Honda GXV390 Engine Complete Workshop Service Repair Manual

I I I GXV390A1_(GEABA·1000001.FORWARD) Specifications Dimensions And Weights Model Length WI~ Helghl Dry Weight Operating Weight Engine Model Type Displacement Bore and Stroke Net Horsepower*" (In accordance with SAE Jl349) Max Net Torque" (In accordance with SAE J1349) Compression Ratio Fuel Consumption Cooling System Ignition System Ignition Timing Spark Plug · Carburetor Air Cleaner Govemor Lubrlcatlon System OM Capacity Starting system Stopping System Fuel Tank Capacity Recommended Fuel PTO Sheft Rota/Ion , locluclng 011 filter change. Specifications are aub)ect to change without notlo8. GXV380Kl 433 mm (17.0 In) 382 mm (15.0 In) 406 mm (15.9 In) 33.3 kg (73.3 Ib) 34.6 kg (76.3 Ib) GXV380Kl 4-Stroke, overhead valve, single cylinder 389 co (23.7 ou In) 6B X 64 mm (3.46 x 2. 52 In) 7.6 kW (10.2 hp)@3,600 rpm 24.2 N'm (17.8IbMt) @2,500 rpm 7.7: 1 2.5 ilhr @ 3,000 rpm Forced air Tranalstorlzed magneto 20"±2" BlOC BPR5ES Horlzonta/ butt8rl1y valve Dual element CentrKugal mechanical govemor Preesure and splash 1.1 f ,'1.4 f (1.2 US qt, '1.5 US ql) Recoil and electric Prlma'Y ctrcutt ground 2.1 £'(2.2 US qt) Regular unleaded with minimum 86 pump octane Counterclockwise (from PTO aide) "The power rating of the engine Indicated In this document Is the net power output tested on a production engine for the engine model and measured in accordance with SAE J1349 at 3,600 rpm (Net Power) anc at 2,500 rpm (Max. Net Torque). Mass production engines may vary from this value. Actual power output for the engine Installed In the final machine will vary depending on numerous factors, including the operating speed of the engine In application, environmental conditions, maintenance , and other variables .

Power Curves GXV390A1 _IGEABA-1000001-FORWARD) NOT TOROU' ""1~~8 :[ I I "~ :: (-<W: NET POW --- GXV390K1 V I" , 10 / , 9 , / , 5 / I' J~!~RANGE , , , , .!OI)O - >l V V -, .~= .. \

DIMENSIONAL DRAWINGS EI_ic starter GXV390A 1_ (GEABA-l00000l-FORWARD) 25~~~ (0_98) Exhaust deflector Unit: mm (In) 111M ... QI • ... ~

GXV390A 1_ (GEABA-1000001-FORWARD) WIRING DIAGRAMS .------"T-+.-!!8--t::J-__+ TO ENGINE lO~rnoH COil BASIC CIlClIIT 12V STARTER CIRCUIT B BLACK Y YELLOW G GREEN R REO W WHITE TO 5T_ SWITCH STOP SWITCH L-.:: 8 _-C::::J-__ TO OIL AU"RT CIRCIJIT IlATmlY TO LOAD G LAMP COIL SYSTE" .. G G COL ~A, CHARGING SYSTEM TO ENGINE STOP8W1TCH OIL ALERT CIRClHT TO LOAD DlOlIE COIl TO LOAD 1A CtiARClloo, GVanM

GXV390A 1_(GEABA-l00000l-FORWARD) GENERAL SAFETY p~ attention to these symbols and their meaning: Id-imilda : Indicates a strong pOS$ibiHty of severe personal injury or death if instructions are not followed. CAUTION : Indicates a possibility of personal injury or equipment damage ~f instructions are not frnlowed . r£ilildlHd • Stop the engine and remove the spark plug cap before servicing. • If the motor must be running to do some work, make sure the area is well ventilated . Never run the engine in a closed area. • The exhaust contains poisonous carbon monoxide gas. • Gasoline is extremely flammable and ls exp\os i ve under certain conditions. Do nat smoke Or allow flames or sparks in your working area. CAUTION: Keep away from rotating or hot parts and spark plug wires when the engine is running.

