52 x 55 mm [2] 07746-0010400
Pilot, 25 mm [3] 07746-0040600
Driver [4] 07749-0010000 [3]
CRANKSHAFT OIL SEAL

CRANKCASE SIDE
Remove the oil seal.
[3]
Drive a new oil seal [1] in the position as shown using
the special tools.
INSTALLATION HEIGHT:
GX120: 5.0 mm (0.20 in) [1]
GX160/GX200: 5.5 mm (0.22 in) [2]
TOOLS:
Attachment, 37 x 40 mm [2] 07746-0010200
Driver [3] 07749-0010000
CYLINDER BARREL SIDE
Remove the oil seal.
the special tools.
INSTALLATION HEIGHT: 1.5 mm (0.06 in)
TOOLS: GX120:
Attachment, 32 x 35 mm [2] 07746-0010100
Driver [3] 07749-0010000
TOOLS: GX160/GX200:
Attachment, 37 x 40 mm [2] 07746-0010200
Driver [3] 07749-0010000
14-13
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MEMO
dummytext
15. REDUCTION UNIT
TOOLS·························································15-2 REDUCTION UNIT INSPECTION ··············· 15-7
REDUCTION UNIT DISASSEMBLY/ REDUCTION UNIT BEARING/OIL SEAL

ASSEMBLY ·················································15-4 REPLACEMENT ········································· 15-9
15-1
dummyhead
REDUCTION UNIT GX120•GX160•GX200UT2

TOOLS
REDUCTION UNIT
Remover weight Attachment, 40 x 42 mm Attachment, 42 x 47 mm

07936-371020A 07746-0010900 07746-0010300
Attachment, 52 x 55 mm Pilot, 20 mm Pilot, 22 mm

07746-0010400 07746-0040500 07746-0041000
Pilot, 25 mm Pilot, 30 mm Driver

07746-0040600 07746-0040700 07749-0010000
Bearing remover, 20 mm Bearing remover, 25 mm Remover handle

07936-3710600 07936-ZV10100 07936-3710100
15-2
dummyhead
GX120•GX160•GX200UT2 REDUCTION UNIT

Attachment, 45 x 50 mm Attachment, 62 x 64 mm
07946-6920100 07947-6340400
15-3
dummyhead

REDUCTION UNIT DISASSEMBLY/
ASSEMBLY
1/6 GEAR TYPE
Drain the reduction case oil (page 3-5).
After assembly, fill the reduction case oil (page 3-5).
REDUCTION CASE PACKING
REDUCTION CASE
BOLT (8 x 32 mm) (4)
P.T.O. SHAFT
P.T.O. SHAFT BEARING (6204) (Gear teeth and journal)
OIL FILL/BREATHER BOLT

(12 x 12 mm)
BOLT (8 x 35 mm) (4)
OIL LEVEL BOLT (12 x 15 mm)

23 N·m (2.3 kgf·m, 17 lbf·ft)
P.T.O. SHAFT BEARING (6305)
OIL LEVEL BOLT WASHER
REDUCTION COVER PACKING
P.T.O. SHAFT OIL SEAL REDUCTION COVER

KEY (Lips) INSTALLATION:
Be careful not to damage the oil seal lips.
15-4
dummyhead

1/2 CHAIN TYPE (without clutch)
DRIVE SPROCKET SPACER

(Gear teeth)
WASHER
BOLT (8 x 25 mm)
P.T.O. SHAFT
(Gear teeth and journal)
THRUST SPRING DOWEL PIN
DRIVE CHAIN
INSTALLATION:
Attach the drive chain to the
P.T.O. shaft and drive sprocket
and install in the reduction case P.T.O. SHAFT
as a set. BEARING (6205)
KEY
CHAIN CASE COVER PACKING

P.T.O. SHAFT OIL SEAL
(Lips)
BOLT (6 x 28 mm) (5)

CHAIN CASE COVER
INSTALLATION:
15-5
dummyhead

1/2 CHAIN TYPE (with clutch)
Drain the reduction case oil (page 3-6).
After assembly, fill the reduction case with oil (page 3-6).
REDUCTION CASE PACKING
OIL FILTER CAP/OIL LEVEL GAUGE
DOWEL PIN
CLUTCH CENTER KEY

DRIVE CHAIN O-RING
INSPECTION: (page 15-9) CHECK:
INSTALLATION: Replace if necessary.
Attach the drive chain to the P.T.O.
shaft and drive sprocket and install
in the reduction case as a set.
DRIVE SPROCKET THRUST

(Gear teeth WASHER
and journal)
INSPECTION: (page 15-9) REDUCTION CASE
INSTALLATION:
CLUTCH CENTER
Be careful not to damage the oil
(Gear teeth and seal lips.
journal)
CLUTCH FRICTION DISC
P.T.O. SHAFT
BEARING (6205) (Entire surface)
BOLT (8 x 22 mm) (5)
P.T.O. SHAFT P.T.O. SHAFT

BEARING (6206) (Gear teeth and journal) CLUTCH PLATE
INSPECTION: (page 15-9) (Entire surface)
BOLT (6 x 55 mm) (9) CLUTCH WEIGHT HOLDER Assy.

INSTALLATION:
Align the groove of the clutch weight
holder Assy. with clutch center key
when installing.
SPRING WASHER
KEY
BOLT (8 x 35 mm)

(Lips)
DRAIN BOLT WASHER
REDUCTION COVER REDUCTION CASE OIL DRAIN BOLT
INSTALLATION: 23 N·m (2.3 kgf·m, 17 lbf·ft)
15-6
dummyhead

CLUTCH WEIGHT HOLDER Assy.
DISASSEMBLY/ASSEMBLY
Remove the clutch weight holder Assy. (page 15-6).
CLUTCH WEIGHT
CLUTCH FREE SPRING
CLUTCH SPRING HOLDER
CLUTCH PRESSURE PLATE
CLUTCH WEIGHT CENTER
CLUTCH WEIGHT HOLDER
REDUCTION UNIT INSPECTION

P.T.O. SHAFT, CRANKSHAFT
BEARING
Turn the inner race of the bearing with your finger and
check for play.
Replace the bearing if it is noisy or has excessive play.
15-7
dummyhead

GEAR TYPE
P.T.O. SHAFT
Check the P.T.O. shaft for wear or damage.
CHAIN TYPE (without clutch)

P.T.O. SHAFT, DRIVE SPROCKET, DRIVE CHAIN
Check the following for wear or damage:
[2]
– P.T.O. shaft [1]
– Drive sprocket [2]
– Drive chain [3]
• Replace the P.T.O. shaft, drive sprocket, and drive

chain as a set.
[3] [1]

CLUTCH FRICTION DISC
Measure the clutch friction disc thickness.
15-8
dummyhead

CLUTCH PLATE
Check the clutch plate warpage on a flat plate using a
feeler gauge.
P.T.O. SHAFT, DRIVE SPROCKET, DRIVE CHAIN,

CLUTCH CENTER
[4]
– Drive chain [3]
– Clutch center [4]

chain as a set.
Check the grooves of the drive sprocket for damage or
wear caused by the clutch plate; replace it if necessary.
Check the drive sprocket bushing [5] for damage or
excessive wear; replace the drive sprocket if necessary.
[1] [2] [5] [3]
REDUCTION UNIT BEARING/OIL SEAL

REPLACEMENT
GEAR TYPE
REDUCTION CASE SIDE P.T.O. SHAFT BEARING
(6204)
Pull out the P.T.O. shaft bearing [1] using the special
[3]
tools.
TOOLS:
Bearing remover, 20 mm [2] 07936-3710600
Remover handle [3] 07936-3710100 [4]
Remover weight [4] 07936-371020A
Drive a new P.T.O. shaft bearing [5] until it is fully
seated on the end using the special tools.
[1]
TOOLS: [2]
Attachment, 42 x 47 mm [6] 07746-0010300
Pilot, 20 mm [7] 07746-0040500
Driver [8] 07749-0010000
[6] [8]
[7] [5]
15-9
dummyhead

REDUCTION COVER SIDE P.T.O. SHAFT BEARING
(6305)
Remove the oil seal and drive out the P.T.O. shaft
[4]
bearing.
Drive a new P.T.O. shaft bearing [1] until it is fully [1]
TOOLS: [2]
Attachment, 62 x 64 mm [2] 07947-6340400
Pilot, 25 mm [3] 07746-0040600
Driver [4] 07749-0010000
[3]

Remove the oil seal from the reduction cover.
[2] [3]
the special tools.
TOOLS:
Attachment, 40 x 42 mm [2] 07746-0010900
Driver [3] 07749-0010000
[1]
CHAIN TYPE (without clutch)

CRANKCASE COVER SIDE CRANKSHAFT
BEARING
Remove the crankcase cover (page 14-3).
[1]
Drive out the crankshaft bearing [1].
on the end using the special tools.
TOOLS: GX120 (62/22):
Attachment, 52 x 55 mm [3] 07746-0010400
Pilot, 22 mm [4] 07746-0041000
Driver [5] 07749-0010000
TOOLS: GX160/GX200 (6205):

Attachment, 52 x 55 mm [3] 07746-0010400
Pilot, 25 mm [4] 07746-0040600
Driver [5] 07749-0010000
[5] [3]
[4] [2]
15-10
dummyhead

CHAIN CASE COVER SIDE P.T.O. SHAFT BEARING
(6205)
[4] [2]
bearing.
TOOLS:
Attachment, 52 x 55 mm [2] 07746-0010400
Pilot, 25 mm [3] 07746-0040600
Driver [4] 07749-0010000
[3] [1]

Remove the oil seal from the chain case cover.
[2] [3]
the special tools.
TOOLS:
Attachment, 40 x 42 mm [2] 07746-0010900
Driver [3] 07749-0010000
[1]

REDUCTION CASE SIDE P.T.O. SHAFT BEARING
(6205)
Pull out the P.T.O. shaft bearing [1] using the special
tools.
TOOLS:
Bearing remover, 25 mm [2] 07936-ZV10100
Remover weight [3] 07936-371020A
[3]
TOOLS:
Attachment, 52 x 55 mm [5] 07746-0010400
Pilot, 25 mm [6] 07746-0040600 [2]
Driver [7] 07749-0010000
[1]
[7]
[5]
[4]
[6]
15-11
dummyhead

REDUCTION COVER SIDE P.T.O. SHAFT BEARING
(6206)
[4] [2]
bearing.
TOOLS:
Attachment, 62 x 64 mm [2] 07947-6340400
Pilot, 30 mm [3] 07746-0040700
Driver [4] 07749-0010000
[3] [1]

Remove the oil seal from the reduction cover.
[2] [3]
Drive a new oil seal [1] until it is flush using the special
tools.
TOOLS:
Attachment, 45 x 50 mm [2] 07746-6920100
Driver [3] 07749-0010000
[1]
15-12
dummytext
16. WIRING DIAGRAMS
HOW TO READ A WIRING DIAGRAM & 1 A/3 A CHARGE COIL TYPE ···················· 16-4
RELATED INFORMATION··························16-2
7 A CHARGE COIL TYPE··························· 16-5
NO CHARGE COIL TYPE ···························16-4
16-1
dummyhead
WIRING DIAGRAMS GX120•GX160•GX200UT2

HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION
WIRING DIAGRAMS
The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained
in this section.
HOW TO READ CONNECTOR DRAWINGS
Connector drawings show the terminal arrangement, terminal No., number of pins, and the shape of terminal (male or female).
Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors are
shown for the dedicated connectors.
The double frame connectors represent the male connectors and the single frame connectors represent the female connectors.
Both the male and female connectors are shown by viewing them from the terminal side.
FEMALE CONNECTOR VIEWING DIRECTION
LOCK
VIEWING DIRECTION MALE CONNECTOR
CONNECTOR No.
TERMINAL ARRANGEMENT
The connector drawing shows the terminal arrangement of
the connector with the lock of the connector toward up.
FEMALE CONNECTOR DRAWING

(SINGLE FRAME)
Female connector viewed from the
terminal side.
CONNECTOR No.
LOCK
MALE CONNECTOR DRAWING
(DOUBLE FRAME)
Male connector viewed from the
terminal side.
TERMINAL No.
The system drawing shows the No.9 terminal of the connector.
16-2
dummyhead
GX120•GX160•GX200UT2 WIRING DIAGRAMS

HOW TO READ WIRING DIAGRAM
SYMBOL OF TERMINAL
It shows the shape of each
terminal to identify whether it is a
male or female terminal.
3
10 5 9 4 6 1 2 7
G/Bl
G/W
R/W
G/R
Br
Br
G
Y
TERMINAL No. T5
G
G
C8 T3 C9 T8
R T7
20A 30A W
R
T4
10 INVERTER UNIT C7 W C10 T6
13
1 4 3 2
MAIN(U)
2 1 3
MAIN(V) AC1 R R R R
MAIN(W) AC2 W W W
-vdc G G
5
2 1
SUB(V)
SUV(N)
10 9 7 8 2 1 5 3 4
ECO ( G /W )
11 HZ
VCC (R/W)
PL ( G /R )
2
PL ( G /Bl)
6 2 3 4 1
VCC B (Bu) R ES
N.C. B (Y) G IND(-)
N.C. A (R) Y IND(+)
V2 A (W) Y LS
RXD G E CPU IGNITION CONTROL MODULE
1 2
Reg
TXD ES (R)
7 10 5
E G Bl/Bu EX
Bl/R IC
4 Bu PC
G
G FRAME GND
2 7 4 5 9 10 1 6
(Br)
(Br)
(Y)
GND2
G
(B l / B u)
(Bu) T1
W/ R W/ R (+)
(-) DC RECEPTACLE
Bl/R Bl/R
C1 1 T2
(Bl) 1
2 1 4 3
1 2
W (B l / R ) Bl/R
ENGINE STOP SWITCH
R Bl Bl
Y
Bu
Bl Black Br Brown
2
Y Yellow O Orange
Bu Blue Lb Light blue
G Green Lg Light green
Indicates the ground.
R Red P Pink
(Circled GND followed with W White Gr Gray
No. in white background)
CONNECTOR/TERMINAL No.
Every connector and terminal has a number to help the users find the location and shape of
the connector and the terminal arrangement by referring to the “Connector general layout
drawing” and/or the “Connector drawing.” All the connector/terminal numbers shown in this
Service Manual are either of those shown in this section.
: Connector that relays from a harness to a harness (Circled No. in black background)
: Connector that connects to electrical equipment (Circled No. in white background)
: Connector (Circled C followed with No. in white background)
: Terminal (Circled T followed with No. in white background)
: Ground (Circled GND followed with No. in white background)
16-3
dummyhead
WIRING DIAGRAMS GX120•GX160•GX200UT2

