Honda Power Equipment GCV135GCV160 manual

1 OWNER’S MANUAL GCV135·GCV160 SERIAL NUMBER AND ENGINE TYP E Honda Motor Co., Ltd. 2001[...]

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 s erv ice if oper ate d acc ording to ins truc ti ons. R ea d and unde rst and the Owner’s Manual before operating the 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-oper at [...]

− 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 a llow f lame s or spa rk s wher e the en gine 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 SPARK PLUG STARTER GRIP RECOIL STARTE R FUEL TANK FUEL VALVE FUEL TANK CAP FLYWHEEL BRAKE LEVER (applicable typ es) AIR CLEANER CONTRO L LEVER[...]

6 PRE-OPERATION CHECK Engine oil l evel Be sure to ch eck the eng ine on a level surface with the eng ine stoppe d. Running the e ngine wi th insuff ici ent oil c an caus e ser ious engine da mage. Usi ng nondeter gent oil or 2 -str oke engi ne oil coul d shorte n the engin e’s service life. 1. UPPER LIMIT LOWER LIMIT OIL FILLER CAP/ DIPSTICK SAE[...]

7 Air cleaner Never run th e engin e wit hout the ai r cle aner . Rapi d engine we ar will result. 2. ELEMENT AIR CLEANER COVER Remove t he air cleaner cover and ch eck the cleaner fo r dirt o r obstruc tion of the ele ment (page 19 ).[...]

8 Fuel Gasoline is extremely f lammable an d is explosive un der certain condit ions. Refue l in a we ll -vent il ate d are a wit h the en gine 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 overf ill t he fuel t ank (the re s hould be no fuel i n the f iller neck). A[...]

9 GASOLINES CONT AINING ALCOH OL If you dec ide to use a ga sol ine con taini ng alc ohol (gas ohol), be sure it’ s octa ne ra ting is at l east a s high a s that r ecomme nded by Honda. Ther e are t wo types of ‘‘ga soho l’’: one contain ing et hano l, and the other conta ining metha nol. Do not use gas ohol that contai ns more than 10 %[...]

10 STARTING THE ENGINE FUEL VALVE CHOKE CONTRO L LEVER ON Do not use the choke if the e ngine is wa rm or the air te mpera ture is high. Turn the fuel v alv e to the ON positi on. Move t he con trol lever t o th e CHOKE p ositio n. 1. 2.[...]

11 Do not all ow the s tar ter grip to snap ba ck aga ins t the e ngine. Return it g ently to p revent dam age to th e starter. FLYWHEEL BRAKE LEVER R R E E L L E E A A S S E E D D Pull the s tarte r gri p lightl y until re si stanc e is f elt, t hen pull briskly. The en gine sw itch, w hich is lin ked wit h th e flywheel b rake lever, is turn ed o[...]

12 SLOW FAST CONTRO L LEVER When en gine warms u p, move t he cont rol lever to FAST or SLOW. 5.[...]

13 High al tit ude oper ati on Oper ati on of the engine at a n alti tude l ower t han the ca rbure tor is jet ted for may r esul t in re duced perfor manc e, ove rhea ting, a nd serious en gine d amage cau sed by an excessively lean air/fu el mixture. At high altitude, the standard carburetor air-fuel mix ture will be ex- ces siv ely r ic h. Perf [...]

14 STOPPING THE ENGINE SLOW CONTRO L LEVER FLYWHEEL BRAKE LEVER E E N N G G A A G G E E D D Move t he con trol lever t o th e SLOW posit ion. The en gine sw itch, w hich is lin ked wit h th e flywheel b rake lever, is turn ed off w hen t he flywh eel brake lever is mo ved to the ENGAGE D posit ion. Return the flyw heel brake lever t o th e ENGAGE D[...]

15 FUEL VALVE O O F F F F S S T T O O P P CONTRO L LEVER Turn the fuel v alv e to the OFF posi tion. Move t he con trol lever t o th e STOP p ositio n. The engin e switc h, whic h is li nked wi th the control l ev er, i s turn ed off when t he cont rol lever is moved to th e STOP posit ion . 3. 4. Without FL YWHEEL B RAKE LEV ER type:[...]

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) Every 2 years (Replace if necessary) (3) Check Change Check Clean Replace Check Check-Ad just Replace Clean Check-Ad just Clean Check-Ad just Clean Check Engine oil Air cleaner Flywheel brake pad (applicable type s) Spark pl ug Spark arre[...]

18 Oil chang e ENGINE OIL CAPA CITY: 1. OIL FILLER NECK 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 dispo se of use d motor oi l i n a ma nner that i s compa tibl e with the envi ronment. W e sugges t you take i t in a seale d containe r to your l ocal s er vic e sta tion f or re clama tion.[...]

