Honda G300 Horizontal Shaft Engine Repair Manual

----- G300_(G300-1000001-FORWARD) <=INDEX A FEW WORDS ABOUT SAFETY SERVICE INFORMATION The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the engine or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the engine. If you need to replace a part, use genuine Honda parts with the correct part number, or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer's Safety Proper service and maintenance are essential to the customer's safety and the reliability of the engine. Any error or oversight while servicing an engine can result in faulty operation, damage to the engine, or injury to others. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (eg, Hot parts- wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Important Safety Precautions A WARNING Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. A WARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. • Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: 0 Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. 0 Protect your eyes by using proper safety glasses, goggles, or face shields any time you hammer, drill, grind, or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. 0 Use other protective wear when necessary, for example, gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. • Make sure the engine is off before you begin any servicing procedures, unless the instructions tell you to do otherwise. This will help eliminate several potential hazards: 0 Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. 0 Burns from hot parts. Let the engine and exhaust system cool before working in those areas. 0 Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the way. • Gasoline vapors are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline. 0 Use only a nonflammable solvent, not gasoline, to clean parts. 0 Never drain or store gasoline in an open container. 0 Keep all cigarettes, sparks, and flames away from all fuel-related parts.

open more bookmarks ' -' click to condense the PERFORMANCE ! ···· ··0 DIMENSIONAL D L ..... D WIRING DIAGRAM 1±1·· ·· 0 SERVICE INFORMA 1±1···· 0 TROUBLESHOOTING MAINTENANCE DISASSEMBLY & SERVI DISASSEMBLY CH P.I~~~~~.~.I:J.L.:..... ....... . . !i :N:§:P.:g:¢.fi : 9.:Ni MUFFLER/AIR CLEANER RECOIL STARTER/FAN C FLYWHEEL GENERATOR G300_(G300-1000001-FORWARD) ODNTROL !iOX GREEN BOX UNK$ Click here to go to this page in the manual

---~ G300_(G300-1000001-FORWARD) <=INDEX General Specifications Medel G3DD Type 4 cyde, side valve, single cylinder Displacement 272 co (16.6 cu in) Bore and stroke 76 x 60 mm (3.0 x 2.4 in) Maximum horsepower 5.2 kW (7.0 hp) a13,600 rpm Maximum torque: Crankshaft PTO type 14.7 N·m (150 kg-em, 10.8 tt-lb) Camshaft PTO type 29.4 N·m (300 kg-em, 21.7 ft-lb) 1/2 reduction type 29.4 N·m (300 kg-em, 21.7 fl-lb) 1 /6 reduction type 88.3 N·m (900 kg-<:m, 65.1 ft-lb) Compression ratio 6.5 to 1 Fuel consumption 390 glkWh (0. 64 lb/hp) Cooling system Forced-air cooling lgnttion system Flywheel magneto or CD~ lgn~lon tlming 20· BTDC Spark plug: Flywheel magneto 1ype NGK 8-4H or BR-4HS COl type NGK BP-4HS or BPR- 4HS-10 Carburetor Hor i zontal type with butterfly valve Air cleaner Single element (foam), dual element (1oam & pap€r} or oil bath Governor Centrifugal Lubrication system Splash Engine oil capac~y 1.21(1.3 us qt) Reduction transmission oil capacity: 112 reduction 0.30 1(0.32 us qt) 1/6 redu ction 0.151(0. j6 us qt) 112 reduction transmission : Clutch engages 1.B OO rpm Clutch locks 3,030 rpm Starting system Recoil or electric stopping system P rimary clrc u~ ground Fuel tank capacity 6.0 1(1 .6 US gal} Soecif1cations are subiect to chanae without notice.

