Honda GX160, Operational Manual

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Page 2: ...or that will cause body damage or death Warning expresses the unsafe factor that is possible to cause body damage or death Notice express the unsafe factor that is possible to cause body damage Important matters expresses the unsafe factor that is possible to cause property loss Remark expresses important information of installation operation and maintenance If there are any problems or you have a...

Page 3: ...n before operation 10 Inspect the engine under general condition 10 Inspect gasoline engine 11 Inspect power equipment matched with the engine 11 Chapter 4 Running 12 Safety tips 12 Start the gasoline engine 12 Switch off the gasoline engine 15 Adjustment the running speed 16 Chapter 5 Maintenance 17 The importance of maintenance 17 Safety tip of maintenance 18 Safety prevention 18 Maintenance tab...

Page 4: ...ngine can t start 33 Gasoline engine have not enough power 33 Chapter 7 Technical consume information 34 Technical information 34 Series number 34 Far away control the connection 35 Adjust the carburetor to suitable the plateau region use 36 Alcohol fuel 37 Emission control system 38 Specification 40 Adjustment 40 Chapter 8 Wiring diagram 41 Chapter 9 Appendix Suggestion 42 Storage 42 Storage prep...

Page 5: ...gine in a good ventilation The fuel oil is quite easy to flame up even cause explosion Do not overfill the fuel tank The place around fuel tank mouse shall be clean not with fuel Make sure the fuel tank cap tighten up If fuel is spilt wipe it away carefully and wait until the fuel has dried before starting the engine Make sure there is not smoking fire or spark around the place for refueling the e...

Page 6: ...r to the relevant legal documents The muffler is very hot during the operation and will last after stopping Please do not touch it when the muffler still is hot In order to avoid the scald or fire please do not remove or stock the engine until it is cooling Safety rules warning location Please read carefully as these warnings express the unsafe factor that may cause damage If the labels drop off o...

Page 7: ...Chapter 2 Operation parts its characteristic Spare parts operation 6 ...

Page 8: ...when the engine runs Fuel valve shall be adjusted to OFF in case that the oil spill from the carburetor reducing the possibility of oil spillage when the engine is stopped On Off Switch On Off Switch controls ignition system Adjust the On Off Switch to ON then the engine will start Adjust the On Off Switch to OFF then the engine will stop 7 ...

Page 9: ...er fuel materials for running but also supply proper fuel materials for restarting Some engines adopt distant chock controlling not controlled by chock handle as the below illustration Throttle Switch Handle Throttle Switch handle controls the speed of the engine Adjust the throttle switch handle to proper running speed that engine need Some engine adopt distant throttle switch controlling not con...

Page 10: ...to scanty fuel of crankcase some models design the fuel alarm system When the lube oil under the safe fuel level the alarm system will shut off the engine automatically but the ON OFF Switch will be still ON If the engine can t restart after stopping please inspect the fuel level prior to other problems Refer to page22 9 ...

Page 11: ...ection before operation Inspection of the engine under general condition Inspect the appearance and bottom of the engine to check if oil leakage Wipe off the dust and residue especially around the muffler and starter grip Inspect the places marked with damage Inspect appearance including checking if the nuts bolt and screw is tighten up 10 WARNING It may cause engine trouble result in serious inju...

Page 12: ...se inspect the fuel level before starting Inspect air filter Refer to Page25 the dirty air filter will limit air flow into carburetor and lower down the power Inspect the fuel level Refer to Page20 the crankcase shall be full of fuel in case of refueling during the operation Inspect the power equipment matched with the engine All the equipments matched with the engine shall be used in accordance w...

Page 13: ...y use we suggest run the new engine about 15 minutes before use All the equipments matched with the engine shall be used in accordance with all the notice tips and this manual before starting Start the gasoline engine 1 Adjust the fuel valve to ON 12 WARNING CO is poisonous sucking into it may result in unconscious even death Keep away from the place surrounded by the CO ...

Page 14: ...ust the chock handle to ON Some engines adopt distant chock controlling not controlled by chock handle as the below illustration 3 Remove the throttle switch handle about 1 3 from low to high Some engine adopt distant throttle switch controlling not controlled by throttle switch as the below illustration 13 ...

