Honda GC135E GC160E, Owner'S Manual

Page 1: ...1 OWNER S MANUAL SERIAL NUMBER AND ENGINE TYPE GC135E GC160E Honda Motor Co Ltd 2003 06 12 01 19 14 14 32Z2L600_001 ...

Page 2: ...chasing a Honda engine This manual covers the operation and maintenance of your engine All information in this publication is based on the latest product information available at the time of printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission This manu...

Page 3: ...ot place flammable objects close to the engine Children and pets must be kept away from the area of operation due to a possibility of burns from hot engine components or injury from any equipment the engine may be used to operate Know how to stop the engine quickly and understand the operation of all controls Never permit anyone to operate the engine without proper instructions Do not place flamma...

Page 4: ... an optional part for this engine It is illegal in some areas to operate an engine without a spark arrester Check local laws and regulations before operating The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful not to touch the muffler while it is hot To avoid severe burns or fire hazards let the engine cool before transporting it or storin...

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

Page 6: ...e or an equivalent high detergent premium quality mo tor oil certified to meet or exceed U S automobile manufacturer s require ments for service classification SG SF Motor oils classified SG SF will show this designation on the container SAE 10W 30 is recommended for gen eral all temperature use If single vis cosity oil is used select the appropri ate viscosity for the average tempera ture in your...

Page 7: ...n the engine without the air cleaner Rapid engine wear will result 2 AIR CLEANER COVER ELEMENT Remove the air cleaner cover and check the cleaner for dirt or obstruction of the element page 19 06 12 01 19 14 57 32Z2L600_007 ...

Page 8: ...ap is closed properly and securely Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled make sure the area is dry before starting the engine Avoid repeated or prolonged contact with skin or breathing of vapor KEEP OUT OF REACH OF CHILDREN 3 UPPER LIMIT MARK Use automotive unleaded gasoline with a Research Octane Number of 91 or higher a Pump Octa...

Page 9: ...ng ethanol and the other containing methanol Do not use gasohol that contains more than 10 ethanol Do not use gasoline containing methanol methyl or wood alcohol that does not also contain cosolvents and corrosion inhibitors for methanol Never use gasoline containing more than 5 methanol even if it has cosolvents and corrosion inhibitors Before buying fuel from an unfamiliar station try to find ou...

Page 10: ...LOSED Pull the choke rod to the CLOSED position Do not use the choke if the engine is warm or the air temperature is high Control lever with engine stop function Move the control lever away from the SLOW position about 1 3 of the way toward the FAST position 1 2 06 12 01 19 15 19 32Z2L600_010 ...

Page 11: ...NTROL LEVER D Di ir re ec ct ti io on n t to o p pu ul ll l Control lever with only engine stop function Move the control lever to the ON position Pull the starter grip lightly until you feel resistance then pull briskly in the direction of the arrow as shown below Return the starter grip gently 3 06 12 01 19 15 24 32Z2L600_011 ...

Page 12: ...gh altitude performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw If you always operate the engine at altitudes higher than 1 830 m 6 000 feet above sea level have your authorized Honda dealer perform these carburetor modifications Even with suitable carburetor jetting engine horsepower will decrease approximately 3 5 for each ...

Page 13: ...where equipped 6 The Oil Alert System is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase Before the oil level in the crankcase can fall below a safe limit the Oil Alert System will automatically stop the engine the engine switch will remain in the ON position 06 12 01 19 15 32 32Z2L600_013 ...

Page 14: ...e rod has been pulled to the CLOSED position to start the engine push it to the OPEN position as soon as the engine warms up enough to run smoothly Position the control lever for the desired engine speed Control lever with engine stop function 1 2 06 12 01 19 15 38 32Z2L600_014 ...

Page 15: ...R CONTROL LEVER STOP STOP OFF OFF Move the control lever to the STOP position Control lever with engine stop function Control lever with only engine stop function Move the control lever to the OFF position 06 12 01 19 15 44 32Z2L600_015 ...

Page 16: ...e The engine should be serviced by an authorized Honda dealer unless the owner has proper tools and service data and feels he is mechanically qualified Periodic inspection and adjustment of the Honda engine is essential if high level performance is to be maintained Regular maintenance will also ensure a long service life The required service intervals and the kind of maintenance to be performed ar...

Page 17: ...he proper tools and is mechanically proficient See the Honda Shop Manual Change engine oil every 25 hours when used under heavy load or in high ambient temperature Service more frequently when used in dusty areas Every 2 years Replace if necessary 3 ITEM Engine oil Air cleaner Timing belt Spark plug Spark arrester optional part Idle speed Valve clearance Fuel line Check Change Check Clean Replace ...

Page 18: ...a sealed container to your local service station for reclamation Do not throw it in the trash pour it on the ground or down a drain Wash your hands with soap and water after handling used oil Remove the oil filler cap and drain plug to drain the oil Install the drain plug and tighten it securely Refill with the recommended oil see page and check the oil level Install the oil filler cap 0 58 0 61 U...

