Honda G400 Horizontal Shaft Engine Repair Manual

NAVIGATION TIPS G400_{G400-1000001-FORWARD) 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 bookmarks RECOIL STARTER/FAN C FLYWHEEL GENERATOR G400 _(G400-1 000001-FORWARD) GREEN BOX UNK$ Click here to go to this page in the manual ... '\ \ &•U!IP!ll

G400_(G400-1000001-FORWARD) <=INDEX General Specifications Model G400 Type 4 cycle, side valve, single cylinder Displacement 406 cc (24.8 cu in) Bora and stroke 86 x 70 mm (3.4 x 2.8 In) Maximum horsepower 7.4 kW (9.9 hp) at 3,600 rpm Maximum torque: Crankshaft PTO type 22.6 N m (2 30 kg-em, 16.6 tt-lb) Camshaft PTO type 44.1 N·m (450 kg-em, 32.5 ft-lb} 112 reduction type 1/6 reduction type Compression ratio G4DO: 6.5 to 1 G4D OK1: 6.8 to 1 Fuel consumption 370 g/kWh (0 . 61 lb/hp) Cooling system Forced-ai r cooling lgniHan system FI)M'heel magneto or CDI Ignition timing 20"BTDC Spark plug: NGK B-4H or BR-4HS Flywheel magneto type CDI1ype NGK BP-4HS or BPR-4HS-W Carburetor Hori zontal type with buttertly valva Air cleaner Single element (foam), dual element (foam & paper) or oil bath Governor Centrifugal Lubrication system Splash Engine oil capacity 1.21(1.3 us qt) Reduction transmission e>ll capac~y: 1 12 reduction 1/6 reduction 1/2 reduction transmission: Clutch engages Clutch locks Starting system Recoil or electric Stopping system Primary circuit ground Fuel tank capacity 6.0 t(1.6 US gal) Specifications are subject to change wi t hout notice.

G400_{G400-1000001-FORWARD) Engine Performance Information IG400 I I r. J ' /. v - :± -1- -: 1--- r-t--+-+-· -r-+-1-- ... -· ·- ·-;-T ' - I - -1-- 7 ; / I - -t-+-i!,...-+-' +-l--+---11--i--t--i 1--+-+-+-+- " L ' / ·-·--- -· +-+-+-+-t-++---'--++-t-i 'I 0. • :§ -+ ·-- -16+--t--h,,., .... __l--+-+-t---7- . _j_ - · 4-f-+~r~;~-1-~-1-~r+~-1-~1--1 f~-4-~-+-r+-+-~-+~-1-~-1-·~~-t- -"··+-+~r+~ ' : I : I ! +-+ -+-t-+-H-+-+-+ .. j - ~+-+-+-t--+-t---i i (rpm} 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 temperarurnof 60" F (t5.6~ C). Power curves are ota standard test engine equipped W11h a staodard muffler. air cleal"ler. and other power consuming devices Power output will decrease 3.5% for each 1,000 foot (305 meters) or elevation above sea level and 1% tor eacl110" (S.s• C) rise 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 develop not less that 95"/o of the "Maximum bhp." For practical operations, the bhp load and engine speed shou1d be within the limits defrned by tha ·recommended Maxrmum Operatng bhp" curve. Continuous operation should be wrthrn 85% of the Ma:xrmum blip.

G400_(G400-1000001-FORWARD) Charging and Lighting Coil Performance Information Charging Coli A. B. [G400] Breaker Point Type \VJ rpm 20 10 0 4 5 iAi When using wiring "A" and the rect[fler hav~ng the regulator. Lightlng Coil Breaker Point Type (Vi 40 ESw: Engine Switch SP: Spark Plug BP: Breaker-Points CO: Condenser IC: Ignition Coil CC: Charging Coil Di Diode Rectifier BP Type: Breaker Points Type CDJ Type: CDI Type IG: Ignition BAT: Battery ST: Starter Motor G: Ground [G400] CDI Type rpm When using the wiring "B" with the rectifier. CDI Type <=INDEX [G400] Breaker Point Type 0 O. !i 1.0 IAI When -using the w~rlng ''B" wnh the rectifier.

<G400 crankshaft PTO type> <G400 camshaft type> 1 ~6. 05 •• Qll 4- ·MS X 1 . 2~ G400_(G400-1000001-FORWARD) \..} - MS X I ZS I ~I

G400_(G400-1000001-FORWARD) <=INDEX <011-ba1h air cleaner> <Silent type air cleaner> <Semi-dry type air cleaner> <Dry type air cleaner> <S11ent type muffler> <MuHier protector> 14--~--- 410 - -- __..._., 111-t

G400 _(G400-1000001-FORWARD) PTO SHAFT DIMENSIONS Type G400 Straight shaft (inches) Taper shaft (inches) ~1--- : i z)l 1>\;A fO()T zl - ~ ! ~ ~! l;i ~ _;,; ~j~ ~ ~l~ r-~--~~~~~ ~ -- "'--

G400~(G400-1000001-FORWARD) GENERAL SAFETY Pay attention to these symbols and their meaning: t&?N:ma CAUTION: l?f&!;Jtttt@ Indicates a strong possibility of severe personul injury or loss of lif• if instructior'IS are not followed. lndicatfi 11 possibility of penonal injury or equipment damage if instructions a.-. not followed. If the engine must be running to do some work, make sure the wea is well ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon moooxide gas. ($?1J;Itll:l:t Gasoline is eKtreme•v flammable and is exp&osive under certain conditions. Do not smoke or allow flames or sparks in. your worklr'IB •rn. CAtJTJQN: Keep away from rotating or h~ parts and high tension wires when the engin& is running.

G400_(G400-1000001-FORWARD) Serial Number Location The serial number is stamped on the crankcase, as shown. Refer to this. number when ordering parts or making technical inquiries.

Honda G400 Horizontal Shaft Engine Repair Manual

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