Honda GCV135E, Owner'S Manual

Page 1: ...1 OWNER S MANUAL SERIAL NUMBER AND ENGINE TYPE GCV135E GCV160E Honda Motor Co Ltd 2007 32Z0M604 00X32 Z0M 6040 08 05 21 13 01 00 32Z0M600_001 ...

Page 2: ...l 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 The illustrations may vary according to the with top cover type If a problem should arise or if you have any questions about your engine consult an authorized Honda dealer Gives helpful information Pay special attention to statements...

Page 3: ... the engine stopped Gasoline is highly flammable and explosive under certain conditions Do not place flammable objects such as gasoline matches etc close to the engine while it is running Know how to stop the engine quickly and understand the operation of all controls Never permit anyone to operate the engine without proper instructions Children and pets must be kept away from the area of operatio...

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: ...NTIFICATION OIL FILLER CAP MUFFLER SPARK PLUG STARTER GRIP RECOIL STARTER TOP COVER applicable types CHOKE LEVER Manual choke type With CHOKE LEVER type FUEL TANK AIR CLEANER FUEL VALVE 08 05 21 13 01 32 32Z0M600_005 ...

Page 6: ...TANK CAP FLYWHEEL BRAKE LEVER applicable types AIR CLEANER CONTROL LEVER Manual choke type Without CHOKE LEVER type Automatic choke type Fixed throttle type Automatic choke type Manual throttle type 08 05 21 13 01 36 32Z0M600_006 ...

Page 7: ...o the upper limit on the dipstick Remove the oil filler cap and wipe the dipstick clean Insert the dipstick into the oil filler neck but do not screw it in Use 4 stroke motor oil that meets or exceeds the requirements for API service category SE or later or equivalent Always check the API service label on the oil container to be sure it includes the letters SE or later or equivalent SAE 10W 30 is ...

Page 8: ...the engine without the air cleaner Rapid engine wear will result 2 ELEMENT AIR CLEANER COVER Remove the air cleaner cover and check the cleaner for dirt or obstruction of the element see page 21 08 05 21 13 01 50 32Z0M600_008 ...

Page 9: ...ueling make sure the tank cap 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 Recommended Fuel UPPER LEVEL FUEL FILLER NECK Unleaded gasoline U S Except U S P...

Page 10: ...mage metal rubber and plastic parts of the fuel system Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty Gasoline spoils very quickly depending on factors such as light exposure temperature and time Using contaminated gasoline can seriously damage the engine carburetor clogged valve st...

Page 11: ... CHOKE LEVER TYPE Do not use the choke if the engine is warm or the air temperature is high Move the control lever to the CLOSE position Move the choke lever to the CLOSE position Turn the fuel valve to the ON position 1 2 Without CHOKE LEVER type With CHOKE LEVER type AUTOMATIC RETURN CHOKE type 08 05 21 13 02 14 32Z0M600_011 ...

Page 12: ...RIP The engine switch which is linked with the flywheel brake lever is turned on when the flywheel brake lever is moved to the RELEASED position Move the flywheel brake lever to the RELEASED position Pull the starter grip lightly until you feel resistance then pull briskly in the direction of the arrow as shown below 3 4 With FLYWHEEL BRAKE LEVER type only 08 05 21 13 02 20 32Z0M600_012 ...

Page 13: ...he engine does not start within several consecutive pulls of the recoil starter move the flywheel brake lever to the ENGAGED position and move the choke lever to the CLOSE position Move the flywheel brake lever to the RELEASED position and immediately begin operating the recoil starter When engine warms up move the control lever to FAST or SLOW With CHOKE LEVER type AUTOMATIC RETURN CHOKE type 5 6...

Page 14: ...LEASED position see page Move the control lever to the FAST position MANUAL THROTTLE type Pull the starter grip lightly until you feel resistance then pull briskly in the direction of the arrow as shown on page Position the control lever for the desired engine speed MANUAL THROTTLE type 1 2 3 4 5 12 11 12 08 05 21 13 02 31 32Z0M600_014 ...

Page 15: ...nsumption will increase Even with suitable carburetor jetting engine horsepower will decrease approximately 3 5 for each 300 m 1 000 feet increase in altitude The effect of altitude on the horsepower will be greater than this if no carburetor modification is made High altitude performance can be improved by specific modifica tions to the carburetor If you always operate the engine at altitudes hig...

Page 16: ...ich is linked with the flywheel brake lever is turned off when the flywheel brake lever is moved to the ENGAGED position Return the flywheel brake lever to the ENGAGED position Move the control lever to the SLOW position MANUAL THROTTLE type 1 2 With FLYWHEEL BRAKE LEVER type 08 05 21 13 02 41 32Z0M600_016 ...

