HONDA G65 G80 HORIZONTAL SHAFT Engine Repair Manual

NAVIGATION TIPS G65-80_(ALL) 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 G6~80_(ALL) GREEN BOX UNK$ Click here to go to this page in the manual ... '\ \ &•U!IP!ll

HONDA G65/G80 G65-BO_(ALL) . . . -~ I .. ·sPECIFICATIONS 1 . SPECIFICATIONS 2. PERFORMANCE CURVES 3. DIMENSIONS D•te of Issue: November ,1 975 ©HONDA MO!OR CO .• L TO. 1

~. . 1 )$PECIF~CA TIONS . . - . .. .. ~· ~. . . . G65-BO_(ALL) <=INDEX HONDA G65/G80 DESCRIPTION i ITEMS G 65 and GS 65 Model Honda G 65 gasoline engine Type Single, 4-evcle. side valve Piston total displacement 240 cc (14. tl cu.in.) Bore x stroke 72X59 mm (2 . 8x2. 3 in.) Compression ratio 6.1 : 1 Continuous rated output 5. 0 PS/3. GOO rpm Maximum output 6. 8 PS/4. 000 rpm Maxi mum torque , . 25 kg·m(9. 08 lbs·ft)/3. 000 rpm Fuel consumption 300 g/PS-H CombYstion chamber type L-tlead Cooring system Forced air cooling lgni 1ion system Flywheel magne1o Ignition 'liming 25" BTDC (Fixed) Spatk plug 8·6 HS • BR-6 HS (NGK) Carburetor Hori2.ontal. battertly valves Air cleaner Semi-dry type /Oil·bath type Lubrication system Splash type LL.Ibricant capacity 0. 82 R (1, 7 U.S.pt., 1. 4 lrnp.pt.) Starling $ystem By recoil starter I By rope starter I By starting motor (GS65) Stopping system Grounding of primary circuit Fuel Regular automobil~ gasoline Fuel tank: eapacity 6. 9 P (1 . S U.S . Qal. 1. 6 lmp.gal.) Dry weight G 65 0 1 : 28 kg(61 . 7 lbs) -tr Tha specificat~ans are subject to change wltnout notice. 2 G 80 Honda G SO .gasoline engine - 296 cc (18. 0 cu.in.) 80 X 59 mm (3 . 2 x 2· . 3 in.) 6. 3:1 6. 0 PS/3. 600 rpm 8. 0 PS/4. 000 fl)m 1. 6 kg·rn(1 1 . 6 lbs- ft)/2. 500 rpm 285 g/PS-H - - - - - - - - 1. 1 i (2. 3 U.S.pt .. 1. 9 lmp.pt.) - - - - G eo o. : 30 kg{f37 lbs) Date of I ssue : November, 1975 ©HONDA MOTOR CO., L TO.

~l:l :J:~ 0 .. zo c-. >Ci" g:; o" -1 .. oz :a~ ~ n9 ocr . .. - .. r~ o-j<Q 0~ • Ul (a) <G65> 1~~~--~------~-----r-----. 61 I I I ,,.....I I 51 I I / .fl I / I ,~ fl' ' 31 I :JH ' {PS .... 10.1 L Ld: I 7 01!a~=:d J; l :: ~II 1.1 B.O .._ (kg-111) (lbs-ft) 350 : ~- 300 I FUEL CONSUMPTION ~ATIO 250, . ' I I (g/PS·h ·L..---=2.o~:---::'::2_s~----==a"=_o------='3.~S --~.a.o·x ICV(RPU) <cso> 8 . ....... ==--'""'' 7 5 1.7 .12.3 L..LA/..!..~---~::.;;::::--t-------rllr 16 In.& f 'tjf/'. I ~......... ,:s 1o.a ~ 3201 l I r . .c IO. t ~L-----+----+-----t--:::::;;1-: 1.3 9." 3001- {kg-mXI!:»s-lr ) IWJtF F+ cON+.iPTION ~AT~ 1260 lg/PS·h) 2.0 2.5 3.0 3.; 4. 0X IOl (RPU) C)= ~0 \:2 ~~ . . . r\) '::_ , ~ . Ci -a c: rrl :a ::c < ., 1'1.0 (/) :::0 . ~ r ...... ' ·. ·: :. :: ·:z ·.··--· 0 ·, :', ..., . : .' ... c;') 0> 'T' 0> lc:. ")> r- .!:

G65-80_(ALL) 460 (18. 11) . . ;--····-···--·····-----.-----·-~ . . t ~ . . . ' • ,l'i!f~:....: ---;;~;.'c~m~ ·~---··-r \......,lll~~~l(...+~ 't-f7.- ' . J 370 (14. 57} I G 66 RD·RG I 180 (7. 09) M ~ ~H-~~~~--~~~ ...... ... oCr Dimtn$ions ere seme as troose of G $5 0 uni&S$ otherwise shown in other types. 4 HONDA G65/GBO [ G 65 HD Unit: mm(in .) I GS65 BD J Oat! of hsue: November, 1975 ·© HONDA MOTOR CO., L TO .

