Honda GD1250 Horizontal Shaft Engine Repair Manual

NAVIGATION TIPS GD1250 _(GD1250-1000001-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 ' -'cl ick to condense the P..~~~~~~-~.l:l.t.:..... ....... . . li:N$:~:g:¢.fi:9:N: MUFFLER/AIR CLEANER RECOIL STARTER/FAN C FLYWHEEL GE NERATOR GD1250_(GD125D-1000001-FORWARD) CDNTROLtiOX. GREEN BOX UNK$ Click here to go to this page in the manual

GD1250_(GD1250-1000001-FORWARD) GENERAL SAFETY Pay attention to safety information preced~d by: tMUOIID : indicates a strong possibility that serious injury Ot dealh could result if instructions are n()'t followed- CAUTION: Indicate a possibility that personal injury or equipment damage can result if instruction are not followed. • Whenever possible. stop the engine before working on it. • Engine exhaust contains pofsonous carbon monoxide gas. If the engine must be r!.-.ning to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area_ • Keep away from rotating, high voJtag9 wire or hot parts while the engine is running. • Diesel fuel is flammable and is explosive under certain conditions- Do not smoke or allow flames or sparks in the work area_ . I • Used motor o~l can cause skin cancer if repeatedly left in contact with the skin for prolonged periods- Although this' is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap 1 and water as soon as possible after handling used oil. . , '---------------------------------------·-·· -- · --------·--------'

GD1250_(GD1250-1000001-FORWARD) ·sERIAL NUMBER LOCATION The engine serial number, the type and the variation are stamped on the crankcase. Ref er to th ese ·V~Jhen o rderi 11g parts or making technical i nquries . ENG NE SERIAL NUMBER

GD1250_(GD1250-1000001-FORWARD) SERVICE RULES 1 . Use genuine Honda or Honda recommended parts and lubricants or their equi v alents. Parts tliat do not meet Honda's design specifications may damage the t .mit . 2. Use the special tools designed for the product. 3. Always install new gaskets, 0-ring, etc. when reassembling. 4. When torqui ng a series of bolts or nuts, begin with larger di ameter or inner bolts firs1. Tigh~en to the specijfied torque. diagonal~y unless a particular sequence is specified. 5. Clean parts in low flash point solvent upon disassembly . l u br icate all sliding surfaces bef ore reassembly. 6. After reassembly, check all parts for proper installation and operation. 7. Many screws used rn this unit are self-tapping. Cross threading or over-tightening th ese screws will strip the female threads and ruin the hole. 8. Use only metric tools when servicing this uni t. Metric bolts, nuts and screws are not interchangeable with nonmetric fasteners. The use of nonmetric tools and fastene rs could damage the unit. 9. Your work area, tools, and hands must be clean when you are work ing on fuel injector components . 10.When you see the symblos shown below, follow the instructions they represent; . -tliiii' Apply g<oase @ ~ l Uw special tool ""-)l ' Apply <»I NOTE • 0 x 0 (OJ: Indicates the type, ~ength, and number of flange bolt used.

