PREFACE This manual provides a wide range of information about Honda float bow! carburetors, Unless otherwise noted, the instructions are based on the GX engine series, but they hold true for the majority of Honda Power Equipment carburetors. Since 1995, Honda has produced engines that comply with either or both the California Air Resources Board (CARB) andlor the Environmental Protection Agency (EPA) regulations. All engines produced since August 31, 1998, are certified 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 any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, elactronic, mechanical, photocopying, recording, or otherwise, without the 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 symbol. The purpose of this message is to help prevent damage to the carburetor 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, itis not practical or possible to warn you about all the hazards associated with servicing these products. You must use your own good judgement. You wil find important safety information in a variety of forms, including + Safety Labels — on the product, + Safety Messages — preceded by a safety alert symbol 4 and one of three signal words: DANGER, WARNING, or CAUTION. ‘These signal words mean: You WILL be KILLED or CSV NNTSSMEE SERIOUSLY HURT if you don't follow instructions You CAN be KILLED or CMTE seriousLY HURT if you don't follow instructions FRTTUTTION I (22 AEE HUST you dont fotow + Instructions — how to service carburetors correctly and safely. CONTENTS INTRODUCTION ee | SERVICE INFORMATION ee | CARBURETOR SERVICE 34 TOOLS HIGH ELEVATION OPERATION | 34 CHOKE SYSTEMS EzMEMOINTRODUCTION INTRODUCTION EeINTRODUCTION INTRODUCTION CARBURETOR All Honda Power Equipment engines (except metering diaphregm, LPG-fueled, CODE and diesel models) have float-bowl-type carburetors. Currently there are eleven. (eight most popular covered in this manual) distinct carburetor code groups. The code is cast into the carburetor as shown in the illustration, ‘The code groups differ in body shape, control location, and jet types, but they all share similar inspection and adjustment procedures. This manual is intended to be a general guide to Honda Power Equipment float bow! type and metering diaphragm carburetors. Refer to the appropriate shop manual for more specific information about individual models, CARBURETOR CODE GROUPS LISTED BY ENGINE TYPE AND MODEL Carburetor Code Engine Type Applicable engine models (Applicable power product) BB | stroke SV (Side Vaive) 100, 6150, 6200, 6300, G400 + G-GV engine GV100, GV150, GV200, GV400, EX800, EM/EXS00 (Generator, Tiler, Snowblower, Pump, Lawn Mower, etc.) {stoke air-cooled HC | Goia5, aci60, Gc90, 65180, GCV1a5, GOVE, GOViE0, SESSISeVIGSV engine | SSV190 (Generator, Tiler, Snowblower, Pump, Lawn Mower, ete) “a-stroke, liquid-cooled OHG (Overhead Cam) SX360K0 BE 4-stroke OHV (Overhead GX110, GX120, GX140, GX160, GX200, GX240, GX270, GX340, Valve) GX990, GXV120, GXV140, GXV160, GXV270, GXV340, GXV390 + GX engine i@xa4o + GXV engine (Generator, Tiller, Snowblower, Pump, Lawn Mower Power Cartier, Tractor, Riding Mower, Lawn Tractor) “4-stroke, water-cooled OHC. (overhead Cam) GX360K1 (Generator, Tractor) BF “4-stroke SV (Side Valve), (Gi00K7, GE100, GV100K7, EGSS0/650, EXBOOK7, EX1000, HC, OHV F 210/220, HR173, GX100, GXH50, GXV50, GXV57 (Generator, Tiller, Lawn Mower) BG 4-stroke, air cooled OHV, (GX610, GXE20, GXV610, GXVE20, GX610K7, GX620K7, | vawin (Overhead Valve) _| GXV610K1, SXV620K1 | 4-stroke, iquid-cooled ORC | | (Onowroad Gann (GX640 (Tractor) BK 4-stroke, air cooled OHV, Vetwin (Overhead Valve) GXBTOIGXVBTO Bw 4-stroke, air cooled OHC, Vetwin (Overhead Cam) GCVS20, GAV530 4-stroke, air cooled ORV, Vawin (Overhead Valve) (GX630, GX860, GX690, GXVE30, GXV660, GXVESO HDA oot ONG (Overhead | 3190 (Rammer engine with diaphragm type carburetor) Wye | Ministre, ORC (Overhead | G25, x95 Tier, Timmer, Water Pum) we vane OHV (Overhead | x20, Gx3t (Tiler, Trimmer, Water Pump)SERVICE INFORMATION ‘SERVICE RULES.. SERVICE INFORMATION ea FUEL LINE AND CLAMP CHANGES... FUEL RECOMMENDATIONS. FUEL SYSTEM PREVENTIVE MAINTENANCE.........2-5 EMISSION REGULATIONS .. PILOT SCREWILIMITER CAP REPLACEMENT. 2-1SERVICE INFORMATION SERVICE RULES 4. Use Honda Genuine parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may damage the unit or result in emission violations (see page 2-8). Use the special tools designed for the product. Always install new gaskets, O-rings, etc. when reassembling. Tighten all fasteners to the specified torque during reassembly, Clean the outside of the carburetor before disassembly. eo aren Clean dissasembled parts with Honda Carburetor/Combustion Cleaner and then blow dry them with low pressure compressed air. ‘Some commercially available chemical carburetor cleaners are very caustic, These cleaners may damage plastic parts such as O-rings, floats, and float valve seats. Check the container for instructions. If you are in doubt, do not use these products to clean Honda carburetors. Honda Carburetor Cleaner is 100% free of chlorinated solvents. This product removes gum, varnish, and deposits from carburetor components, Honda Carburetor Cleaner is available in 15-ounce aerosol cans and is specially formulated for use in California, Description Part Number Multiple Carburetor Corban Chamber cleaner AbGRIS, 12 7. After reassembly, check all parts for proper operation, and always check for fuel leakage atter repairing a carburetor. 2-2SERVICE INFORMATION FUEL LINE AND CLAMP CHANGES. All Honda Power Equipment manufactured after January 1, 2009 (and some manufactured after 1/1/06), uses low- permeable fuel line. The low-permeable fuel line is easy to spot. The fuel line has the EPA Executive Order (C-U-05-003) printed on it and requires *D” style hose clamps. This type of fuel line is required to ensure proper emissions compliance. Substituting non-low-permeable fuel line is considered tampering (page 2-8). ec & The low-permeable fuel line has a coating on the inside to keep fuel vapors from escaping. The coating makes the inside of the fuel line slick. To ensure the fuel line stays in place, you must only use the “OD” style fuel clamps. The old wire-type clamps will not hold the low-permeable fuel line in place. ‘The old-style fuel line and wire hose clamps are shown below, ‘You may use *D' style fuel clamps on the old-style fuel line, but never use wire fuel line clamps on low-permeable fuel line, 2-3SERVICE INFORMATION FUEL RECOMMENDATIONS Engines are certified to operate on regular unleaded gasoline with @ pump octane rating of 86 or higher. Never use stale or contaminated gasoline or an cil/gasoline mixture. Avoid getting dirt or water in the fuel tank. You may use regular unleaded gasoline containing no more than 10% ethanol (E10) or 5% methanol by volume. In addition, methanol must contain cosolvents and corrosion inhibitors. Use of fuels with a content of ethanol or methanol greater than shown above may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system. Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty. If the equipment will be used on an infrequent basis, please refer to STORAGE AND FUEL DETERIORATION (see page 2-6) for additional information regarding fuel deterioration and storage. Ethanol and Honda Engines Honda engines are designed and certified to run on regular unleaded gasoline. Honda product owner's manuals specify a maximum of 10% ethanol in gasoline for our products; other oxygenates are also listed. Honda engines are designed for good performance and efficient operation using gasoline containing from 0 to 10% ethanol. ‘Some facts about ethanol: + Ethanol is hygroscopic, which means it attracts and retains water. The lower the fuel evel in the tank, the more likely you are to experience water contamination. Water from the air ends up in your fuel tank and engine. + Ethanol is produced from com, soybeans, sugar cane, and other organic material. Itis blended with gasoline (10% ethanol, 80% gasoline) to produce E10, + Ethanol has less energy than gasoline, so it reduces fue! efficiency. + Ethanol is an excellent solvent. In high concentrations it will clean and dissolve deposits, rust in the fuel system, and some fuel tank materials. The dissolved material can clog filters or pass through and leave deposits on carburetor jets. + £85, a mixture of 85% ethanol and 15% gasoline, has been in the news recently. E85 is an alternative fuel; itis not gasoline. Honda engines are not designed or certified to run on E85. + Refer to the owner's manual for your Honda to get information about the recommended fuels and the currently approved additives. + Tohelp prevent water contamination problems when using E10, always keep your fuel tank full when storing your equipment. 2-4SERVICE INFORMATION FUEL SYSTEM PREVENTIVE MAINTENANCE (IN SEASON) Fuel deterioration is a significant issue affecting carbureted engines. This may cause engine hard starting, fluctuating or no idle, hunting or surging at fll throttle, or low power. Current gasoline formulations have a limited shelf life when ‘exposed to heat and air, and can deteriorate in as litle as 3 to 4 weeks. So if your equipment is only used once a month of so, storage preparation should be considered. Carburetor ‘When exposed to air or heat, the fuel in a carburetors float bow! begins to oxidize, turning into a vanish-like or gummy substance that will restrict or block the carburetor jets. All carburetor float bowls are vented to the atmosphere, allowing the fuel to oxidize at a siow, steady rate. Potential problems can be reduced by closing the fuel valve and running the engine out of gas after each use. Equipment Fuel tank ‘The gasoline in the equipment's tank is also exposed to the air through the tank's vent. To slow the deterioration of gasoline in the tank, keep as much air as possible out of the tank by keeping the tank full during periods of inactivity. Fuel Storage Container Gasoline should be stored in a clean, plastic, sealed container designed for fuel storage. Close the vent (if equipped) and store the container away from direct sunlight in a cool area if possible. The use of metal fuel containers is discouraged, as overtime, they can rust. Ifthe tiny particles of rust are transported into the carburetor by the fuel, they may block the tiny passages in the carburetor. Ifittakes more than 3 months to use the fuel in the container, we suggest adding a fuel stabilizer to the fuel when the container is filled ‘The Distributor’s Limited Warranty does not cover fuel system damage or engine performance problems resulting from improper storage. 2-5SERVICE INFORMATION STORAGE (OFF SEASON) Depending on the region where the equipment is operated, fuel formulations may deteriorate and oxidize rapidly. Fuel deterioration and oxidation can occur in as litte 2s 30 days and may cause damage to the carburetor andlor fuel system. Gasoline will oxidize and deteriorate in storage. Old gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in the engine deteriorates during storage, the carburetor and other fuel system components may need to be serviced or replaced. The length of time that gasoline can be left in the fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend, storage temperatures, and whether the fuel tank is partially or completely filed. The air in a partially filled fue! tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel deterioration problems may occur within @ few months, or even less ifthe gasoline was not fresh when you filed the fuel tank. ‘The Distributor's Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation. You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor. Service according to the table below: RECOMMENDED SERVICE PROCEDURE TO STORAGETONE PREVENT HARD STARTING Less than 1 month ‘No preparaion required a Siatibe 4. Fillwith fresh gasoline 2. Add gasoline stabilizer". 1. Fi fresh gasoline 2 months to 1 year 2. Add gasoline stablizer 3. Drain the carburetor float bowl. 1. Drain the fuel tank and carburetor. 4 year or more 2. Change the engine oll 3. Lubricate the cylinder. * Use Honda's fuel stabilizer that is formulated to ‘extend storage life. Follow the instructions on the container. Fuel Stabilizer, 500m! Part Number: CA66926 2-6SERVICE INFORMATION Using a Fuel Stabilizer Use a fuel stabilizer if the equipment will be used infrequently, but more than once a year. To counteract the deterioration of gasoline, use Honda’s fuel stabilizer (see page 2-6) al the recommended ratio. The amount of stabilizer required varies, depending on how long the fuel will be stored. Follow the manufacturer's instructions listed on the fuel stabilizer container. If the equipment is used less than twice monthly, you should keep fuel stabilizer in the equipment's fuel tank at all times. Be sure you run the engine for at least 10 minutes after adding the stabilizer. This allows the stabilized fuel mixture to reach and fll the carburetor. Draining the Fuel ‘The fuel tank and carburetor should be drained for long term storage (one year or longer). Even fuel stabilizer will not prevent fuel deterioration problems when the equipment is in long-term storage. The volatile components of the fuel will vaporize and flow out the fuel tank vent and carburetor vent, leaving gummy non-volatile deposits in the fuel system In many cases, the equipment can simply be run out of fuel. Or the fuel can be drained from the fuel tank by removing the carburetor float bow! drain bolt (if applicable), leaving the fuel valve open, and draining the fuel into an appropriate ‘container for proper disposal ‘The owner’s manual describes the procedure for proper storage of the equipment. See the STORAGE or HELPFUL TIPS AND SUGGESTIONS chapter of your owner's manual. 