Honda FG400, Owner'S Manual

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Page 2: ...any time This owner s manual is considered a permanent part of the tiller and should remain with the tiller if resold The information and specifications included in this publication were in effect at the time of approval for printing Honda Motor Co Ltd reserves the right however to discontinue or change specifications or design atany time without notice and without incurring any obligation whateve...

Page 3: ...help you avoid damage to your tiller other property or the environment We suggestyou readthe warranty policyto fully understand itscoverage and your responsibilitiesof ownership Thewarranty policyis aseparate document that should have been given to you by yourdealer When your tiller needsscheduledmaintenance keepin mindthat your Honda servicingdealer isspeciallytrained inservicing Hondatillers and...

Page 4: ...ler You must useyour own good judgment You will find important safety information in a variety of forms including Safety Labels on the tiller Safety Messages preceded byasafetyalertsymbolAandoneofthree signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructi...

Page 5: ...ARTED 13 ISYOUR TILLER READY TO GO 13 Check the Engine 14 Check the Tiller 14 OPERATION 15 SAFE OPERATING PRECAUTIONS 15 STARTING THE ENGINE 16 OPERATING THE CONTROLS FOR TILLING 19 STOPPING THE ENGINE 23 SERVICING YOUR HONDA TILLER 24 THE IMPORTANCEOF MAINTENANCE 24 MAINTENANCE SAFETY 25 MAINTENANCE SCHEDULE 26 REFUELING 27 FUEL RECOMMENDATIONS 27 ENGINE OIL LEVELCHECK 29 ENGINE OIL CHANGE 30 ENG...

Page 6: ...CAREOF UNEXPECTED PROBLEMS 48 ENGINE PROBLEMS 48 Engine Will Not Start 48 Engine Lacks Power 49 TILLING PROBLEMS 50 Poor Tilling Quality 50 TECHNICAL CONSUMER INFORMATION 51 TECHNICAL INFORMATION 51 Serial Number Locations 51 Carburetor Modification for High AltitudeOperation 52 Oxygenated Fuels 53 EmissionControl System Information 54 Air Index 56 Specifications 57 CONSUMER INFORMATION 58 Honda P...

Page 7: ...ratingthetillerinREVERSE A2type especially if attachments are being used Keep a firm hold on the handlebars They may tend to lift during clutch engagement Be sure the drag bar is inplace and properly adjusted Be sure that anyone who operates the tiller receives proper instruction Do not letchildren operatethe tiller Keepchildren and pets away from the area of operation Carbon Monoxide Hazard Exhau...

Page 8: ...k Never smoke near gasoline and keep otherflames and sparks away Always storegasoline in an approvedcontainer Make sure that any spilled fuel has been wiped up before starting the engine Avoid Rotating Tines Rotating tines can cause seriouscuts and even amputatebody parts Keep away from the tine area whenever theengine is running If you need to work aroundthe tines to clear a object accumulationor...

Page 9: ...ng the Tiller If you need to leave the tiller for any reason even just to inspect the area ahead always turn the engine off Slope Operation When tilling on slopes keepthe fueltank lessthan half fullto minimizefuel spillage Till acrossthe slope at equally spaced intervals ratherthan up and down it Be very careful when changing the direction of the tiller on a slope Do notusethe tiller on a slopeof ...

Page 10: ...FETY SAFETY LABEL LOCATONS These labelswarnyouof potentialhazardsthatcancauseseriousinjury Read them carefully If a label comes off or becomes hard to read contact your Honda servicing dealer for a replacement 8 ...

Page 11: ...ENT CONTROL LOCATIONS THROTTLE LEVER AIR CLEANER COVER ENGINE SERIAL lFT V BELT COVER FRONT WHEEL ROTOR CLUTCHLEVER PARK PLUG CAP HANDLEBAR HEIGHT ADJUSTER CHOKE ROD FRAME SERIAL NUMBE ECOIL STARTER TRANSMISSION OIL 9 ...

Page 12: ...itionenrichesthe fuelmixture for startingacold engine The OPEN position provides the correct fuel mixture for operation after starting and for restarting a warm engine Engine Switch I ON Theengineswitchcontrolsthe ignition system OFF Stops the engine ON Running position ENGINE SWITC Recoil STARTER GRIP 10 ...