GD1250_(GD1250-1000001-FORWARD) MAINTENANCE STANDARDS Unit mm(ii'l) f ____ __ - -_- ___ ~_ --- --------,ie;:n-- · ~~ -=~----~---==---- ·===-· --si-andar~(~- ----=-----=-~--= Servi~-e limi t -=:] [ Engine tdle rpm 925 ± 25 min- 1 (rpm) - I Max. rpm 2750.... :.2800 m in- ' (r pm ) -- -- Cylind er compresSion 2647 kPa (27 kg/ cm- 2 , 384 psi} ~ at 200 min 1 (rpm) Cylinde-r -he_a_(T - --- - \ial;:.;cleara~-c-e ------~-N- 1-EX ~ - -f-o:-, B ~ ~ 0.22 co . o_o_ 7 ___ o ___ o~d9-y -- --· ·-· -- - ------=--- --- -- Glow plug Valve seat width Valve guide LD. WarpaQe IN/ EX 1 .25 1 .55 (0 . 049--0. 061) IN 6.600-6.6 15 (0.2598 0'.2604-) EX I 6.600~6 .61 5 (0.2598-0. 2 604} Resistance (at normal temp) 0.8 ± 0.36.Q 2.0 { 0.08} 6. 66 (0_262) 6. 72 { 0.265 ) 0. 05 (0.002) Valve Stem O . D. IN . 6.575-6.590 (0.2859-0.2594) 6. 55 ( 0.258 ) EX 6.545-6.560 (0.2577-0.2583) 6. 52 { 0.257 ) Stem-t o-guide clear ance IN 1 0.010 -0.040 (0 . 0004-0.0016) 0. 11 (0.004) EX . 0.040-0 070 {0 . 0016- . 0.0028} 0 .20 {O.OOB) I Valve spring ' Free len gth -------- · ··- 1 3s~1(1.56)- . .. -.- : .. --. -- ---~7 : 1-( 1.4:6) f--=----- ----. ---------r·---- --- -- - -·-- ·-. -·· - ---- - -- -- - - --- ---· -· ---- ·-·· ---- ---- -- · ---·, Rockar a rm, 1 Rocker arm I. D. 16.0 12-16. 030 (0. 6304-0 .631 1) 16 . 04 (0.631 } rocker arm shaft • Rocker shaft O.D. 15. 976-15. 994 (0. 6290-0 .6297 } 15. 96 (0 .628} I ShafHo- roker arm cl ea r ance 0. ~ -~~--0·?!? ~?_: 0007-0 . 002_~) I O :SJ B (O.O.?~_ } __ ··-_j Camshaft , Axi al pl ay 0. 0 5-0.25 (0 . 002 -0 . 010) , 0.5 (0 . 02 ) • Camsha ft ru nout - ' 0.03 (0 .001 ) 1· Oil clearance 0. 050-0.098 (0 . 0020 · 0 .0040) 10. 15 (0.006} I Cam lobe height IN/ EX 39 .538-39 . 938 (1 .5566-1.5724 } 39.0 (1. 54}

GD1250_(GD1250-1000001-FORWARD) MAINTENANCE STANDARDS Unit mm(ii1) r ------~---- -............ ----. .... ---·· · ----· . ----····· -- .. --·- ·-----.. · ··- --· · ·-- ---· . -- .·- -- -·- . .. . !tam ---- - ----··- --·· Standard Se.-..,ice li~~t~_j \ P~ston . ~iston ring. ; p1ston p1n Connec ting rod ! Piston O. D. 81 93--:-81 . 95 (3 225-3 . 22.6) 81 90 (3.224) ' 1 P~ston p~n hole f. D. 23.002-23.008 (0 . 9056-0.9058 ) 23.03 (0 . 907) l . P1ston pm 0. D. · 22.994-23.000 ( 0.9053-0.9055) 22.98 (0 . 905} ·Piston-to-piston pin cle<>rance 0.002 -·· 0.014 (0 . 0001-0 . 0006} 0.04 ( 0.002) . 1 · Piston ri ng side Top 0.085-0.115 (0 . 0033 0. 0045} 0. 17 (0.007) · c learance Second 0.055-:-0.085 (0 . 0022-0.0033) 0. 13 (0.005} Oil 0.020-=-0.055 (0 . 0008-0 . 0022} 0. 09 (0.004) : Piston ri ng end gap Top 0.25 · 0.40 {0.0 1 0-0 . 016) 0.6 (0 . 02} Second 0.25 0.40 (0.0 1 0· 0.016) 0.6 (0 . 02) Oi l 0.20 0.40 (0.008-0 . 016) 0.6 ( 0.02) Piston pin-to-connecting . rod small end clearance 0.010 ·-0.034 {0 . 0004-0.0013.1 0. 06 (0.002) Small end I.D. 23.010-23.028 {O 905. 9-0.9066) 23 . 04 ( 0.907) Big end s~de c.lea.rance 1 0.15-0.30 (0.006-0 . 012) 0.40 {0.016) '----------- __ Bearin!? __ o ___ il clea-c_a __ nee __ -• 0.026-0.044 [0 . 0010~0.0017) 0. 07 {0.003) · .-- Axial oleanmce ----~ . To.1 -o: .. 0.35 ("o. Oo4=·o .m4}H -· ···-~_ 45-·{0.01·B- ) -·-- Crank3haft Marn bearing oil clearance · 0.026 0.044 (0 . 0010-0.0017) 0. 07 (0.003) ~- -·--------'--R_un_o_u_t ___________ ~----------·--· ~- - __ 0. 03 {0.001)