Page 17: ...l valve to the OFF position Move the control lever to the STOP position The engine switch which is linked with the control lever is turned off when the control lever is moved to the STOP position 3 4 Without FLYWHEEL BRAKE LEVER type 08 05 21 13 02 46 32Z0M600_017 ...

Page 18: ...he owner has proper tools and service data and feels he is mechanically qualified To perform maintenance on the lower part of the engine Machine turn it 90 and lay it down with the carburetor air cleaner always at the top 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 req...

Page 19: ...rvice more frequently when used in dusty areas Change engine oil every 25 hours when used under heavy load or in high ambient temperature These items should be serviced by your Honda servicing dealer unless you have the proper tools and are mechanically proficient Refer to the Honda shop manual for service procedures For commercial use log hours of operation to determine proper maintenance interva...

Page 20: ...ce 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 Install the oil filler cap Refill with the recommended oil and check the oil level see page Remove the oil filler cap and drain the oil into the oil container by inclining the engine toward the oil filler neck Turn the fuel valve to the OFF posit...

Page 21: ...NER COVER 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 Remove the air cleaner cover by unhooking the two upper tabs on the top of the air cleaner cover and the two lower tabs Remove the element Carefully check the element for holes or tears ...

Page 22: ...ove excess dirt or blow compressed air through 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 3 4 08 05 21 13 03 19 32Z0M600_022 ...

Page 23: ... SCREWS ALL TYPES Remove the top cover by removing the three tapping screws with top cover type only Remove the recoil starter by removing the three 6 mm nuts Remove the fuel tank taking care not to disconnect the fuel tube from the fuel tank and fuel valve and keeping the fuel tank to a level 1 2 3 08 05 21 13 03 26 32Z0M600_023 ...

Page 24: ...d recoil starter and tighten the three 6 mm nuts securely Install the top cover and tighten the three tapping screws securely with top cover type only Check the brake shoe thickness If it is less than 3 mm 0 12 in take the engine to an authorized Honda dealer 4 5 6 08 05 21 13 03 30 32Z0M600_024 ...

Page 25: ... Never use a spark plug of incorrect heat range For Hover Lawn mower 4 BPR4ES NGK BPR5ES NGK Remove the spark plug cap and use a spark plug wrench to remove each spark plug To ensure proper engine operation the spark plug must be properly gapped and free of deposits BPR6ES NGK 1 GCV135E GCV160E GCV135E GCV160E 08 05 21 13 03 37 32Z0M600_025 ...

Page 26: ...ark 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 Measure the plug gap with a feeler gauge Correct as necessary by bending the side electrode The gap should be Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross...

Page 27: ...intenance applicable types 5 MUFFLER PROTECTOR SPARK ARRESTER SCREW 6 mm BOLTS MUFFLER SCREW 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 Check for carbon deposits around the exhaust port and the spark arrester and clean if necessary 1 2 08 05 21 13 03 50 32Z0M600_027 ...

Page 28: ...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 08 05 21 13 03 54 32Z0M600_028 ...

Page 29: ...osen the carburetor drain bolt 1 1 1 2 turn and drain the carburetor Turn the fuel valve to the ON position and drain the fuel in the fuel tank into the container Retighten the carburetor drain bolt so that the float chamber cannot be warped and turn the fuel valve to the OFF position Before storing the unit for an extended period Be sure the storage area is free of excessive humidity and dust Dra...

Page 30: ...il resistance is felt This closes the valves and protects them from dust and corrosion Change the engine oil see page If you can not drain from the carburetor Empty the fuel tank into an approved gasoline container using a commercially available hand siphon Operate the engine until it stops from the lack of fuel 3 4 5 20 6 A B 08 05 21 13 04 09 32Z0M600_030 ...

Page 31: ...er positioned to the RELEASED position see page 12 applicable types Is the spark plug in good condition see page 25 Is the fuel valve ON Is there fuel in the fuel tank Is gasoline reaching the carburetor To check loosen the carburetor drain bolt 1 1 1 2 turn with the fuel valve ON see page 29 1 2 3 4 5 6 7 GCV135E GJAFE 351 mm 13 8 in 331 mm 13 0 in 340 mm 13 4 in 10 7 kg 23 6 lbs GCV160E GJAAE 36...

Page 32: ...n mower 0 77 L 0 203 US gal 0 169 lmp gal 0 91 L 0 240 US gal 0 200 lmp gal 0 55 L 0 58 US qt 0 48 lmp qt Specifications may vary according to the types and are subject to change without notice The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine model and measured in accordance with SAE J1349 at 3 600 rpm Net Power and at 2...