NO CHARGE COIL TYPE
1 A/3 A CHARGE COIL TYPE
16-4
dummyhead
GX120•GX160•GX200UT2 WIRING DIAGRAMS

7 A CHARGE COIL TYPE
16-5
dummyhead
MEMO
INDEX
dummytext
INDEX
1 A/3 A CHARGE COIL TYPE ······································16-4 IGNITION SYSTEM TROUBLESHOOTING··················· 9-3
Numerics
7 A CHARGE COIL TYPE·············································16-5 LUBRICATION & SEAL POINTS···································· 2-7

L
AIR CLEANER CHECK/CLEANING/REPLACEMENT ···3-7 MAIN FUSE INSPECTION ··········································· 11-7

A M
AIR CLEANER REMOVAL/INSTALLATION ···················6-5 MAINTENANCE SCHEDULE ········································· 3-2

BEFORE TROUBLESHOOTING ····································4-2 MAINTENANCE STANDARDS ······································ 2-2
B
CARBURETOR BODY CLEANING ······························6-12 MAXIMUM SPEED ADJUSTMENT ································ 7-7

C
CARBURETOR DISASSEMBLY/ASSEMBLY ··············6-11 MUFFLER REMOVAL/INSTALLATION························ 12-2

CARBURETOR INSPECTION ······································6-12 NO CHARGE COIL TYPE ············································ 16-4
N
CARBURETOR REMOVAL/INSTALLATION················6-10 OIL ALERT UNIT INSPECTION ··································· 11-8

O
CARBURETOR STUD BOLT REPLACEMENT············6-14 OIL ALERT UNIT REMOVAL/INSTALLATION············· 11-6

CHARGE/LAMP COIL INSPECTION······························8-8 OIL LEVEL SWITCH INSPECTION······························ 11-7
CHARGE/LAMP COIL REMOVAL/INSTALLATION ·······8-7 OIL LEVEL SWITCH REMOVAL/INSTALLATION ······· 11-5
CHARGING SYSTEM TROUBLESHOOTING················8-4 P.T.O. DIMENSIONAL DRAWINGS····························· 1-21
P
CHOKE REPLACEMENT ·············································6-14 P.T.O. TYPE VARIATION··············································· 1-2

CIRCUIT PROTECTOR INSPECTION ·························11-7 PERFORMANCE CURVES·········································· 1-12
COMBINATION SWITCH INSPECTION·······················11-6 PILOT SCREW REPLACEMENT ································· 6-13
COMBUSTION CHAMBER CLEANING ·······················3-15 PISTON Assy. DISASSEMBLY/ASSEMBLY················ 14-5
COMPONENT LOCATION ···········································11-2 RECOIL STARTER Assy. DISASSEMBLY/
R
CONTROL BASE Assy. DISASSEMBLY/ASSEMBLY ···7-4 ASSEMBLY ·································································· 10-4

CONTROL BOX DISASSEMBLY/ASSEMBLY ·············11-4 RECOIL STARTER Assy. REMOVAL/INSTALLATION 10-3
CONTROL BOX REMOVAL/INSTALLATION···············11-3 RECOIL STARTER INSPECTION································ 10-6
COOLING FAN/FLYWHEEL REMOVAL/ REDUCTION CASE OIL LEVEL CHECK/CHANGE······· 3-4
INSTALLATION·······························································8-5 REDUCTION UNIT BEARING/OIL SEAL
CRANKCASE COVER REMOVAL/INSTALLATION·····14-3 REPLACEMENT························································· 15-9
CRANKCASE COVER/CYLINDER BARREL/PISTON/ REDUCTION UNIT DISASSEMBLY/ASSEMBLY ········ 15-4
CONNECTING ROD/CRANKSHAFT/CAMSHAFT REDUCTION UNIT INSPECTION ································ 15-7
INSPECTION ································································14-6 REGULATOR/RECTIFIER INSPECTION ···················· 11-8
CRANKSHAFT BEARING/OIL SEAL SEDIMENT CUP CLEANING ······································· 3-10
S
REPLACEMENT ·························································14-13 SERIAL NUMBER LOCATION ······································· 1-2

CRANKSHAFT/PISTON REMOVAL/INSTALLATION ··14-4 SILICON RECTIFIER INSPECTION ···························· 11-6
CYLINDER HEAD DISASSEMBLY/ASSEMBLY ··········13-4 SPARK ARRESTER CLEANING·································· 3-12
CYLINDER HEAD REMOVAL/INSTALLATION············13-3 SPARK PLUG CAP INSPECTION ································· 9-6
CYLINDER HEAD/VALVES INSPECTION ···················13-5 SPARK PLUG CHECK/ADJUSTMENT ························ 3-11
DIMENSIONAL DRAWINGS·········································1-15 SPARK PLUG REPLACEMENT··································· 3-11
D
DIMENSIONS AND WEIGHTS SPECIFICATIONS ······1-10 SPARK TEST ································································· 9-5

ENGINE OIL LEVEL CHECK/CHANGE ·························3-3 STARTER MOTOR DISASSEMBLY/ASSEMBLY········ 10-8
E
ENGINE SPECIFICATIONS ·········································1-11 STARTER MOTOR INSPECTION································ 10-9

ENGINE STOP SWITCH INSPECTION ·······················11-8 STARTER MOTOR REMOVAL/INSTALLATION ········· 10-7
ENGINE STOP SWITCH REMOVAL/INSTALLATION ·11-5 STARTING SYSTEM TROUBLESHOOTING··············· 10-2
EXHAUST PIPE STUD BOLT REPLACEMENT···········12-3 SYSTEM DIAGRAM
FAN COVER REMOVAL/INSTALLATION ······················5-2 CHARGING SYSTEM ················································ 8-3
F
FUEL TANK AND FILTER CLEANING ·························3-15 IGNITION SYSTEM ··················································· 9-2
FUEL TANK REMOVAL/INSTALLATION ·······················6-3 STARTING SYSTEM ··············································· 10-2
FUEL TUBE CHECK·····················································3-16 TOOL ·············································································· 8-2
T
GOVERNOR ADJUSTMENT ··········································7-5 TOOLS

G
GOVERNOR ARM/CONTROL BASE Assy. REMOVAL/ CRANKCASE··························································· 14-2

INSTALLATION·······························································7-3 CYLINDER HEAD ···················································· 13-2
GOVERNOR DISASSEMBLY/ASSEMBLY ····················7-6 FUEL SYSTEM ·························································· 6-2
GOVERNOR MECHANISM ············································7-2 REDUCTION UNIT ·················································· 15-2
HARNESS AND TUBE ROUTING ································2-10 SERVICE INFORMATION ········································· 2-8
H
HOW TO READ A WIRING DIAGRAM & RELATED TORQUE VALUES ························································· 2-6
INFORMATION ·····························································16-2 TROUBLESHOOTING···················································· 4-2
IDLE SPEED CHECK/ADJUSTMENT ··························3-13 VALVE CLEARANCE CHECK/ADJUSTMENT ············ 3-13
I V
IGNITION COIL AIR GAP CHECK/ADJUSTMENT ········9-5 VALVE GUIDE REAMING ············································ 13-9
IGNITION COIL INSPESTION ········································9-6 VALVE GUIDE REPLACEMENT·································· 13-8
IGNITION COIL REMOVAL/INSTALLATION··················9-4 VALVE SEAT RECONDITIONING ····························· 13-10
2-1
dummytext
INDEX
2-2
SHOP
MANUAL
GX120RT2 • GX200RT2
ENGINE
Supplement Z
to the
GX120UT2 • GX160UT2 • GX200UT2
Engine Shop Manual
© 2011 Honda Motor Co., LTD.—All Rights Reserved 61Z4H00ZE1

SERVICE INFORMATION
require the use of special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to his or her personal safety and the safe operation of this product.
Improper service or repairs can create an

unsafe condition that can cause your customer
or others to be seriously hurt or killed.
For Your Safety

practices (Hot parts-wear gloves, for example). If you have not received shop safety training or do not feel confident about your
knowledge of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual.

precautions can cause you to be seriously hurt
or killed.
manual carefully.

• Protect yourself and others whenever you have engine-power equipment up in the air. Anytime you lift this product with a hoist,
make sure that the hoist hook is securely attached to the product.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from battery are explosive. To reduce the possibility of a fire or explosion, be careful when
INTRODUCTION OUTLINE OF CHANGES

This supplement covers the construction, function, and SPECIFICATIONS 1
servicing procedures of the Honda
GX120RT2·GX200RT2 Engines. SERVICE INFORMATION 2
For service information that is not covered in this
supplement, please refer to the MAINTENANCE
GX120UT2·GX160UT2·GX200UT2 base shop manual.
3
TROUBLESHOOTING 4
All information contained in this manual is based on the
latest product information available at the time of COVER
printing. We reserve the right to make changes at
5
anytime without notice. FUEL SYSTEM 6
No part of this publication may be reproduced, stored in GOVERNOR SYSTEM
a retrieval system, or transmitted, in any form, by any
7
means, electronic, mechanical, photocopying,
CHARGING SYSTEM 8
recording, or otherwise, without prior written permission
of the publisher. This includes text, figures, and tables.
IGNITION SYSTEM 9
As you read this manual, you will find information that is
STARTING SYSTEM 10
preceded by a symbol. The purpose of this
message is to help prevent damage to this Honda OTHER ELECTRICAL 11
product, other property, or the environment.
MUFFLER 12
SAFETY MESSAGES
Your safety and the safety of others are very important. CYLINDER HEAD 13
To help you make informed decisions, we have
provided safety messages and other safety information CRANKCASE 14
throughout this manual. Of course, it is not practical or
possible to warn you about all the hazards associated REDUCTION UNIT 15
with servicing these products. You must use your own
good judgement. WIRING DIAGRAMS 16
You will find important safety information in a variety of INDEX
forms, including:
The marked sections contain no changes.
They are not covered in this supplement.
· Safety Labels – on the product.
· Safety Messages – preceded by a safety alert symbol
and one of three signal words, DANGER,
WARNING, or CAUTION.
You WILL be KILLED or SERIOUSLY

HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY

You CAN be HURT if you don’t follow

instructions.
· Instructions – how to service these products correctly

and safely.

Date of Issue: October, 2011
i (Z)
SYMBOLS
Use the recommended engine oil, unless otherwise specified.
Apply sealant.

ii (Z)
OUTLINE OFHowCHANGES
to use this manual
MODEL
ITEM
NEW GX120RT2 EXISTING GX120UT2
CRANKCASE
COVER
OIL TANK
CRANKSHAFT
iii (Z)
OUTLINE
How OFthis
to use CHANGES
manual
MODEL
ITEM
FAN COVER
SIDE PLATE
CARBURETOR
iv (Z)
OUTLINE OFthis
How to use CHANGES
manual
MODEL
ITEM
AIR CLEANER
MUFFLER
AIR VENT
TUBE/
STRAINER
v (Z)
OUTLINE
How OFthis
to use CHANGES
manual
MODEL
ITEM
CONTROL
LEVER
CHAIN CASE
COVER
vi (Z)
OUTLINE OFthis
How to use CHANGES
manual
MODEL
ITEM
AUTO
THROTTLE
GOVERNOR
ARM
vii (Z)
MEMO
1. SPECIFICATIONS
P.T.O. TYPE VARIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 (Z)