GD1250~(GD1250-1000001-FORWARD) MAINTENANCE STANDARDS Unit· mrn(in) Rot~~: clearance . I 0.02-0 . 14 ~~-~~~;-~0.0055 ) --0~-~~~~~ir' nl Outer rotor-to~body cleara'"'ce 0. 100-0.175 (0.0039-0.0069) 0.20 (0 . 008) · RotoHo-cover cl earance . 0.030 -0.080 (0.001 2-0.003 1) ' 0.15 (0 .006~ . t-C-yl-in_d_e_r_b-lo_c_k ___ +-W-arp_a_g_e-------~----.--------'-----------'--+-0-.-0-5-('--0-. 0-0-2) -- ··-· I Oil punp Cy l inder I.D. 82 . 000-82 077 (3.2283-3 . 2290) 82 .10 (3 . 232} Cylinder-to-piston clearance 0. 050-0.087 (0.0020-0.0034) ; 0.15 (0.006} Fuel camshafthole 1. 0: 29 . 000-29.021 (1.1417~1.1426) 29.05 {1 . 144) Block-to-fuel camshaft clearance 0.050---0.086 mm (0.0020-0.0034 in} 0.15 rrvn (0.001 in} Fuel cams haft, Fuel i::arri ashaftjoumaiO.D. 28 .935· 28 .950 (1.1392-1.1398). 28 . 90 { 1. 138} fuel cam cover OJver I.D. 29 . 000· -29.021 (1.1417-1.1426). 29.05 {1. 144) Shaft-to-hole clea rance 0. 050-0.086 (0.0020_:0.0034) I 0., 5 {0 .006} r---- ·- --- ·--- -- 1--- - -----· -- -- ---- -- ··-- ···- -- ·· ··- -- .. ·-- ---- -r--· , Fuel injection nozzle Opening Pressu re Primary 1 8,142~19 , 1 23 kPa (185-195 - .. 1 kg / cm 2 , 2,631-2 , 773 psi} I Seco~dary 20.104-21.084 kPa (205- 215 . · -- ·- I Fuel injection timing adjustment kg / cm2. , 2,91 5 -3 . 058 psi) Mark: 17° ·· -·-··· · -·· ·~· - --· ··-· -- ··-· · ··-- Starter motor , Brush length 17 .o (0.68) 11 5 !0.45) ~ ; Mica depth ; 0.5-0.8 (0.02.-0.03 ) 0.2 !0 . 01) Engine stop solenoid Res i stance Black-White 1.8--2.2.0. Black-Blue: 34-42Q Thermostat Starts opening 74-80cC j165-176oF) Fully open 90"C (194"F) Lift heiaht 8 mm (0.03 inl Thermoswitch Continuity temperature 103-107ac (217-225°F)