Page 13: ...on the tines will rotate at the highest speed Movingthe throttle levertowardthe idle position will decrease the tine speed Handlebar Height Adjuster Handlebar height can be adjusted to match operator height For normal tilling the most comfortableoperatorpositioniswith the handlebars at waist height Main Clutch Lever The mainclutch leverengages and disengages the transmission that drives the tines ...

Page 14: ... the soil Ideal drag bar height will depend on the type of soil being tilled and soil conditions at the time of tilling In general the drag bar should be adjusted so that the tiller is tilted slightly backward EVER PIN HITCH Front Wheel The front wheel is used to help move the tiller from one place to TILLING another Lift POSITION handlebars to roll the tiller on the front wheel Returnthe wheelto ...

Page 15: ... in case of an emergency IS YOUR TILLER READYTO GO For yoursafety and to maximizethe service life of your equipment it is very important to take a few moments before you operate the tiller to check its condition Besureto take care of any problemyou find or haveyour servicing dealer correct it before you operate the tiller Improperly maintaining this tiller or failing to correct a problem beforeope...

Page 16: ...the OFF position Check the Engine Check the oil level see page29 Check the air filter see page33 A dirty air filter will restrict air flow to the carburetor reducing engine and tiller performance Checkthe fuel level see page 27 Starting with a fulltankwill helpto eliminate or reduce operating interruptions for refueling Check the Tiller Check the transmission oil see page 32 14 ...

Page 17: ...r safety avoid starting or operatingthe tiller in an enclosed area such as a garage Your tiller s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death Carbon monoxide gas is toxic Breathing it can cause unconsciousnessand even kill you Avoid any enclosed areas or activities that expose you tocarbon monoxide 15 ...

Page 18: ...erely and can amputate body parts Wear protective footwear Keep your hands and feet away from the tines while the engine is running Stop the engine before performing any adjustment inspection or maintenance 1 Pull the chokerodtotheCLOSED position to start a cold engine LeavethechokerodintheOPEN positionto restartawarmengine CHOKE ROD 16 ...

Page 19: ...rom the SLOW position about 1 3of the way toward the FAST position THROTTLE LEVER ow 4 Pull the starter grip lightly until STARTER GRIP you feel resistance then pull briskly Do not allow the starter grip to snap back against the engine Returnitgentlytoprevent damage to the starter 17 ...

Page 20: ...OPERATION 5 If the choke rod was pulled to the CLOSED position to start the engine gradually move it to the OPEN position as the engine warms up CHOKE ROD t 18 ...

Page 21: ...turning easier Handlebar Height Adjustment 111 I Stop the engine before adjusting HE the handlebar height To adjust the handlebar height loosen the handlebar height adjuster select theappropriate holes andtighten it Clutch When the main clutchleveris squeezed the clutch is engaged andpower is transmitted to the transmission When the lever is released the clutch is disengaged and power is not trans...

Page 22: ...e slowest position 2 Release the clutch lever to disengage the clutch 3 Move the shift lever tothe desired gear position If the shift lever will not engage the desired gear squeeze the clutch lever and move the tiller slightly to repositionthe gears HANGE LEVER RACKET I NEUTRAL 20 ...

Page 23: ...d make sure itis clear of any obstacles 2 Verify the transport wheel is raised 3 Move the throttle to the SLOW position 4 Raise the handlebar up so the transport wheel contacts the ground This raisesthe drag bar out of the soil to allow easyreversgear operation 5 Make sure the clutch lever is released Move the shift lever to the REVERSE position 6 Engage the clutch lever and carefully walk the til...

Page 24: ...ejerks forward while tilling press down on the handlebars This will cause the drag bar to dig more deeply into the soil Front Wheel After gettingto thetilling site movethefront wheelto the raisedpositionbefore tiling Always stop the engine before lowering or raising the wheel To raiseor lower thewheel pulloutthewheel assembly movethewheel then release the wheel assembly TILLING POSITION TRANSPORT ...

Page 25: ...he OFF position Under normal conditions use the following procedure 1 Releasethe mainclutch leverto the DISENGAGEDposition and movetheshift levertothe neutral position A2 type 2 Move the throttle lever to the slowest position 3 Turn the engine switch to the OFF position OFF OFF ENGINE SWITCH 23 ...

Page 26: ...s sustained high load or high temperatureoperation or useindustyconditions consultyour servicing dealer for recommendations applicable to your individual needs and use Impropermaintenance or failureto correct a problembefore operation cancause a malfunction in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual...

