Replacing Honda Gx200 Fuel Tank: Step-By-Step Guide

Replacing the fuel tank on a Honda GX200 engine is a straightforward process that can be completed in a few steps. The first step is to remove the air filter. Next, loosen the screw holding the gas tank in place on the backside of the engine, followed by the two bolts on the front side. The fuel line can then be disconnected, and the nozzle replaced if needed. The fuel line should be clamped to position for reattachment before connecting it to the new tank. Finally, the new tank can be attached, and the bolts and air filter replaced.

Remove the air filter

To remove the air filter from a Honda GX200 engine, follow these steps:

Firstly, make sure your engine is cool. Never service a hot engine. Then, unplug the wire and boot from the spark plug. Turn the fuel valve to the off position.

Now, you can begin to remove the old air filter. Unscrew the wing nut at the top of the air filter cover. Pull the air filter cover off. Next, unscrew the wing nut holding the air filter in place. If you have never replaced an air filter before, take a photo of the old air filter before removing it, so you can refer to it when installing the new one. Finally, slide the old air filter off the mounting bolt.

Once the air filter has been removed, you can install the new one. Slide the new air filter onto the mounting bolt, referring to the photo you took to ensure it is in the correct orientation. Screw the wing nut onto the top of the new air filter to secure it in place. Put the air filter cover back on, and screw the remaining wing nut to the top of the cover.

Finally, prepare your machine for use. Turn the fuel valve back on, and plug the spark plug wire and boot back onto the spark plug.

Loosen the screw holding the gas tank

To loosen the screw holding the gas tank, you will need to identify whether the screw has a left-handed or right-handed thread. Gas line fittings often have reverse, left-handed threads, which you would need to turn clockwise to loosen.

If the screw is not loosening, try tightening it slightly first. This may be enough to unstick it, or you may find that you were turning it the wrong way. If the screw is very tight, try using an impact driver or an electric screwdriver.

Before attempting to loosen the screw, clean the area around it with a sharp implement such as a screwdriver or chisel. Then, apply a penetrating oil like PB Blaster or Liquid Wrench to the screw. Leave the oil to sit for at least half an hour, and try again. You can also try heating the screw with a hairdryer before applying the penetrating oil. If the screw still won't budge, try tapping it gently with a hammer or drilling it out.

Loosen and remove the two bolts

To loosen and remove the two bolts on the front side of the engine, you will need to use the appropriate-sized wrench or socket. Before starting, ensure you have a safe and well-lit workspace and that the engine is switched off and cooled down.

First, locate the two bolts on the front side of the engine. These bolts are what secure the fuel tank in place, so you will need to loosen them before you can remove the tank. Place your wrench or socket on the first bolt and turn it counter-clockwise to loosen it. You may need to apply some force, but be careful not to strip the threads or round off the bolt head. Once the bolt is loose, continue turning it counter-clockwise until it is removed. Repeat this process for the second bolt.

With both bolts removed, the fuel tank should now be free to be removed from the engine. Be careful when lifting out the fuel tank, as there may still be some residual fuel inside. Place the fuel tank aside in a safe place, away from any open flames or sparks.

Now that the old fuel tank has been removed, you can prepare to install the new one. Ensure that you have a compatible replacement fuel tank for your Honda GX200 engine. Carefully lift the new fuel tank into place, positioning it exactly where the old tank was. With the new tank in place, you can now secure it by re-inserting the two bolts you previously removed. Tighten these bolts by turning them clockwise with your wrench or socket. Ensure that the bolts are tight and secure, but be careful not to over-tighten them, as this could strip the threads or damage the fuel tank.

With the new fuel tank securely bolted in place, you can now proceed with the rest of the fuel tank replacement procedure, including disconnecting and reconnecting the fuel lines and reattaching any other necessary components.

Disconnect the fuel line

Disconnecting the fuel line of your Honda GX200 engine is a straightforward process, but it requires careful attention to detail. Here is a step-by-step guide to help you through the process:

Step 1: Gather Your Tools

Before you begin, ensure you have the necessary tools for the job. You will need needle-nose pliers for this task, as they provide precision and help you avoid any accidental damage to the fuel line or surrounding components.

Step 2: Locate the Fuel Line

The fuel line is connected to the carburetor of your Honda GX200 engine. It is usually easy to spot, but if you're unsure, refer to the engine's diagram or seek assistance from a qualified technician.

Step 3: Clamp the Fuel Line

Using the needle-nose pliers, carefully clamp the fuel line near the connection point to the carburetor. This step is crucial to prevent any accidental spills or leaks when you disconnect the line.

Step 4: Disconnect the Fuel Line

With the fuel line securely clamped, you can now proceed to disconnect it from the carburetor. Use the needle-nose pliers to gently pull and detach the fuel line from its connection. Be cautious and apply only the necessary force to avoid damage.

Step 5: Secure the Fuel Line

Once the fuel line is disconnected, you must secure it to prevent any accidental reconnection or interference with other engine components. You can use a zip tie or a small piece of wire to carefully fasten the fuel line away from the carburetor and any moving parts.

Step 6: Check for Leaks

Before proceeding with the rest of the replacement process, it is essential to ensure that there are no fuel leaks from the disconnected line. Visually inspect the area, and if you notice any signs of leakage, address them immediately. Absorb any spilled fuel with a clean cloth, and ensure proper ventilation during the entire process.

Remember to exercise caution when working with fuel lines, as they involve flammable substances. Always work in a well-ventilated area and avoid any open flames or hot surfaces. By following these steps, you can safely and effectively disconnect the fuel line of your Honda GX200 engine during the replacement process.

Reattach the fuel line and attach the new tank

Now that you have your new fuel tank for your Honda GX200, it is time to reattach the fuel line and attach the new tank.

First, ensure that the fuel line is clamped into position for reattachment. This will make it easier to connect the fuel line to the new tank. Once the fuel line is clamped into place, you can proceed to connect it to the new tank.

Take your time with this step to ensure that the fuel line is securely connected to the new tank before fastening it into place. With the fuel line connected, you can now attach the new tank to your Honda GX200. Line up the mounting holes and bolts, and carefully attach the new tank, ensuring it is securely in place.

With the new tank attached, you can now reattach any remaining components that were removed during the fuel tank replacement process, such as the air filter and the gas tank cover. Ensure that all components are securely fastened and that there are no leaks before starting your engine.

It is important to note that working on fuel systems can be dangerous, and it is recommended that you have sufficient knowledge and experience before attempting any repairs or replacements. If you are unsure about any part of the process, it is best to consult a qualified technician or mechanic.

Frequently asked questions