GXV390A l_IGEABA-l00000l-FORWARD) SERIAL NUMBER LOCATION The engine serial number , the type and the variation are stamped on the crankcas.e. Refer to these when ordering parts or making technical inquiries . :~~- _/ .-""-_c--~ TYPE ~'j~~ ... " I I I" I . .. VARIATION

GXV390A l_IGEABA-l00000l-FORWARD) SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants Or their equivalents. Parts that do not meet Handa's design specifications may damage the unit. 2. Use the speci al tools designed for the product . 3. Install new gaskets. O-rings. etc . when reassembling. 4. When torquing bolts or nuts, begin with larger-diameter or inner bolt f1fst and tighten to the specified torque diagonally, unless a particular sequence is specified. 5. Clean parts in cleaning solvent upon disassembly. lubricate any sliding surface before reassembly. 6. After reassembly, check all parts for proper illstallation and operation. 7. Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the female threads and ruin the hole. B. Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with fKlnmetric fasteners. The use of incorrect tools and fasteners may damage the unit. 9. Follow too unstructions represented by these symbols when they are used: I p. Indicates the reference p8ge Ox 0 (0) : Indicates the size and quaflti ty of flange bolts used. ~ : Apply oil. ... fiiiiiffi : Apply grease . Cs TOOL) : Use special tool.

GXV390A 1_(GEABA-l00000l-FORWARD) MAINTENANCE STANDARDS Unit: mm tin) Part Item Standard Service limit Valve Valve clearance IN O. 10:tO,02 {0.004:tO.OO1' - EX O. 15:t0.02 (0.006%0.001) - Stem 00 IN 6.590 (0.25941 6.425 (0.253(» EX 6.550 (0.25791 6.375 (0.25101 Guide 10 INJEX 6.600 (0.2598) 6.662 (0.2623) Guide-to-stam clearance IN 0.010-0.037 (0.0004--0.0015) 0.10 (0.0041 EX 0.050--0.077 (0.00~.O030) 0.12 (0.0051 Seat width 1.1 (0.O43) 2.0 (0.08) Spring free length 39.011.54) 37.511 .48)

GXV390A 1_(GEABA-l00000l-FORWARD) MAINTENANCE STANDARDS Unit: mm lin) Part Item Standard Service limit Spar~ plug Gap O.7--{).8 10.02!Hl. 031) Ignition coil Resistance Primary coli 0.7-0.90 Seoondarycoil 8.3-7.7 kn - Air gap O.4±O.2 {O.016±O.O08) - Starter Brush langth 1210.471 8.510.34) motor Commutator mica depth 1.0 (0.04) 0.2 (0.01) Charging coil Reisitance 3_0-4.00 - all pump Pump body ID 29.00 (1_142) 29.2 (1.150) Inner rator.-to-outar rotor clearance 0.18 (0.0011 0.30 (0.0121 Outer rotor-tc-body claai"8nce 0.15-0.20 (O.O()6--{).OOB) 0.26 (0.0101 Outer rotor height 7AB (0.2941 7.45 (0.2931 Pump body depth 7_50 10.2951 7.66 {O.29B} Rotor-to-body side clearance 0.02--{).09 (0.008-0.0035 0_1110.00431 - - - ---_._- -_.

GXV390A 1_(GEABA·l00000l·FORWARD) MAINTENANCE STANDARDS Unit: mm lin) Part Item Standard Servioo limit Cylinder Sleeve 10 88.000 (3.4646) 88.17 (3.471) Piston Skirt 00 87.985 (3.4540) 87 .85 (3.459) Piston·to-cytinder clearance 0.015-0.052 (0.0000-0.0020) 0.12 (0.0051 Piston pin bore 10 20.002 (0.7876) 20.042 (0.78911 Piston pin 00 20.000 (0.7874) 19.95 (0.785) Piston-ta-piston pin ei<larance 0.002-0.014 (0.0001-0.0006) O.OB (0.0031 Piston ring Ring sid& Clearance 0.030-0.060 (0.0012-0.0024) 0.16 (0.0061 Ring end gap 0.2-0.4 (O.0~.016) 1.0 (0.04)

Honda GXV390 Engine Complete Workshop Service Repair Manual

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