DIMENSIONS AND WEIGHTS SPECIFICATIONS . . . . . . . . . . . . . . . 1-4 (Z)
ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 (Z)
DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 (Z)
P.T.O. DIMENSIONAL DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 (Z)
1-1 (Z)
SPECIFICATIONS GX120RT2 • GX200RT2
GX120RT2
P.T.O. type KR V
Type AR DKR KRF4 KRR4 KRS4 KRS5 KRS6 KRSB VPR4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Low profile (With protector)
Rammer
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Auto throttle
Charge coil 1A
3A
7A
Lamp coil 12 V - 15 W
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear (1/6)
Chain (1/2) Without clutch
With clutch
Chain (1/1)
1-2 (Z)
GX120RT2 • GX200RT2 SPECIFICATIONS
GX200RT2
P.T.O. type S V VE
Type RHG4 RMG2 SWG4 VEE9 VGGN VPM4 VS19 VENN
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Auto throttle
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
With clutch
Chain (1/1)
1-3 (Z)
P.T.O. type GX120RT2 GX200RT2
Overall length KR * 313 mm (12.3 in) –
S* – 313 mm (12.3 in)
V* 315.5 mm (12.42 in) 331 mm (13.0 in)
VE * – 287 mm (11.3 in)
Overall width KR * 331 mm (13.0 in) –
S* – 376 mm (14.8 in)
V* 346 mm (13.6 in) 376 mm (14.8 in)
VE * – 376 mm (14.8 in)
Overall height KR * 321 mm (12.6 in) –
S* – 346 mm (13.6 in)
V* 329 mm (13.0 in) 346 mm (13.6 in)
VE * – 346 mm (13.6 in)
Dry weight KR * 16.5 kg (36.4 lbs) –
S* – 16.1 kg (35.5 lbs)
V* 13.0 kg (28.7 lbs) 16.1 kg (35.5 lbs)
VE * – 16.1 kg (35.5 lbs)
Operating weight KR * 16.9 kg (37.3 lbs) –
S* – 19.6 kg (43.2 lbs)
V* 15.5 kg (34.2 lbs) 19.6 kg (43.2 lbs)
VE * – 19.6 kg (43.2 lbs)
*: P. T. O. type. (page 1-2)
1-4 (Z)
Model GX120RT2 GX200RT2
Description code GCBMT GCBTT
Displacement 118 cm3 (7.2 cu-in) 196 cm3 (12.0 cu-in)
Bore x stroke 60.0 x 42.0 mm (2.36 x 1.65 in) 68.0 x 54.0 mm (2.68 x 2.13 in)
Net power (SAE J1349) *1 2.6 kW (3.5 HP)/3,600 min-1 (rpm) 4.1 kW (5.6 HP)/3,600 min-1 (rpm)
Continuous rated power 2.1 kW (2.9 HP)/3,600 min-1 (rpm) 3.7 kW (5.0 HP)/3,600 min-1 (rpm)
Maximum net torque (SAE J1349) *1 7.3 N·m (0.7 kgf·m, 5.4 lbf·ft)/ 12.4 N·m (1.3 kgf·m, 9 lbf·ft)/
2,500 min-1 (rpm) 2,500 min-1 (rpm)
Compression ratio 8.5 : 1
Fuel consumption (at continuous rated 1.0 Liter (0.26 US gal, 1.7 Liters (0.45 US gal,
power) 0.22 Imp gal)/h 0.37 Imp gal)/h
Ignition timing B.T.D.C. 20°/1,400 min-1 (rpm)
Recommended spark plug BPR4ES (NGK)/ BPR6ES (NGK)/
W14EPR-U (DENSO) W20EPR-U (DENSO)
Oil capacity 0.40 Liter 0.60 Liter
(0.42 US qt, 0.35 Imp qt) *2 (0.63 US qt, 0.53 Imp qt)
Recommended oil SAE 10W-30 API service classification SJ or higher
Starting system Recoil Starter Recoil, Recoil and Starter motor
Carburetor Horizontal type, float valve Horizontal type, butterfly valve
Air cleaner Dual type, Dual silent type, Dual type, Low profile type
Low profile type, Rammer type
Fuel tank capacity – 3.1 Liters (0.82 US gal,
0.68 Imp gal)
Reduction case oil Chain type Shared with engine oil –
capacity (without clutch)
Chain type – 0.50 Liter (0.53 US qt, 0.44 Imp qt)
(with clutch)
Reduction unit: Type – Centrifugal
Chain type (with clutch) Engagement – 1,800 min-1 (rpm)
start
Lock – 2,200 min-1 (rpm)
*1: The power rating of the engine indicated in this document is the net power output tested on a production
engine for the engine model and measured in accordance with SAE J1349 at 3,600 rpm (net power) and at
2,500 rpm (max net torque). Mass production engines may vary from this value. Actual power output for the
engine installed in the final machine will vary depending on numerous factors, including the operating speed of
the engine in application, environmental conditions, maintenance, and other variables.
*2: When tilted at 14°
1-5 (Z)
GX120RT2 (RAMMER TYPE)
Unit: mm (in)
144.5 (5.69)
321
(12.6)
94
(3.7)
158 (6.2) 173 (6.8) 313 (12.3)
162 (6.4)
5 (0.2)
96 (3.8)
39.5 (1.56)
80 (3.1)
1-6 (Z)
Unit: mm (in)
Φ14.976 – 14.994
188 (7.4) (0.5896 – 0.5903)
Φ100.000 – 100.054
(3.9370 – 3.9391)
4.00 – 4.03
(0.157 – 0.159)
34
(1.3)
102.6
(4.04)
3.70 – 3.80
78
(0.146 – 0.150)
(3.1)
M12 x 1.25
31 (1.2)
43 (1.7)
102.6 (4.04)
GX200RT2
VE type* Unit: mm (in)
45° 45°
M8 x 1.25
M8 x 1.25
TAPER 1/5
27.3 (1.07)
30.3 (1.19)
65.1
(2.56)
Φ20 (0.8)
Φ24.947 – 24.980 (0.9822 – 0.9835)
74 (2.9)
88 (3.5)
CRANKSHAFT (P.T.O.)
1-7 (Z)
MEMO
MAINTENANCE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 (Z)

TORQUE VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 (Z)
2-1 (Z)
SERVICE INFORMATION GX120RT2 • GX200RT2
GX120RT2
Carburetor Main jet BE62J A #62 –
BE62K A #62 –
Pilot screw opening BE62J A 1-1/2 turns out –
BE62K A 1-5/8 turns out –
Float height BE62J A 18.7 mm (0.74 in) –
BE62K A 13.7 mm (0.54 in) –
GX200RT2
BE74V A #78 –
BE74Z A #78 –
BE59P A #75 –
BE74V A 2-3/4 turns out –
BE74Z A 2-3/4 turns out –
Float height 13.7 mm (0.54 in) –
TORQUE VALUES
(*) Refer to page of base shop manual (GX120UT2/160UT2/200UT2).
Other items should be tightened to standard torque values (page 2-6*).
Torque values
N·m kgf·m lbf·ft
Connecting tube band screw M4 x 0.7 2 0.2 1.5
Air cleaner elbow nut M6 x 1.0 9 0.9 6.6
Air cleaner mounting bolt M6 x 1.0 12 1.2 9
Muffler stay bolt M8 x 1.25 24 2.4 18
Muffler stay bolt M6 x 1.0 12 1.2 9
Muffler stay nut M6 x 1.0 12 1.2 9
Muffler nut M8 x 1.25 24 2.4 18
Crankcase cover bolt M6 x 1.0 12 1.2 9
Auto throttle solenoid screw M5 x 0.8 5 0.5 3.7
Regulator/rectifier bolt M6 x 1.0 10 1.0 7
2-2 (Z)
3. MAINTENANCE
AIR CLEANER CHECK/CLEANING/REPLACEMENT. . . . . . . . . . . . 3-2 (Z)
3-1 (Z)
MAINTENANCE GX120RT2 • GX200RT2
AIR CLEANER CHECK/CLEANING/
REPLACEMENT
(*) Refer to page of base shop manual (GX120UT2/
160UT2/200UT2).
CASE SIDE
COVER SIDE
• Never use gasoline or low flash point solvents for
cleaning the air filter element. A fire or explosion
could result.
[1]
Unhook the clip [1] and remove the following:
– Air cleaner element (Paper) [3] [3]
Carefully check the element and filter for holes or tears
and replace if damaged.
Clean the filters if they are to be reused (page 3-9*).
• Install the air cleaner element in the direction as

shown.
• When installing the air cleaner cover, align the hole
[5] with the tab [6] of the air cleaner case.
[4]
[6]
[2]
[5]
3-2 (Z)
6. FUEL SYSTEM
AIR CLEANER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . 6-2 (Z)

CARBURETOR DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . . . 6-3 (Z)
6-1 (Z)
FUEL SYSTEM GX120RT2 • GX200RT2
INSTALLATION
160UT2/200UT2).
Remove the muffler (page 12-2).
• Route the breather tube properly (page 2-11*).
AIR CLEANER CONNECTING TUBE BAND (2)

AIR CLEANER Assy.
AIR CLEANER MOUNTING BOLT (6 x 16 mm) (2)

12 N·m (1.2 kgf·m, 9 lbf·ft)
5.6 ± 1.0 mm
(0.22 ± 0.04 in)
SCREW: 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
MUFFLER STAY
MUFFLER STAY BOLT
(8 x 20 mm) (2)
24 N·m (2.4 kgf·m, 18 lbf·ft) MUFFLER STAY NUT (6 mm)
12 N·m (1.2 kgf·m, 9 lbf·ft)
AIR CLEANER
CONNECTING TUBE
MUFFLER STAY BOLT

(6 x 25 mm) BOLT (6 x 20 mm)
12 N·m (1.2 kgf·m, 9 lbf·ft)
COLLAR
AIR CLEANER
COLLAR (2)
CARBURETOR SPACER
INSTALLATION: BREATHER TUBE
Before installing, check for damage.
AIR CLEANER ELBOW
Remove and install the air cleaner
elbow with the choke lever in the
CLOSE position.
Before installation, clean the inside AIR CLEANER ELBOW NUT (6 mm) (2)
of the air cleaner elbow. 9 N·m (0.9 kgf·m, 6.6 lbf·ft)
6-2 (Z)
GX120RT2 • GX200RT2 FUEL SYSTEM
CARBURETOR DISASSEMBLY/ASSEMBLY
(*) Refer to page of base shop manual (GX120UT2/160UT2/200UT2).

fuel.

goggles or other eye protection when using com-
pressed air.

– Carburetor (page 6-10*) Tampering is a violation of Federal and
California law.
PILOT JET SET CLAMP STRAINER

ASSEMBLY:
Before installing, clean FUEL TUBE
thoroughly with low-pressure CLAMP
compressed air. CLAMP
O-RING CHOKE LEVER
Lightly lubricate the O-ring [1]
to ensure easy installation THROTTLE STOP SCREW
into the carburetor body. [1] ADJUSTMENT: (page 3-13*)
PILOT SCREW
REPLACEMENT: (page 6-13*)
AIR VENT TUBES
MAIN NOZZLE SPRING PIN
UPPER LIMITER CAP CLIPS
ASSEMBLY: FLOAT VALVE
Before installing, clean SIDE INSPECTION: (page 6-13*)
thoroughly with low-
pressure compressed air.
PILOT SCREW SPRING Except RAMMER type:
CARBURETOR
FUEL STRAINER
BODY
MAIN JET
ASSEMBLY: UPPER CLIP
thoroughly with low FLOAT
compressed air.
FLOAT PIN
FLOAT CHAMBER
ASSEMBLY:
O-RING FUEL TUBE
Install the float chamber to the carburetor body
at an angle as shown.
RAMMER type: Except RAMMER type:
300° FUEL RUBBER
DRAIN
SCREW FLOAT VALVE SPRING
SET BOLT GASKET

90° DRAIN SCREW
GASKET SET BOLT
6-3 (Z)
MEMO
7. GOVERNOR SYSTEM
GOVERNOR ARM/CONTROL BASE Assy. REMOVAL/INSTALLATION. . . 7-2 (Z)

AUTO THROTTLE Assy. REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . 7-3 (Z)
MAXIMUM SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 (Z)
AUTO THROTTLE SOLENOID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 7-5 (Z)
7-1 (Z)
GOVERNOR SYSTEM GX120RT2 • GX200RT2
GX200RT2 (AUTO THROTTLE TYPE)
160UT2/200UT2.
Remove the following parts.
– Air cleaner (page 6-7*)
– Fuel tank (page 6-3*)
– Muffler (page 12-2)
– Auto throttle Assy. (page 7-3)
• After installation, adjust the maximum speed (page

7-4).
GOVERNOR ROD/THROTTLE RETURN SPRING GOVERNOR ARM RETURN SPRING

Pull the carburetor to a point where the groove [1] of NUT (6 mm)
the throttle arm lines up with the governor rod [2], and
then lift the governor rod out of the hole of the throttle GOVERNOR ARM Assy.
arm and unhook the throttle return spring [3].
[2] GOVERNOR ARM BOLT
GOVERNOR SPRING
[3]
[1]
BOLT (6 x 12 mm) (2)

BOLT (6 x 8 mm) (2)
SCREW (5 x 35 mm)
UPPER SHROUD Assy.
CONTROL ADJUSTING SPRING
7-2 (Z)
GX120RT2 • GX200RT2 GOVERNOR SYSTEM
AUTO THROTTLE Assy. REMOVAL/
INSTALLATION
160UT2/200UT2).
Remove the fuel tank (page 6-3*).
• After installation, adjust the maximum speed (page

7-4).
REGULATOR/RECTIFIER
CONDENSER UNIT
NUT (6 mm) REGULATOR/RECTIFIER BOLT
(6 x 16 mm) (2)
10 N·m (1.0 kgf·m, 7 lbf·ft)
CHOKE RETURN SPRING
AUTO THROTTLE SOLENOID

5 N·m (0.5 kgf·m, 3.7 lbf·ft)
SUB HARNESS
SPRING PIN
HARNESS CLIPS
SOLENOID THROTTLE LEVER
BOLT (6 x 25 mm) (2)
7-3 (Z)
GOVERNOR SYSTEM GX120RT2 • GX200RT2
MAXIMUM SPEED ADJUSTMENT
160UT2/200UT2).
[6] [1]
Loosen the bolts (6 x 25 mm) [1] and nut (6 mm) [2].
Release the solenoid throttle lever [3] from the governor
sub arm [4] by moving the auto throttle assy. [5].
Loosen the nut (6 mm) [6] of the governor arm.
[5]
[3]
[4] [1]/[2]
Turn the governor sub arm [1] clockwise to fully open

[5]
the carburetor throttle valve [2].
Make sure the stoppers of the governor arm [3] with the
governor sub arm are aligned.
[3]
Rotate the governor arm shaft [4] as far as it will go in
the same direction the governor sub arm moved to [4]
open the throttle valve.
Make sure the carburetor throttle valve is fully opened.
Tighten the nut (6 mm) [5] securely.
[1]
[2]
Align
Align the solenoid throttle lever [1] to the governor sub

[4]
arm [2] by moving the auto throttle assy. [3] and tighten
the bolts (6 x 25 mm) [4] and nut (6 mm) [5].
[1]
Install the fuel tank (page 6-3*).
Turn the auto throttle switch to "OFF" position.
Use a tachometer with graduations of 50 min-1 (rpm) or [6]
changes.
Start the engine and allow it to warm up to normal oper- [8]
ating temperature.
Move the control lever [6] to run the engine at the spec- Align [3]
ified maximum speed, and hold the control lever.
MAXIMUM SPEED: 3,900 ± 100 min-1 (rpm)
[7]
Make sure the carburetor throttle valve [7] is fully [2]
opened and turn the screw [8] until its end lightly
[4]/[5]
touches the control lever.
If necessary, adjust the idle speed (page 3-13*).
7-4 (Z)
GX120RT2 • GX200RT2 GOVERNOR SYSTEM
INSPECTION
160UT2/200UT2).
Connect a fully charged 12 V battery to the auto throttle
solenoid terminals [1] and check the auto throttle sole-
noid operation. [3]
Make sure that the auto throttle solenoid [2], throttle
solenoid lever [3], and governor sub arm [4] move as
shown when a 12 V battery is connected.
Also make sure that the auto throttle solenoid, throttle
solenoid lever, and governor sub arm return to the orig-
inal position when disconnecting battery.
[4] [2]
[1]
7-5 (Z)
MEMO
12. MUFFLER
MUFFLER REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 12-2 (Z)
12-1 (Z)
MUFFLER GX120RT2 • GX200RT2
The muffler becomes very hot during operation

and remains hot for a while after stopping the
engine. Be careful not to touch the muffler while it
is hot.
BOLT (6 x 16 mm) (2)
MUFFLER Assy.
WASHER (8 mm) (2)

