Honda Power Equipment GC135E GC160E manual

1 OWNER’S MANUAL SERIAL NUMBER AND ENGINE TYP E GC135E • GC160E Honda Motor Co., Ltd. 2003 06/12/01 19:14:14 32Z2L600_001[...]

2 Indicates a strong possib ility of severe perso nal injur y or deat h if instr ucti ons are not fol lowe d. Indic ate s a possi bili ty of per sonal i njury or e quipment damage i f instr ucti ons are not fol lowe d. Indic ate s that e quipment or pr opert y damage c an result if in struction s are not f ollowed . The Honda engine i s des igned t[...]

− 3 SAFETY INSTRUCTIONS To ensure s afe oper ati on Honda engi ne is de si gned to giv e sa fe and dependa ble se rvi ce if oper ate d accor ding to ins truc ti ons. R ea d and unde rst and the Owner’s Manual before operating t he engine . F ail ure to do so could r es ult i n pers onal inj ury or equi pment dama ge. Alwa ys mak e a pre-ope ra [...]

− 4 Safety Instruction SAFETY INDICATION LOCATION If any fuel is spilled, clean i t up completely and allow petroleum vapour s to diss ipat e before s tar ting the e ngine. To ensure s afe oper ati on Do not smoke or all ow fla mes or s park s whe re t he engi ne is refueled or where g asoline is sto red. Exhaus t gas c onta ins poi sonous c arbo[...]

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

6 PRE-OPERATION CHECK Engine oil l evel Usi ng nondete rgent oil or 2 -str oke e ngine oi l coul d short en the engin e’s service life. Be sure to ch eck the eng ine on a level surface with the en gine stoppe d. Running t he engi ne wi th ins uffic ient oil c an ca use s eri ous engine da mage. 1. Ambient te mperature SINGLE VISCOSITY MULTI VISCO[...]

7 Air cleaner Never run th e engin e wit hout the ai r cle aner . Rapi d engine we ar will result. 2. AIR CLEANER COVER ELEMENT Remove t he air cleaner cover and check th e cleaner for dirt or obstruc tion of the ele ment (page 19 ). 06/12/01 19:14:57 32Z2L600_007[...]

8 Fuel Gasoline is extremely f lammable an d is explosive un der certain condit ions. Refue l i n a we ll -vent il ate d ar ea w it h the e ngine st opped. Do not smoke or allow f lames or sparks in the area where the engine is refueled or where g asoline is sto red. Do not over fill t he fuel t ank (t here s hould be no fuel a bove the upper li mi[...]

9 GASOLINES CONT AINING ALCOH OL Gas oline spoil s ve ry qui ckl y depe nding on fa ctors such a s li ght expos ure, temper ature and time . In worst cases, gaso line can be cont aminat ed with in 1 mont h. Using contaminated gasoline can seri ously damage the engine (car buretor c logged, v alv e stuck ). Such da mage due to spoi led f uel is dis [...]

10 STARTING THE ENGINE CONTRO L LEVER FAST SLOW STOP SLOW STOP CHOKE ROD C C L L O O S S E E D D CLOSED Pull the chok e rod to the CLOS ED position. Do not use the choke if the e ngine is wa rm or the air te mpera ture is high. Cont rol lever with eng ine stop fu nctio n: Move t he con trol lever aw ay from t he SLOW po sition , a bout 1/ 3 of the [...]

11 Do not al low the sta rte r gr ip to snap ba ck agai nst the e ngine . Return it gently to preven t damage to the starter. ON O O N N CONTRO L 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 Cont rol lever with on ly engine sto p funct ion: Move t he con trol lever t o th e ON posit ion. Pull the s tarte r gri p lightl y until [...]

12 High al tit ude oper ati on Oper ati on of the e ngine a t an a lti tude lowe r tha n the c arbur etor is jet ted for may re sult in re duced pe rformanc e, overhe ati ng, and serious en gine d amage cau sed by an excessively lean air/fu el mixture. At high altitude, the standard carburetor air -fuel mixture will be ex- ces siv ely r ic h. Perf [...]

13 Oil alert system If the en gine stop s and will no t restart, check the engin e oil level (page ) before tr oubles hooting i n other are as. (wher e equippe d) 6 The Oi l Al ert S yste m is desig ned to pre ve nt engi ne dama ge caus ed by a n insuf fic ient a mount of oil in the cr ankc ase . Be fore the o il level in th e crankcase can fall b [...]

14 OPERATION CHOKE ROD OPEN CONTRO L LEVER SLOW FAST O O P P E E N N If the choke r od has be en pul led to the CL OSED pos iti on to star t the engi ne, pus h it to the O PEN posi tion as soon as the engi ne warms up enough to run s moothly. Posit ion t he con trol lever fo r the d esired eng ine speed . Cont rol lever with eng ine stop fu nctio n[...]

15 STOPPING THE ENGINE CONTRO L LEVER CONTRO L LEVER STOP STOP OFF OFF Move t he con trol lever t o th e STOP p ositio n. Cont rol lever with eng ine stop fu nctio n: Cont rol lever with on ly engine sto p funct ion: Move t he con trol lever t o th e OFF posit ion. 06/12/01 19:15:44 32Z2L600_015[...]

16 MAINTENANCE Shut off the engi ne before pe rformi ng any maint enanc e. To p revent acciden tal start-up , disc onnect the s park pl ug cap. Use onl y genui ne Honda par ts or t heir e quiv ale nt. The us e of replacemen t parts which are not o f equ ivalent qu ality may damage t he engine . The engine s hould be ser vic ed by an author ize d Ho[...]