19 Air cleaner service Never run th e engin e wit hout the ai r cle aner . Rapi d engine we ar will result. Never use gasoline or lo w flash poin t solvents for cleanin g the air cleaner element. A fire or explo sion cou ld result. 2. LOWER TA BS UPPER TABS ELEMENT AIR CLEANER CO VER A dirt y air cleaner will restrict air flow t o th e carbureto r.[...]

20 ELEMENT Tap t he elemen t light ly several times on a hard surface to remov e ex ces s dir t, or blow com pres se d air through the f ilte r from th e inside out. Never try to brush t he dirt o ff; brushing w ill force dirt into th e fibers. Replace th e element if i t is excessively dirty . Install th e element and air cleaner cover. 3. 4.[...]

21 Flywheel brake in spection 3. RECOIL STARTER 6 mm NUTS B B R R A A K K E E S S H H O O E E T T H H I I C C K K N N E E S S S S BRAKE SHOE FUEL TANK FUEL TUBE Check the b rake shoe thickness. If it is less than 3 mm (0.12 in), repl ace i t with new one . Remov e the rec oil sta rter by r emoving the thre e 6 mm nuts. Remov e the fue l tank tak in[...]

22 Spark plug service Rec ommended s park pl ug: 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 muffler . 4. 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 de posits . Remov e the s[...]

−− − − 23 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 spar k plug with a wire br ush if it is to be re used. 0.70 0.80 mm ( 0.028 0.031 in) Meas ure the pl ug gap wi th a f eel er ga uge. Corre ct as n[...]

− 24 The spar k plug must be s ecur ely t ighte ned. An impr operl y tighten ed spark p lug can become very ho t and may d amage th e 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- th reading . When in stalling a new spark plug , tight en 1/2 turn after th e spark plu[...]

25 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 to cool be fore proc eedi ng. The sp ark arrester must be serviced every 100 h ours to m aintain its efficien cy. 5. MUFFLER PROTECTOR SPARK ARRESTER SCREW 6m mB O L T S MUFFLER SCREW Remove the muffler protector by rem[...]

26 Be careful n ot to d amage th e spark arrester screen. SCREEN Use a brush to rem ove carbon dep osits from th e 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.[...]

27 TRANSPORTING/STORAGE When tr ans port ing the e ngine , turn t he fuel v alv e OF F and ke ep the eng ine level to p revent fuel sp illage. Fuel vapo r or spilled fuel may igni te. Gasoline is extremely flam mable and i s explosive un der certain condit ions. Do not smok e or all ow flame s or spar ks in the a rea . DRAIN BOLT FUEL VALVE O O N N[...]

28 Change the e ngine oil (pa ge 18 ). Pull the s tarte r rope s lowl y until r esi sta nce is felt. Th is cl ose s the val ves , and pr otects the m from dus t and cor rosi on. Coat a rea s that ma y r ust with a light f ilm of oil. 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.[...]

29 TROUBLESHOOTING If any f uel is spilled , make sure th e area is dry bef ore testing the spark plu g or startin g the en gine. Fu el vapor o r spilled f uel may ignit e. DRAIN BOLT FUEL VALVE O O F F F F O O N N When the engi ne will not sta rt: Is the fu el valve ON? Is ther e fuel i n the fuel tank ? Is gas oline r eac hing the car buretor ? T[...]

30 Remov e the s park plug cap. Clea n any di rt f rom ar ound the spark plu g base, t hen rem ove th e spark plu g. Insta ll the spa rk plug in the plug ca p. Groundi ng the side e le ctrode t o any engin e ground, pul l the recoil start er to see if sp arks jump across th e gap. If there is n o spark, rep lace the p lug. If O K, r eins tal l the [...]

31 SPECIFICATIONS Engine Countercloc kwise Transist or magneto Forced air 313 g/k Wh (230 g/ PSh) 4-stroke, overhead cam, 1 cylinder 0.55 (0.58 US qt , 0.48 Imp qt) Service classification SG or SH; SAE 10W-30 BPR6ES (NGK) GCV135 GJAF 351 mm (13.8 in) 331 mm (13.0 in) 353 mm (13.9 in) 9.5 kg (20.9 lbs) 135 cm (8.2 cu-in) 6 4x4 2m m( 2 . 5x1 . 7i n )[...]

32 Engine GCV160 Countercloc kwise Transist or magneto Forced air 313 g/k Wh (230 g/ PSh) 11.4 N·m (1.16 kgf-m)/ 2,500 rpm 4.1 kW (5.5 PS)/3,600 rpm 6 4x5 0m m( 2 . 5x2 . 0i n ) 160 cm (9.8 cu-in) 4-stroke, overhead cam, 1 cylinder 9.8 kg (21.6 lbs) 360 mm (14.2 in) 331 mm (13.0 in) 367 mm (14.4 in) GJAE 1.1 (0.29 US gal , 0.24 Imp gal) 0.55 (0.58[...]