Page 27: ...tenanceor repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be surethere is adequateventilationwhenever you operatethe engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Readthe instructions beforeyou begin and makesure you havethe tools and sk...

Page 28: ... Combustion chamber Clean I Fuel tube L 1 Check Every 2 years Replace if necessary 3 0 Emission related items 1 Service more frequently when used in dusty areas 2 Change engine oil every 25 hourswhen used under heavy load or in high ambient temperatures 3 These itemsshould beservicedbyyour servicingdealer unlessyou have the proper tools and are mechanically proficient Refer to Honda shop manual fo...

Page 29: ...rting the engine If the engine has been running allow it to cool Refuelcarefully to avoid spilling fuel Do not fill the fueltankabove the fuel levelmark After refueling tightenthefueltankcap securely Never refuel the engine inside a building where gasoline fumes may reach flames or sparks Keepgasoline away from appliance pilot lights barbecues electric appliances power tools etc Spilled fuel is no...

Page 30: ...avy loads This is no cause for concern Ifspark knock or pingingoccursat a steady engine speed under normalload changebrands of gasoline If spark knock or pinging persists seean authorized Hondaservicing dealer I NOTICE I Running the engine with persistent spark knock or pinging can cause e damage Running the engine with persistent spark knockor pinging is misuse and the Distributor s Limited Warra...

Page 31: ...oil filler cap dipstick and wipe it clean 2 Insert and remove the dipstick without screwing it into the filler neck Check the oil level shown on the dipstick 3 If the oil level is low fill to the top of the oil filler neck with the recommended oil see page31 4 Screw in the filler cap dipstick securely OIL FILLER CAPlDlPSTlCK NECK t l LOWER LlMT 29 ...

Page 32: ...x E i a Improper disposal of engine oil can be harmful to the environment If you change your own oil please dispose of the used oil properly Put it ina sealed container andtake it to arecycling center Donot discard it in a trash bin or dump it on the ground 3 With the tiller in a level position fill to the outer edge of the oil filler hole with the recommendedoil see page29 Oil Capacity 0 61 US qt...

Page 33: ...edfor general use Otherviscosities shown inthe chart may be used when the average temperature in your area is within the recommended range The SAE oil SAE VISCOSITY GRADES 20 0 20 40 60 80 100 F I I 30 20 10 0 10 20 30 40 C AMBIENTTEMPERATURE viscosit and service classification are in the API label on the oil container Honda recommendsthat you use API SERVICE category SJ oil 31 ...

Page 34: ...ndthe engine stopped 1 Removethe transmissionoilfiller cap The oilshould be levelwiththe lower edge of theoil filler hole 1 2 Addthe sameoil as recommendedfor the engine seepage31 if the level is low 3 Screw in the filler cap securely TRANSMISSION OIL FILLER CAP OIL FILLER HOLE LOWER EDGE OF THE OIL FILLER HOLE I 32 ...

Page 35: ... filteris dirty remove the filter and cleanit as described on page 34 Replace the filterif it Reinstallthe filterandair cleaner cover Makesure the latchtabs are secured is damaged Operating the engine without an air filter or with a damaged air filter will all dirt to enter the engine causing rapid engine wear This type of damage is not covered by the Distributor s Limited Warranty AIR e AIR CLEAN...

Page 36: ...e 1 Tap the air filter element several times on a hard surfaceto removedirt or blowcompressed air notexceeding30 psi 207kPa 2 1 kgf cm2 through the air filter from the air cleaner housing side Never try to brush off dirt brushingwill force dirt intothe fibers Replacethe air filter if it isexcessively dirty I 2 Wipe dirt from the air cleaner housing and cover using a moist rag Be carefulto preventd...

Page 37: ...I 1 I f PULG WRENCH 3 Inspectthe spark plug Replace it ifthe electrodes areworn or if theinsulator 0 70 0 80 mm is cracked or chipped 4 Measure thespark plug electrode gap with a suitable gauge The gap should be 0 028 0 031 in 0 70 0 80 mm Correct the gap if necessary by care fully bendingthe side electrode 5 Installthesparkplug carefully by hand to avoidcross threading 6 After the spark plug seat...