2-7SERVICE INFORMATION EMISSION REGULATIONS REPLACEMENT PARTS ‘The use of non-original equipment replacement parts may impair the effectiveness of the engine's emission control system. if such a replacement partis used in the repair or maintenance of the engine and itis determined that it causes a failure of a warranted part, any claims for repair of the engine may be denied. If the part in question is not related to the reason your engine requires repair, the ciaim will not be denied. If the use of a non-original part causes, the engine's emission level to change, you may be tampering {see below). The easiest way to insure the proper parts are placed on the engine is to use only Honda Genuine parts and have the equipmentengine model, type, and serial number when accessing the appropriate parts diagram. When replacing a carburetor assembly, it may also help to have the carburetor ID number. COMPLIANCE: TAMPERING ‘Tampering is defined simply as doing something that adversely affects engine emissions. Don't modify the engine. Make all necessary engine adjust ments and repairs according to the engine manufacturer's shop manuals and service bulletins. Manufacturers, distributors, and dealers are held to a different standard on tampering than owners of the equipment. 2-8SERVICE INFORMATION PILOT SCREWI/LIMITER CAP REPLACEMENT Removal of the limiter cap requires breaking the pilot screw. A new pilot screw and limiter cap must be installed 1. When the limiter cap has been broken off, remove the broken pilot screw. 2. Place the spring on the replacement pilot screw, and install it on the carburetor. 3. Turn the pilot screw in until itis lightly seated, then tum the screw out the required number of turns. Refer to the appropriate shop manual for carburetor pilot ‘screw initial opening setting, 4. Apply Loctite® 638 to the inside of the limiter cap, then install the cap so the stop prevents the pilot screw from being turned counterclockwise. Be careful to avoid turning the pilot screw while installing the limiter cap. The pilot screw must stay at its required setting 2-9SERVICE INFORMATION 2-10BB-TYPE [APPLICATIONS PAGE (GG135/160/180 = 65160/180 32 ‘Gevi36;160/190- GSVT6O/I90, 32 (10/200/3007400 322 ‘ev1s012001400 382 BE-TYPE [APPLICATIONS PAGE EU300015, 342 (GXTTO/T2071407200/160727O/S40/380 380 {GxV20/140/1607270;407300 3.60 exes 370 Gxa60 380 BF-TYPE [APPLICATION PAGE EU t000 3.80 E2000 3.88 ‘Si00K1 3-108 (Gx100 316 [6x100 (anmer, bowl te) 35126 (ext 3-136 jexve0rs? 3146 BG-TYPE [APPLICATIONS PAGE [EXBt0KO» GXE20KO 3-186 [GX610Kt « Gx620Kt 3-168 [GaveiOKD - GXVEZOKO 3176 [GXVBIOKt + GXVE20KT 3-186 [exe40 3-196 BK-TYPE [APPLICATIONS PAGE [oxe70 3206 jexvaro 3216 BW-TYPE [APPLICATIONS PAGE [Sev520530- GXvE20060, 3-226 [ex301660/680 3.236 [GX va3016601690 3286 HDA-TYPE [APPLICATION PAGE [GX160 (rammer, diaphraam fee) 3.256, WYB-TYPE [APPLICATIONS PAGE (Gx25 X35; 3-262 WYL-TYPE [APPLICATIONS PAGE [GXx22- Gxt 3270 CARBURETOR SERVICE Ee 3-1BB-TYPE GC135/160/190 - GS160/190 BB-TYPE GC135/160/190 » GS160/190 THEORY OF OPERATION Float Chamber When the float chamber is emply, fuel from the fuel tank can fow past the float valve into the float chamber. As the fuel level in the chamber rises, the float rises with it. When the float pushes the float valve into its seat, the flow of fuel stops. As fuel is drawn out of the float chamber, the float moves down and opens the float valve. This cycle assures a constant level of fuel in the float chamber. Main Circuit When the throttle valve opens, air passes through the venturi in the carburetor's throat. Because the venturi's. diameter is smaller than the intake opening, the air speeds up as it passes through. This increased air velocity produces low pressure at the outlet of the main nozzle. The float chamber is vented to the atmosphere (bow! vent). Since atmospheric pressure is higher than the pressure in the venturi, fuel is pushed out ofthe float chamber, through the main jet and into the main fuel nozzle. Air passing through the air jet mixes with fuel flowing through the main nozzle's air bleed holes. This rich mixture is then drawn into the venturi where it mixes with more air to produce the final airfuel mixture. Slow (Idle) Circuit When the throttle valve is completely closed (idle), engine vacuum (low pressure) is present atthe pilot outlet in the intake tract. Atmospheric pressure in the float chamber then forces fuel through the main jet and into the slow circuit bypass. The pilot jet controls fuel flow through the slow circuit bypass, The fuel then mixes with air that is metered by the pilot air jet. The resulting fuel/air mixture then flows through the pilot outlet and into the intake tract. The pilot screw Controls the amount of fuel mixture that can flow through the gilot out. Transition Circuit The transition ctcuit supplies fuel to the engine during the transition from the slow (ile) circuit to the main circuit and vice versa. When the throttle is opened slightly, high velocity air flows between the edge of the throttle valve and the transition ports, which are located upstream of the pilot outlet. The resulting low pressure (vacuum) draws fuel/air mixture from the slow circuit bypass through the transition ports and into the intake tract, providing the proper fuel charge for low speed operation. “The pilot screw does not control the fuel/air mixture that passes through the transition ports. ‘As the throttle plate opens farther, the vacuum at the transition ports decreases. As a result, there is very litle flow through these orifices, and the air/fuel mixture for mid- and high-speed operation is provided almost completely by the main circuit 3-2BB-TYPE GC135/160/190 + GS160/190 (Stow ciRcurT set (stow sot PILOT SCREW LIMITER CAP: PILOT AIR JET OPENING Bow. VENT. MAIN AIR JET PILOT AIR JET fF sem a (CHOKE VALVE \Aee wines OPENING. J FLOAT. VALVE SEAT FLOAT VALVE FLOAT (CHAMBER FLOAT ARM FLOAT CHAMBER BODY Ben ouceo nour MAIN JET 3-3BB-TYPE GC135/160/190 - GS160/190 CARBURETOR TROUBLESHOOTING INSPECTION POINTS ‘The information in this chapter applies to the carburetor and fuel system only. Use the Troubleshooting Chapter of the appropriate shop manual to confirm that the fuel system is the cause of the problem before using the table below. ©... Inspection order before disassembly @ 2. Reference number shown on next page Le [Fauty rote vate operation oh, @ [uisacjstes pot serow @ § [fsmeumtislon tn iteoow | 6} caged plot ott a [Hard Staring 1 @ |hisadjstes tte sto sere & 1 | [- Poor perfomance at Engine stats but @ |watertorogn materiale inthe ustsedimentaup | @ | Lop” tow spend soon stops @ [Fauty tote vate operation ® stpmdoes nt — © [Faviy throtie shat operation @ docresse [clogged main jet ary, Improper instalation of carburetor goatat OEM Improper instalation ofnelator gasket @bM Airleaking trough broken eacburtor, rsuator | Gasket or broken near Googged pia et @ logged pit air jot Ou [| Gagged main jet ® rong mai jt size e Clogged foal bow etmospheric vent 3 [ning im Clogged main az jt 9 + Poor peromance pm does not Clogged main nozzle a bead hole QI | f ahihesee Eabize [| @ | watertorign material in ie us ster g | + pm doesnot [1 @ | Waterforegn materials inthe foa chamber, | @ incre corroded chamber ‘ © | Seterirated gasotn in the fat chamber ® ©] Damagedicontaminated float val seating suracd @ | © | Foreign mattis onthe tp of foetvaie | © = Float bow! overflowing @ | clogged oat bow! atmospheric vent 2 |S Gasoline leaks || ©} Fauty chamber gasket (improper installed) | G | uct inside te fost |e Fauly oat operation, foat does rot operate | @ ‘moot Deformed chamber (mating fce, nt @ + Hunting + Al leaking past the carburetor insulator gasket Lenn fuel micture > SS ing J]; Sea et wom ote shat 1 Percolation ne etal Ovemeatng of te carouretor chamber! passage + overeating Hard Sain rng mans 2 Baten ovation + Resticted pt et + wet outed spar - Clogged air cleaner Rh el mire P0 |___|+ Fatty choke operation + Icing (Low ambient temperature, + Bower crops, rpm virong main et size nigh amis snow tte |, $208 ot iti * Detereratod gasoine nezctooe} Bick emote |+ Bloked main nozzloventr bore | 3-4BB-TVPE GC135/160/190 - GS160/190 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT.) @ CHOKE LevER @® INSULATOR GASKET INSULATOR: @ Ftoat cHaMBER @Por air ser (stow circum @ THROTTLE STOP. SCREW A qd Hee { Li j | @cuoKe vatve ! | \ Qdvanseronnce PLOTAR JET @Froar som, OPENING a vr’ PILOT OUTLET @MaN Nozze 3 @ casket WAIN AIR JET OPENING @ruoar. @AIR BLEED HOLE VALVE SEAT @rtoar valve Loar CHAMBER @Ftoar arm FLOAT CHAMBER BODY @maww Jet 3-5BB-TYPE GC135/160/190 : GS160/190 CARBURETOR REMOVAL ‘Your type may be different. Refer to the appropriate shop manual for carburetor removal and installation. GOVERNOR ROD/THROTTLE RETURN SPRING. REMOVAL: Foomove tha choke fod and grommet from the ful tank stay A, and then remove the ‘hake “od fom the choke lover Remove tha thrtle return spring, and then "emove the ‘overnor rod from the carburetor THROTTLE RETURN SPRING INSULATOR GASKET Replace: CaRauRETOR INSULATOR [AIR GUIDE AND AIR GUIDE GASKET (2), Replace, GOVERNOR SPRING CHOKE SBSKE coke ROD GROMMET CARBURETOR SSEMBLY AIR CLEANER GASKET ‘CARBURETOR GASKET [Replace. | [Reoiace. | — ——! |< air ceaner ASSEMBLY a S pesier nee, sae INSTALLATION: Be sure the breather {Ube passes in rant athe governor spring with adequate clearance. FUEL STRAINER Fuel, TANK TOBE GOVERNOR SPRING 625 mm WASHER aN BOLT (2) serfns 6 mm FLANGE NUT 3-6BB-TYPE GC135/160/190 - GS160/180 DISASSEMBLY/INSPECTION 1. Drain all the float chamber fuel into an approved container. 2. Clean the outside of the carburetor before disassembly, 3. Disassemble and inspect the carburetor as indicated below. Use a 6 mm (1/4 in) flat cabinet screwdriver to remove the main jet. Disassembly Inspection BE-type carburetor shown. No. tem Clean ‘The BE-type has some components that are not Check he pilot jethole for clogging. | CO) Teund on ther Honda carburetors OBREME gp Oryoret SHAFT @ (conttea ype witn limiter cap) heck he fel ran screw Og forcamage ® @ cxoKe Check the slop screw for proper setting ‘SHAFT (Check screw tp for contamination. Oo ®©|®|O/E/O ‘Al Honda cerified engines have a | tamper resistant limiter cap installed on e the plot sera. Any attempt o remove the cap will break he plot screw, requiring screw and miter cap @twRome replacement, Generally leave this type STOP SCREW (of pit srew insallad an the carburetor. o~ @ @Pwor screw @eanourteror @oraces MAIN NOZZLE: AIR BLEED Maser @ MAN et—__@ HOLDER @rioarew — G——GBrvoarvawwe & @ roar JS @rioar cramoer | = | @rtosr cHahaer GASKET Check the air bleed holes for clogging O ‘Cheek the main jet size. heck the jot orifice for clogging 0 ®|O|@/O|9/ ©/©/O|e/® (Check the float height, and make sure there is no gasoline In the oa e ‘Check the gasket for damage (De not remove the gasket. | Check te ehat for emooh vere tnaeoteect e ‘Check the orcas in the carburetor boay for cogging, Oo ‘Check the choke shalt for smooth e 5e° ‘Check he main jet holder Oo {or corrosion Check the tp of the valve for contarnation or damage O|®@ FUEL DRAIN SCREW (Check the float pin for wear or Toose ft | SETBOLT heck or dito orsign materi inthe chamber ° ® Coeck te ehamber for coroson fd dtoraton, ® 3-7BB-TYPE GC135/160/180 - GS160/190 CLEANING BB-type carburetor shown. ‘The BB-type has some components that are not found on other Honda carburetors. [_}: Indicates parts that are likely to be clogged; clean carefully. (enor ‘OUTLET tarorme SHaer cHoKe VANE @wanaie ie Deuor ® AIR JET FLOAT ARM PS | Stow Great @ @vave sear wan nozae AiRBLECD @ 7 Honda Remove foreign materia fm Carburetor the main nozzle air bloed holes, Cleaner Low pressure ET ‘compressed alr Clean the main airet oer. Float Creat : Remove foreign materials from Honda the valve seat Carburetor Clean the foat valve and seat Cleaner x Low pressure ® ® e@ tem Remove foreign material rom the pilt jet. Clean the pilot alr jt orice, Clean the pilot outlet. pilot air jet. fa good spray patterns ‘screw does not need to be removed, the man Jet @®| Te pict screw must be broken tobe removed. Replace wth a new ane on reassembly. Sm | Main Great | ®|_ Remove tesgn ntaattom | | S-—O Inspection! Gieaning Too! Jt Cleaner Set Honda Carburetor Cleaner Spray carburelor cleaner through the | | Low pressure ‘observed fom the pilot ou, the plat | COMPTESSed air et Cleaner Set Do not damage the seat and valve Check the faa level Remove foreign material rom the float chamber. compressed air Float level gauge 3-8BB-TYPE GC135/160/190 - GS160/190 CLEANING (cont.) Use Honda Carburetor/Combustion Chamber Cleaner PIN CA68916 with is plastic spray nozzle to clean the ports ‘Some commercially-available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as (O-rings, floats, choke valves, and float valve seats. Check the container for instructions. If you are in doubt, do not use these products to clean Honda carburetors, NOTICE High air pressure may damage the carburetor. Use low pressure settings when cleaning passages. 1. Clean the jets and passages with Honda Carburetor Cleaner (P/N 08732-CC000). 2. Use low air pressure and clean the following passages and ports: + Vent port * Pilot screw hole + Pilot jet hole + Main air jt + Transition ports + Pilot outlet + Main nozzle holder 3. Refer to the jet range chart on the back of the Jet Cleaner Sot (PIN 07JPZ-001010B), and select the appropriate leaning needle to remove any dust, di, etc. that remains after Step 1 and 2. NOTICE Using a cleaning needle that is too large may damage the carburetor. Never force a needle, and never use a needle with a bent or damaged tip. ‘Due to manufacturing tolerances, it may be necessary to use a needle that is smaller than the one indicated on the chart 4, Be sure to clean the transition ports located in the side of the carburetor throat near the throttle valve. If these ports are blocked, the engine will run rough or stall just above idle. 5. Reassemble the carburetor carefully. Take care not to overtighten the main jet. 6. Install the carburetor in reverse order ofits removal using new gaskets where appropriate. 