G300_(G300-1000001-FORWARD) I <=INDEX Engine Performance Information I G300I j 1'-t---1--1-+--1--+ +--+-+-++ 1-+-HI-+-1-t-+-r.-<t-+--H--+-t·· r- ~~r-r~~~~+--t l-+-~ 1-~~ ~ ~.- ~-+-~+-t-~~- r- . f-- · ··i --'- ; +-+-++-+~-+-.,- 1 1 -+; -+-f- . +- +· - ,_·_ . -f- Performance Curves Expfanation A. Maximum bhp Curve B. Recommended Maximum Operating bhp Curve C. Maximum Torque Curve Test were conducted according to SAE standard No . J607a. Power curves are for standard sea level atmospheric pressure of 29.92 in. {760 mm) Hg at a temperature of 60" F (15.6~ C). Power curves are of a standard test engine equipped wnh a stMdard muffler. a ir deal"ler. and other power consuming devices Power output will decrease 3.5% for each 1,000 foot (305 meters) or elevabon above sea level and 1% for each 10" (5.6° C) ri se above the standard temperature of 60° F (15.6" C). As shipped, production engines will develop not less that 90 ' %, of the "Maximum bhp.' After being run-In, they will devetop not less that 95" /., of lhe "M~imum bhp." For practical operations, the bhp load and engine speed shou,d be within lhe limits defined by the ·recommended Max1mum Operating bhp" curve. Continuous operation sho uld be w1th1n 85% of me Ma:x1mum bhp .

G300_{G300-1000001-FORWARD) Charging and Lighting Coil Performance Information Charging Con A. B. [G300] COl Type rpm 0 0 5 I 0 ·AI When usi ng the wiring "B" wi th the ree1ifier. Lighting Coli Break er Point Type ESw: Engine Swi tch SP: Spark Plug BP: Breake r. Polnts CO: CDndenser IC: Ignit ion Coil CC: Charging Coil Dl Di ode RectHier BP Type : Breaker P oi n ts Type CDJ Type: COl Type I G: I gnition BAT: Battery ST: Starter Motor G: Gro und [G300 I Breaker Point Type 0 0.5 1.0 lA) When using th e wi ring ·a~ w~h the redifier. COl Type

G300_(G300-1000001-FORWARD) Engine Dimensions <G300 crankshaft PTO type> ~----· __ ____!!..Q. __ .. .. .. ...... - .. __ J..!. O ::c o 02S _ _ _ <G300 camshaft PTO type> \ '• 6- MSXU?) i----·-------.. ·-·····---- ... ..i!.Q . _ _______ ~·· ··· -' . I , ...., ~ i ~~~;;;;.;fQ_L_ __ ...tl ------ <=INDEX 365

G300_(G300-1000001-FORWARD) <G300 1/2 reduction type> 4 10 <G300 1/6 reduction type> A

- G300_(G300-1000001-FORWARD) <=INDEX <011-bath air cleaner> <Semi-dry type air cleaner> <Silent type muffler> ~----.....-. 410 _ ___ .,.. (420) <Silent type air cleaner> <Cry type air cleaner> ,.__ __ ....,.,.., ... 4 2n ----+t (430) <Muffler protector> 14- -- -- 410 - --- .... ,

G300_(G300-1000001-FORWARD) PTO SHAFT DIMENSIONS Type Straight shaft (Inches) Taper shaft (Inches) straight shaft with sorew ~nches) I Iii - - ...... . - ~ ~ - ~ G300 ! ., tli .

G300~(G300-1 000001-FORWARD) l <=INDEX GENERAL SAFETY Pay attention to these symbols and their meaning: CAUTION: Indicates~ strong possibility of severe personal injury or loss of life •f instructior'IS are not followed. lndicatw u possibility of pusonal iniurv or equipment damage if instructions aNt not followed. l}tH!tiit@ If the engine must be running to do some work, make sure the area is well ventilated. Nenr run the engine in u closed area. The exhaust contains poisonous carbon monoxiM gas. t4W3M!Wd Gasoline is eKtremety fiiiJilmable and is exp&osive under certain conditions. Do not smok& or allow flames or sparks in your worklfl9 1rn. CAUTlQN: Keep away from rotating or b01 parts end high tension wires when the engin& is running.

Honda G300 Horizontal Shaft Engine Repair Manual

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