Page 38: ... 1 8 1 4turn after the spark plug seats If installing a new spark plug tighten 1 2turn after the spark plug seats A loose spark plug can overheat and damage the engine Overtightening the sparkplugcan damage the threads in the cylinder he 7 Attach the spark plug cap 36 ...

Page 39: ...incorrect loosenthe lock nut andturn the adjusting bolt in or outjust enough to eliminate free play Do not overtighten ADJUSTING NUT THROlTLE CABLE LOCK NUT ADJUSTMENT Measure the free play at the lever tip Free play 1 3 16 1 9 16 in 30 40 rnm If the free play is incorrect turn the adjusting nut in or out as required 1 3 16 1 9 16 in 30 40 mm 37 ...

Page 40: ... mountingboltsand the three inner belt cover tightening bolts and move the engineforward or backwardto get proper tension on the belt After adjusting the tension usea straight edge to make sure that the outside face of the drivepulley isflush with the outside face of thedriven pulley MOUNTING BOLTS 3 Loosenthe belt stopper attaching bolts Adjustthe clearance betweenthe belt stopper and the belt as...

Page 41: ...Honda servicing dealers The spark arrester must beserviced every 100hoursto keep itfunctioning as designed If the engine has been running the muffler will be very hot Allow the muffler to cool before servicing the spark arrester 1 Remove the three 6 mm bolts from the muffler protector and remove the muffler protector 2 Remove the two special screws from the spark arrester and remove the spark arre...

Page 42: ...the sparkarrester screen Be careful to avoid damagingthe screen The spark arrester must be free of breaks andholes Replacethe spark arrester if it is damaged SPARK ARRESTER SCREEN 4 Install the spark arrester and mufflerprotector in the reverse order of disassembly 40 ...

Page 43: ...er from enteringthe air cleaner 1 NOTICE 1 Using a garden hose or pressure washing equipment can force water into the air cleaner Water in the air cleaner will soak the filter elements and can enter the carburetor or engine cylinder causing damage Water contacting a hot engine can cause damage If the engine has been running allow it to cool for at least half an hour before washing Tiller Ifusinga ...

Page 44: ...aporate any water remaining on the engine 4 Whilethe engineisrunning operatethe clutch leverto expelwater fromthe pulleys belts and other moving items 5 Stop the engine and allow it to cool 6 After the tiller is clean anddry touch up any damaged paint andcoat other areas with a light film of oil Lubricatethe throttle cable core with a silicone spray lubricant 42 ...

Page 45: ...less if the gasoline was not fresh when you filled the fuel tank The Distributor s Limited Warranty does not cover fuel system damage or engine performance problems resultingfrom neglected storage preparation You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose or youcan avoid fuel deterioration problems by draining the fuel tank and carburetor Addin...

Page 46: ... 2 Place an approved gasoline container below the carburetor and use a funnel to avoid spilling fuel 3 Loosen the carburetor drain screw to drain the carburetor Gasoline is highlyflammable and explosive You can be burned or seriously injured Never use gasoline to clean engine parts Use a nonflammable solvent CARBURETOR 4 After all the fuel has drained into the container tighten the drain screw sec...

Page 47: ...5 10 cc of clean engine oil into the cylinder 4 Pull the starter rope several times to distribute the oil in the cylinder 5 Reinstallthe spark plug 6 Pullthe starter ropeslowly until resistanceisfelt This will closethe valves so moisture cannot enter the engine cylinder Return the starter rope gently 45 ...

Page 48: ...f fuel leakage Place the tiller on a level surface Tilting can cause fuel or oil leakage With the engine and exhaust system cool cover the tiller to keep out dust A hotengineandexhaustsystemcanigniteor meltsomematerials Donotuse sheet plastic as adust cover A nonporouscoverwill trap moisturearoundthe tiller promoting rust and corrosion REMOVAL FROM STORAGE Check your tiller as described in the BEF...

Page 49: ...turn the ignition switch to the OFF position LOADING AND UNLOADING Ifasuitable loadingrampisnotavailable two peopleshouldliftthetiller onand off the transport vehicle while holding the tiller level Positionthe tiller so it sits flat on the bed of the transport vehicle Tie the tiller down with rope or straps Keep the tie down rope or straps away from the controls adjustment levers cables and the ca...