24 N·m (2.4 kgf·m, 18 lbf·ft)
NUT (6 mm) (2)
EXHAUST PIPE GASKET
12-2 (Z)
GX120RT2 • GX200RT2 MUFFLER
GX200RT2 (LOW PROFILE TYPE)

24 N·m (2.4 kgf·m, 18 lbf·ft)
EXHAUST PIPE EXHAUST PIPE GASKET
BOLT (8 x 20 mm) (2)
MUFFLER GASKET
MUFFLER PROTECTOR SEAL
SPARK ARRESTER
MUFFLER OUTER PROTECTOR
MUFFLER INNER PROTECTOR MUFFLER
12-3 (Z)
MEMO
14. CRANKCASE
CRANKCASE COVER REMOVAL/INSTALLATION . . . . . . . . . . . . . 14-2 (Z)
14-1 (Z)
CRANKCASE GX120RT2 • GX200RT2
INSTALLATION
160UT2/200UT2).
Drain the engine oil (page 3-3*).
Remove the reduction unit (page 15-2).
CRANKSHAFT BEARING (62/22) TUBE
TUBE CLIP
BOLT
(6 x 16 mm)
OIL TANK
WASHER
DOWEL PIN
BOLT
(6 x 14 mm)
CASE COVER PACKING
OIL FILLER CAP

O-RING

CHECK:
CRANKCASE COVER BOLT
(6 x 28 mm) (7)
12 N·m (1.2 kgf·m, 9 lbf·ft)
CRANKCASE COVER
INSTALLATION:
14-2 (Z)
15. REDUCTION UNIT
REDUCTION UNIT DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . . . . . 15-2 (Z)

REDUCTION UNIT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3 (Z)
REDUCTION UNIT BEARING/OIL SEAL REPLACEMENT . . . . . . . . . . . . 15-3 (Z)
15-1 (Z)
REDUCTION UNIT GX120RT2 • GX200RT2
ASSEMBLY
(Gear teeth and journal)

P.T.O. SHAFT
DRIVE CHAIN
INSTALLATION:
Attach the drive chain to the
P.T.O. shaft and drive sprocket
and install in the reduction case
as a set.
SPACER
DRIVE SPROCKET
P.T.O. SHAFT BEARING (6005) INSPECTION: (page 15-3)
(Gear teeth)
WASHER
BOLT (8 x 25 mm)
THRUST SPRING BOLT (8 x 55 mm)
DOWEL PIN

CHAIN CASE COVER (Lips)
INSTALLATION:
Be careful not to
damage the oil seal
BOLT (8 x 35 mm) (4) lips.
15-2 (Z)
GX120RT2 • GX200RT2 REDUCTION UNIT
P.T.O. SHAFT, DRIVE SPROCKET,
DRIVE CHAIN
[1]
– Drive chain [3]
[2]
chain as a set.
[3]

REPLACEMENT
CHAIN CASE COVER SIDE P.T.O.
SHAFT BEARING (6005)
Remove the oil seal and drive out the P.T.O. shaft bear-
[4]
ing.
seated on the chain case cover using the special tools.
TOOLS [2]
Bearing driver attachment, 07746-0010300
42 x 47 mm [2]
Pilot, 25 mm [3] 07746-0040600
Driver handle [4] 07749-0010000
[3] [1]

[2] [3]
the special tools.
TOOLS
Bearing driver attachment, 07746-0010200
37 x 40 mm [2]
Driver handle [3] 07749-0010000
[1]
15-3 (Z)
MEMO
dummytext
INDEX
A
AIR CLEANER CHECK/CLEANING/REPLACEMENT……3-2

AIR CLEANER REMOVAL/INSTALLATION……6-2
AUTO THROTTLE Assy. REMOVAL/INSTALLATION……7-3
AUTO THROTTLE SOLENOID INSPECTION……7-5
C
CARBURETOR DISASSEMBLY/ASSEMBLY……6-3
CRANKCASE……14-1
CRANKCASE COVER REMOVAL/INSTALLATION……14-2
D
DIMENSIONAL DRAWINGS……1-6
DIMENSIONS AND WEIGHTS SPECIFICATIONS……1-4
E
ENGINE SPECIFICATIONS……1-5
F
FUEL SYSTEM……6-1
G
GOVERNOR ARM/CONTROL BASE Assy. REMOVAL/INSTALLATION……7-2

GOVERNOR SYSTEM……7-1
M
MAINTENANCE……3-1
MAINTENANCE STANDARDS……2-2
MAXIMUM SPEED ADJUSTMENT……7-4
MUFFLER……12-1
MUFFLER REMOVAL/INSTALLATION……12-2
P
P.T.O. DIMENSIONAL DRAWINGS……1-7

P.T.O. TYPE VARIATION……1-2
R
REDUCTION UNIT……15-1
REDUCTION UNIT BEARING/OIL SEAL REPLACEMENT……15-3
REDUCTION UNIT DISASSEMBLY/ASSEMBLY……15-2
REDUCTION UNIT INSPECTION……15-3
S
SERVICE INFORMATION……2-1
SPECIFICATIONS……1-1
T
TORQUE VALUES……2-2
1-1
MEMO
SHOP
MANUAL
GX160RT2
ENGINE
Supplement Y
to the
Engine Shop Manual
© 2011 Honda Motor Co., LTD.—All Rights Reserved 61Z4H00YE1

SERVICE INFORMATION

For Your Safety


or killed.
manual carefully.

INTRODUCTION
servicing procedures of the Honda GX160RT2
Engines. SERVICE INFORMATION 2
GX120UT2·GX160UT2·GX200UT2 base shop manual
3
and supplement Z. TROUBLESHOOTING 4
All information contained in this manual is based on the COVER
latest product information available at the time of
5
printing. We reserve the right to make changes at FUEL SYSTEM
anytime without notice.
6
GOVERNOR SYSTEM 7
No part of this publication may be reproduced, stored in
CHARGING SYSTEM 8
IGNITION SYSTEM 9

STARTING SYSTEM 10
preceded by a symbol. The purpose of this OTHER ELECTRICAL 11
message is to help prevent damage to this Honda
product, other property, or the environment. MUFFLER 12
SAFETY MESSAGES CYLINDER HEAD 13
Your safety and the safety of others are very important.
To help you make informed decisions, we have CRANKCASE 14
provided safety messages and other safety information
throughout this manual. Of course, it is not practical or REDUCTION UNIT 15
possible to warn you about all the hazards associated
with servicing these products. You must use your own WIRING DIAGRAMS 16
good judgement.
INDEX
You will find important safety information in a variety of
forms, including: The marked sections contain no changes.



instructions.

and safely.

Date of Issue: October, 2011
i 0-2
(Y)
SYMBOLS
Apply sealant.

ii0-3
(Y)
1. SPECIFICATIONS
P.T.O. TYPE VARIATION························ 1-2 (Y) ENGINE SPECIFICATIONS ···················· 1-3 (Y)
DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS··················· 1-4 (Y)

SPECIFICATIONS ··································· 1-3 (Y)
1-1 (Y)
SPECIFICATIONS
SPECIFICATIONS
P.T.O. type Q S V VE
Type QHG4 RHG4 SWG4 VGE4 VGE5 VHH4 VPM5 VS19 VWS VWWN EMAN VSE6
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Remote choke lever
Cyclone
standard
Remote Internal
Internal S
EXP
Cyclone
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
With clutch
Chain (1/1)
1-2 (Y)
SPECIFICATIONS
P.T.O. type GX160RT2
Overall length Q* 312.5 mm (12.30 in)
S* 304 mm (12.0 in)
V* 322.5 mm (12.70 in)
VE * 281 mm (11.1 in)
Overall width Q* 347 mm (13.7 in)
S* 347 mm (13.7 in)
V* 347 mm (13.7 in)
VE * –
Overall height Q* 337 mm (13.3 in)
S* 337 mm (13.3 in)
V* 337 mm (13.3 in)
VE * –
*: P. T. O. type (page 1-2).
Model GX160RT2
Description code GCBPT
Displacement 163 cm3 (9.9 cu-in)
Bore x stroke 68.0 x 45.0 mm (2.68 x 1.77 in)
Net power (SAE J1349) *1 3.6 kW (4.9 HP)/3,600 min-1 (rpm)
Continuous rated power 2.9 kW (3.9 HP)/3,600 min-1 (rpm)
Maximum net torque (SAE J1349) *1 10.3 N·m (1.1 kgf·m, 8 lbf·ft)/2,500 min-1 (rpm)
Compression ratio 9.0 : 1
Fuel consumption (at continuous rated power) 1.4 Liters (0.37 US gal, 0.31 Imp gal)/h
Ignition timing B.T.D.C. 18°/1,400 min-1 (rpm)
Oil capacity 0.58 Liter (0.61 US qt, 0.51 Imp qt)
Starting system Recoil, Recoil and Starter motor
Air cleaner Dual type, Dual silent type, Low profile type
Reduction case oil capacity: Chain type
0.50 Liter (0.53 US qt, 0.44 Imp qt)
(with clutch)
Reduction unit: Type Centrifugal
Chain type (with clutch) Engagement
1,800 min-1 (rpm)
start
Lock 2,200 min-1 (rpm)
1-3 (Y)
SPECIFICATIONS
*: P.T.O. type (page 1-2).
EXCEPT LOW PROFILE TYPE
Unit: mm (in)
108 (4.3) 239 (9.4)
347 (13.7) 93 (3.7) 160 (6.3)
317 (12.5)
106
(4.2)
75.5 (2.97)
162 (6.4)
5 (0.2)
96 (3.8) 39.5 (1.56)

Q type*: 321.5 (12.30)
S type*: 304 (12.0)
V type*: 322.5 (12.70)
80 (3.1)
1-4 (Y)
MAINTENANCE STANDARDS ··············· 2-2 (Y)
2-1 (Y)
SERVICE INFORMATION
SERVICE INFORMATION

Carburetor Main jet BE54C A #70
BE54D A #68 –
BE67W A #75 –
Pilot screw opening BE54C A 2-1/4 turns out
BE67W A 2-7/8 turns out –
2-2 (Y)
6. FUEL SYSTEM
AIR CLEANER REMOVAL/ CARBURETOR DISASSEMBLY/

INSTALLATION······································· 6-2 (Y) ASSEMBLY ············································· 6-3 (Y)
6-1 (Y)
FUEL SYSTEM
FUEL SYSTEM
INSTALLATION
REMOTE CHOKE LEVER TYPE
160UT2/200UT2).
• Route the breather tube properly (page 2-11*).
AIR CLEANER COVER

NUT
CARBURETOR SPACER INSTALLATION:
Install the air cleaner cover with the long
INSTALLATION:
skirt portion facing toward the front.
Before installing, check for damage.

BOLT (6 x 20 mm)
WING NUT
GROMMET
COLLAR
INNER FILTER (PAPER) OUTER FILTER

(FOAM)
SCREW (4 x 8 mm)
BREATHER TUBE
WIRE
HOLDER NOISE SILENCER
AIR CLEANER ELBOW

cleaner elbow with the remote
choke lever in the CLOSE
position.
Before installation, clean the CIRCLIP
inside of the air cleaner elbow.
CABLE
HOLDER
AIR CLEANER
REMOTE CABLE ELBOW SEAL
SCREW (5 x 8 mm)
CHOKE CONTROL STAY

9 N·m (0.9 kgf·m, 6.6 lbf·ft)
6-2 (Y)
FUEL SYSTEM
ASSEMBLY
REMOTE CHOKE LEVER TYPE
160UT2/200UT2).
Tampering is a violation of Federal and

California law.
fuel.

pressed air.

– Carburetor (page 6-10*)
PILOT JET SET SCREW (3 x 6 mm) (2) LEVER SETTING PLATE

ASSEMBLY:
Before installing, clean REMOTE VALVE LEVER SPRING
thoroughly with low-pressure CHOKE LEVER
O-RING
compressed air. FUEL VALVE LEVER
Lightly lubricate the O-ring THROTTLE STOP SCREW
[1] to ensure easy installation
ADJUSTMENT: (page 3-13*)
into the carburetor body. [1]
FUEL VALVE PACKING
PILOT SCREW
CHECK:
MAIN NOZZLE REPLACEMENT: (page 6-13*)
ASSEMBLY: UPPER LIMITER SPRING PIN
Before installing, clean SIDE CAP
thoroughly with low- RETURN SPRING
pressure compressed air. CARBURETOR BODY
PILOT SCREW
SPRING CUP FILTER
MAIN JET (page 3-10*)
ASSEMBLY:
UPPER
Before installing, clean
SIDE O-RING
thoroughly with low
FLOAT
compressed air.
FLOAT PIN SEDIMENT CUP
FLOAT CHAMBER 3.9 N·m (0.4 kgf·m, 2.9 lbf·ft)
O-RING
ASSEMBLY:
Install the float chamber to the FLOAT VALVE
carburetor body at an angle as shown. INSPECTION: (page 6-13*)
0 – 30°
FLOAT VALVE SPRING
SET BOLT GASKET DRAIN SCREW GASKET
6-3 (Y)
FUEL SYSTEM
LOW PROFILE TYPE
160UT2/200UT2).
Gasoline is highly flammable and explosive. You Tampering is a violation of Federal and
can be burned or seriously injured when handling California law.
fuel.

pressed air.
Remove the carburetor (page 6-10*).

