Honda Automobiles GC135E GC160E manual

1 OWNER’S MANUAL SERIAL NUMBER AND ENGINE T YPE GC135E • GC160E Honda Motor Co., Ltd. 2003 06/12/01 19:14:14 32Z2L600_001[...]

2 Indicates a stro ng po ssibility o f severe perso nal inj ury or de at h if inst ruc ti ons ar e not foll owe d. Indi ca te s a poss ibi li t y of pers onal i njur y or equi pment dama ge if ins tr uct ions a re not fol low ed. Indi ca te s tha t equi pment or pr oper ty da mage c an result if instru ctions are n ot f ollo wed. The Honda engi ne [...]

− 3 SAFETY INSTRUCTIONS To ensur e sa fe oper at ion Honda e ngine i s de si gne d to giv e s afe a nd depe ndabl e se rv ic e if oper at ed ac cor ding to i nst ruc t ions . R ea d a nd unde rs ta nd the Owner’s Manual before opera ting the engi ne. Fa il ur e t o do so could r e sul t i n per sona l inj ury or e quipme nt dama ge. Alw ay s ma[...]

− 4 Safety Instruction SAFETY INDICATION LOCATION If any fuel is spilled, clean it up comp letely and allow petroleum va pours t o diss ipa te be fore s ta rt ing the e ngine . To ensur e sa fe oper at ion Do not smok e or a ll ow fl ame s or s par k s whe r e the e ngi ne is refu eled or wh ere gaso line is sto red. Exha ust ga s cont a ins poi [...]

5 COMPONENT IDENTIFICATION OIL FILLER CAP MUFFLER AIR CLEANER FUEL TANK CAP FUEL TANK SPARK PLUG CHOKE ROD CONTR OL LEVER STARTE R GRIP RECOIL STARTE R 06/12/01 19:14:44 32Z2L600_005[...]

6 PRE-OPERATION CHECK Engine oi l l evel Us ing nonde te rge nt oi l or 2 -st rok e e ngine oil c ould s hort en t he eng ine’s service life. Be sure to check th e engin e on a level surf ace with th e engin e st opped. Runni ng the engi ne w it h ins uffi ci ent oil ca n ca use se ri ous engi ne dama ge. 1. Ambien t tempera ture SINGLE VISCOSITY[...]

7 Air clean er Never run the en gine wit hout the air c le ane r. R api d engine w ea r will result. 2. AIR CLEANER CO VER ELEMENT Remo ve the air cleaner co ver and ch eck th e cleaner for d irt or obstr ucti on of the ele ment (page 1 9 ). 06/12/01 19:14:57 32Z2L600_007[...]

8 Fuel Gasolin e is extremely flammab le and is explo sive und er certain condi ti ons. Re fuel i n a w el l -ve nti l at ed a r ea wi t h the en gine st oppe d. Do not smo ke or allow flames or sparks in the area where the engin e is refu eled or wh ere gaso line is sto red. Do not over fi ll t he fue l ta nk (t her e shoul d be no fuel a bove t h[...]

9 GASOLINE S CONTAINING A LCOHOL Ga sol ine s poil s v er y qui ck ly depe nding on f ac tor s s uch a s l ight ex posur e, tempe ra ture and time . In wo rst cases, gasoline can be con tam inat ed with in 1 mon th . Using contaminated gasoline ca n s eri ously damage the engine (ca rbur etor c logge d, va lv e stuc k). Suc h dama ge due to s poi l[...]

10 STARTING THE ENGINE CONTR OL LEVER FAST SLOW STOP SLOW STOP CHOKE ROD C C L L O O S S E E D D CLOSED Pull the c hoke r od to the C LO SED posi tion. Do not us e the chok e if the e ngine i s war m or the air te mper atur e is hi gh. Con trol lever with en gin e stop fu nctio n: Mo ve the co nt rol lever aw ay from t he SLOW p ositio n, a bout 1/[...]

11 Do not a l low t he s ta rt er gr ip t o sna p ba ck a gai ns t t he e ngi ne. Return it gen tly to prevent damag e to the starter. ON O O N N CONTR OL LEVER D D i i r r e e c c t t i i o o n n t t o o p p u u l l l l Con trol lever with o nly eng ine sto p fun ction : Mo ve the co nt rol lever t o th e ON po sitio n. Pull the s ta rte r gr ip l[...]