Page 50: ...rstoredwith out treating or draining gasoline or refueledwith bad gasoline Refuel p 27 Drainfueltank andcarbu retor p 44 Refuelwithfreshgasoline P 27 Low oil level caused Oil Add oil p 29 Alert to stoDenaine Spark plug faulty fouled spark plug p 35 or improperly gapped Clean gap or replace Spark plug wet with fuel plug Start engine with flooded engine Dry andreinstall spark throttle lever in FAST ...

Page 51: ... Cause Air filterclogged Badfuel tillerstored without treating or drain ing gasoline or refueled with bad gasoline Fuel filter clogged carburetor malfunction ignition malfunction valves stuck etc Correction Clean or replace air filter P 34 Drainfueltankand carbu retor p 44 Refuelwithfreshgasoline Replace or repair faulty components as neces sary P 27 49 ...

Page 52: ...heck tines Possible Cause I Correction Engine speed is too slow FAST position p 11 to till well Move the throttle to the Tiller is movingtoofastfor to slower speed soil conditions Drag bar adjustment set ment p 22 to high Lower drag bar adjust Tines dull worn or dam tines if neces aged Wrong tines installed I Install correct tines Tinesinstalledincorrectly I Install tines correctly 50 ...

Page 53: ...l Number Loc FRAME Record the engine and frame serial numbers in the spaces below You will need this serial number when ordering parts and when making technical or warranty inquires see page 59 Engine serial number Frame serial number 51 Serial Number Location ...

Page 54: ...cing dealer perform this carburetor modification This engine when operated at high altitudewith the carburetor modifications for high altitude use will meet each emission standard throughout its useful life Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increaseinaltitude The effectof altitude on horsepowerwill be greater than this ifno ca...

Page 55: ...e containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE Methyl Tertiary Butyl Ether 15 by volume Youmay use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as longasitalsocontainscosolvents andcorrosion inhibitors to protect the fuel system Gaso...

Page 56: ...d hydrocarbons The U S and California Clean Air Act EPA and California regulations require all manufacturers to furnish written instruction describing the operation and maintenance of emission control systems The following instructions and procedures must be followed in order to keep the Honda engine emissions within the emission standards Tampering and Altering Tampering with or altering the emis...

Page 57: ... replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacementpartsthat are not of the original design and quality may impair the effectiveness of your emission control system A manufacturerof an aftermarketpart assumesthe responsibilitythatthe part will notadverselyaffectemissionperformance The manufactureror reb...

Page 58: ...cription is intended to provide you with information relating to the engine s emission durability period The descriptive term indicates the useful lifeperiodfor the engine s emissioncontrol system Seeyour Emission Control Warrantyfor additional information Descriptive Term Applicable to Emissions Durability Period Moderate 50 hours 0 65 cc Intermediate 300 hours 0 65cc Extended 125 hours 0 65 cc 1...

Page 59: ...in 64x42 mm Bore x Stroke 9 8 cu in 160 cm3 8 2 cu in 135 cm3 Ignition System BPR6ES NGK Spark Plug Transistorized magneto 0 61 US qt 0 58 4 Oil Capacity I Fuel Tank Capacity I 0 45 US gal 1 7 E I 0 53US gal 2 0 E I Clutch 1 OUS qt 0 95e 0 84 Imp qt Transmission Oil Capacity Belt tension type Tune up Specifications ITEM MAINTENANCE SPECI ISpark Plug Gap 0 028 0 031 in 0 70 0 80 mm Refer to page 35...

Page 60: ...ditional information for maintaining and repairing your tiller You may order them from your Honda tiller dealer Shop Manual This manual covers complete maintenance and overhaul procedures It is intended to be usedby a skilled technician Parts Catalog This manual provides complete illustrated parts lists 58 ...

Page 61: ...his way If you are dissatisfied with the decision made by dealership s management contact the Honda PowerEquipmentCustomerRelations Office You can write American Honda MotorCo Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia30005 8847 Or telephone 770 497 6400 When youwrite or call please give us this information Model and serial numbers see page 51 Name...

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Page 63: ...f 86 or higher page 27 FG400 0 45 US gal 1 71 FG500 0 53 US gal 2 01 SAE 10 W 30 API SJ for general use page 31 0 51 US qt 0 581 BPR6ES NGK 0 028 0 031 in 0 7 0 8 mm 1 400 f 150 rpm Check engine oil level Check air filter Tiller outside Each lever function Bolt and nut torque Cables and wires Engine operation Transmission oil Change engine oil Referto maintenanceschedule page26 ...

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