PILOT JET SET VPM5 type:

ASSEMBLY: CHOKE LEVER
Before installing, clean FUEL
STRAINER CLIP
thoroughly with low-pressure
compressed air. O-RING
Lightly lubricate the O-ring
[1] to ensure easy installation THROTTLE STOP SCREW FUEL TUBE
into the carburetor body. [1] ADJUSTMENT: (page 3-13*)
PILOT SCREW
REPLACEMENT: (page 6-13*)
CLIP
SPRING PIN
LIMITER CAP
MAIN NOZZLE FUEL TUBE
ASSEMBLY: UPPER
thoroughly with low-
pressure compressed air. PILOT SCREW SPRING FUEL RUBBER
CARBURETOR BODY
MAIN JET
FLOAT VALVE
ASSEMBLY: UPPER INSPECTION: (page 6-13*)
thoroughly with low
compressed air. FLOAT PIN FLOAT VALVE SPRING
FLOAT CHAMBER
FLOAT
ASSEMBLY:
Install the float chamber to the
carburetor body at an angle as shown.
O-RING
300°
SET BOLT GASKET DRAIN SCREW GASKET

6-4 (Y)
7. GOVERNOR SYSTEM
GOVERNOR ARM/CONTROL BASE Assy. 7

REMOVAL/INSTALLATION···················· 7-2 (Y)
7-1 (Y)
dummyhead
GOVERNOR SYSTEM
GOVERNOR SYSTEM
INTERNAL S TYPE
160UT2/200UT2).
• After installation, adjust the following:

– Governor (page 7-5*)
– Idle speed (page 3-13*)
– Maximum speed (page 7-7*)
GOVERNOR ROD/THROTTLE RETURN SPRING

NUT (6 mm)
GOVERNOR ARM
Pull the carburetor to a point where the groove [1]
of the throttle arm lines up with the governor rod
[2], and then lift the governor rod out of the hole of GOVERNOR ARM BOLT
the throttle arm and unhook the throttle return
spring [3]. GOVERNOR SPRING
[2]
SCREW
[3] (5 x 16 mm)
[1]
SCREW
(4 x 6 mm)
BOLTS (6 x 12 mm)
CABLE HOLDER
CONTROL BASE Assy.
REMOTE CABLE
7-2 (Y)
INDEX
AIR CLEANER REMOVAL/INSTALLATION ···················6-2 GOVERNOR ARM/CONTROL BASE Assy. REMOVAL/
A G
CARBURETOR DISASSEMBLY/ASSEMBLY ················6-3 INSTALLATION ······························································ 7-2

C
DIMENSIONAL DRAWINGS···········································1-4 MAINTENANCE STANDARDS ······································ 2-2

D M
DIMENSIONS AND WEIGHTS SPECIFICATIONS ········1-3 P.T.O. TYPE VARIATION··············································· 1-2

P
ENGINE SPECIFICATIONS ···········································1-3

E
1-1
NOTES
SHOP
MANUAL
GX120T2 • GX160T2 • GX200T2

ENGINE
Supplement X
to the
Engine Shop Manual
© 2011 Honda Motor Co., LTD.—All Rights Reserved 61Z4H00XE1

SERVICE INFORMATION

For Your Safety


or killed.
manual carefully.

INTRODUCTION
servicing procedures of the Honda
GX120T2·GX160T2·GX200T2 Engines. SERVICE INFORMATION 2
GX120UT2·GX160UT2·GX200UT2 base shop manual
3
and supplements Z and Y. TROUBLESHOOTING 4
All information contained in this manual is based on the COVER
5
printing. We reserve the right to make changes at FUEL SYSTEM
6
GOVERNOR SYSTEM 7
CHARGING SYSTEM 8
IGNITION SYSTEM 9

STARTING SYSTEM 10
preceded by a symbol. The purpose of this OTHER ELECTRICAL 11
product, other property, or the environment. MUFFLER 12
good judgement.
INDEX
forms, including: The marked sections contain no changes.



instructions.

and safely.

Date of Issue: December, 2011
i 0-2
(X)
SYMBOLS
Apply sealant.

0-3
ii (X)
dummytext
1. SPECIFICATIONS
P.T.O. TYPE VARIATION························ 1-2 (X) ENGINE SPECIFICATIONS ·················· 1-13 (X)
DIMENSIONS AND WEIGHTS P.T.O. DIMENSIONAL DRAWINGS ····· 1-14 (X)

SPECIFICATIONS ································· 1-12 (X)
1-1 (X)
SPECIFICATIONS
SPECIFICATIONS
GX120T2
P.T.O. type KR L Q
Type ARH L1C1 LH LH2 LHL LJ LTK1 QD QH QHB1 QMP4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Standard (With lower protector)
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Remote choke lever
Control base Manual
Remote* Internal
Internal S
EXP
Norton
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Auto throttle
With clutch
Camshaft P.T.O.
Chain (1/1)
*: Remote type
·Internal S
·Norton
·Internal
·Norton
·EXP
1-2 (X)
SPECIFICATIONS
P.T.O. type Q S
Type QTN QX S1P4 SAJ SD SD2 SJ SK SM11 SMJ SYA
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Remote choke lever
Control base Manual
Remote Internal
Internal S
EXP
Norton
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Auto throttle
With clutch
Camshaft P.T.O.
Chain (1/1)
1-3 (X)
SPECIFICATIONS
P.T.O. type T V W WB
Type TH TX VSP VSX VSX1 VT W1A3 WMK WBT
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Remote choke lever
Control base Manual
Remote Internal
Internal S
EXP
Norton
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Auto throttle
With clutch
Camshaft P.T.O.
Chain (1/1)
1-4 (X)
SPECIFICATIONS
GX160T2
P.T.O. type L N Q
Type LDW LHB3 LJG LSK NJG QHB1 QHP1 QM QMPB QTB QTD
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Remote choke lever
Control base Manual
Remote Internal
Internal S
EXP
Norton
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Auto throttle
With clutch
Camshaft P.T.O.
Chain (1/1)
1-5 (X)
SPECIFICATIONS
P.T.O. type Q R S
Type QTN QX R1P0 R1U0 RMD SJG SJH SM11 SMJ SMJ1 SNX
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Remote choke lever
Control base Manual
Remote Internal
Internal S
EXP
Norton
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Auto throttle
With clutch
Camshaft P.T.O.
Chain (1/1)
1-6 (X)
SPECIFICATIONS
P.T.O. type S V
Type ST SYA VH VHB VPM6 VSW3 VSW5 VSX VSX1 VX
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Remote choke lever
Control base Manual
Remote Internal
Internal S
EXP
Norton
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Auto throttle
With clutch
Camshaft P.T.O.
Chain (1/1)
1-7 (X)
SPECIFICATIONS
P.T.O. type VE W WB
Type VED VED3 W1B0 WMK WB1
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Remote choke lever
Control base Manual
Remote Internal
Internal S
EXP
Norton
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Auto throttle
With clutch
Camshaft P.T.O.
Chain (1/1)
1-8 (X)
SPECIFICATIONS
GX200T2
P.T.O. type L N Q
Type LHB2 LJG LSK NJG NW QAPW QHB1 QHP1 QM QMP4 QTB
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Remote choke lever
Control base Manual
Remote Internal
Internal S
EXP
Norton
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Auto throttle
With clutch
Camshaft P.T.O.
Chain (1/1)
1-9 (X)
SPECIFICATIONS
P.T.O. type Q S V
Type QTD QTN QX SJG SM11 SMG1 SMG2 VHB VSP VSW VX
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Remote choke lever
Control base Manual
Remote Internal
Internal S
EXP
Norton
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Auto throttle
With clutch
Camshaft P.T.O.
Chain (1/1)
1-10 (X)
SPECIFICATIONS
P.T.O. type VE
Type VEN VES VES1
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Rammer
Muffler Standard
Silent
Low profile
Rammer
Spark arrester
Fuel gauge
Remote choke lever
Control base Manual
Remote Internal
Internal S
EXP
Norton
Charge coil 1A
3A
7A
12 V - 25 W
12 V - 50 W
Combination switch
Starter motor
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Auto throttle
With clutch
Camshaft P.T.O.
Chain (1/1)
1-11 (X)
SPECIFICATIONS
P.T.O. type GX120T2 GX160T2 GX200T2
Overall length KR* 313 mm (12.3 in) – –
L* 332 mm (13.1 in) 343 mm (13.5 in) 352 mm (13.9 in)
N* – 288.8 mm (11.37 in) 312 mm (12.3 in)
Q* 305.5 mm (12.03 in) 312.5 mm (12.30 in) 321.5 mm (12.66 in)
R* – 391 mm (15.4 in) –
S* 297 mm (11.7 in) 304 mm (12.0 in) 313 mm (12.3 in)
T* 305.5 mm (12.03 in) – –
V* 315.5 mm (12.42 in) 322.5 mm (12.70 in) 331.5 mm (13.05 in)
VE* – – 290.1 mm (11.42 in)
W* 317.5 mm (12.50 in) 329.5 mm (12.97 in) –
WB* 284.5 mm (11.20 in) 291.5 mm (11.48 in) –
Overall width KR* 331 mm (13.0 in) – –
L* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
N* – 362 mm (14.3 in) 376 mm (14.8 in)
Q* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
R* – 362 mm (14.3 in) –
S* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
T* 346 mm (13.6 in) – –
V* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
VE* – – 376 mm (14.8 in)
W* 346 mm (13.6 in) 362 mm (14.3 in) –
WB* 346 mm (13.6 in) 362 mm (14.3 in) –
Overall height KR* 321 mm (12.6 in) – –
L* 318 mm (12.5 in) 335 mm (13.2 in) 335 mm (13.2 in)
N* – 335 mm (13.2 in) 335 mm (13.2 in)
Q* 318 mm (12.5 in) 335 mm (13.2 in) 335 mm (13.2 in)
R* – 335 mm (13.2 in) –
S* 318 mm (12.5 in) 335 mm (13.2 in) 335 mm (13.2 in)
T* 318 mm (12.5 in) – –
V* 318 mm (12.5 in) 335 mm (13.2 in) 335 mm (13.2 in)
VE* – – 335 mm (13.2 in)
W* 318 mm (12.5 in) 335 mm (13.2 in) –
WB* 318 mm (12.5 in) 335 mm (13.2 in) –
Dry weight KR* 16.5 kg (36.4 lbs) – –
N* – 15.1 kg (33.3 lbs) 16.1 kg (35.5 lbs)
Q* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) 16.1 kg (35.5 lbs)
R* – 20.0 kg (44.1 lbs) –
T* 13.0 kg (28.7 lbs) – –
VE* – – 16.1 kg (35.5 lbs)
W* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) –
WB* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) –
Operating KR* 16.9 kg (37.3 lbs) – –
weight L* 16.5 kg (36.4 lbs) 19.6 kg (43.2 lbs) 20.6 kg (45.4 lbs)
N* – 18.6 kg (41.0 lbs) 19.6 kg (43.2 lbs)
Q* 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs) 19.6 kg (43.2 lbs)
R* – 24.0 kg (52.9 lbs) –
T* 15.5 kg (34.2 lbs) – –
VE* – – 19.6 kg (43.2 lbs)
W* 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs) –
WB* 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs) –
*: P. T. O. type (page 1-2).
1-12 (X)
SPECIFICATIONS
Model GX120T2 GX160T2 GX200T2
Description code GCBNT GCBST GCBUT
Displacement 118 cm3 (7.2 cu-in) 163 cm3 (9.9 cu-in) 196 cm3 (12.0 cu-in)
Bore x stroke 60.0 x 42.0 mm 68.0 x 45.0 mm 68.0 x 54.0 mm
(2.36 x 1.65 in) (2.68 x 1.77 in) (2.68 x 2.13 in)
Net power (SAE J1349) *1 2.6 kW (3.5 HP)/ 3.6 kW (4.8 HP)/ 4.1 kW (5.5 HP)/
Continuous rated power 2.1 kW (2.8 HP)/ 2.9 kW (3.9 HP)/ 3.7 kW (5.0 HP)/
Maximum net torque 7.3 N·m (0.7 kgf·m, 5.4 10.3 N·m (1.1 kgf·m, 7.6 12.4 N·m (1.3 kgf·m, 9
(SAE J1349) *1 lbf·ft)/2,500 min-1 (rpm) lbf·ft)/2,500 min-1 (rpm) lbf·ft)/2,500 min-1 (rpm)
Compression ratio 8.5 : 1 9.0 : 1 8.5 : 1
Fuel consumption 1.0 Liter (0.26 US gal, 1.4 Liters (0.37 US gal, 1.7 Liters (0.45 US gal,
(at continuous rated power) 0.22 Imp gal)/h 0.31 Imp gal)/h 0.37 Imp gal)/h
Ignition timing B.T.D.C. 20°/ B.T.D.C. 18°/ B.T.D.C. 20°/
Recommended Except
BPR6ES (NGK)/W20EPR-U (DENSO)
spark plug rammer type
Rammer type BPR4ES (NGK)/
– –
W14EPR-U (DENSO)
Oil capacity Except 0.56 Liter (0.59 US qt, 0.58 Liter (0.61 US qt, 0.60 Liter (0.63 US qt,
rammer type 0.49 Imp qt) 0.51 Imp qt) 0.53 Imp qt)
Rammer type 0.40 Liter (0.42 US qt,
– –
0.35 Imp qt) *2
Starting system Recoil Starter Recoil, Recoil and Starter motor
Carburetor (Rammer type) Horizontal type, butterfly
Horizontal type, butterfly valve
valve (float valve)
Air cleaner (Rammer type) Dual type, Dual silent Dual type, Dual silent Dual silent type,
type, Low profile type, type, Low profile type, Low profile type,
Semi dry type, Oil bath Semi dry type, Oil bath Semi dry type, Oil bath
type, (Rammer type) type type
Fuel tank capacity 2.0 Liters (0.53 US gal,
3.1 Liters (0.82 US gal, 0.68 Imp gal)
0.44 Imp gal)
Reduction case Chain type
Shared with engine oil
oil capacity (Without clutch)
Chain type 0.50 Liter (0.53 US qt,
– –
(With clutch) 0.44 Imp qt)
Camshaft P.T.O. – Shared with engine oil
Clutch Type – Centrifugal –
Engagement -1
– 1,800 min (rpm) –
start
-1
Lock – 2,200 min (rpm) –
*2: When tilted at 14°
1-13 (X)
SPECIFICATIONS
*: P.T.O. type (page 1-2).
VE type* Unit: mm (in)
45° 45°
M8 x 1.25
TAPER 1/5
30.3 (1.19)
3.954 (0.1557) M8 x 1.25
65.1
(2.56)
5.9 – 6.0 Φ20 (0.8)
(0.23 – 0.24)
Φ24.947 – 24.980
(0.9822 – 0.9835)
Φ74 (2.9)
M8 x 1.25
(4 PLACES) 88 (3.5)
CRANKSHAFT (P.T.O.)
N type* Unit: mm (in)
65.1 (2.56) 36.5 (1.44)
P.T.O. SHAFT
33.1 (1.30)
M8 x 1.25
62 (2.4) 52.5 (2.07)
65.1 5.00 – 5.03
50 (2.0)
(2.56) (0.197 – 0.198)
16.90 – 17.00 23 (0.9)