7. Proceed to the Adjustment section (next page). ENGINE BLOCK SIDE: ‘TRANSITION PORTS puorouret | PILOT SCREW HOLE PILOT JET HOLE, MAIN NOZZLE HOLDER. (AIR CLEANER SIDE: VENT PILOT AIR JET MAIN AIR JET {JET RANGE CHART JET CLEANER SET PIN O7JPZ-0070108 3-9BB-TYPE GC135/160/190 - GS160/190 ADJUSTMENT Before making any adjustments: + Verify that the governor is properiy adjusted before starting the engine. Refer to the appropriate shop manual. + Check that the throttle and choke controls operate properly before starting the engine. + Check that there are no fuel leaks before starting the engine. + Start the engine and allow it to warm up to normal operating temperature. Be sure that all engine components are within specifications and there are no air leaks into the intake path, Idle Speed Adjustment 4. Start the engine and allow it to warm up to normal operating temperature, 2. With the engine idling, tum the throttle stop screw to, obtain the standard idle speed. Refer to the appropriate shop manual for the standard idle speed specification. Throttle stop screw: + Tum clockwise. . rpm increases + Tum counterclockwise... rpm decreases Maximum Engine Speed Adjustment 4. Move the throttle to FAST. 2. Start the engine, let it warm up, and then check the engine speed with the throttle set to FAST 3. Ifthe engine speed is not within specification, bend the governor spring arm tab, + Right increases spring tension and engine speed, + Left decreases spring tension and engine speed, DECREASE | INCREASE SPEED — | SPEED GOVERNOR SPRING TAB 3-10B-TYPE GC135/160/190 - GS160/190 NOTES 3-11BB-TYPE GCV135/160/190 - GSV160/190 BB-TYPE GCV135/160/190 » GSV160/190 THEORY OF OPERATION Float Chamber When the float chamber is emply, fuel from the fuel tank can flow past the float vaive into the float chamber. As the fuel level in the chamber rises, the float rises with it. When the float pushes the float valve into its seat, the flow of fuel stops. As fuel is drawn out of the float chamber, the float moves down and opens the float valve. This cycle assures a constant level of fuel in the float chamber. Main Circuit When the throttle valve opens, air passes through the venturi in the carburetor's throat. Because the venturi's diameter is smaller than the intake opening, the air speeds up as it passes through. This increased air velocity produces low pressure at the outlet of the main nozzle. ‘The float chamber is vented to the atmosphere (bow! vent). Since atmospheric pressure is higher than the pressure in the venturi, fuel is pushed out of the float chamber, through the main jet and into the main fuel nozzle. Alr passing through the air jet mixes with fuel flowing through the main nozzie's air bleed holes. This rich mixture Is then drawn into the venturi where it mixes with more air to produce the final airfuel mixture, Slow (Idle) Circuit When the throtle valve is completely closed (idle), engine vacuum (low pressure) is present atthe plot outlet in the intake tract. Atmospheric pressure in the float chamber then forces fuel through the main jet and into the slow circuit bypass The pilot jet controls fuel flow through the slow circuit bypass. The fuel then mixes with air that is metered by the pilot air jet. The resulting fuel/air mixture then flows through the pilet outlet and into the intake tract. The pilot screw controls the amount of fue! mixture that can flow through the plot outlet. Transition Circuit I | | | | ‘The transition circuit supplies fuel to the engine during the transition from the slow (idle) circuit to the main circuit and vice versa, When the throttle is opened slightly, high velocity air lows between the edge of the throttle valve and the transition ports, ‘which are located upstream of the pilot outlet. The resulting low pressure (vacuum) draws fueV/air mixture from the slow circuit bypass through the transition ports and into the intake tract, providing the proper fuel charge for low speed operation. ‘The pilot screw does not control the fuel/air mixture that passes through the transition ports. As the throttle plate opens farther, the vacuum at the transition ports decreases. As a result, there is very itle flow through these orifices, and the air/fuel mixture for mid- and high-speed operation is provided almost completely by the main circuit. ‘TRANSITION PORTS 3-12BB-TYPE GCV135/160/190 + GSV160/190 PILOT AIR JET (stow circum VENTURI (CHOKE VALVE | os MAIN AIR JET PILOT SCREW THROTTLE VALVE Lier cap: I PILOT AIR JET ~ (main circurn OPENING Bow. —_ VENT. sy MAIN NOZZLE ain an JET OPENING sa Flor | LEED HOLE ——| | vatve sear g ain FLOAT VALVE’ -—, FLOAT CHAMBER FLOAT ARM FLOAT CHAMBER BODY MAIN JET 3-13BB-TVYPE GCV135/160/190 - GSV160/190 CARBURETOR TROUBLESHOOTING INSPECTION POINTS The information in this chapter applies to the carburetor and fel system only. Use the Troubleshooting Chapter of the appropriate shop manual to confirm that the fuel system is the cause of the problem before using the table below. ©... Inspection ordorbotore disassembly @ 1. Retorence number shown on next page inspection Poin © [Faull choke valve operation © @ [Msadjusted pict screw ab fromm sate tpatenttecey — |B |Goaged plot outer im Ti Sana @ [tcadusle! tet sop sew 8 CL [-pewpotomncea Engine stars but pT @ jwatarorgn metas the fel secimentcup | © low speed s00n S098 171 @ [Faulty erate vaveoperaton |@ + rpm doesnot 5} © |Fauity thot shatt operation @ decrease Clogged main jet © + ~Jimoreper instalation of carburetor gasket OMY Improper insation of insulator gasket ery Aloaking tough broken carburtr insuator | @ 4 gasket or broken insulator logged pitt @H loosed pilot aot ot T] | Googged maint @ Wrong main jt size |e __ Clogged oat tow atmospheric vert 3 = Hunting LEA | ctegged main a jt @ * Poor perfomance }+ mpm does not - | Clogged main nozzle air bleed hole eo athigh speed apie © | Wstertoceign material in the fel or 9 + tom does ot [1@ |Watertorogn materais inthe feat cramber, — | © increase corroded chamber © | Detercrated gasoline in the float chamber @ © | Damagesiconaminated float valve seating sutace] @ — Foreign matte onthe tp of foal valve @ Float bow! overtowing © | Clogged toat bon! atmosphere vert 8 > Gasoline eake | Faulty chamber gasket (improperly nstaled) é |] | Fuel inside the float @ 1 |] | Fauity ost operation, toat does no:operate | © |] | smectniy Deformed chamber (mating face, ont) @ Hunting ‘A eaking past the carburetor insiaor gasket * Loan fuel mature Spitting ——|+ Clogged jets, worn throttle shaft ++ Percolation + Engine staing Overheating af the carauretorchomberfuel passoge 5 Overheating + Herd Staring + vrong main jet size + Set for high elevation + Resid pot t = Wet foes sparc = Cogged air cleaner + Fich fl mature aus Fel choke oporation “Teing (Low ambient temperature, = Power dons, rom |: wong main jet size high nomi, snow in he oes not ttilee Weng maine size rozzeiboe) + Black smoke from fs Deveirsted geo te mtr, engine stalls locked main nozzleiventut bore 3-14BB-TYPE GCV135/160/190 - GSV160/190 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT.) BE-type carburetor shown. The BE-type carburetor has some components that are not found on other Honda carburetors. @ choke vever 2.PIECE FUEL TANK! {.PIECE FUEL TANK! ENGINE COVER ENGINE COVER GASKET INSULATOR @ caRBURETOR GASKET D Fue. OTe @ Front CHAMBER @ THROTTLE STOP —_——_————_ ©) PILOT AIR JET ® SCREW 9 ORIFICE |__ @ venruri x ® cuoxe vave @ MAIN AIR JET ORIFICE co @ THROTTLE VALVE PILOT SCREW ell @ Ftoat sow. “D ‘ATMOSPHERIC VENT: @ main nozzie @ casket @ ARR BLEED HOLE @nom— | '@ FLOAT VALVE SEAT ® u @ FLoat VALE @ rioar anu 3-15BB-TYPE GCV135/160/190 - GSV160/190 CARBURETOR REMOVAL Your type may be different. Refer to the appropriate shop manual for carburetor removal and installation, Refer to Section 6 for types with ARCS (Auto Return Choke System) and ACS (Auto Choke System) GOVERNOR ROD/THROTTLE RETURN SPRING REMOVAL: Remove the tht return spring, and then rotate the carburetor in the direction shown and remove the govemat rod fom the cauretor ‘THROTTLE RETURN SPRING CONTROL BASE CONTROL BASE _ { The spacer replaces the contol ‘ase on macls tat Nave fxed {rote and ACS (Auto Choke GoveRNor | System. SPRING INSULATOR GASKET [Reviace. ] AIR GUIDE GASKET (2) ewer engines have the metal 2 guide ang ai guide gaskots feplaced with ar guide gasket Newer engineshave atseeadbow0] [Repo Sergent a ented [Feseee. BREATHER TUBE INSTALLATION: Con rohit mark fo the breath ‘AIR GUIDE 6x5 mm FLANGE BOLT AIR CLEANER GASKET Replace, | 6x 14 mm FLANGE BOLT The end withthe cover hole a8 Shown, Connect the other end othe ar ‘leaner ease. PAINT | MARK AIR CLEANER Case BREATHER TUBE BREATHER 6x83 mm STUD (2) CoveR [PART NUMBER: 90013-2G0-T00 | §86mm FLANGE ‘Temporarlyinstalto make carburetor | BOLT 2) oon cst 3-16BB-TVPE GCV135/160/190 - GSV160/190 DISASSEMBLY/INSPECTION 1 2. 3 Drain all the float chamber fuel into an approved container. Clean the outside of the carburetor before disassembly. Disassemble and inspect the carburetor as indicated below. Use a 6 mm (1/4 in) flat cabinet screwdriver to remove the main jet Disassembly @rroar Ghamoer @ tcorted ype with Inge) @ruorser @ Rome SHAFT Inspection item Check the pilot jet hole for cogging (Check the fuel drain serew Oving for damage, Check the stop scrw for proper setting FF _ @uorscnew @ cHoKe gaxe 3) rHROTME STOP SCREW @ carsureTor | ORIFICES ; MAIN Jer @ wan nozzte HOLDER AIR BLEED @rtonr chamoer GASKET © @ | Chose sre oor centarnaon, Oo [| Hondo cated engines ave a tamper | ® | resistant iter cap installed onthe pilot e screw ("Any attempt to remove the cap will break the pilot screw, requiing screw and limiter cap replacement. Generally, leave ths type of pot screw installed on the carburetor (Check the ar bleed holes for clogging, ‘Check tho main jot sie, Chock the jet oifce for clogaing. (Check the float haight, and make sure there is no gasoline in the ost. elele CGheck the gasket for damage (Donot remove the gasket. ® ‘Check the shaft fr smooth movement and looseness. © ‘Check the oriicos in he carburetor body for clogging @ ‘Check the choke shaft for smooth movement and looseness. ‘Check the main jt holder @|®|e for corrosion ‘Check the tp of the valve for c contamination or damage, oO | @ Ga | Check he Not pin for wear or © | toose e@| ‘Check for ctor foreign material c in te chamber, Oo ®@ Check the chamber fr corrosion and deformation * GCV160 engines with ACS (Auto Choke System) do not have a pilot screw. 3-17BB-TYPE GCV135/160/ 90 + GSV160/190 CLEANING Use Honda Carburetor/Combustion Chamber Cleaner with it's plastic spray nozzle to clean the carburetor ports. ‘Some commercially-available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as O-rings, floats, choke valves, and float valve seats. Check the container for instructions. If you are in ‘doubt, do not use these products to clean Honda carburetors. NOTICE High air pressure may damage the carburetor. Use low pressure settings when cleaning passages. 1. Completely disassemble the carburetor except for the pilot jet screw (P. 3-17). This cleaning procedure is, performed without removing the pilot jet screw. 2. Clean the main nozzle thoroughly using carburetor cleaner, appropriate size jot cleaning tool, and compressed air. D0 not use a welding tip cleaning needle. Using @ welding tip cleaning needle or a jet needle that is too large may damage the carburetor. Never force a needle, and never use 4 needle with a bent or damaged tip. Inspect the center and side holes for damage or contamination by holding the main nozzle up to a light to verify they are clean. 3. Clean the main jet by spraying carburetor cleaner through the jet and using the appropriate size jet cleaning tool and compressed air. Do not use a welding tip cleaning needle. Using a welding tip cleaning needle or a jet needle that is too large may damage the carburetor. Never force a needle, and never use a needle with @ bent or damaged tip. Carefully inspect the main jet for damage or contamination. 4, Clean the float valve seat using carburetor cleaner and compressed air. (cx) lJer CLEANER —————>| orspz-oo10108 | MAIN NOZZLE JET CLEANER ———>{_ HONDA o7sPz0010108 Sten FLOAT VALVE. ‘SEAT 3-18BB-TYPE GCV135/160/190 - GSV160/190 5. Clean the main jet and nozzle bore thoroughly using [ MAIN JET AND. carburetor cleaner and compressed alr. NOztie BORE Inspect the inside of the bore for contamination. 6. Clean the pilot jot thoroughly by using the appropriate size = jet cleaning tool, carburetor cleaner, and compressed air. HONDA ‘The passage is small and easily obstructed, so repeat several times. IIs not necessary to remove the pilot screw at this point. PILOT JET 7. Clean the high speed air passage with carburetor cleaner and compressed air. ich SPEED. AIR PASSAGE 8. Clean the float chamber vent hole with carburetor cleaner and compressed air. FLOAT CHAMBER VENT HOLE 3-19BB-TYPE GCV135/160/190 - GSV160/190 9. Reinstall the 5 x 6 mm screw covering the pilot jet 10. Check the slow speed air/pllot screw channels for obstructions, Spray carburetor cleaner through the slow speed air passage. From the opposite end, confirm that a steady stream of carburetor cleaner sprays out from around the pilot screw tip and transition ports. If it does not flow around the pilot screw tip, remove the pilot screw and clean the passage The pilot screw must be destroyed and replaced if it is removed. It may be more cost-effective to replace the carburetor. 