12 High a lt it ude ope ra ti on Ope ra ti on of the engi ne a t a n al ti tude l owe r t han t he c ar bure tor is je tt ed for may r es ult i n re duce d per forma nc e, ove rhe at ing, and seriou s engin e dam age cau sed by an excessively lean air/ fuel mixtu re. At h igh altitude, the standard carburetor air -fuel mixture will be ex- ce ss iv [...]

13 Oil alert system If th e engine sto ps an d will no t restart, check the engin e oil level (page ) before tr ouble shoot ing i n othe r a re as . (whe re e quippe d) 6 The O il Ale rt S ys te m is desi gne d to pre v ent e ngi ne dama ge ca use d by a n ins uff ic ie nt amount of oi l i n the c ra nkc as e. B ef ore th e oil level in t he cran k[...]

14 OPERATION CHOKE ROD OPEN CONTR OL LEVER SLOW FAST O O P P E E N N If the c hoke r od has been pu ll ed to the C LO SED pos iti on to s tar t the e ngine , pus h it to the O PEN pos iti on as s oon as the e ngine war ms up e nough to run s moothly . Po sition th e con tro l lever for th e desired eng ine sp eed. Con trol lever with en gin e stop [...]

15 STOPPING THE ENGINE CONTR OL LEVER CONTR OL LEVER STOP STOP OFF OFF Mo ve the co nt rol lever t o th e STOP po sitio n. Con trol lever with en gin e stop fu nctio n: Con trol lever with o nly eng ine sto p fun ction : Mo ve the co nt rol lever t o th e OFF po sitio n. 06/12/01 19:15:44 32Z2L600_015[...]

16 MAINTENANCE Shut off the e ngine be fore pe rfor ming any ma int ena nce . To preven t accidental start- up , disc onnect t he spa rk pl ug cap. Us e only ge nui ne Honda pa rt s or t hei r equi v al ent . The us e of replacem ent parts wh ich are n ot o f equ ivalent q uality m ay dama ge the e ngine . The engi ne shoul d be ser vi ce d by an a[...]

− − − 17 Mai nte nanc e Sc hedul e REGU LAR SERVICE PERI OD (4) Perform at every indicated month or operating hours interval, whi chever comes first . First month or 5h r s . Every season or 25 hrs. (1) Every season or 50 hrs. (2) Check that there is no c rack and abnormal wear-out in the belt, and replace if it is abnormal. For commercial us[...]

18 Oil chan ge ENGINE OIL CAP ACITY: 1. DRAIN PLUG OIL FILLER CAP Dra in the oi l whi le th e engi ne i s sti l l war m to ass ur e ra pi d and compl ete dr ai ning. Ple as e dis pos e of us ed mo tor oi l in a ma nner tha t i s c ompa tibl e with the e nvi ronme nt. W e s ugges t you t ak e i t in a s eal ed c ontai ner to your loc al se rv ic e s[...]

19 Air clean er service Never run the en gine wit hout the air c le ane r. R api d engine w ea r will result. 2. AIR CLEANER CO VER ELEMENT LATCH TABS TABS A d irty air cleaner w ill restrict air flo w t o th e carburet or. T o preven t ca rbur etor ma l func tion, s e rv ic e the ai r c le ane r re gul ar ly . Se rv ic e more f re quentl y when op[...]

20 ELEMENT Tap th e element lig ht ly several times o n a hard su rface to re move e xc es s d ir t, or b low c ompr es se d a ir thr ough th e f il ter from th e inside o ut. Never t ry to brush the d irt o ff; brush ing w ill force d irt int o t he fib ers. Replace the elem ent if i t is excessively dir ty. Inst all the elem ent and air cleaner c[...]

21 Spark plu g service Re comme nded s par k pl ug: Never use a sp ark plug of inco rrect heat ran ge. If the engi ne ha s be en r unnin g, the muffl er w i ll be v e ry ho t. B e ca re ful not to t ouch t he muffl er . 3. BPR6E S (NGK) To ensur e pr ope r engi ne ope ra ti on, the s par k pl ug must be prope rl y ga pped a nd fr ee of de posi ts. [...]