(0.665 – 0.669)
Φ19.972 – 19.993
(0.7863 – 0.7871)
Φ41.25 (1.624)
51.5 (2.03)
50.1 (1.97)
1-14 (X)
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MAINTENANCE STANDARDS ··············· 2-2 (X)
2-1 (X)
SERVICE INFORMATION
SERVICE INFORMATION
GX120T2
Carburetor Main jet BE60N A #62 –
BE60W A #62 –
BE60Y A #62 –
BE60Z A #60 –
BE61L A #62 –
BE61M A #62 –
BE61N A #60 –
BE62J A #62 –
BE99A A #60 –
BE99D A #62 –
Pilot screw opening BE60N A 2-1/8 turns out –
BE60Z A 1-5/8 turns out –
BE61L A 2-1/8 turns out –
BE62J A 1-1/2 turns out –
BE99A A 1-5/8 turns out –
Float height BE60N A 13.7 mm (0.54 in) –
BE60W A 13.7 mm (0.54 in) –
BE60Y A 13.7 mm (0.54 in) –
BE60Z A 13.7 mm (0.54 in) –
BE61L A 13.7 mm (0.54 in) –
BE61M A 13.7 mm (0.54 in) –
BE61N A 13.7 mm (0.54 in) –
BE62J A 18.7 mm (0.74 in) –
BE99A A 13.7 mm (0.54 in) –
BE99D A 13.7 mm (0.54 in) –
GX160T2
Carburetor Main jet BE54D A #68 –
BE54G A #70 –
BE54H A #68 –
BE54J A #68 –
BE54K A #68 –
BE54M A #70 –
BE54P A #70 –
BE54Q A #70 –
BE66U A #68 –
BE66V A #68 –
BE67V A #75 –
Pilot screw opening BE54D A 1-7/8 turns out –
BE54G A 2 turns out –
BE54H A 1-7/8 turns out –
BE54J A 1-7/8 turns out –
BE54K A 1-7/8 turns out –
BE54Q A 2-1/2 turns out –
2-2 (X)
SERVICE INFORMATION
GX200T2
BE59M A #75 –
BE59N A #75 –
BE59Q A #75 –
BE59S A #75 –
BE59U A #75 –
BE59V A #75 –
BE59W A #75 –
BE69D A #75 –
BE74W A #78 –
BE74Y A #78 –
BE59Q A 1-7/8 turns out –
BE59S A 2-1/4 turns out –
2-3 (X)
MEMO
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6. FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION ···· 6-2 (X)
6-1 (X)
FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION
FUEL SYSTEM

160UT2/200UT2). ENGINE SERVICE BULLETIN #40

fuel.
Remove the fan cover (page 5-2*).

[1]
Starter motor type: Remove the starter motor (page 10-7*).
Place a suitable container under the carburetor.
Turn the fuel valve lever [1] to the ON position.
Loosen the drain screw [2] and drain the fuel.
• Route the fuel tube properly (page 2-11*).
[2]
FUEL FILLER CAP PACKING

FUEL GAUGE FUEL FILLER CAP CHECK:
(GX160T2/GX200T2) Check for deterioration or cracks.
If equipped:
SCREW (5 x 10 mm) (2)
FUEL FILTER (If equipped)

CHECK:
Check the fuel filter for clogs or damage.
O-RING FUEL GAUGE (GX120T2)
FUEL TANK JOINT

2 N·m (0.2 kgf·m, 1.5 lbf·ft)
CHECK: FUEL TANK
Check the screen of the fuel tank
joint for clogs or damage.
FUEL TANK NUT (6 mm) (2)
10 N·m (1.0 kgf·m, 7 lbf·ft)
FUEL TANK BOLT (6 x 29 mm)

10 N·m (1.0 kgf·m, 7 lbf·ft)
FUEL TUBE
CHECK:
6-2 (X)
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12. MUFFLER
MUFFLER REMOVAL/INSTALLATION···· 12-2 (X)
12
12-1 (X)
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MUFFLER
MUFFLER
The muffler becomes very hot during operation and

remains hot for a while after stopping the engine.
Be careful not to touch the muffler while it is hot.

MUFFLER PROTECTOR
If equipped: MUFFLER GUIDE
SCREW
(4 x 8 mm) (2)
MUFFLER SCREW
(4 x 6 mm)
DEFLECTOR

24 N·m (2.4 kgf·m, 18 lbf·ft) SPARK ARRESTER (If equipped)
EXHAUST PIPE GASKET

If equipped:
If equipped:
SCREW
(4 x 6 mm) (3)
BOLT (6 x 14 mm)
LOWER PROTECTOR
12-2 (X)
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15. REDUCTION UNIT
REDUCTION UNIT DISASSEMBLY/ REDUCTION UNIT BEARING/OIL SEAL

ASSEMBLY ··········································· 15-2 (X) REPLACEMENT ··································· 15-3 (X)
REDUCTION UNIT INSPECTION ········· 15-3 (X)
15
15-1 (X)
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REDUCTION UNIT
REDUCTION UNIT
ASSEMBLY
CHAIN (1/2) CAMSHAFT P.T.O. TYPE
160UT2/200UT2).
Drain the engine oil (page 3-3*).
PISTON Assy. CONNECTING ROD LOWER

(Outer surface and big end bearing) (Big end bearing)
INSTALLATION: INSTALLATION:
Install the piston Assy. to the cylinder barrel with Set the connecting rod lower with the oil dipper toward the camshaft.
the mark [1] on the piston head toward the push
rod hole [2] of the cylinder head.
CYLINDER BARREL
[1] (Cylinder inner surface) CRANKSHAFT
(Pin and gear teeth)
INSPECTION: (page 14-6*)
[2] INSTALLATION:
DOWEL PIN
VALVE LIFTER
(Pivot, pivot end and slipper surface)
REMOVAL:
Mark the valve lifters so that the intake and
exhaust sides can be distinguished.
INSTALLATION:
Attach the valve lifters to the cylinder barrel
immediately before installing the camshaft.
CAMSHAFT (Cam profile and journal)

OIL SEAL
(Lips) DRIVE CHAIN
CRANKSHAFT P.T.O. SHAFT

BEARING (6205) BEARING (6205)
CASE COVER
CONNECTING ROD BOLT (2) PACKING
GX160: (6 x 34 mm)
10 N·m (1.0 kgf·m, 7 lbf·ft)
GX200: (7 x 34 mm)
12 N·m (1.2 kgf·m, 9 lbf·ft)

INSTALLATION: CRANKSHAFT
Align the timing marks [1] on the crankshaft [2] and BEARING (6304)
camshaft [3] sprockets, install the drive chain [4]
onto the sprockets, and install them into the cylinder
barrel as a set.
OIL FILLER CAP
[3] (With oil level gauge)
[2] P.T.O. SHAFT
OIL SEAL
OIL FILLER CAP PACKING (Lips)
CHECK:
Replace if necessary. BOLT (8 x 32 mm) (6)
CRANKCASE COVER
[1] INSTALLATION:
[4] Be careful not to damage the oil seal lips.
15-2 (X)
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REDUCTION UNIT
CAMSHAFT, CRANKSHAFT, DRIVE
CHAIN
[1]
– Camshaft (driven sprocket) [1]
– Crankshaft (drive sprocket) [2]
– Drive chain [3]
• Replace the camshaft, crankshaft and, drive chain

as a set.
[2] [3]

REPLACEMENT
CRANKCASE COVER SIDE BEARING
CRANKSHAFT BEARING (6304)
Pull out the crankshaft bearing [1] using the special
[4] [3]
tools.
TOOLS:
Bearing remover shaft set, 20 mm
[2] 07936-3710600
Bearing remover shaft handle [3] 07936-3710100
Sliding hammer weight [4] 07741-0010201
on the end using the special tools. [2]
TOOLS:
Bearing driver attachment,
52 x 55 mm [6] 07746-0010400
Pilot, 20 mm [7] 07746-0040500
Driver handle [8] 07749-0010000 [1]
[8]
[5]
[6]
[7]
15-3 (X)
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REDUCTION UNIT
P.T.O. shaft bearing (6205)
[4]
bearing.
TOOLS: [2]
Bearing driver attachment,
52 x 55 mm [2] 07746-0010400
Pilot, 25 mm [3] 07746-0040600
Driver handle [4] 07749-0010000
[3] [1]

[3]
the special tools.
TOOLS: [2]
Bearing driver attachment, [1]
37 x 40 mm [2] 07746-0010200
Driver handle [3] 07749-0010000
15-4 (X)
INDEX
DIMENSIONS AND WEIGHTS SPECIFICATIONS ······1-12 P.T.O. TYPE VARIATION··············································· 1-2
D
ENGINE SPECIFICATIONS ·········································1-13 REDUCTION UNIT BEARING/OIL SEAL

E R
FUEL TANK REMOVAL/INSTALLATION ·······················6-2 REPLACEMENT··························································· 15-3

F
INTRODUCTION································································· i REDUCTION UNIT DISASSEMBLY/ASSEMBLY ········ 15-2

MAINTENANCE STANDARDS·······································2-2 REDUCTION UNIT INSPECTION ································ 15-3
M
MUFFLER REMOVAL/INSTALLATION ························12-2 SAFETY MESSAGES··························································i

P.T.O. DIMENSIONAL DRAWINGS ·····························1-14 SYMBOLS ··········································································ii
P
1-1
NOTES
SHOP
MANUAL
GX160T2 QPW • GX200T2 QAPW

ENGINE
Supplement W
to the
Engine Shop Manual
© 2017 Honda Motor Co., LTD.—All Rights Reserved 61Z4H00WE1

SERVICE INFORMATION

For Your Safety


or killed.
manual carefully.

dummyhead

INTRODUCTION OUTLINE OF CHANGES

This supplement covers the construction, function, and SPECIFICATIONS
servicing procedures of the Honda GX160T2 QPW
1
type/GX200T2 QAPW type engines.
supplement, please refer to the base shop manual (part
MAINTENANCE 3
number 61Z4H00) and supplements (part number
61Z4H00X, 61Z4H00Y, 61Z4H00Z).
TROUBLESHOOTING 4
COVER 5
FUEL SYSTEM 6

GOVERNOR SYSTEM 7
CHARGING SYSTEM 8
of the publisher. This includes text, figures, and tables. IGNITION SYSTEM 9

STARTING SYSTEM 10
OTHER ELECTRICAL 11
MUFFLER 12
Your safety and the safety of others are very important. CRANKCASE 14
provided safety messages and other safety information REDUCTION UNIT 15
possible to warn you about all the hazards associated WIRING DIAGRAMS 16
good judgment. INDEX
You will find important safety information in a variety of The marked sections contain no changes.
forms, including: They are not covered in this supplement.



instructions.
and safely.

Date of Issue: January 2017 PSV61Z4H00W.2017.01
0-1
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SYMBOLS
Apply sealant.

0-2
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to use this manual
Item Before modification After modification

CONTROL BASE
QX2 type:
MANUAL OPERATION TYPE FIXED THROTTLE

OPERATION TYPE
IGNITION COIL
IGNITION COIL
(Built-in oil alert unit type)
IGNITION COIL
SIDE PLATE
QX2 type:
OIL ALERT UNIT
0-3
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OUTLINE
How to useOF CHANGES
this manual
CRANKCASE COVER
OIL FILLER CAP
OIL FILLER CAP OIL FILLER CAP

(With oil level gauge) (With oil level gauge)
OIL FILLER CAP PACKING OIL FILLER CAP PACKING
CYLINDER BARREL
DRAIN PLUG BOLT WASHER (2) DRAIN PLUG BOLT WASHER
DRAIN PLUG BOLT (2) DRAIN PLUG BOLT

CRANKSHAFT
BEARING (6205)
BEARING (6205) THRUST WASHER
0-4
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OUTLINE OFthis
How to use CHANGES
manual
CAMSHAFT
0-5
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MEMO
dummytext
1. SPECIFICATIONS
P.T.O. TYPE VARIATION······························1-2 ENGINE SPECIFICATIONS ·························· 1-3
DIMENSIONS AND WEIGHTS PERFORMANCE CURVES··························· 1-4

SPECIFICATIONS ·········································1-3
1-1
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SPECIFICATIONS
SPECIFICATIONS
P.T.O. type Q
Model GX160T2 GX200T2
Type QPW QAPW
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil Alert® unit
Oil Alert® unit (built into ignition coil)
Circuit protector
Reduction Gear
With clutch
1-2
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SPECIFICATIONS
P.T.O. type GX160T2 GX200T2
Overall length Q 312 mm (12.3 in) 321 mm (12.6 in)
Overall width 362 mm (14.3 in) 376 mm (14.8 in)
Overall height 346 mm (13.6 in) 346 mm (13.6 in)
Dry weight 14.8 kg (32.6 lbs) 15.8 kg (34.8 lbs)
Operating weight 17.5 kg (38.6 lbs) 18.5 kg (40.8 lbs)
*: P. T. O. type. (page 1-2)
Model GX160T2 GX200T2
Description code GCBRT GCBUT
Displacement 163 cm3 (9.9 cu–in) 196 cm3 (12.0 cu–in)
Bore x stroke 68.0 x 45.0 mm 68.0 x 54.0 mm
(2.68 x 1.77 in) (2.68 x 2.13 in)
Net power (SAE J1349) *1 3.6 kW (4.8 HP)/ 4.6 kW (6.2 HP)/
3,600 rpm 3,600 rpm
Continuous rated power 2.9 kW (3.9 HP)/ 3.8 kW (5.0 HP)/
3,600 rpm 3,600 rpm
Maximum net torque 10.3 N·m (1.05 kgf·m, 7.6 lbf·ft)/ 12.4 N·m (1.26 kgf·m, 9.1 lbf·ft)/
(SAE J1349) *1 2,500 rpm 2,500 rpm
Compression ratio 9.0 : 1 8.7 : 1
Fuel consumption (at
1.6 Liters (0.42 US gal, 0.35 Imp gal)/h 2.0 Liters (0.53 US gal, 0.44 Imp gal)/h
continuous rated power)
Ignition system Transistor magneto ignition
Ignition timing B.T.D.C. 18° ± 2 /3,850 rpm B.T.D.C. 20° ± 2 /3,850 rpm
Oil capacity 0.58 Liter (0.61 US qt, 0.51 Imp qt)
Starting system Recoil Starter
Stopping system Ignition primary circuit ground
Air cleaner Silent type
Governor Centrifugal weight system
Fuel tank capacity 3.1 Liters (0.82 US gal, 0.68 Imp gal)
1-3
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SPECIFICATIONS
PERFORMANCE CURVES
GX200T2 QAPW type
(N·m)
(lbf·ft) (kgf·m)
13
NET TORQUE 9.5 1.3
12 9.0
TORQUE
1.2
8.5
11 8.0 1.1
10
(HP) (PS)
(kW) 7 7
5
6 6
NET POWER
4
5 5
3 4 4
OUTPUT
3 3
2
2 2
1 1