11, Reassemble the carburetor carefully. Take care not to overtighten the main jet. 12, Install the carburetor in reverse order ofits removal using new gaskets where appropriate 13. Proceed to the Adjustment section (next page). Steady stream round the pilot serew tip En transition ports. CHOKE SIDE © THROTTLE SIDE PILOT SCREW REPLACEME} ——~ 5x 6mm SCREW ‘SLOW SPEED AlPILoT SCREW. PASSAGES a [| 3-20BB-TYPE GCV135/160/190 + GSVi160/190 ADJUSTMENT Before making any adjustments: + Ifthe pilot screw was removed, it must be properly set, before making any the idle speed adjustment, Refer to the appropriate shop manual. + Verify that the govemor is property adjusted before starting the engine. Refer to the appropriate shop manual. + Check that the throttle and choke controls operate properly before starting the engine. + Check that there are no fue! leaks before starting the engine. + Start the engine and allow it to warm up to normal operating temperature. Be sure that all engine components are within specifications and there are no air leaks into the intake path. Idle Speed Adjustment Types with fixed throttie do not have a throttle stop screw. 1. Start the engine and allow it to warm up to normal operating temperature. 2. With the engine idling, turn the throttle stop screw to obtain the standard idle speed. Refer to the appropriate shop manval for the standard idle speed specification Throttle stop screw: + Tum ClOckWiS@..nn _fpm increases + Tum counterclockwise. rpm decreases Maximum Engine Speed Adjustment + Types With Control Base - Throttle Cable 1. Move the throttle to FAST. 2. Check the clearance between the choke arm and contro! lever. 3. The control lever should just contact, but not move, the choke arm. 4, If necessary, loosen the throttle cable clamp to achieve the proper position 5, Start the engine, let it warm up, and then check the engine speed with the throttle set to FAST 6. If the engine speed is not within specification, bend the governor spring arm tab. + Left increases spring tension and engine speed, + Right decreases spring tension and engine speed. + Types With Fixed Throttle - No Throttle Cable 4. Check the maximum engine speed. Refer to the appropriate shop manual for maximum engine speed specification. 2. adjustment is necessary, bend the governor spring tab Con the throtie control plate very slighty. + Left increases spring tension and engine speed. + Right decreases spring tension and engine speed. ‘THROTTLE STOP sci | tHRortLe CABLE, TYPES BEND. BEND GOVERNOR SPRING ARM ‘GOVERNOR SPRING TAB FUKED | THROTTLE | TRE DECREASE SPEED FUKED THROTTLE TE INCREASE ‘SPEEDBB-TYPE G150/200/300/400 BB-TYPE 6150/200/300/400 THEORY OF OPERATION Float Chamber ‘When the float chamber is empty, fuel from the fuel tank can flow past the float valve into the float chamber. As the fuel level in the chamber rises, the float rises with it. When the float pushes the float valve into its seat, the flow of fuel ‘stops. As fuel is drawn out of the float chamber, the float moves down and opens the float valve. This cycle assures a constant level of fuel in the float chamber. Main Circuit When the throttle valve opens, air passes through the venturi i the carburetors throat. Because the venturi's| diameter is smaller than the intake opening, the air speeds up as it passes through. This increased air velocity produces low pressure at the outlet of the main nozzle. The float chamber is vented to the atmosphere (bowl vent). Since atmospheric pressure is higher than the pressure in the venturi, fuel is pushed out of the float chamber, through the main jet and into the main fuel nozzle. Air passing through the air jet mixes with fuel flowing through the main nozzle's air bleed holes. This rich mixture is then drawn into the venturi where it mixes with more ar to produce the final air/fuel mixture. Slow (Idle) Circuit When the throttle valve is completely closed (idle), engine vacuum (low pressure) is present at the pilot outlet in the intake tract. Almospheric pressure in the float chamber then forces fuel through the main et and into the slow circuit bypass. The pilot jt controls fuel flow through the slow circuit bypass. The fuel then mixes with air that is metered by the pilot air jet. The resulting fuel/air mixture then flows through the pilct outlet and into the intake tract. The pilot screw Controls the amount of fuel mixture that can flow through the pilot outlet Transition Circuit ‘The transition circuit supplies fuel to the engine during the transition from the slow (idle) circuit to the main circuit and vice versa. When the throttle is opened slightly, high velocity air flows between the edge of the throttie valve and the transition ports, which are located upstream of the pilot outlet. The resulting low pressure (vacuum) draws fuel/air mixture from the slow circult bypass through the transition ports and into the intake tract, providing the proper fuel charge for low speed operation. ‘The pilot screw does not control the fuel/air mixture that passes through the transition ports. As the throttle plate opens farther, the vacuum at the transition Ports decreases. As a result, there is very litte flow through these orifices, and the air/fuel mixture for mid- and high-speed operation is provided almost completely by the main circuit. TRANSITION PORTS. 3-22(stow circum FLOAT FLOAT VALVE fost CHAMBER FLOAT ARM FLOAT CHAMBER BODY BB-TYPE G150/200/300/400 PILOT AIR JET | venue (CHOKE VALVE MAIN AIR JET ‘THROTTLE VALVE MAIN NOZZLE MAIN JET i | ur aves vous 3-23BB-TVPE G150/200/300/400 CARBURETOR TROUBLESHOOTING INSPECTION POINTS The information in this chapter applies to the carburetor and fuel system only. Use the Troubleshooting Chapter ofthe appropriate shop manual to confirm that the fuel system is the cause of the problem before using the table below 7 Hard Staring + Engine stars but soon stops = Hunting 1pm does not Stablize + Float bow overtiowing + Gasoline leaks Inspection Point> Inspection order before clsassembly Reference number shown on next page @ [Faulty choke valve operation @ |Wisacjusted pilot screw [Foreign material on te tip ofthe pat screw ICiogged pict outlet @ |biszcjusted trotte stop sorew © |Waterforeign materials in the fuel sediment cup @ [Fauty thot vaive operation © [Fauity trate shah operation [clogged main et Tmmproper installation of carburetor gasket Improper installation of ineuator gasket Air teaking through broken carburts, insulator (gasket or broken insulator Clogged pit jet Clogged plot air jet Clogged main jot wrong main jet size ‘Clogged foat bow! atmosphecc vert Clogged main ai jot ‘Clogged main nozzle air bleed hale \Wateritoreign material inte fue sesiment cup Wiatecforeign materia inthe oat chamber, Deteriratas gasoline inthe oat chamber oy re + Poor performance at low speed + rpm does not secrease Damagedicontaminated float valve seating sua Foreign materials on te tip of float valve Clogged float bowl atmospheric vort Faulty chamber gasket (improper installs) Fuel inside te fat Faulty float operation, float does not operate ‘smoothly Deformed chamber (rating face cnt) $88008| | © ©9GO2ESO9 OOG|\29E088880 ® + Poor performance athigh spoed + pm ses not = Hanting * Spiting + Engine stling + Hard Staring + Wet fouled spark plo + Power drops, rpm dove not sabilee + Black smoke from ‘muffler engine stalls + Air Toaking past the carburetor insulato! gasket (Clogged ets, worn throttle shatt + Overheating ofthe carburetor chamberfusl passage + Wirong main jt size + Restricted pot jet Lean fuel miure Percolation Overneatng Set for high elevation + Clogged air eleanor Fauly choke operation Wrong maint size + Doteriorated gasoline Blocked main nezzeiventut bre 1 Rich fuel mixture + Keng (Low ambient temperature, high humidity, snow nthe noalelbore) 3-24BB-TYPE G150/200/300/400 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT.) @ choxe Lever @© insucator asker INSULATOR FUEL ‘SEDIMENT cur, @ CARBURETOR GASKET @ FLOAT CHAMBER PILOTAIR JET Oey 9 ORIFICE, f @ Fost sow, AR q A = VENT = © CHOKE VALVE @ venturi @ puoryer a @overss pH © MAINAIR JET ORIFICE THROTTLE VALVE @ maw wozzve ® casxer @ AiR BLEED HOLE @ FLOAT VALVE SEAT @rtoar @rowtvawve @ man ser FLOAT ARM, 3-25BB-TYPE G150/200/300/400 CARBURETOR REMOVAL Your type may be different. Refer to the appropriate shop manual for carburetor removal and installation. GOVERNOR ARM ANTLSURGE SPRING. CARBURETOR INSULATOR DISASSEMBLY: Hook the spring on the smaller Note the instalation decton, Removerinstall the carburetor and holes inthe governor am and govemor arm simvitaneousy. carburetor ttt. a Be sure thatthe shot, straight end ofthe spring steward the CYLINDER, (CARBURETOR SIDE SIDE 4 GOVERNOR ROD Insert the gaveror rod into the holes inthe governor am and carburetor as shown. ‘CARBURETOR THROTTLE CABLE RETURN SPRING ‘CARBURETOR GOVERNOR ARM, ‘SHAFT GOVERNOR ARM 6 x20(1) GOVERNOR SPRING 5mm SCREW ‘eveneese “F% evensenine 3-26BB-TYPE G150/200/300/400 DISASSEMBLY/INSPECTION 4. Drain all the float chamber fuel into an approved container. 2. Clean the outside of the carburetor before disassembly, 3. Disassemble and inspect the carburetor as indicated below. Use a 6 mm (1/4 in) flat cabinet screwativer to remove the main jet. Disassembly Inspection | (ven ~Tetean Renice Crack el ran sow On) e @ tome Druor ser {or damage. | @choxe ‘SHAFT | Ogee , / error soren Chuck eto cow fr proper eating } heck ew br covariation K & Check hear bleed holes forcoaging. | O Check he ase o )CARBURETOR ‘STOP SCRE\ ‘Check the float height, and make sure {hare iso gasoline inthe float ORIFICES, @uan.er @rroar vatve HOLDER, f-® MAIN NOZZLE @uancer ONE as “Check the gasket for damage: (Bonot remove the gasket), ‘Check the shaft for smooth movement ‘and looseness, Check theories inthe carburetor body for dogging Oo ‘Check the choke shaft for smooth ‘movement and looseness, @/@|8|2|9|e/o/o/o/olelo/ele | ‘Check the main jt holder @rtoar for corrosion oO CHAMBER, ‘heck the tp of he valve foe GASKET contamination of camage, oO | @ J@Brvoar cHammer FUELORAIN ‘heck he oat pin for wear oF e SoREW loose | ‘Check for dito foregn material in bw chamber, oO ® Check the chamber for erosion sedate Lie seraott | @orwe 3-27BB-TYPE G150/200/300/400 CLEANING [ | BB-type carburetor shown | The BB-type has some components that are not found on other Honda carburetors. | + Indicates parts that are likely to be logged Goan ee. OR, | eter [@eor screw @uanvome @vaveSear A gi me oe Inspection! tem leaning Toot ‘Slow Giruit| @|__ Remove foreign materia om the O| sea @| clean the pot airjet orice. @|__ Gian te pit oulet @|_ Remove any contamination tom fe ee Jot Cleaner Set Honda Carburetor Cleaner Low pressure comprassed air Main Creu @| Remove foreign material tom the main je S-—-O Romave foreign material fom the main nozzle air bleed holes, pS @|_ctean te main art orc. Jet Cleaner Set Honda Carburetor Cleaner Low pressure ‘compressed at Float Circuit ®|__ Remove torsign materia tom the valve seat. @|__ Giean the oat vave and seat o not damage the seat and valve, Check the float ave Romove foreign material from the float chamber Honda Carburetor Cleaner Low pressure compressa air Float level gauge 3-28CLEANING (cont.) Use Honda Carburetor/Combustion Chamber Cleaner PIN CA86916 with it's plastic spray nozzle to clean the ports. ‘Some commercially-available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as (O-rings, floats, choke valves, and float valve seats. Check the container for instructions. If you are in doubt, do net use these products to clean Honda carburetors. NOTICE Fiigh air pressure may damage the carburetor. Use low pressure settings when cleaning passages. 4. Clean the jets and passages with Honda Carburetor/Combustion Chamber Cleaner P/N CA68916 2. Use low air pressure and clean the following passages and ports: + Vent port + Pilot screw hole + Pilot jet hole + Main air jet + Transition ports + Pilot outlet + Main nozzle holder 3. Refer to the jet range chart on the back of the Jet Cleaner Set (PIN 07.PZ-0010108), and select the appropriate cleaning needle to remove any dust, dirt, etc. that remains after Step 1 and 2. NOTICE Using a cleaning needle that is too large may damage the carburetor. Never force @ needle, and never use a needle with a bent or damaged ti. Due to manufacturing tolerances, it may be necessary to use 2 needle that is smaller than the one indicated on the chart 4, Be sure to clean the transition ports located in the side of the carburetor throat near the throttle valve. If these ports are blocked, the engine will run rough or stall just above idle, 5. Reassemble the carburetor carefully. Take care not to overtighten the main jet. 6. Install the carburetor in reverse order ofits removal using new gaskets where appropriate. 7. Proceed to the Adjustment section (next page). B-TYPE G150/200/300/400 ENGINE BLOCK SIDE: ‘TRANSITION PiLot oureT PORTS MAIN NOZZLE — HOLDER ‘AIR CLEANER SIDE: “De PILOT AIR JET MAIN AIR JET {JET RANGE CHART JET CLEANER SET PIN 074PZ-0010108, TRANSITION PORTS. 