− − − 17 Maint enanc e Sche dule REGULAR SERVI CE PERIOD ( 4) Perform at every indicated month or operating hours interval, whichever 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 crac k and abnormal wear-out in the belt, and replace if it is abnormal. For commercial use, l[...]

18 Oil chang e ENGINE OIL CAPA CITY: 1. DRAIN PLUG OIL FILLER CAP Drai n the oil whi le the e ngine i s sti ll war m to ass ure ra pid and comple te drai ning. Plea se dispose of used mo tor oi l in a manner tha t is compatibl e with the e nvir onment. W e sugge st you t ake it i n a se ale d contai ner to your l ocal se rvi ce s tatio n for r ecl [...]

19 Air cleaner service Never run th e engin e wit hout the ai r cle aner . Rapi d engine we ar will result. 2. AIR CLEANER COVER ELEMENT LATCH TABS TABS A dirt y air cleaner will restrict air flow t o th e carbureto r. To p revent car buretor ma lf unction, s er vic e the air cle aner r egul arl y. Se rvi ce more fr equentl y when opera ting the en[...]

20 ELEMENT Tap t he elemen t light ly several times on a hard surface t o remov e e xce ss d irt, or b low com pres se d air thr ough the f ilte r from t he insid e out. Never t ry to b rush th e dirt o ff; brushin g will force dirt into the fib ers. Replace the eleme nt if it is excessively dirty . Install t he elemen t and air cleaner cover. Remo[...]

21 Spark plug service Rec ommended s park plug: Never use a spark p lug o f inco rrect heat rang e. If the e ngine ha s bee n runnin g, the muffl er w il l be ve ry hot . Be car eful not to touc h the muffl er. 3. BPR6ES ( NGK) To ensur e prope r engin e opera tion, t he spar k plug mus t be proper ly ga pped and f ree of depos its. Remov e the s p[...]

−− − − 22 0.70 0.80 mm (0.028 0.031 in) Vis uall y insp ect the spa rk pl ug. Disc ard the s park pl ug if ther e is appar ent wea r, or i f the ins ula tor is c rac ke d or chippe d. Cl ean the spa rk pl ug with a wi re br ush if it is to be re used. 0.70 0.80 mm ( 0.028 0.031 in) Meas ure the plu g gap wit h a fe el er ga uge. Corr e ct a[...]

− 23 The spar k plug must be s ecur ely t ighte ned. An impr operl y tighten ed spark p lug can become very h ot and may dam age the engine . Chec k that the s park pl ug washe r is i n good conditi on and thread t he spark plug in b y hand to p revent cross- thread ing. When installin g a new spark plug, tight en 1/2 t urn after the spark plug s[...]

24 Spar k arr est er mai ntena nce (opti onal par t) If the engi ne has be en runnin g, the muffle r wi ll be ve ry hot . Allow it t o cool be fore pr ocee ding. The sp ark arrester must be serviced every 100 h ours to m aintain its efficien cy. 4. MUFFLER PROTECTOR SPARK ARRESTER 6m mB O L T S MUFFLER SCREW (2) Chec k for car bon deposi ts ar ound[...]

25 Be careful n ot to d amage th e spark arrester screen. SCREEN Use a brush to remove carb on dep osits from the spark arrester screen. The spa rk ar re ster mu st be fr ee of br eak s and hole s. R epl ace , if necessary. Install th e spark arrester and the m uffler in the reverse order o f disassemb ly. 3. 4. 06/12/01 19:16:43 32Z2L600_025[...]

26 TRANSPORTING/STORAGE Gas oline is e xtr eme ly fla mmabl e and is e xplos iv e under c ert ain condit ions. Do not smok e or all ow flame s or spar ks in the a rea . When transpo rting the engine, keep the engine level to prevent fuel sp illage. Fuel vap or or sp illed fu el may ign ite. DRAIN SCREW CARBURETOR Bef ore s toring the unit for an ex[...]

27 Change the e ngine oil (pa ge 18 ). Pull the s tarte r rope s lowl y until r esi sta nce is fe lt. Thi s clos es the val ves , and pr otects them fr om dust and c orros ion. Coat a rea s that ma y r ust with a li ght fi lm of oi l. C ove r the e ngine and st ore it o n a level surface in a dry, du st free area. 5. 3. 4. 06/12/01 19:16:52 32Z2L60[...]

28 TROUBLESHOOTING If any f uel is spilled , make sure th e area is dry bef ore testing the spark plug o r starting the engin e. Fuel vapor or spilled fuel may ignit e. DRAIN SCREW CARBURETOR When the engi ne will not sta rt: Is ther e fuel i n the fuel tank ? Is gas oline r eac hing the car buretor ? To check, loo sen the drain screw . 1. 2. 06/12[...]

29 If the e ngine s till d oes not sta rt, ta ke the e ngine to a n authori zed Honda deal er. Is the co ntro l lever posit ioned prop erly (pag e 10, 11)? Is the spar k plug i n good conditi on? (page 21) 3. 4. 5. 06/12/01 19:17:01 32Z2L600_029[...]

×× 30 SPECIFICATIONS Engine Dimensions Specification s may vary according to the t ypes, and are sub ject to change without notic e. Engine type Displacem ent B o r exS t r o k e Max. output Max. torque Fuel consumption Cooling system Ignition sys tem PTO shaft r otation Fuel tank capacity Engine oil capac ity Engine oil Spark plug BPR6ES (NGK) S[...]

×× 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 Displacem ent B o r exS t r o k e Max. output Max. torque Fuel consumption Cooling system Ignition sys tem PTO shaft r otation Fuel tank capacity Engine oil capac ity Engine oil Spark plug BPR6ES (NGK) Service classification SF o[...]

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