0 0 0
2000 3000 3600
ENGINE SPEED (rpm)
1-4
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MAINTENANCE STANDARDS ·····················2-2 HARNESS AND TUBE ROUTING ················ 2-3
LUBRICATION & SEAL POINTS··················2-2
2-1
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SERVICE INFORMATION
SERVICE INFORMATION
GX160T2
Unit: mm (in)
Engine Maximum speed (at no load) 3,850 ± 150 rpm –
Idle speed – –
Cylinder compression 0.44 – 0.64 MPa (4.5 – 6.5 kgf/cm2, –
64 – 93 psi) /600 rpm
Crankshaft Crankshaft thrust clearance 0.15 – 0.97 (0.006 – 0.038) 1.20 (0.047)
Crankshaft journal O.D. 24.967 – 24.980 (0.9830 – 0.9835) 24.950 (0.9823)
Crankcase Crankshaft journal holder I.D. 25.007 – 25.028 (0.9845 – 0.9854) 25.050 (0.9862)
cover
EX 27.547 – 27.947 (1.0845 – 1.1003) 27.500 (1.0827)
Carburetor Main jet BEA4Y A #75 –
Pilot screw opening 2-3/4 turns out –
EX 0.20 ± 0.02 (0.008 ± 0.001) –
GX200T2
Unit: mm (in)
Engine Maximum speed (at no load) 3,850 ± 150 rpm –
Idle speed – –
Cylinder compression 0.36 – 0.56 MPa (3.7 – 5.7 kgf/cm2, –
52 – 81 psi) /600 rpm
Crankshaft Crankshaft thrust clearance 0.15 – 0.97 (0.006 – 0.038) 1.20 (0.047)
Crankshaft journal O.D. 24.967 – 24.980 (0.9830 – 0.9835) 24.950 (0.9823)
Crankcase Crankshaft journal holder I.D. 25.007 – 25.028 (0.9845 – 0.9854) 25.050 (0.9862)
cover
Carburetor Main jet BEA3J A #75 –
LUBRICATION & SEAL POINTS

Material Location Remarks
Engine oil Crankshaft journal P.T.O. side
Crankcase cover bearing part
2-2
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SERVICE INFORMATION
HARNESS AND TUBE ROUTING
CYLINDER BARREL RIBS CYLINDER BARREL RIBS
BREATHER TUBE
HIGH-TENSION CORD
FUEL TUBE
IGNITION COIL WIRE
IGNITION COIL WIRE
IGNITION COIL
CORD HOOK OIL ALERT CONNECTOR

(Yellow cord)

(Black cord)
2-3
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SERVICE INFORMATION
IGNITION COIL WIRE
CORD CLAMP
ENGINE STOP SWITCH CORD
OIL LEVEL SWITCH CORD
2-4
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9. IGNITION SYSTEM
IGNITION SYSTEM IGNITION COIL

TROUBLESHOOTING···································9-2 REMOVAL/INSTALLATION ························· 9-3
IGNITION COIL INSPECTION ······················ 9-4 9
9-1
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IGNITION SYSTEM
IGNITION SYSTEM TROUBLESHOOTING
IGNITION SYSTEM
NO OR WEAK SPARK AT SPARK PLUG

– Spark plug (base shop manual : page 3-11)
– Engine oil level (base shop manual : page 3-3)
Check the oil level switch Abnormal Replace the oil level switch
(base shop manual : page 11-7). (base shop manual : page 11-5).
Normal
Check for continuity between the ignition coil wire Abnormal Replace the ignition coil wire.
connectors.
Normal
Check the engine stop switch Abnormal Replace the engine stop switch
(base shop manual : page 11-8). (base shop manual : page 11-5).
Normal
Check the ignition coil (page 9-4). Abnormal Replace the ignition coil (page 9-3).
Normal
Check the spark plug cap

(base shop manual : page 9-6).
If necessary, replace the spark plug cap.
9-2
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IGNITION SYSTEM
IGNITION COIL
REMOVAL/INSTALLATION
– Fan cover (base shop manual : page 5-2)
– Fuel tank (base shop manual : page 6-3)
– Carburetor (base shop manual : page 6-10)
• Route the ignition coil wire and high-tension code

• After installation, check the ignition coil air gap (base
shop manual : page 9-5).
IGNITION COIL WIRE
IGNITION COIL
BOLT (6 x 25 mm) (2)
HIGH-TENSION CORD
SPARK PLUG CAP

INSPECTION:
(base shop manual : page 9-6) OIL ALERT CONNECTOR
(Yellow cord)

(Black cord)
9-3
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IGNITION SYSTEM
IGNITION COIL INSPECTION
Disconnect the spark plug cap from the spark plug.
Remove the spark plug cap from the high tension
cord [1]. 1
Disconnect the ignition coil connector [2] and oil alert

connector [3] from the ignition coil.
Measure the resistance between the terminals and be
sure that the measurements are within the
[1]
specifications in the below.
Use a tester that is equivalent to or higher than the
performance specified, internal resistance: 20 kΩ/VDC,
2
9 kΩ/VAC
Be careful not to touch the metallic part of the tester
probe with your fingers; otherwise, the correct
resistance value cannot be obtained.
Read the tester manufacturer‘s operation instructions
carefully before operating the tester. Follow the
instructions of the Service Manual. Be sure the tester‘s
battery is fully charged, and check the meter before
using the tester. 3
4
[3]
[2]
Unit: kΩ
(+) Prove
HIGH- TENSION GND IGN ALERT
CORD 1 2 3 4
HIGH-TENSION
9 - 14 9 - 14
CORD 1
GND
(-) Probe
9 - 14 0.4 - 0.7
2
IGN
9 - 14 0.4 - 0.7
3
ALERT
4
- - -
9-4
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14. CRANKCASE
CRANKCASE COVER CRANKCASE COVER/CYLINDER BARREL/

REMOVAL/INSTALLATION························14-2 PISTON/CONNECTING ROD/CRANKSHAFT/
CAMSHAFT INSPECTION·························· 14-3
14
14-1
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CRANKCASE
CRANKCASE COVER
CRANKCASE
Drain the engine oil (base shop manual : page 3-3).
(Journal)
CASE COVER PACKING
THRUST WASHER (25 mm)
KEY
(Bearing)
DOWEL PIN (2)
OIL SEAL
(Lips)
OIL FILLER CAP


CHECK:
BOLT (8 x 32 mm) (6)
24 N·m (2.4 kgf·m, 18 lbf·ft)
CRANKCASE COVER
INSTALLATION:
14-2
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CRANKCASE
CRANKCASE COVER/CYLINDER
BARREL/PISTON/CONNECTING ROD/
CRANKSHAFT/CAMSHAFT
INSPECTION
CRANKSHAFT THRUST CLEARANCE
Set the dial indicator [1] perpendicularly so that its tip
contacts the end of the crankshaft.
Move the crankshaft left and right and read the runout
of the dial indicator. It must be within the specified
range.
[1]
STANDARD: 0.15 – 0.97 mm (0.006 – 0.038 in)

replace the faulty part(s).
CRANKSHAFT JOURNAL O.D.

Measure the crankshaft journal O.D. of the crankshaft.
STANDARD: 24.967 – 24.980 mm (0.9830 – 0.9835 in)

CRANKSHAFT JOURNAL HOLDER I.D.

Measure the crankshaft journal holder I.D. of the
crankcase cover.
STANDARD: 25.007 – 25.028 mm (0.9845 – 0.9854 in)

replace the crankcase cover.
Inspect the crankshaft journal O.D. (page 14-3).
14-3
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CRANKCASE
DECOMPRESSOR WEIGHT
Check for worn and weakened spring.
[1]
If the return spring [1] is worn or weakened, replace the
weight return spring.
Check that the decompressor weight moves smoothly.
If the decompressor weight does not move correctly,
14-4
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16. WIRING DIAGRAMS
WIRING DIAGRAMS ···································16-2
16
16-1
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WIRING DIAGRAMS
WIRING DIAGRAMS
WIRING DIAGRAMS
Bl Bl
Y Y
ENGINE
STOP
SWITCH
OIL
IGNITION LEVEL
Tr-MAG OIL SWITCH
SPARK COIL
UNIT ALERT
PLUG
ENGINE SWITCH Bl Black Br Brown

CONTINUITY
Y Yellow O Orange
IG E Bu Blue Lb Light blue
OFF G Green Lg Light green
R Red P Pink
ON W White Gr Gray
16-2
INDEX
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INDEX
CRANKCASE COVER REMOVAL/INSTALLATION·····14-2 IGNITION COIL REMOVAL/INSTALLATION ················· 9-3
C
CRANKCASE COVER/CYLINDER BARREL/PISTON/ IGNITION SYSTEM TROUBLESHOOTING··················· 9-2

CONNECTING ROD/CRANKSHAFT/CAMSHAFT LUBRICATION & SEAL POINTS···································· 2-2
L
INSPECTION ································································14-3 MAINTENANCE STANDARDS ······································ 2-2

M
DIMENSIONS AND WEIGHTS SPECIFICATIONS ········1-3 P.T.O. TYPE VARIATION··············································· 1-2

D P
ENGINE SPECIFICATIONS ···········································1-3 PERFORMANCE CURVES············································ 1-4

E
HARNESS AND TUBE ROUTING ··································2-3 WIRING DIAGRAMS ···················································· 16-2

H W
IGNITION COIL INSPESTION ········································9-4

I
17
17-1
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INDEX
17-2
SHOP
MANUAL
GX160UT2 • GX200UT2
CYCLONE AIR CLEANER
Supplement V
to the
Engine Shop Manual
© 2017 Honda Motor Co., Ltd.—All Rights Reserved 61Z4H00VE1

SERVICE INFORMATION

For Your Safety


or killed.
manual carefully.

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INTRODUCTION
OUTLINE OF CHANGES
This supplement covers the construction, function, and SPECIFICATIONS
servicing procedures of the Honda GX160UT2,
1
GX200UT2 engines (Cyclone type air cleaner).
supplement, please refer to the base shop manual (part
MAINTENANCE 3
number 61Z4H00) and supplements (part number
61Z4H00W, 61Z4H00X, 61Z4H00Y, 61Z4H00Z).
TROUBLESHOOTING 4
COVER 5
FUEL SYSTEM 6

GOVERNOR SYSTEM 7
CHARGING SYSTEM 8

STARTING SYSTEM 10
OTHER ELECTRICAL 11
MUFFLER 12
Your safety and the safety of others are very important. CRANKCASE 14
provided safety messages and other safety information REDUCTION UNIT 15
possible to warn you about all the hazards associated WIRING DIAGRAMS 16
good judgment. INDEX
You will find important safety information in a variety of The marked sections contain no changes.
forms, including: They are not covered in this supplement.



instructions.

and safely.

Date of Issue: April 2017 PSV61Z4H00VE1.2017.04
0-1
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SYMBOLS
Apply sealant.

0-2
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to use this manual

AIR CLEANER
CONTROL BASE
0-3
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MEMO
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1. SPECIFICATIONS
P.T.O. TYPE VARIATION······························1-2 ENGINE SPECIFICATIONS ·························· 1-3
DIMENSIONS AND WEIGHTS PERFORMANCE CURVES··························· 1-4

SPECIFICATIONS ·········································1-2
1-1
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SPECIFICATIONS
SPECIFICATIONS
Model GX160UT2 GX200UT2

P.T.O. type Q
Type QC9 QC9
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Control base Manual
Standard
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil Alert® unit
Circuit protector
Reduction Gear
With clutch

P.T.O. type GX160UT2 GX200UT2
Overall length Q* 312 mm (12.3 in) 321 mm (12.6 in)
*: P. T. O. type. (base shop manual : page 1-2).
1-2
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SPECIFICATIONS
Model GX160UT2 GX200UT2
Description code GCBPT GCBTT
Bore x stroke 68.0 x 45.0 mm (2.68 x 1.77 in) 68.0 x 54.0 mm (2.68 x 2.13 in)
Net power (SAE J1349) *1 3.5 kW (4.7 HP)/3,600 rpm 4.1 kW (5.5 HP)/3,600 rpm
Continuous rated power 2.8 kW (3.8 HP)/3,600 rpm 3.5 kW (4.7 HP)/3,600 rpm
Maximum net torque 9.9 N·m 12.0 N·m
(SAE J1349) *1 (1.01 kgf·m, 7.3 lbf·ft)/2,500 rpm (1.22 kgf·m, 8.8 lbf·ft)/2,500 rpm
Fuel consumption
1.4 Liters (0.37 US gal, 0.31 Imp gal)/h 1.7 Liters (0.45 US gal, 0.37 Imp gal)/h
(at continuous rated power)
Ignition system Transistor magneto ignition
Ignition timing B.T.D.C. 18° ± 2 /1,400 rpm B.T.D.C. 20° ± 2 /1,400 rpm
Recommende STD BP6ES (NGK)/W20EP-U (DENSO)
d spark plug Resistor
spark BPR6ES (NGK)/W20EPR-U (DENSO)
plug
Oil capacity 0.58 Liter (0.61 US qt, 0.51 Imp qt) 0.60 Liter (0.63 US qt, 0.53 Imp qt)
Starting system Recoil starter
Air cleaner Cyclone type
Fuel tank capacity 3.1 Liters (0.82 US gal, 0.68 Imp gal)
1-3
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SPECIFICATIONS
PERFORMANCE CURVES
GX160UT2
(N·m)
(lbf·ft) (kgf·m)
11
8.0 1.1
TORQUE
7.5
10
1.0
NET TORQUE 7.0
9
0.9
(kW)
4
(HP) (PS)
5 5
3 4 4
NET POWER
3 3
OUTPUT
2 2
1 1
0 0 0
2000 3000 3600
ENGINE SPEED (rpm)
1-4
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SPECIFICATIONS
GX200UT2
(N·m)
(lbf·ft) (kgf·m)
13
9.5 1.3
12 9.0
TORQUE
1.2
8.5
NET TORQUE
11 8.0 1.1
10
(kW)
5
(HP) (PS)
6 6
5 5
3 4
NET POWER 4
OUTPUT
3 3
2
2 2
1 1
0 0 0
2000 3000 3600
ENGINE SPEED (rpm)
1-5
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MEMO
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MAINTENANCE STANDARDS ·····················2-2
2-1
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SERVICE INFORMATION
SERVICE INFORMATION
GX160UT2
Unit: mm (in)
Carburetor Main jet BEA4Z A #72 –
GX200UT2
Unit: mm (in)
Carburetor Main jet BEA3K A #82 –
2-2
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3. MAINTENANCE
AIR CLEANER
CHECK/CLEANING/REPLACEMENT ··········3-2
3-1
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MAINTENANCE
AIR CLEANER
MAINTENANCE
CHECK/CLEANING/REPLACEMENT
A dirty air filter will restrict air flow to the carburetor,
reducing engine performance. If the engine is operated
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE.
• Operating the engine without the air filters or with the

filter installed loosely will allow dirt to enter the
engine, causing rapid engine wear. Install the air
filters securely.
CYCLONE TYPE
Remove the air cleaner cover assembly [1].
[1]
Check the outlet port in the pre air cleaner case [1] on
the air cleaner cover assembly [2] for clogs. Remove [1]
dust and dirt with a thin rod [3] such as a piece of a wire
if clogged.
[3] [2]
3-2
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MAINTENANCE
1. Place the air cleaner cover assembly [1] upside
down and tap it lightly to remove dust out of the pre [1]
air cleaner case.
2. With the pre air cleaner case [2] upward, tap the
assembly lightly and get dust together to one side.
3. Clean away dust. 1
[2]
Clean the air cleaner elbow around the element with