3-29BB-TYPE G150/200/300/400 ADJUSTMENT Before making any adjustments: + Verify that the governor is properly adjusted before starting the engine, Refer to the appropriate shop manual. + Check that the throttle and choke controls operate properly before starting the engine. + Cheok that there are no fuel leaks before starting the engine. + Start the engine and allow it to warm up to normal operating temperature. Be sure that all engine components are within specifications and there are no air leaks into the intake path. 4. IDLE SLOW SPEED ADJUSTMENT UNDER NO LOAD Use the throttle stop screw and pilot screw (non-certfied engines) to adjust the idle slow speed Throttle stop screw: + Tum clockwise sf inoreases + Tum counterclockwise... rpm decreases Pilot screw (non-certified engines): Refer to the appropriate shop manual for adjustment and reassembly procedures. + Tum clockwise leaner fuel mixture + Turn counterclockwise... figher fuel mixture Idle Adjustment (1) With the engine off, turn the throttle stop screw clockwise until it contacts the throttle lever, and then make 3 more turns to open the throttle plate. Be sure the throttle lever is touching the end of the screw. (2) Turn the pilot screw clockwise until it lightly seats, and then back it out the number of turns specified in the appropriate shop manual, NOTICE Overlightening the pilot screw may damage the carburetor. (3) Start the engine, and let it warm up to normal operating temperature. ‘When the engine is warm, slowly tur the throttle stop screw counterclockwise until the engine is running at the standard idle speed specified in the shop manual. (4) Tum the pilot screw (non-certifed engines) in or out to obtain the highest engine rpm, (6) Repeat steps (3) and (4) above unt the pilot screw (non-certiied engines) setting is as close as possible to the standard idle speed. If the pilot screw (non-certified engines) must be tumed more than one tur in either direction from the shop ‘manual specification, the carburetor may have a blocked passage. Be sure all air and fuel passages are clear before proceeding, (6) Adjust the throttle stop screw to obtain the standard idle speed. 3-30BB-TYPE 150/200/300/400 2, MAXIMUM SPEED ADJUSTMENT UNDER NO LOAD Set the throttle cable on the control lever to set maximum speed. Maximum Speed Adjustment (1) Start the engine, and let it warm up to normal operating temperature, When the engine is warm, turn the control lever adjusting screw until the engine is running at the specified maximum speed at ful throttle. (2) Close the throttle, and then slowly open it again. (3) If hunting occurs as the throttle is opened, adjust the pilot screw (non- certified engines). (4) Check the idle slow speed, and adjust the throttle stop screw if necessary. ‘STOP SCREW 3-31BB-TYPE GV150/200/400 BB-TYPE GV150/200/400 THEORY OF OPERATION Float Chamber When the float chamber is empty, fuel from the fuel tank can flow past the float valve into the float chamber. As the fuel level in the chamber rises, the float rises with it. When the float pushes the float valve into its seat, the flow of fuel stops. As fuel is drawn out of the float chamber, the float moves down and opens the float valve. This cycle assures a constant level of fuel in the float chamber. Main Circuit When the throttle valve opens, air passes through the venturi in the carburetor's throat. Because the ventur's diameter is smaller than the intake opening, the air speeds up as it passes through. This increased air velocity produces low pressure at the outlet of the main nozzle, The float chamber is vented to the atmosphere (bow! vent). Since atmospheric pressure is higher than the pressure in the venturi, fuel is pushed out of the float chamber, through the main jet and into the main fuel nozzle. Air passing through the air jet mixes with fuel flowing through the main nozzle's air bleed holes. This rich mixture is then drawn into the venturi where it mixes with more air to produce the final arfluel mixture, Slow (Idle) Circuit When the throttle valve is completely closed (idle), engine vacuum (low pressure) is present at the pilot outlet in the intake tract. Atmospheric pressure in the float chamber then forces fuel through the main jet and into the slow circuit bypass The pilot jet controls fuel flow through the slow circuit bypass. The fuel then mixes with air that is metered by the pilot air jet. The resulting fuel/air mixture then flows through the pilot outlet and into the intake tract. The pilot screw controls the amount of fuel mixture that can flow through the ilot outlet. Transition Circuit ‘The transition circuit supplies fuel to the engine during the transition from the slow (idle) circuit to the main circuit and vice versa. ‘When the throttle is opened slightly, high velocity air flows between the edge of the throttle valve and the transition ports, Which are located upstream of the pilot outlet, The resulting low pressure (vacuum) draws fuel/air mixture from the slow circuit bypass through the transition ports and into the intake tract, providing the proper fuel charge for low speed operation. The pilot screw does not control the fuel/air mixture that passes through the transition ports. As the throttle plate opens farther, the vacuum at the transition ports decreases. As a result, there is very litle flow through these offices, and the air/fuel mixture for mid- and high-speed operation is provided almost completely by the main circuit "TRANSITION PORTS 3-32BB-TYPE GV150/200/400 PILOT AIR JET (sow ciRcur) VENTURI | | Puc (CHOKE VALVE a, ow J ss) eiRcum | MAMWAIR JET | PILOT gcREW | THROTTLE VALVE i Plor OUTLET MAIN NOZZLE Float. ‘AIR BLEED HOLE. VALVE SEAT FLOAT VALVE FLOAT — CHAMBER FLOAT ARM FLOAT CHAMBER BODY MAIN JET 3-33BB-TYPE GV150/200/400 CARBURETOR TROUBLESHOOTING AND INSPECTION POINTS ‘The information in this chapter applies to the carburetor and fuel system only. Use the Troubleshooting Chapler of the appropriate shop manual to confirm that the fuel system is the cause of the problem before using the table below. ° @ inspection Point> [Fauty choke valve operation IMisacjusted pt screw Foreign material on the tip ofthe plat sorew > Hard Staring Engine stars but soon stops [Clogged plot out IMisadjusted tote stop screw lWaterforeign materials inthe fuel sediment cup Faulty trate valve operation Faulty throttle shat operation [Clogged main jot Improper instalation of autor gasket Air leaking through broken carburetor, insulator ‘gasket or broken insulator Clogged plot jet Ciogged plot air jet F] | ciogges main jet | wrong msi jt size ‘Clogged float bowl atmospheric vont Hunting rpm does not Stabilize Float bow! avertowing > Gasoline leaks | Glogged main air ot ‘Clogged main nozzle air blood hole [7 @ | Wiatertoreign material inthe fut sitar [1 @ | Watertoreign materials in tne fost chamber, corroded chamber {© | deteriorated gasoline in the float chamber Inspection order before disassembly Reference number shown on next page - + Poor performance at low specs + 1pm does not decrease + Poor performance igh speea + pm does not increase © GOOGOHHHOH GOGO) ©9S9O8S99O Foreign materials onthe tin of lat valve © | Clogged float bow! atmospheric vert © | Faulty chamber gasket enpropedy installed) Fuel inside the oat | Fauty fat operation, float does not operate | ‘smoothly eformed chamber (malting face ent), ©) Damagectcontaminates float valve seating surat © 889808 Honting + Spiting + Engine stating = Hard Starting |= Wet foutes spark ug * Air leaking past the carburetor insulator gasket Clogged ets, worn thottie shart * Wrong main jet size + Restricted pilot jot + Overheating of the carburetor chambertuel passage + Lean fuel mixture | + Percolation | + overeating + Set or high elevation = Clogged air cleaner + Faulty choke operation + Power drops, rpm does not stabilize + Black smoke from mfr, engine stalls > Wong main jt size + Dsterorated gasoline + Blocked main nozzleventuh bore Rich fuel mixture * ling (Low ambient temperature, igh um, snow inthe nozzle} 3-34BB-TYPE GV150/200/400 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT) © choke Lever © INsuLaTOR Gasket INSULATOR @ CARBURETOR GASKET @ floss cHaMBeR ® weome stor ——— tor ance SCREW / ORIFICE | @ nosrsow, q ATMOSPHERIC VENT C la. SIG © CHOKE vaLvE @ venruri d| | L il) / © Nan an ser OFFICE Jf roe ave @ Puorouner @ wan nozze @ casker = a }~@ anoieeonae ‘® Font vaLve sear @rtoar Onostvave VV @ nomen @ war RRABB-TVYPE GV150/200/400 CARBURETOR REMOVAL Your type may be different. Refer to the appropriate shop manual for carburetor removal and installation. GOVERNOR VANE DISASSEMALY: Removesinstall the carburetor ang ‘governar arm simultaneously. GOVERNOR ROD Insert the govemor rod into the hales Inthe governor vane and carburetor 28 shown (CARBURETOR THROTTLE GOVERNOR SPRING INSULATOR GASKET (CARBURETOR INSULATOR ‘Nate the installation direction. CAREURETOR GASKET CYLINDER, (CARBURETOR AIR CLEANER GASKET SIDE SIDE CARBURETOR a 3-36BB-TYPE GV150/200/400 DISASSEMBLY/INSPECTION 1. Drain all the float chamber fuel into an approved container. 2. Clean the outside of the carburetor before disassembly, 3. Disassemble and inspect the carburetor as indicated below. Use a 6 mm (1/4 in) flat cabinet screwdriver to remove the main jet Disassembly Inspection ~ No. Item - Clean _|Replace| © | Chock the pilot jet hole for cogging. Oo @ twrome A) PILOT JET (Check the fuel drain eerew Oving for damage, @® choKe SHAFT Ogee @puorscrew CCheck the stop screw for proper setng ‘Check screw tip for contamination ‘Check the ar bleed holes for clogging, Pr @tHrome ‘Check the main et size Check he jet once for logging. STOP SCRE! elelelelele @careureror {Sheak the fot height, anc make eure theres no gasoline inthe Nout ORIFICES @ man ser @rvoarvawve Hower |__| f° wai nozze ele ‘Check the gasket for damage (Go not remove the gasket (Check the shaft for smooth movement and looseness, ‘Check the oifces inthe carburetor rion 5 S @nom @ | peer ° GASKET | contamination oF damage. Oo|}e@ @rvoay cHaMBER = _ eee one e @ (Check for dit or foreign material In the chamber, ‘Check the chambe fr corrosion ‘and eeformation @— sxreor @orne 3-37B-TYPE GV150/200/400 CLEANING BB-type carburetor shown. The BB-type has some components that are not found on other Honda carburetors. Indicates parts that are likely to be clogged; clean carefully 5 Pee] (© AIR BLEED , Inspection! Cleaning Too! tem Slow Gireut| @|__ Remove foreign material rom the pit jet. Clean the plot airjet orf. CGiean the pict outlet. Remove ary contamination from Main Gicult Jt Cleaner Set Honda: Carburetor Cleaner | Low pressure compressed air Do not damage the seat and valve. (Check the float level Romove foreign material fom the Komori mae fon — — ® ‘the main jet. set Cl ‘Sot S-+OQ)ene Remove forsign material from caparter Seria sale Srey Lae irs say | sone @|__ Clean the main a jet ore. | Pst Great @|__ Remove foreign materials from Honda | Baie Se Sota | @|_ clon the oat valve and seat Greener | Lo eure compressed sr Float lovel gauge feat chamber. | 3-38CLEANING (cont.) Use Honda Carburetor/Combustion Chamber Cleaner PIN CA68916 with is plastic spray nozzle to clean the ports ‘Some commercially-available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as O-rings, floats, choke valves, and float valve seats. Check the container for instructions. If you are in doubt, do not use these products to clean Honda carburetors. NOTICE High air pressure may damage the carburetor. Use low pressure settings when cleaning passages. 4. Clean the jets and passages with Honda Carburetor/Combustion Chamber Cleaner PIN CA66916 2. Use low air pressure and clean the following passages and ports: + Vent port + Pilot screw hole + Pilot jet hole + Main air jet + Transition ports + Pilot outlet + Main nozzle holder 3. Refer to the jet range chart on the back of the Jet Cleaner Set (PIN 07JPZ-0010108), and select the appropriate cleaning needle to remove any dust, dirt, etc. that remains after Step 1 and 2. NOTICE Using @ cleaning needle that is too large may damage the carburetor. Never force a needle, and never use a needle with a bent or damaged tip. Due to manufacturing tolerances, it may be necessary to use a needle that is smaller than the one indicated on the chart. 4, Be sure to clean the transition ports located in the side of the carburetor throat near the throttle valve. If these ports are blocked, the engine will run rough or stall just above idle. 5. Reassemble the carburetor carefully. Take care not to overtighten the main jet. 6._ Install the carburetor in reverse order of its removal using new gaskets where appropriate, 7. Proceed to the Adjustment section (next page). BB-TYPE GV150/200/400 ENGINE BLOCK SII TRANSITION PORTS. ‘AIR CLEANER SIDE: MAIN AIR JET VENT PORT PiLoT ‘SCREW HOLE PILOT AIR JET JET JET CLEANER SET Pn 073P2-0010108, RANGE CHART ‘TRANSITION PORTS: 3-39BB-TYPE GV150/200/400 ADJUSTMENT Before making any adjustments: + Verify that the governor is properly adjusted before starting the engine. Refer to the appropriate shop manual. + Check that the throttle and choke controls operate properly before starting the engine. + Check that there are no fuel leaks before starting the engine. + Start the engine and allow it to warm up to normal operating temperature. Be sure that all engine components are within specifications and there are no air leaks into the inteke path. Idle slow speed adjustment under no load Use the throttle stop screw and pilot screw (non-certitied engines) to adjust the idle slow speed. Throttle stop screw: + Tum clockwise pm increases, + Tum counterclockwise..........fpm decreases Pilot screw (non-certified engines): Refer to the appropriate shop manual for adjustment and reassembly procedures. + Tum clockwise... leaner fuel mixture + Tum counterclockwise... richer fuel mixture IDLE ADJUSTMENT (1) With the engine off, turn the throttle stop screw clockwise until it contacts the throttle lever, and then make 3 more tums to open the throttle plate, Be sure the throttle lever is touching the end of the screw. (2) Turn the pilot screw clockwise until it lightly seats, and then back it out the number of tums specified in the appropriate shop manual. On certified engines, after the pilot screw is backed out the correct number of tums. NOTICE Overtightening the pilot screw may damage the carburetor. (3) Start the engine, and let it warm up to normal operating temperature. When the engine is warm, slowly tum the throttle stop screw counterclockwise until the engine is running at the standard idle speed specified in the shop manual. (4) Tum the pilot screw (non-certified engines) in or out to obtain the highest engine rpm. (5) Repeat steps (3) and (4) above until the pilot screw (non-certfied engines) setting is as close as possible to the standard idle speed. If the pilot screw (non-certified engines) must be turned more than one turn in either direction from the shop ‘manual specification, the carburetor may have a blocked passage. Be sure all air and fuel passages are clear before proceeding, (6) Adjust the throttle stop screw to obtain the standard idle speed. 