−− − − 22 0.70 0.80 mm (0.028 0.031 in) Vi sua ll y ins pe ct the spa rk p lug. Di sc ar d the spa rk pl ug if the re i s appa re nt wea r , or if t he ins ul ator i s c ra c ke d or chi pped . Cl ea n the s par k pl ug with a wir e br ush i f i t is to be r eus ed. 0.70 0.80 mm (0.028 0.031 in ) Mea sur e the pl ug ga p wit h a f ee l er g[...]

− 23 The spa rk pl ug must be s ec ure ly t ight e ned. An impr oper ly tigh tened sp ark plu g can beco me very ho t and may damag e the engi ne. Che ck tha t the s par k pl ug was her i s i n good condi tion a nd th read the spark plu g in by han d to p revent cross- th readin g. When in stalling a new spark plug, tig hten 1/2 turn after the sp[...]

24 Spa rk a rr es te r mai nte nanc e (opti onal pa rt ) If the e ngine h as be en runni ng, t he muffle r w il l be ve ry h ot. Al low it to c ool be fore proc ee ding. Th e spark arrester must b e serviced every 100 ho urs to m aintain its eff iciency. 4. MUFFLER PROTECTOR SPARK ARREST ER 6m mB O L T S MUFFLER SCREW (2) Che ck f or c ar bon depos[...]

25 Be carefu l not to dam age th e spark arrester screen . SCREEN Use a bru sh to rem ove carb on d epo sits from t he sp ark arrester screen. The spa r k ar re s ter mu st be fr e e of br ea ks a nd hole s . Re pl ac e, i f necessary. Inst all the spark arrester and t he mu ffler in the reverse order o f disassem bly. 3. 4. 06/12/01 19:16:43 32Z2L[...]

26 TRANSPORTING/STORAGE Ga sol ine i s ex tr em el y fla mma ble a nd is e xpl osi v e under c e rt ai n condi ti ons. Do not smok e or al low fl ame s or spa rk s in the a re a. When transp orting the engin e, keep the e ngin e le vel to prevent fu el spillage. Fu el vapo r or sp illed f uel may ig nite. DRAIN SCREW CARBURETOR Be for e s tori ng t[...]

27 Cha nge the engi ne oil (pa ge 18 ). Pull the s tar ter r ope sl owl y unti l re si s tanc e is f el t. Thi s cl os es the va lv es , a nd prote cts them f rom dus t and c orr osi on. Coa t ar ea s tha t ma y r ust wi th a l igh t fi lm of oi l. C ov er the e ngine and sto re it on a level surface in a dry, d ust free area. 5. 3. 4. 06/12/01 19:[...]

28 TROUBLESHOOTING If an y fuel is sp illed, m ake sure th e area is dry bef ore testin g th e spark plu g or starting the eng ine. Fuel vapor or spilled f uel may igni te . DRAIN SCREW CARBURETOR Whe n the engine wi ll not sta rt: Is the re f uel i n the fuel ta nk? Is ga sol ine r ea chi ng the car bure tor? To ch eck, loosen th e drain screw. 1.[...]

29 If the e ngi ne s til l doe s not sta rt , tak e the e ngi ne to an autho ri zed Honda dea le r. Is th e cont rol lever p osit ioned pro perly ( pag e 10, 11)? Is the s par k pl ug in good c onditi on? (pa ge 2 1) 3. 4. 5. 06/12/01 19:17:01 32Z2L600_029[...]

×× 30 SPECIFICATIONS Engine Dimensions Specificatio ns may vary accordin g t o th e types, and are subject to cha nge wi thout notic e. Engine type Displa cemen t B o r exS t r o k e Max. output Max. torque Fuel consumpti on Cooling system Ignition s ystem PTO shaf t rotation Fuel tank capaci ty Engine oil c apacity Engine oil Spark plug BPR6ES ([...]

×× 31 Engine Dimensions 11.5 kg (25.4 lbs) 331 mm (13.0 in) 369 mm (14.5 in) 337 mm (13.3 in) GCABE GC160E Engine type Displa cemen t B o r exS t r o k e Max. output Max. torque Fuel consumpti on Cooling system Ignition s ystem PTO shaf t rotation Fuel tank capaci ty Engine oil c apacity Engine oil Spark plug BPR6ES (NGK) Service classification S[...]

32 MEMO 06/12/01 19:17:23 32Z2L600_032[...]