HONDA G65/G80 J G 80 D·DN·G I G65-BO_{ALL) 57" l- 1 I g~~~.J r------------- ~ Oimertsions ar• sam• as those ot G 80 D unless otherwise shown in other types. Date of luue: November, 1975 ~ HONDA MOTOR CO .• L TO. <=INDEX [Gao HD I I G 80 BD I 5

MOO a iYPE G65 D "' ON • G GSG5 BD G65 0 G65V G65RO ., RG G65 HD 6 P. T. C. Shaft lmtala1ioo Omens ions G65-BO_{ALL) HONDA G65/G80 P. T. 0. Shaft Rotation & Sizes & Omensions Diec:ta'l 22 mm dill. 3.600rprn. flat kill crartshaft Counterekdwisa 1. 00 it dia. 3. 600rpm. fla1 key crarlcshaft CounterclocXwls.a 0. 87 n. d~a . 3. 600 rpm. taper crar»:sl'laft Ccunterclockiwse Romark& Sundard type n mm dinensicn system Stardard type in i'lch drnnion system 22 mm dia. 1. 800 rpm. With 1 : 2 reduction unit flat kev crari:shaft C0111tercloclcwise , 00 in. clia' 600 rpm. Wrth 1 : 6 reduction lrit flat key aari:sha ft Ccurtercloc:twiSe Date of [uue: November. 1975 ©HONDA MOTOR CO .• L TO.

HONDA G65/G80 MOD a TYP£ P. T. O.Shaft lnstalatkn Dimensions G800 r--·~--~ r- FVll D£1DTH 11 =~=r !!I •• I • DN 1. :!! - ~1~~-; e , G 1 , • .!51 • BO X l , ;r, ~·::· >-f ULLDI:PTH [1 i' ~ ..... G80Q --- ----------ir ~ , 80 -~ --- : =-·-:...7~:~ ~&----!!!'~ 1U . "' . • ~· -IIUNF ~~· CEEP ~oJl '. I-ii - rr ' I I - ~~ ~ G80V •• ... c ··- ·-- - -·-· ::.-· . . -1 ... .(.,,, , .,, n :,-.~ • I' II -I-UN!' T DEEP f'~.A.a. et., .. :.- t- ~ ..• ~ IL r- '1¥·· ~ ' -t ' .i-'~: ~F- G80AD --i '- r- ~ r-r-\ ,_____. . ~ ...... -.aJ.••'T'W p~ 1 ..... _ .. r-tf~'- ..... ~ ...... ~ G60HD •.• l,. f-i__J . cp -~\ Date of Iuve: November, 1975 ©HONDA MOTOR CO .. L TO. G65-BO_(ALL) P. T. 0. Shaft Rotation & Remarks Sizes & Omensms Oirec1ion 25 mm dia. 3. 600 rpm . Standard type in mm flat key crartshaft C ounterclociwtle dmensian &y5tam 1. oo rulia. 3, 600rpm. Standard type in riCh flat key crar«shaft Count erclocl; wise d'mensioo system o. a 1 in. dia. 3. 600rpm. Equ~ent direct taper crankshaft Counterclocl::iws e couping 1ype. 25 mm dia. 1. 800 rpm. With 1 : 2 reduction ri flat key erar*sl'laft Counterclockwise 1. oo .,_ era. 600rpn. Wdh 1 : 6 reductoo unit flat key cr1,.shlft COI.I1t81'clod:W is & 7

G65-BO_(ALL) TI -<~:.~PERIODIC MAINTE- . -:~;NANCE -_:scHEDULE HONDA G65/G80 Before First 20 E"Very 50 operation nrs hts Inspection 0 Engine oil ·····················~·-·············· ...................... ·····~·-·········~· ...................... Renewal 0 Fuel strainer Cleaning Inspection 0 Air cleaner .. ......... ............. ........... ·~···· ...... ...................... ..................... ...... u ..... . . .. .... Clear'ling 0* Cletming 1 Spark plug Adjustment Ignition timing Inspection 1 Adjustment Inspection I · Tappet clearance Adjustment Cleaning inc. Combustion chamber Valve Iappin iii Fuel tube Replacement Renew. if necessary Speed reduction gear Inspection 0 .......................................... ....................... ..................... ...................... oil (where equipped} Renewal 0 Electrolyte level (starting motor equip· Inspection 0 ped modeJ) 1i! Clean more frequently_ when operated under dusty or sandy condition_ 8 Every 100 Every 300 Referenc& hrs hrs/1 :2 page rnontt1s .. , ................ ~--····-·········- P. 34 0 0 P.15 ••••••••••n••••••• .............. ...... p_, 6 0 P.31 P. 32 0 P.27 p_ 31 0 p_ 33 0 P. 32 P. 33 P. 1 B P.42 oooonooO•ooooonoo •••••••••••oono'Ooo 0 P.43 P. 46 Date of Issue: Novrmb~r. 197 5 @ HONOA MOTOR CO .• LTD.

HONDA G65 G80 HORIZONTAL SHAFT Engine Repair Manual

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