3-40BB-TYPE GV150/200/400 2. Maximum speed adjustment under no load Set the throttle cable on the control lever to set maximum speed. MAXIMUM SPEED ADJUSTMENT (1) Start the engine, and let it warm up to normal operating temperature. When the engine is warm, turn the control lever adjusting screw until the engine is running at the specified maximum speed at full throttle, THROTTLE GABLE (2) Close the throttle, and then slowly open it again. (3) If hunting occurs as the throttle is opened, adjust the pilot screw (non- certified engines) (4) Check the idle siow speed, and adjust the throttle stop screw if necessary. 3-41BE-TYPE EUZ000is BE-TYPE EU3000is THEORY OF OPERATION Float Chamber When the float chamber is empty, fuel from the fuel tank can flow past the float vaive into the float chamber. As the fuel level in the chamber rises, the fioat rises with it. When the float pushes the float valve into its seat, the flow of fuel stops. As fuel is drawn out of the float chamber, the float moves down and opens the float valve. This cycle assures a constant level of fuel in the float chamber. Main Circuit When the throttle valve opens, alr passes through the venturi in the carburetor’s throat. Because the venturis diameter is smaller than the intake opening, the air speeds up as it passes through. This increased air velocity produces low pressure at the outlet of the main nozzle. The float chamber is vented to the atmosphere (bow! vent). Since atmospheric pressure is higher than the pressure in the venturi, fuel is pushed out ofthe float chamber, through the main jet and into the main fuel nozzle. Air passing through the air jat mixes with fuel flowing through the main nozzle's air bleed holes. This rich mixture is then drawn into the venturi where it mixes with more air to produce the final arlfuel mixture. Slow (Idle) Circuit When the throttle valve is completely closed (idle), engine vacuum (low pressure) is present atthe pilot outlet in the intake tract. Atmospheric pressure in the float chamber then forces fuel through the main jet and into the slow circuit bypass. The pilot jet controls fuel flow through the slow circuit bypass. The fuel then mixes with air that is metered by the pilot air jet. The resulting fueVair mixture then flows through the pilot outlet and into the intake tract. The pilot screw Controls the amount of fuel mixture that can flow through the pilot outlet, Transition Circuit The transition circuit supplies fuel to the engine during the transition from the slow (idle) circuit to the main circuit and vice versa, When the throttle is opened slightly, high velocity air flows between the edge of the throttle valve and the transition ports, which are located upstream of the pilot outlet. The resulting low pressure (vacuum) draws fuel/air mixture from the slow circuit bypass through the transition ports and into the intake tract, providing the proper fuel charge for low speed operation, The pilot screw does not control the fuel/air mixture that passes through the transition ports. AAs the throttle plate opens farther, the vacuum at the transition ports decreases. As a result, there is very tle flow through these orifices, and the airffuel mixture for mid- and high-speed operation is provided almost completely by the main circu. Electronic Governor/Throttle Control ‘The inverter’s CPU compares the current output voltage, current, and engine speed with what is programed it its memory and sets the throttle position accordingly. The actual required engine speed is based on generator load ratio and temperature. As a load is applied, the engine speed, and generator output power will drop momentarily, The inverter will calculate the type of load (how much of power drop is occurring) and set the engine speed accordingly. 3-42BE-TYPE EUZ0O0is PILOTAIR JET (stow ciRcurr) A sow.—_/| , —~ Bypass VENT VENTURI i = aH yor CHOKE VALVE (stow w circum MAIN AIR JET TRANSITION PORTS PILOT ScREW THROTTLE VALVE LMrteR cap = (wan circu PILOT OUTLET 8 0 MAIN NOZZLE © Je CaS FLOAT ————} | = ave sear | | ‘AIR BLEED HOLE FLOAT VALVE FLOAT CHAMBER FLOAT ARM FLOAT CHAMBER BODY MAIN JET 3-43BE-TYPE EUZOOOis CARBURETOR TROUBLESHOOTING AND INSPECTION POINTS ‘The information in this chapter applies to the carburetor and fuel system only. Use the Troubleshooting Chapter of the appropriate shop manual to confirm that the fuel system is the cause of the problem before using the table below. - 7 Hard Staring + Engine stats but soon stops, o @ Inspection Point> Inspection order before disassembly Reference number shown on next page Faulty choke vaive operation IMisedjusted plot screw Foreign material on the tip of the plot sorew Iciogges pict outer IMisadjusted trate stop sew |contaminated fuel sediment cupsvel iter Faulty throttle contr motor operaton Faulty theote shatvalve operation [Giogged main jet Tnsproper italian af carburetor gasket Improper installation of insulator gasket Air leaking through broken carbureter, insulator ‘gasket or broken insulator Clogged plot jt Clogged pilot air jet Clogged main jet wrong main jt size Clogged float bowl atmosphere vent [> Hunting |= rpm coes not |" Sabiize LS Flot bow! overiowing Gasoline leaks Lu Clogged main air jot Clogged main nazz air bleod hols Contaminated fuel sediment cupuelfiter waterfoceign materia inthe foal chamber, Deterirated gasoine in the feat chamber OEE + Poor performance at low speed + rpm does not ecrease © O9GOWOSO®: OOO) @99O8SEOO Damagedicantaminated float valve seating sure Foreign materials on the tip of float valve Clogged fost bow! atmospheric vent Faulty chamber gasket (improperl install) Fuel inside the fat Faull float operation, float does rot operate smoothiy Deformed chamber (mating face, jit) @@ 6] [eo e000 @89800 + Poor performance |” athigh speea | = tom does not Inereate 7 Hunting + Spitting + Engine staling 1 Hard Starting = Wet fouled spark pug + Power drops, rpm does not stabilize + Black smoke from mute, engine stats + Air eaking past the carburetor insulator gasket + Clogged jets, wom thrctle shat + Overeating ofthe carburetor chamberful passage * Wrong maint size | + Restrictes ptt Lean fuel mixture Percolation Overheating Set or high elevation {+ Clogged air cleaner + Faulty choke operation 1 Wrong main jt size + Deteriorated gasoline + Blocked main nozlelventsri bore + Reh fuel mixture + Icing (Lew ambient temperature, igh amity, snow in the rozaelbore) 3-44BE-TYPE EUZ0O0is CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT.) & = Oo @® INSULATOR GASKET @ THROTTLE CONTROL MOTOR! ‘THROTTLE VALVEISHAFT. © choke Lever FLTER INSULATOR. © carsuReToR asker bw O—~o nn @ roar GHawaer’ ‘SEDIMENT cur @ puorair ser ===] PLOT Al J | Opowteow. Cc rnosereric | VENT, LS @ venturi @puorset CHOKE VALVE @ NaN aiRueT ORIFICE @ PILOT SCREW LiMiTER CAP @ MAN NozzLE ~] _-@ asker ei T—~@ ir BeeD HOLE 4 @ FLOAT vatve seat CS - [P @ Frost aru OMANSET @ Ftoar @ roar vawwe 3-45BE-TYPE EU3000is CARBURETOR REMOVAL ‘Your type may be different. Refer to the appropriate shop manual for carburetor removal and installation THROTTLE CONTROL MOTOR SUB-HARNESS CONNECTOR CARBURETOR INSULATOR i SeReUR GasKeT Replace ‘CARBURETOR INSULATOR CARBURETOR GASKET BREATHER TUBE ‘6 mm FLANGE NUT) AIR CLEANER CASE EZOF (018074 and subsequent AIR CLEANER COVER CLIP (s) 6x16mm FLANGE BOLT 3-46BE-TYPE EU3000is DISASSEMBLY/INSPECTION 1. Drain all the float chamber fuel into an approved container. 2, Clean the outside of the carburetor before disassembly. 3, Disassemble and inspect the carburetor as indicated below. Use a 6 mm (1/4 in) flat cabinet screwdriver to remove the main jet Disassembly Inspection BE-type carburetor shown. No. Item, Clean ‘The BE-type has some components that are not @ | creck ne petit holes foregoing. | O | found on other Honda carburetors. (Check the plot jet ©-ing for damage. @ THROTTLE CONTROL MOTOR 3x8mm LINK LEVER SCREW (2) Check the stop ser for proper eating, @muorser PILOT JET O-RING ® LINK LEVER THROTTLE] "Al Honda catiied engines have @ tamper resistant iter cap installed on the plot screw. Any attempt to remove the e2p will break the plot screw, requiring screw and kmiter cap replacement. General leave ris type Of pilot screw installed onthe carburetr. Check the air bleed hole for clogging. @rwrorne »> [sane Lever Beeeaiew trom Sarr See |e Check the main jt size, heck tne jet orice Tor clogging, CCheck the float height, and make sure {heros no gasclne Inthe Not e|9 ‘Check the gasket for damage (Conot remove the gasket), (Check the gasket for damage i gasoline leaks from the ful valve. Check the O-ring for damage. @|O/@ ‘Check the thatle control motor for worn ears, Replace f necessary. CGheck the main et holder for corrosion, PILOT SCREW, @ wan ser HOLDER cHoKe WMaIN Nozz.E: lever NR BLEED o é FLOAT @ man er: hoe @rioarrn ©|® (Check the tip ofthe vaive for contamination or damage. THROTTLE CONTROL, MOTOR BRACKET FLOAT @rLoar chaser @ rucar |® (Check the foat pin for wear or loose tt, @ (Check for dir or foreign material in the chamber Check the chamber for corrosion ‘and deformation, CHAMBER GASKET ®oaws @Fvet vawve GASKET (Check the onions inthe carburetor body for clogging ‘Check the shaft for smooth movement, 3-47BE-TVPE EUZ3OOOis CLEANING BEAype carburetor shown, ‘em oe, The Be-ype has some components that poo | are not found on other Honda carburetors. ‘Slow Circuit Indicates parts that are likely to be @|_ Remove foreign material from the ott clogged: clean carefully. Pilot {@rcor PILOT] @)THROTTLE| let Cleaner (Oekge (ore TROT | (tii-+—O Jet Cleaner Set woToR } Honda Carburetor | Cleaner Ciean the plot ait orf. Clean the pit out ©68 * Remove any contamination fom 7 | 3 the plot sorew tp Low pressure @ piorair ser \ compressed air MAIN AIR. g tt B | warcea 7 @| Remove foreign material rom | the maln et Jot Cleaner Set 2 Se @| Remove reign materi fom Honda @vave sear Seman necig a iedheles. | Cebu [Swannozae ] [Caretce | pea Low pressure FLORTARM compressed ar @| Clan te main ai et once wane Foal Creat — @|__ Remove foreign materials trom the valve seat Honda @|_ Clean the oat valve and seat. Carburetor Cleaner Low pressure ‘compressed air Do not damage the seat and valve. | @ Check the fat level, G9) | Remove foreign materlal from the | Fioat evel gauge @) erates saves @|__ Check ne thrtte control motor for \? |__woen gears, Replace it necessary “The pilot serew must be broken to be removed on engines wth a limter cap. Replace the plot serew. 3-48CLEANING (cont.) Use Honda Carburetor/Combustion Chamber Cleaner PIN CA66916 with i's plastic spray nozzle to clean the ports, ‘Some commercially-available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as O-rings, floats, choke valves, and float valve seats. Check the container for instructions. If you are in doubt, do not use these products to clean Honda carburetors. NOTICE High air pressure may damage the carburetor. Use low pressure settings when cleaning passages. ‘1. Clean the jets and passages with Honda Carburetor/Combustion Chamber Cleaner PIN CA66916 2. Use low air pressure and clean the following passages and ports: + Vent port + Pilot screw hole Pilot jet hole + Main air jet + Transition ports, Pilot outlet + Main nozzle holder 3. Refer to the jet range chart on the back of the Jet Cleaner ‘Set (P/N 07JPZ-001010B), and select the appropriate cleaning needle to remove any cust, drt, etc. that remains after Step 1 and 2. NOTICE Using a cleaning needle that is too large may damage the carburetor. Never force a needle, and never use a needle with a bent or damaged tip. Due to manufacturing tolerances, it may be necessary to use a needle that is smaller than the one indicated on the chart. 4, Be sure to clean the transition ports located in the side of, the carburetor throat near the throttle valve. If these ports are blocked, the engine will run rough or stall just above idle, 5. Reassemble the carburetor carefully. Take care not to overtighten the main jet. 6. Install the carburetor in reverse order of its removal using new gaskets where appropriate, 7. Prooeed to the Adjustment section. ADJUSTMENT No adjustments are necessary. E-TYPE EU3OOOis ENGINE BLOCK SIDE: VENT PORT [AIR CLEANER SIDE: PLoT MAIN NOZZLE HOLDER MAIN AIR JET {JET RANGE CHART JET CLEANER SET Pav o7PZ-0010108 ‘TRANSITION PORTS. 