GD1250_{GD1250-1000001-FORWARD) TORQUE VALUES I I I I I Torque Item I Thead type x p1toh lmm} I N· m kg-m tt-lb · ---'- ·- -· ··--- ··----·--f-- ----· Camshaft holder bolts M8 X 1. 25 22 2.2. 15.9 Head cover rtuts M6 x 1.0 10 1 .0 7.2 Cylinder head bolts NOTE {1) M 12 X 1.25 45 4.5 32.5 I M8 X 1 .25 30 3.0 21.7 Timing oelt drive11 pulley bolt M8 x 1.25 38 I 3.8 27 .5 Timing belt adjust bolt M 10 X 1. 25 43 4.3 31.1 Crankshaft bearing cap bolt M11x1.5 68 6.8 .49.2 Connecting rod cap nuts MS X 1.25 32 I "3.2 23.1 Flywheel bolts M12x1.25 115 11 -5 83.2 Flywheel housing M12x1.25 55 5.5 39.8 Oil filt er holder M22 -x 1.5 55 5.5 39.8 Oil filter cartridge M20 X 1.5 28 2.8 20.2 Fuel pipe loint nuts M12x1.5 22.5 2..25 16.3 Fuel joint bolt M12x1 .25 22 .5 2.25 16.3 Injection nozzle nuts NOTE(2) M6 X 1.0 10 1.0 7.2 Grovernor shaft M10x1.25 43 4 .3 31.1 Glow plugs Ml 0 X 1 .25 17.5 1.75 12.7 Glow plug nuts M4 x 0.7 1.25 0.125 0.90 : injection pump nut and bolts M8 x 1.25 22 2.2 15.9 r Oil pressure swltch PT 1/ 8 20 2 .0 14 .5 Oil pressure switch screw-washer - ·· - 2 .25 0.225 1.672 Breathing water bolt M10x1.25 10 1.0 7.2 I Nozzle fuel joint nuts M8x 1.0 12 .5 0.125 9.0 ruel pump bolts M6 X 1.0 9 0.9 6.5 Thermostat switch Ml6x1.5 22.5 2.25 16.3 12mm special bolt (Crankshaft Puley) M12x1.25 115 11 . 5 83.2 Rack cover bolts M6 x 1.0 13 1.3 ; 9.4 Oil pan bolts and nuts M6 X 1.0 12 1 . 2 8.7 Cooling fan bo~ts M7 X 1.0 12 1.2 B.7 Timing cover bolt MS X 1.0 10 1 .0 7 .2 Standard torque values 5mm bolt, nut 5 0.5 3.6 6mm bolt, nut 10 1 .0 7.2 6mm SH flange bolt 9 0.9 6.5 6mm flange bolt, nut ·I 11 1 . 1 8.0 Smm bolt nut 21 2.1 15.2 8mm flange bolt, nut 22 2.2 15.9 1 Omm boJt, nut 35 3.5 25.3 1 Omm flange bolt, nut 40 4 .0 28.9 12mm bolt, nut 60 6.0 43 .4 / --- -- --- -- ·- -- ---- -- NOTE (1 ): Apply greHse to bolt threads. First tighten all bolts to 45 N· m (4.5 kg.:m, 32. 54 ft-lbL then tighten th em 90"and tighen them 90°once more. NOTE {2): Apply grease to the threads and tighten in two steps. lnitia~l: 5 N·m {0 .5 kg-m , :3.62 ft -lb), Final : 10 N·mm (1.0 kg-m, 7.23 ft -lb)

. ---~~ GD1250_(GD1250-1000001-FORWARD) I <=INDEX SP. E'CIAL TOOLS No. Tool mane Tool number Application 1---+------------+---------l -···• "' ,. .. . __ .. ____________ _..:.. ______ __,_ _ __ -1 1 !Jniversal holder 2 Valve guide driver, 6.6mm 3 Valve spring compressor 4 Va~ve seat cutter 45°9129 5 Valve seat cutter 45°(,1133 6 Valve seat cutter 31 °q) 2B 7 Valve seat cutter 31°r,b33 8 Valve seat cutter 60°st\37.5 9 Solid pilot bar, 6.60 mm fo Solid pilot bar, 6 . 62 mm 11 Solid pilot bar, 6. 65 mm 12 T- Wrench , # 505 13 T -Wrench adapte~. # 603- ·1 14 A~essory package, #246 15 Oil filter wrench 16 Oil seal driver 17 Valve guide reamer 18 Oil seal driver 19 Ring gear holder ®®@ @ ® 07725..0030000 07942 -85701 OQ 07757-0010000 07780- P01 030A 07780-POl 01 OB 07780-P01 040A 07780 -P01 01 OB 07780-P01 020A 07781 -P0201 OA 07781 -P02020A 07781-P02030A 07782 -P01 01 OA 07782-P . Ol 020A 07782- POl 030A 07912-61 10001 07947-7070300 07984-ZE2000A 07GAD-SD40200 07JPB-ZG60100 Timing belt driv en pulley removal/installation Valve g.uide removal /i nsta.l lation Va.lve cotter removal/installation Valve seat refacing EX . Valve seat rafacing IN. Valve seat refacing EX. Valve seat refacing JN. Valve seat refacing EX/ IN. Valve seat reconditioning Valve seat recondit ioning V. alva seat · reconditioning Valve seat recondi tioning Valve seat recondi tioning Valve seat reconditioning Oi1 filter cartridge removaVinstallatlon Camshaft oil seal installation Valve guide I. D. reaming Crankshaft oil seal installation Flywheel removal ___ c__ _____ ., ..... _______________ . @· @. Q}l @ 0 II' · , ~ r Q

Honda GD1250 Horizontal Shaft Engine Repair Manual

You're Reading a Preview

Recently Viewed