Page 19: ...BS A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor malfunction service the air cleaner regularly Service more frequently when operating the engine in extremely dusty areas Press the latch tabs on the fuel tank side of the air cleaner cover and remove the air cleaner cover 1 06 12 01 19 16 13 32Z2L600_019 ...

Page 20: ...h the filter from the inside out Never try to brush the dirt off brushing will force dirt into the fibers Replace the element if it is excessively dirty Install the element and air cleaner cover Remove the element Carefully check the element for holes or tears and replace if damaged 3 4 2 06 12 01 19 16 17 32Z2L600_020 ...

Page 21: ...ne has been running the muffler will be very hot Be careful not to touch the muffler 3 BPR6ES NGK To ensure proper engine operation the spark plug must be properly gapped and free of deposits Remove the spark plug cap and use a spark plug wrench to remove each spark plug 1 06 12 01 19 16 23 32Z2L600_021 ...

Page 22: ...re is apparent wear or if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 0 70 0 80 mm 0 028 0 031 in Measure the plug gap with a feeler gauge Correct as necessary by bending the side electrode The gap should be 2 3 06 12 01 19 16 27 32Z2L600_022 ...

Page 23: ...hread the spark plug in by hand to prevent cross threading When installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer When reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer After the spark plug is seated tighten with a spark plug wrench to compress the washer 5 4 06 12 01 19 16 32 32Z2L600_023 ...

Page 24: ... to maintain its efficiency 4 MUFFLER PROTECTOR SPARK ARRESTER 6 mm BOLTS MUFFLER SCREW 2 Check for carbon deposits around the exhaust port and the spark arrester and clean if necessary Remove the muffler protector by removing the three 6 mm bolts Remove the spark arrester from the muffler by removing the two screws Taking care not to damage the wire mesh 1 2 06 12 01 19 16 37 32Z2L600_024 ...

Page 25: ...EEN Use a brush to remove carbon deposits from the spark arrester screen The spark arrester must be free of breaks and holes Replace if necessary Install the spark arrester and the muffler in the reverse order of disassembly 3 4 06 12 01 19 16 43 32Z2L600_025 ...

Page 26: ...ed fuel may ignite DRAIN SCREW CARBURETOR Before storing the unit for an extended period Be sure the storage area is free of excessive humidity and dust Drain the fuel tank and carburetor into a suitable gasoline container Empty the fuel tank into an approved gasoline container using a commercially available hand siphon Loosen the carburetor drain screw to drain the carburetor Retighten the drain ...

Page 27: ...slowly until resistance is felt This closes the valves and protects them from dust and corrosion Coat areas that may rust with a light film of oil Cover the engine and store it on a level surface in a dry dust free area 5 3 4 06 12 01 19 16 52 32Z2L600_027 ...

Page 28: ...re testing the spark plug or starting the engine Fuel vapor or spilled fuel may ignite DRAIN SCREW CARBURETOR When the engine will not start Is there fuel in the fuel tank Is gasoline reaching the carburetor To check loosen the drain screw 1 2 06 12 01 19 16 57 32Z2L600_028 ...

Page 29: ...he engine still does not start take the engine to an authorized Honda dealer Is the control lever positioned properly page 10 11 Is the spark plug in good condition page 21 3 4 5 06 12 01 19 17 01 32Z2L600_029 ...

Page 30: ...gine oil Spark plug BPR6ES NGK Service classification SF or SG SAE 10W 30 0 58 0 61 US qt 0 51 Imp qt 1 7 0 45 US gal 0 37 Imp gal Counterclockwise Transistor magneto Forced air 313 g kWh 230 g PSh 8 6 N m 0 88 kgf m 2 500 rpm 2 9 kW 4 0 PS 3 600 rpm 64 42 mm 2 5 1 7 in 135 cm 8 2 cu in 4 stroke overhead cam 1 cylinder 11 2 kg 24 7 lbs 315 mm 12 4 in 369 mm 14 5 in 330 mm 13 0 in GCAAE GC135E Mode...

Page 31: ...PR6ES NGK Service classification SF or SG SAE 10W 30 0 58 0 61 US qt 0 51 Imp qt 2 0 0 53 US gal 0 44 Imp gal Counterclockwise Transistor magneto Forced air 313 g kWh 230 g PSh 10 3 N m 1 05 kgf m 2 500 rpm 3 7 kW 5 0 PS 3 600 rpm 64 50 mm 2 5 2 0 in 160 cm 9 8 cu in 4 stroke overhead cam 1 cylinder Model Power equipment description code Length Width Height Dry weight Specifications may vary accor...

Page 32: ...32 MEMO 06 12 01 19 17 23 32Z2L600_032 ...