3-49BE-TYPE GX1 10/120/140/200/160/270/340/390 BE-TYPE GX110/120/140/200/160/270/340/390 THEORY OF OPERATION Float Chamber When the float chamber is empty, fuel from the fuel tank can fow past the float valve into the float chamber. As the fuel level in the chamber rises, the float rises with it. When the float pushes the float valve into its seat, the flow of fuel stops. As fuel is drawn out ofthe float chamber, the float moves down and opens the float valve. This cycle assures a constant level of fuel in the float chamber. Main Circuit When the throttle valve opens, air passes through the venturi in the carburetor's throat. Because the ventur's diameter is smaller than the intake opening, the air speeds up as it passes through. This increased air velocity produces low pressure at the outlet of the main nozzle. ‘The float chamber is vented to the atmosphere (bowl vent). Since atmospheric pressure Is higher than the pressure in the venturi, fuel is pushed out of the float chamber, through the main jet and into the main fuel nozzle. Air passing through the air jet mixes with fuel flowing through the main nozzle's air bleed holes. This rich mixture is then drawn into the venturi where it mixes with more air to produce the final airfuel mixture. Slow (Idle) Circuit When the throttle valve is completely closed (Idle), engine vacuum (low pressure) is present at the pilot outlet in the intake tract. Atmospheric pressure in the float chamber then forces fuel through the main jet and into the slow circuit bypass ‘The pilot jet controls fuel flow through the slow circuit bypass. The fuel then mixes with air that is metered by the pilot air jet. The resulting fuel/air mixture then flows through the pilot outlet and into the intake tract. The pilot screw controls the amount of fuel mixture that can flow through the pilot outlet Transition Circuit ‘The transition circuit supplies fuel to the engine during the transition from the slow (idle) circuit to the main circuit and vio= versa When the throttle is opened slightly, high velocity air flows between the edge of the throttle vaive and the transition ports, which are located upstream of the pilot outlet. The resulting low pressure (vacuum) draws fuel/air mixture from the slow circuit bypass through the transition ports and into the intake tract, providing the proper fuel charge for low speed operation, The pilot screw does not control the fuel/air mixture that passes through the transition ports. As the throttle plate opens farther, the vacuum at the transition ports decreases. As a result, there is very litle low through these | orifices, and the air/uel mixture for mic- and high-speed | operation is provided almost completely by the main circuit TRANSITION PORTS 3-50BE-TYPE GX1 10/120/140/200/160/270/340/390 PILOT AIR JET (Stow ciRcurT) — / // BY-PASS ~ VENTURI of | i PILOT ioe (CHOKE VALVE x (stow ‘ciRCUIT) MAIN AIR JET TRANSITION PORTS PILOT SCREW THROTTLE VALVE LIMITER CAP. PILOT OUTLET MAIN NOZZLE nose a Bi | ar ecezo nour FLOAT VALVE’ oo, stom 2c FLOAT CHAMBER BODY MAIN JETBE-TYPE GX1 10/120/140/200/160/270/340/380 CARBURETOR TROUBLESHOOTING AND INSPECTION POINTS ‘The information in this chapter applies to the carburetor and fuel system only. Use the Troubleshooting Chapter of the appropriate shop manual to confirm that the fuel system Is the cause of the problem before using the table below. - [> Hard Staring + Engine stars but soon stone ° ° Inspection Poin [Fauty choke valve operation IMisadjused plot scrow [Foreign material on the tip of th plot screw \cioaged plot outlet IMisadjusted thote stop screw |waterforeign materials inthe fuel sediment cup Faulty throtte valve operation [Fauty tnrote shaft operation [Crogged main jet OO _oo Inspection order before disassembly Reference number shown on next page irspraperInataliaton of carburetor gasket Improper installation of insulator gasket Air leaking tough broken carburetor, insulator ‘gasket of broken insulator Clogged pict jet Cloaged pot ae et Clogged main jet wrong main jt size [- Runtng * ep does not ‘stablize Clogged float bow atmospheric vent logged main ai jet |. Float bow ovediowing + Gasaline leaks Clogged main nozzle air bleed hoe Wiaterfreign material in the fuel sediment cup Wiaterforeign materials in the fost chambo, cottedod chamber Detoriorated gasoline n the float chamber ©O8988899 O99) oS re decrease + Poor performance at low speed + 1pm does not Damaged/cantaminated float valve seating surtac Foreign materials on th tip of fat valve ‘Clogged fost owl atmospheric vant Faulty chamber gasket (improper installed) Fuel inside the float Faull Naat operation, feat does nat operate ‘smoothly Deformed chamber (mating face, Joint) © 8890090) + Poor performance athigh speed + pm does not [Hunting > Spiting * Engine stalng + Hard Starting = Wet fouled spark ug + Power drops, rpm does not stabilize + Black smoke fom ruff, engine stalls + Air leaking past the carburetor insulator gasket + Clogged ets, worn tote shaft + Overeating ofthe carburetor chamberfue passage + Wrong main jet size + Restricted plo jot Lean fuel mixture + Percolation + overheating * Set for high elevation + Clogged ar cleaner | + Faulty choke operation = Wrong main jt size * Dotoriorated gasoline + Blocked main noezialventu bore + Rich fuel mixture ‘eing (Low ambient temperature, high humidity, snow inthe nozziefbore) 3-52BE-TYPE GX1 10/120/140/200/160/270/340/390 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT.) © choke Lever @ INSULATOR GASKET INSULATOR a (leak fer broken tower sation) @ canBuRETOR GASKET @ Float chamBer @ rue. @ trom stor @pLorar ser ‘SCREW — ORIFICE SeOWENT @ Float sow. Pp ao / Timosenenio NE vent @ venturi A tS PLOT JET @ py iF @everss Hy — © Hoke vave [|| 2 j @ NAAR JET ORIFICE co THROTTLE VALVE @ Puot screw UNL } LuMiTER cAP: He ( @ wan nozze XG3 @ asker | i | — @ AIR BLEED HOLE | ~@ rtoarvaive sear @ iow cD “FE ww @ roa vatve @wanser @ ruorarm 3-53BE-TYPE GX1 10/120/140/200/160/270/340/390 CARBURETOR REMOVAL Your type may be different. Refer to the appropriate shop manual for carburetor removal and installation, Do net strike or tap on the carburetor with 2 hammer during removal Do nat bend the governor rod or antv-surge spring. Be caret not ANTI-SURGE pull them with excessive force, Governorrop ANTI SU FUEL TUBE NOTICE Excessive force may damage the thrttle lever CARBURETOR Bxcossive force INSULATOR CHOKE LEVER DISASSEMBLY: Disconnect the Tue tube from the tarburgtor then lun the bose the Choke lever into the hose to prevent fuel leakage CARBURETOR GASKET CARBURETOR ASSEMBLY GOVERNOR RODIANTI-SURGE SPRING REMOVAL: Pall the carburetor slowly toward you GOVERNOR ROD lui the tote groove and governor fod are aligned, and then remove the lgovencr ro, Uninook the ant-surge spring and then remove the carouretor fom the lovinder head Not a products have an antsurge spring 3-54BE-TYPE GX1 10/120/140/200/1 60/270/340/390 DISASSEMBLY/INSPECTION 41. Drain all the float chamber fuel into an approved container. 2. Clean the outside of the carburetor before disassembly, 3. Disassemble and inspect the carburetor as indicated below. Use a 6 mm (1/4 in) flat cabinet screwdriver to remove the main jet Disassembly Inspection BE-type carburetor shown. No.| Item Clean [Replace] The BE-type has some components that are not @ | Check the piot jet holes for cogging Oo found on other Honda carburetors, - @® | Check the pitt jt O-ring for damage. @ @puorver agers —— SHAFT @ | check te stop seow fr prope attng. cHoxe ever | | @ | check srew tp for contamination. Oo B)PILOT JET = one | Onworne | ‘STOP SCREW Tl onda rfid anges hae © eee ina ap heated on @ Sepicace any tert oro 4 ‘the cap will break the pilot screw, 0 See ee rue wave Stott owen ted ove cater eee ® a Check the a tleed Role foregoing. | O \@Fuorscrew as ‘Check ihe main jet size. O cee Sie Renker |@ tert ype wth A heck te tot i @ Yeomenr cur Stoo a ah ® go ‘Check the @ ae (Do not remave the gasket) e@ © sles SRST e _ eee ! roar Ouanier” /_—— roar n ‘Check the O-ring for damage. | e@ ‘Check fora or foreign materials in the oup (Check the main jet holder for corosion, ‘Check he tp of the valve for | contamination or damage, O1O FLOAT CHAMBER a, ® FLonr cHahteeR ® GASKET 2 oO e ‘Check the float pin for wear or locee ft e@ FUEL DRAIN SCREW ‘Check for dit or foreign materia inthe chamber. Oo} ser BOLT @ [ele/elelelolelelole] ‘Check he chamber for canosion and deformation @ ‘Check the orfices in the earburelor ° (Check he shaft for smooth movement eBE-TYPE GX1 10/120/140/200/160/270/340/390 CLEANING BE-type carburetor shown. The BE-type has some components that are not found on other Honda carburetors, [= Indicates pants that are likely to be clogged: clean carefully FUEL SEDIMENT cup vem [secre a Remove foreign material from the ® pilot jet. | | ipee-—O Clean the plot outet. * Remove any contamination trom | the pilot screw tp ©©8 Inspection! Gearing Toot Jet Cleaner Set Honda Carburetor Gleaner Low pressure compressed air Man Cs ®|__ Remove foreign material rom themain et SO Remove foreign material from the main nozzle alr bleed holes, ap @]__ Clean the main air jet orice. Jet Cleaner Set Honda Carburetor Cleaner Low pressure | compressed air Float Gul @®| Remove foreign materials rom the vave seat @|__ clean the oat vave and seat. A 1 nat damage the seat end vaio | @| checkthe noat level @|__ Remove trsign materia tom the fost chamber | @|_ Remove fran mae om the fuel sediment cup. Honda: Carouretor Geaner Low pressure compressed air Flat level gauge "The pilot screw must be broken tobe removed on engines with ‘limiter cap. Replace the plt scrow.BE-TYPE GX1 10/120/140/200/160/270/340/390 CLEANING (cont.) Use Honda Carburetor/Combustion Chamber Cleaner PIN CA66916 with it's plastic spray nozzle to clean the ports ‘Some commercially-available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as O-tings, floats, choke valves, and float valve seats. Check the container for instructions. If you are in doubt, do not use these products to clean Honda carburetors, NOTICE High air pressure may damage the carburetor. Use low pressure settings when cleaning passages. 1. Clean the jets and passages with Honda Carburetor/Combustion Chamber Cleaner P/N CA86916 2. Use low air pressure and clean the following passages and ports: + Vent port + Pilot screw hole + Pilot jet hole + Main air jet * Transition ports * Pilot outlet * Main nozzle holder 3. Refer to the jet range chart on the back of the Jet Cleaner Sot (P/N 07JPZ-001010B), and select the appropriate cleaning needle to remove any dust, dirt, etc. that remains after Step 1 and 2. NOTICE Using a cleaning needle that is too large may damage the carburetor. Never force a needle, and never use a needle with a bent or damaged tip. ‘Due to manufacturing tolerances, it may be necessary to se a needle that is smaller than the one indicated on the chart. 4, Be sure to clean the transition ports located in the side of the carburetor throat near the throttle valve. If these ports are blocked, the engine will run rough or stall just above idle. 5. Reassemble the carburetor carefully. Take care not to ‘overtighten the main jet 6. Install the carburetor in reverse order of its removal using new gaskets where appropriate, 7. Proceed to the Adjustment section (next page). Plot AIR CLEANER SIDI MAIN NOZZLE HOLDER MAIN AIR JET ENGINE BLOCK SIDE: VENT PORT PILOT AIR JET J JET CLEAN PI 07sP2:0010108 JET RANGE CHART IER SET TRANSITION PORTS:BE-TYPE GX1 10/120/140/200/160/270/340/380 ADJUSTMENT Before making any adjustments: + Verify that the governor is properly adjusted before starting the engine. Refer to the appropriate shop manual + Check that the throttle and choke controls operate properly before starting the engine. + Check that there are no fuel leaks before starting the engine + Start the engine and allow it to warm up to normal operating temperature. Be sure that all engine components are within specifications and there are no air leaks into the intake path. 4, IDLE SLOW SPEED ADJUSTMENT UNDER NO LOAD Use the throttle stop screw and pilot screw (non-certified engines) to adjust the idle slow speed. Throttle stop screw: + TUrn CIOCKWIS@ ...nosnneee PM increases + Turn counterclockwise... rpm decreases Pilot screw (non-certified engines): + Turn clockwise + Turn counterclockwise... «leaner fuel mixture _Ficher fuel mixture Pilot screw (certified engine: Refer to the appropriate shop manual for adjustment and reassembly | procedures. Idle Adjustment | (1) With the engine off, turn the throttle stop ecrew clockwise until it contacts THROTTLE STOP: the throttle lever, and then make 3 more turns to open the throttle plate. Be ‘SCREW sure the throttle lever is touching the end of the screw. (2) Turn the pilot screw clockwise unt it lightly seats, and then back it out the ‘number of tums specified in the appropriate shop manual, On certified engines, after the pilot screw is backed out the correct number of turns, install the limiter cap. NOTICE Overtightening the pilot screw may damage the carburetor {@) Start the engine, and let it warm up to normal operating temperature. When the engine is warm, slowly tun the throttle stop screw counterclockwise until the engine is running atthe standard idle speed specified in the shop manual. (4) Turn the pilot screw (non-certified engines) in or out to obiain the highest engine rpm. (©) Repeat steps (3) and (4) above until the pilot screw (non-certified engines) setting is as close as possible to the standard idle speed. If the pilot screw (non-certified engines) must be turned more than one turn in either direction from the shop manual specification, the carburetor may have a blocked passage. Be sure all air and fuel passages are clear before proceeding, (6) Adjust the throttle stop screw to obiain the standard idle speed. 3-58BE-TYPE GX1 10/120/140/200/1 60/270/340/390 2. MAXIMUM SPEED ADJUSTMENT UNDER NO LOAD Use the adjusting screw on the control lever to set maximum speed, Control lever adjusting screw: + Turn clock Wise......::snemee pm decreases: + Tum counterclockwise. rpm increase Maximum Speed Adjustment (1) Start the engine, and let it warm up to normal operating temperature. When the engine is warm, turn the control lever adjusting screw until the engine is running at the specified maximum speed at full throttle, (2) Close the throttle, and then slowly open it again. ‘CONTROL LEVER ADJUSTING SCREW (3) I hunting occurs as the throttle is opened, adjust the pilot screw (non-certified engines) (4) Check the idle slow speed, and adjust the throttle stop screw if necessary. 