[5] [1]
low pressure compressed air (206 kPa, [2.11 kgf/cm2, [2]
30 psi] or less).
– Wing nut [1]
– Element assembly.
– Grommet [2]
– Inner filter (Paper) [3] [3]
– Air cleaner cover seal [5]
replace if damaged.
Clean the filters if they are to be reused (page 3-5). [4]
Check that the air cleaner cover seal is in good

condition; replace it if necessary.
Cover the air intake port [1] with a clean shop towel [2]
to prevent dust from entering the air cleaner elbow [3].
[1] [2]
Wipe dirt from the elbow.
[3]
• Make sure the air cleaner cover edge is fitted in the

groove in the elbow securely and then tighten the
nut (page 6-2).
3-3
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MAINTENANCE
ELEMENT CLEANING
FOAM
Clean the filter [1] in warm soapy water, rinse, and allow
[1] Wash Dip
it to dry thoroughly, or clean with a non-flammable
solvent and allow it to dry thoroughly.
Dip the filter in clean engine oil, and squeeze out all the Squeeze
excess oil. and dry
Excess oil will restrict air flow through the foam element
and may cause the engine to smoke at startup.
Squeeze thoroughly
PAPER
Tap the inner filter [1] lightly several times on a hard
[1]
surface to remove excess dirt, or blow compressed air
lightly (206 kPa [2.11 kgf/cm2, 30 psi] or less) through
the paper filter from the inside out. Never try to brush
the dirt off; brushing will force dirt into the fibers.
3-4
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6. FUEL SYSTEM
AIR CLEANER
REMOVAL/INSTALLATION··························6-2
6-1
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FUEL SYSTEM
AIR CLEANER
FUEL SYSTEM
CYCLONE TYPE
AIR CLEANER COVER ASSEMBLY

INSTALLATION:
Make sure the air cleaner NUT
CARBURETOR SPACER cover edge [1] is fitted in
the groove [2] in the elbow
INSTALLATION: securely and then tighten
Before installing, check for damage. the nut.
[1]
[2]
WING NUT
BOLT (6 x 20 mm)
GROMMET
ELBOW PACKING
INNER FILTER
(PAPER)
AIR CLEANER
COVER SEAL
COLLAR
BREATHER TUBE
OUTER FILTER
(FOAM)
TUBE CLIP (2)

AIR CLEANER ELBOW
cleaner elbow with the fuel
valve lever in the OFF
position and the choke lever
in the CLOSE position.
Before installation, clean the
NUT (6 mm) (2) inside of the air cleaner
AIR CLEANER COLLAR (2) 9 N·m (0.9 kgf·m, 6.6 lbf·ft) elbow.
6-2
INDEX
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INDEX
AIR CLEANER CHECK/CLEANING/REPLACEMENT ···3-2 MAINTENANCE STANDARDS ······································ 2-2
A M
AIR CLEANER REMOVAL/INSTALLATION ···················6-2 P.T.O. TYPE VARIATION··············································· 1-2

P
DIMENSIONS AND WEIGHTS SPECIFICATIONS ········1-2 PERFORMANCE CURVES············································ 1-4

D
ENGINE SPECIFICATIONS ···········································1-3

E
7-1
SHOP
MANUAL
GX160UD • GX200UD
ENGINE
Supplement T
to the
Engine Shop Manual
© 2019 Honda Motor Co., Ltd.—All Rights Reserved 61Z4H00TE1

SERVICE INFORMATION
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
Improper service or repairs can create an unsafe

condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual and other service materials carefully.
For Your Safety

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.
Failure to properly follow instructions and precau-

tions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual carefully.

pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
0-1
INTRODUCTION
servicing procedures of the Honda GX160UD/200UD
Engines. SERVICE INFORMATION 2
supplement, please refer to the GX120UT2/160UT2/ MAINTENANCE 3
200UT2 base shop manual (part number 61Z4H00).
TROUBLESHOOTING 4
latest product information available at the time of COVER 5
printing. We reserve the right to make changes at any
time without notice. FUEL SYSTEM 6
No part of this publication may be reproduced, stored in GOVERNOR SYSTEM 7
means, electronic, mechanical, photocopying, CHARGING SYSTEM 8
As you read this manual, you will find information that is STARTING SYSTEM 10
message is to help prevent damage to this Honda OTHER ELECTRICAL 11
MUFFLER 12
SAFETY MESSAGES
CYLINDER HEAD 13
good judgment.
INDEX
The marked sections contain no changes.
forms, including:



instructions.
and safely.
© Honda Motor Co., Ltd. 2019
0-2
SYMBOLS
Use molybdenum oil solution (mixture of engine oil and molybdenum grease in a ratio of 1:1).
Apply sealant.

0-3
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1. SPECIFICATIONS
P.T.O. TYPE VARIATION ························ 1-2 PERFORMANCE CURVES ······················ 1-5
DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS ···················· 1-7

SPECIFICATIONS·································· 1-3
P.T.O. DIMENSIONAL DRAWINGS··········· 1-9
ENGINE SPECIFICATIONS ····················· 1-4
1-1
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SPECIFICATIONS
SPECIFICATIONS
GX160UD
P.T.O. type S
Type SX4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear
With clutch
1-2
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SPECIFICATIONS
GX200UD
P.T.O. type S
Type SX4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
12 V – 25 W
12 V – 50 W
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear
With clutch

GX160UD GX200UD
Overall length 304 mm (12.0 in) 313 mm (12.3 in)
1-3
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SPECIFICATIONS
Model GX160UD GX200UD
Description code GCAHD GCAJD
Bore x stroke 68.0 x 45.0 mm 68.0 x 54.0 mm
(2.7 x 1.8 in) (2.7 x 2.1 in)
Net power (SAE J1349) *1 3.6 kW (4.9 PS)/ 4.3 kW (5.8 PS)/
3,600 min-1 (rpm) 3,600 min-1 (rpm)
Continuous rated power 2.9 kW (3.9 PS)/ 3.7 kW (5.0 PS)/
3,600 min-1 (rpm) 3,600 min-1 (rpm)
Maximum net torque 10.3 N·m (1.05 kgf·m, 7.6 lbf·ft)/ 12.4 N·m (1.26 kgf·m, 9.1 lbf·ft)/
(SAE J1349) *1 2,500 min-1 (rpm) 2,500 min-1 (rpm)
Fuel consumption (at
1.4 L (0.37 US gal, 0.31 Imp gal)/h 2.0 L (0.53 US gal, 0.44 Imp gal)/h
continuous rated power)
Ignition system Transistor type magneto ignition
Ignition timing B.T.D.C. 22° ± 2°/ B.T.D.C. 20° ± 2°/
1,400 min-1 (rpm) 1,400 min-1 (rpm)
Recommended spark plug BPR6ES (NGK)
Oil capacity 0.58 L 0.60 L
(0.61 US qt, 0.51 Imp qt) (0.63 US qt, 0.53 Imp qt)
Starting system Recoil starter
Air cleaner Dual type Dual silent type
Fuel used Unleaded gasoline E10
Fuel tank capacity 3.1 L (0.82 US gal, 0.68 Imp gal)
model and measured in accordance with SAE J1349 at 3,600 min-1 (rpm) (net power) and at 2,500 min-1 (rpm) (max net torque).
Mass production engines may vary from this value. Actual power output for the engine installed in the final machine will vary
depending on numerous factors, including the operating speed of the engine in application, environmental conditions, maintenance,
and other variables.
1-4
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SPECIFICATIONS
PERFORMANCE CURVES
GX160

11 8.0 1.1
TORQUE
10 7.5
NET TORQUE 1.0
7.0
9
0.9
(kW)
4
(PS)
5
3 4
NET POWER
OUTPUT
3
2
0 0
2000 3000 3600
ENGINE SPEED min-1 (rpm)
1-5
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SPECIFICATIONS
GX200

13 9.5
1.3
9.0
TORQUE
12
NET TORQUE 1.2
8.5
11 8.0 1.1
10
(kW)
5
(PS)
NET POWER
3 4
OUTPUT
3
2
0 0
2000 3000 3600
ENGINE SPEED min-1 (rpm)
1-6
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SPECIFICATIONS
GX160
Unit: mm (in)
123 (4.8) 239 (9.4)

337 (13.3)
93 (3.7) 160 (6.3)

362 (14.3)
346
(13.6)
106 (4.2)
75.5 (2.97)
5 (0.2)
162 (6.4)
39.5 (1.56)
96 (3.8)
304 (12.0)
80 (3.1)
1-7
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SPECIFICATIONS
GX200
Unit: mm (in)
123 (4.8) 253 (10.0) 339 (13.3)
376 (14.8) 106 (4.2) 160 (6.3)
346
(13.6)
106 (4.2)
75.5 (2.97)
5 (0.2)
162 (6.4)
39.5 (1.56)
96 (3.8)
313 (12.3)
80 (3.1)
1-8
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SPECIFICATIONS
Unit: mm (in)
45° 45°
M8 x 1.25
65.1 (2.56)
88 (3.5)
CRANKSHAFT (P.T.O.)
53.2 (2.09)
5.00 – 5.03 M8 X 1.25

50 (2.0)
(0.197 – 0.198)
16.90 – 17.00 23 (0.9)

(0.665 – 0.669) Φ 19.947 – 19.980 (0.7853 – 0.7866)
Φ 74 (2.9)
1-9
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MEMO
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MAINTENANCE STANDARDS ················· 2-2
2-1
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SERVICE INFORMATION
SERVICE INFORMATION
GX160UD
Unit: mm (in)
Secondary resistance 8 – 14 kΩ –
GX200UD
Unit: mm (in)
Secondary resistance 8 – 14 kΩ –
2-2
INDEX
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INDEX
DIMENSIONAL DRAWINGS····································1-7 P.T.O. DIMENSIONAL DRAWINGS ··························1-9
D P
DIMENSIONS AND WEIGHTS SPECIFICATIONS·······1-3 P.T.O. TYPE VARIATION ·······································1-2

ENGINE SPECIFICATIONS ····································1-4 PERFORMANCE CURVES ·····································1-5
E
MAINTENANCE STANDARDS ································2-2

M
3-1

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How to use this manual

Improper service or repairs can create an unsafe

For Your Safety

Failure to properly follow instructions and

Important Safety Precautions

How to use this manual

How to use this manual

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

© Honda Motor Co., Ltd.

How to use this manual

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

Use the recommend engine oil, unless otherwise specified.

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

Use marine grease (water resistant urea based grease).

Use automatic transmission fluid.

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

How to use this manual

Bl Black G Green Br Brown Lg Light green

SERIAL NUMBER LOCATION ·····················1-2 ENGINE SPECIFICATIONS ························ 1-11

P.T.O. TYPE VARIATION······························1-2 PERFORMANCE CURVES························· 1-12

DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS······················· 1-15

P.T.O. TYPE VARIATION

(N·m) (lbf·ft) (kgf·m)

(kW) (HP) (PS)

RECOMMENDED OPERATING SPEED RANGE

2000 3000 3600

ENGINE SPEED (rpm)

(N·m) (lbf·ft) (kgf·m)

RECOMMENDED OPERATING SPEED RANGE

2000 3000 3600

ENGINE SPEED (rpm)

(N·m) (lbf·ft) (kgf·m)

NET TORQUE 1.2

RECOMMENDED OPERATING SPEED RANGE

2000 3000 3600

ENGINE SPEED (rpm)

Dual/dual silent: 160 (6.3)

S type*: 75.5 (2.97)

H type*: 45.1 (1.78)

H, L type*: 106 (4.2)

H type*: 151.2 (5.95)

H type*: 370 (14.6)

Dual/dual silent: 160 (6.3)

419 (16.5) Standard: 93 (3.7)

S type*: 75.5 (2.97)

H type*: 45.1 (1.78)

H, L type*: 106 (4.2)

H type*: 151.2 (5.95)

Dual/dual silent: 160 (6.3)

S type*: 75.5 (2.97)

H, L type*: 106 (4.2)

H type*: 151.2 (5.95)

P type* Unit: mm (in) Q type* Unit: mm (in)

5/16-24UNF-2B 61.7 (2.43)

Φ 19.025 – 19.050 GX120: Φ 78 (3.1) GX120: Φ 19.000 – 19.050

S type* Unit: mm (in) T type* Unit: mm (in)