3-59BE-TVPE GXV120/140/160/270/340/390 BE-TYPE GXV120/140/160/270/340/390 THEORY OF OPERATION Float Chamber When the float chamber is empty, fuel from the fuel tank can flow past the float valve into the float chamber. As the fuel level in the chamber rises, the float rises with it. When the float pushes the float valve into its seat, the flow of fuel stops. As fuel is drawn out ofthe float chamber, the float moves down and opens the float valve, This eycle assures a constant level of fue! in the float chamber. Main Circuit When the throttle valve opens, air passes through the venturi in the carburetors throat. Because the venturi diameter is smaller than the intake opening, the air speeds up as it passes through. This increased air velocity produces low pressure at the outlet of the main nozzle. The float chamber is vented to the atmosphere (bow! vent). Since atmospheric pressure is higher than the pressure in the venturi fuel is pushed out ofthe float chamber, through the main jet and into the main fuel nozzle. Air passing through the air jet mixes with fuel flowing through the main nozzle's air bleed holes. This rich mixture is then drawn into the venturi where it mixes with more air to produce the final airffuel mixture. Slow (Idle) Circuit When the throttle valve is completely closes (idle), engine vacuum (ow pressure) is present atthe pilot outlet in the intake tract. Atmospheric pressure in the float chamber then forces fuel through the main jet and into the slow circuit bypass. The pilot jet controls fuel flow through the slow circuit bypass. The fuel then mixes with air that is metered by the pilot air jet. The resulting fueVair mixture then flows through the pilot outlet and into the intake tract, The pilot screw controls the amount of fuel mixture that can flow through the pilot outlet. Transition Circuit ‘The transition circuit supplies fuel to the engine during the transition from the slow (idle) circuit to the main circuit and vice versa. ‘When the throttle is opened slightly, high velocity air flows, between the edge of the throttle valve and the transition ports, which are located upstream of the pilot outlet. The resulting low pressure (vacuum) draws fuel/air mixture from the slow circuit bypass through the transition ports and into the intake tract, providing the proper fuel charge for low speed operation. ‘The pilot screw does not control the fuel/air mixture that passes through the transition ports. As the throttle plate opens farther, the vacuum at the transition ports decreases. As a result, there is very little flow through these orifices, and the airfuel mixture for mid- and high-speed operation is provided almost completely by the main circuit. TRANSITION PORTS 3-60BE-TYPE GXV120/1 40/160/270/340/390 (stowerrcur) BY-PASS [IOP Sen x (sLow tLe ‘CIRCUIT) ‘TRANSITION PORTS PILOT SCREW LIMITER CAP. PILOT AIR JET LF ce VENTURI CHOKE VALVE MAIN AIR JET i i ‘THROTTLE VALVE / (WAIN ciRcUT) MAIN NOZZLE FLoar: FLOAT VALVE. VALVE SEAT FLOAT ~ CHAMBER FLOAT ARM FLOAT CHAMBER BODY MAIN JET ‘AIR BLEED HOLEBE-TYPE GXV120/140/160/270/340/390 CARBURETOR TROUBLESHOOTING AND INSPECTION POINTS The information in this chapter applies to the carburetor and fuel system only. Use the Troubleshooting Chapter of the appropriate shop manual to confirm that the fuel system is the cause of the problem before using the table below. - Hard Staring + Engine starts but soon stops, ° ® Inspection Point> Inspection order before disassembly Reference number shawn on next page - [Fauty choke vaive operation IMisadjusted plot screw [Foreign material on te tip ofthe pl: serew [Clogged pict outet IMisadjuted trate stop screw |waterfforeign materials in he fuel seximent cup [Fauty trot vaive operation [Faulty throttle sha operation \Crogged main jet_ CT + Poor performance at low speeo + rpm does not Gecrease Trproper installation of carburetor gasket Improper installation of insulator gascet Alrleaking through broken carbureter, insulator (gasket or broken insulator = Hunting + rpm does not stabilize Clogged plat jet Clogged plot air jet Clogged main ot wrong main jt sze Clogged float bowl atmospheric vent Clogged main air jot Clogged main nozze air bleed hole wateiforeign material inthe fuel iter wateiforeign materials n the Noat chamber, Deterirated gasoline in the Noat chamber © G8GOGSHOH G0O]|@SO02008O + Poor performance at high speed + 1pm dos not + Float bow overfowing * Gasoline leaks Damagedicontaminated float valve seating eur Foreign materials on the tp of float valve Clogged feat bowl atmospheric vent Faulty chamber gasket (mpropery installed) Fuel inside the fast Faulty float operation, float does notoperate ‘smoathiy Deformed cham tating face, jit) © 980800 [Hurting Spiting + Engine staling + Hard Staring = Wet fouled spark plug + Power drops, rpm ‘ove not stabize + Black smoke fram maf, engine stalls * Air leaking past the carburetor insulator gasket + Clogged jets, won tote shat + Overneating ofthe carburetor chamberfuel passage + Wirang main jet size + Restrictes plat jet Lean fuel misture Percolation Overheating Set for high elevation + Clogged air cleaner + Faulty choke operation Wrong main jet size + Deterorated gasoline + Blocked main nozzleWventur bore leh fuel miture + eing (Low ambient temperature, high Rumity, snow in the nozeibore) 3-62BE-TYPE GXV 120/140/160/270/340/390 CARBURETOR TROUBLESHOOTING INSPECTION POINTS (CONT.) @ cHoxE Lever @ wsurktor casker Ss INSULATOR @ Fue rurer @ caRBURETOR GASKET @FLoar cHaMeER @ tHrome stoP @ PLoTARueT SCREW ORIFICE @venturt x CHOKE VALVE ( @ Puorouner @ Ma Nozae @ caswer LA ~@ areteeo Hove © Fioar vawve sear @ roar Se @ Float valve ® FLOAT ARM Oman ser 3-63BE-TYPE GXV 120/140/160/270/340/390 CARBURETOR REMOVAL Your type may be different, Refer to the appropriate shop manual for carburetor removal and installation, CRANKCASE BREATHER TUBE ‘CARBURETOR SPACER INSULATOR GASKET CARBURETOR INSULATOR CARBURETOR GASKET ‘CARBURETOR ASSEMBLY GOVERNOR ROD/ANTI-SURGE SPRING REMOVAL: ‘GOVERNOR ROD ull the carburetor slowiy toward you ‘uni the thre groove and governor rod are aligned, ana then remove the GROOVE govenor roc, ANTESURGE, Unhook the ant-surge spring and then ‘SPRING remove the carburetor fom the Syinder hea Not al products have an ant-surge spng, THROTTLE, ccHOKE 3-64DISASSEMBLY/INSPECTION 1 BE-TYPE GXV120/140/160/270/340/390 Drain all the float chamber fuel into an approved container. 2. Clean the outside of the carburetor before disassembly, 3. Disassemble and inspect the carburetor as indicated below. Use a 6 mm (1/4 in) flat cabinet screwdriver to remove the main jet Disassembly Inspection UMTER CAP @ trom Srop sonew f+ — OPuorver PILOT JET Site cap @Ppuorscrew {nomcerttes p=) @ carsuretor soy MAIN JET robe © man nozare A teeD @FLOAT VALVE @ man ser’ Low No. tem [clean Oo Replace| Q {Check the pilot jet holes for clogging ® (Check the pilot jet Oxing for damage. Check the stop screw for proper setting ®|9 (Check screw ip fr contamination. ‘Al Honda cerfed engines have a tamper resistant limiter cap installed on the plot screw. Any attempt to remove the c9p wil break the plot screw, requing screw and enter eap | replacement. General leave this type | of pilot serew installed onthe carburetor, | ‘Check the ar bleed hole for clogging oO oO ‘Check the main jot sie, Check the jet once for clogging. Check he fot height nd ake sre Sores mo govaine ne tat | ‘Check the gasket for damage (Bo net remove tha gasket) ‘Check the gasket for damage gasoline leaks from the fuel vale, CHAMBER GASKET @rvoar CHAMBER : SET BOLT ‘Check the main jet helder {or eorrosion ‘Check the tip ofthe valve for cntamination of damage ‘Check the fat pin for wear or loose ft ‘Check Tor di or foreign material inthe chamber. ‘Check the chamber fr carresion ‘and deformation ‘Check the offices in the carburetor body for clogging ® ‘Check the trate and choke shatts for smoath movement. 3-65BE-TYPE GXV120/140/160/270/340/390 CLEANING aN One -type carburetor shown, lnpectn’ BE-typ buretor shot {tem Cleaning Toot The BE-type has some components that ‘Sow Circuit ~ are not found on other Honda carburetors GD] remove ton mateo ne (J: Indicates parts that are likely to be pilot et | clogged; clean carefully | st ceaner sat Rae—-O | onda @| clean the pot sr jt orcs. Garburtor ®| clan ne pot ute cer 3) | “Ramee ay contamination tom 0 Low presire ®| “Neri scrw tp Low pressure 5 g \ Main Circuit | Remove sgn natal tom ® ‘the main jet. Jot eae et Oho ———— Remove foreign materia from Carburetor Twa NozAE theman nossa arcieactes, | Cleaner hreslseo 4 9 Low posse ; al — comcssedair | @|__ clean the main ait jt orice Float Gireult @®|__ Remove toreion materia om Honda thovvave oat Carburetor | @|__ clean the fost valve anc seat. Cleaner Low pressure compressed air ‘Do not damage the seat and valve. @| check the teat eve Float level gauge @J__ Remove foreign material rom the float chamber. “The pilot screw must be beoken tobe removed on engines with alimter cap. Replace the pot screw. 3-66BE-TYPE GXV 120/140/160/270/340/390 CLEANING (cont.) Use Honda Carburetor/Combustion Chamber Cleaner PIN CA66916 with it's plastic spray nozzle to clean the ports. ‘Some commercially-available chemical carburetor cleaners are very caustic. These cleaners may damage plastic parts such as O-tings, floats, choke valves, and float valve seats. Check the container for instructions. If you are in doubt, do not use these products to clean Honda carburetors. NOTICE High air pressure may damage the carburetor. Use low pressure settings when cleaning passages. 1. Clean the jets and passages with Honda Carburetor/Combustion Chamber Cleaner P/N CAG6916 2. Use low air pressure and clean the following passages and ports: + Vent port + Pilot screw hole + Pilot jet hole + Main air jot + Transition ports + Pilot outlet + Main nozzle holder 3. Refer to the jet range chart on the back of the Jet Cleaner Set (PIN 07JPZ-0010108), and select the appropriate cleaning needle to remove any dust, dirt, ete. that remains after Step 1 and 2. NOTICE Using a cleaning needle that is too large may damage the carburetor. Never force a needle, and never use a needle with @ bent or damaged tip. Due to manufacturing tolerances, it may be necessary to Use a needle that is smaller than the one indicated on the chert. 4. Be sure to clean the transition ports located in the side of the carburetor throat near the throttle valve. If these ports are blocked, the engine will run rough or stall just above idle. Reassomble the carburetor carefully. Take care not to overtighten the main jet 3. Install the carburetor in reverse order of its removal using new gaskets where appropriate. 7, Proceed to the Adjustment section (next page). ENGINE BLOCK SIDE: ‘TRANSITION MAIN AIR JET JET RANGE CHART JET CLEANER SET PIN O7JPZ-0010108 TRANSITION PORTS 3-67BE-TYPE GXV120/140/160/270/340/390 ADJUSTMENT Before making any adjustments: + Verify that the governor is properly adjusted before starting the engine. Refer to the appropriate shop manual. + Check that the throttle and choke controls operate properly before starting the engine. + Check that there are no fuel leaks before starting the engine. + Start the engine and allow it to warm up to normal operating temperature. Be sure that all engine components are within specifications and there are no air leaks into the intake path. + GXV120/140/160 Engines -_ 7 Idle Speed Adjustment 1. Start the engine and allow it to warm up to normal operating temperature, 2. With the engine idling, turn the throttle stop serew to obtain the standard idle speed. Refer to the appropriate | shop manual for the standard idle speed specification. THROTTLE STOP ‘SCREW Throttle stop screw: | + Tum clockwise rpm increases | + Tur counterclockwise .......TPm decreases uum Engine Speed Adjustment 1. Move the throttle lever to the FAST position 2, The throttle lever should just contact the choke arm (0~ 1 mm clearance) and the choke should be fully open. If adjustment is necessary, loosen the throttle cable holder and adjust the cable as required. 3, Move the throttle lever to the CHOKE position and verify that the choke arm is fully raised (choke fully closed). If necessary, adjust screw B (upper screw) so itjust contacts the choke arm when the lever is fully raised. 4, Start the engine and move the throttle lever to the FAST position. 5. Adjust screw A (lower screw) to obtain the specified engine speed. GOVERNOR If the engine speed is too slow and cannot be adjusted SPRING using screw A, reposition the governor spring in the — lower hole of the contro! lever. Control lever adjusting screw: + Turn clockwise + Turn counterclockwise rpm decreases rpm increase 3-68BE-TYPE GXV 120/140/160/270/340/390 + GXV240/270/340/390 Engines Idle Speed Adjustment 1. Start the engine and allow it to warm up to normal operating temperature. 2. With the engine idling, tum the throttle stop screw to obtain the standard idle speed. Refer to the appropriate shop manual for the standard idle speed specification. Throttle stop screw: + Turn clockwise. ‘pm increases + Tum counterclockwise. rpm decreases Maximum Engine Speed Adjustment THROTTLE, 1. Move the throttle to FAST. LEVER 2. Start the engine, let it warm up, and then check the engine speed with the throttle set to FAST. Use the adjusting screw on the control lever to set maximum speed. Control lever adjusting screw: + Tum clockwise.... rpm decreases + Tum counterclockwise... fpm increase ADJUSTING SCREW R2_-KQ