Page 15: ...ghtly pull the starter grip until feeling of resistance then quickly pull it with force and slowly release handle finally 6 Start the engine If the chock handle is adjusted to OFF turn it to ON and preheat the engine at the same time 14 ...

Page 16: ...n the ON OFF Switch to OFF Usually please stop the engine by the below step 1 Turn the throttle switch handle to low speed position Some engine adopt distant throttle switch controlling not controlled by throttle switch as the below illustration 2 Turn the ON OFF Switch to OFF 15 ...

Page 17: ...ch handle to the speed what the engine need Some engine adopt distant throttle switch controlling not controlled by throttle switch as the below illustration Regarding the recommendation of speed please refer to power equipment instruction matched with the engine 16 ...

Page 18: ...he maintenance sheet is only apply to regular running condition If start the engine under abnormal condition like overload or high temperature use in wet or dusty circumstance please consult the service store and design the maintenance sheet as per your need Important matters The maintenance of exhausting controlling system replacing repairing shall be separately operated by gasoline engine specia...

Page 19: ...ease read carefully this instruction and make sure you have the tools to repair and maintenance skills Be careful when there is gasoline around the working circumstance in case of the possibility of explosion and burning Only use nonflammable impregnant No smoking spark and fire Keep in mind that your supplier who learn more about the engine and have the power to maintain In order to assure highes...

Page 20: ...check adjustment 2 31 Valve clean check adjustment 2 Chamber clean Fuel tank air cleaner clean 2 Fuel pipe check Every 2years if it s necessary to replace Remark is maintenance items is the relative items with the emission replace the washer 1 operation in the place of big dust you have to increase the maintenance time 2 if the user have suitable tools or maintenance capacity otherwise these items...

Page 21: ...l material Keep the fuel oil away from optical test vessel high temperature articles electrical instrument power tools etc The fuel spilt shall be wiped off immediately because they may cause fire and pollution Important matters Fuel oil could erode the paint and rubber Please assure it won t happen oil spillage Because all the troubles caused by the fuel spillage couldn t claim for compensation 2...

Page 22: ... hear the noise of spark striking the cylinder or metal beating noise when overload If you hear the noise of striking cylinder when the engine is normally loading we suggest you replace it with qualified gasoline If the problem still occurs please contact the special service department authorized by JIALING HONDA Remark If there is still the noise of the spark striking cylinder or bang noise when ...

Page 23: ...3 If the fuel level is lower than lowest oil level fill in the gasoline oil through the fill in hole till the fuel level reach highest oil level 4 Tighten the oil dipstick Remark Run the engine if the gasoline is not enough it will result in engine serious damage If the fuel level is lower than safe level the fuel alarm system will stop the engine automatically In order to avoid the inconvenience ...

Page 24: ... a sealed vessel and delivery it to local waste oil recycle place Don t throw it to dustbin or gutter 3 Put the engine at a level of plane and fill in recommended gasoline Refer to Page 24 Gasoline engine fuel oil 0 6L Important matters Run the engine if the gasoline is not enough it will result in engine serious damage If the fuel level is lower than safe level the fuel alarm system will stop the...

Page 25: ...ube oil If the average temperature belongs to relevant recommended scopes other viscous lube oil as below illustration will be also available JIALING HONDA specific lube oil Characteristics of specific lube oil 1 Excellent abrasion resistance 2 Stable viscosity 3 Good oxidated safety 4 Wonderful desperation of clean 5 Effective anti corrosion rust resistance 24 ...

Page 26: ...ine engine without using the air cleaner also don t running the gasoline engine when the air filter element is broken or there is dirty material go into the gasoline engine otherwise it will accelerate the damage of gasoline engine and these damage is not in the field of warranty claim Double filter element type 1 Take off the butterfly nuts from the air cleaner cover and unload the air cleaner co...

Page 27: ...the foam filter element it will case the gasoline engine smoke during first start 6 Using a wet wiper wipe the dust on the air cleaner cover and inside bottom notice don t let the dust go into the air pipe of connecting to the carburetor 7 Put the foam filter element upper to paper filter element and return back to the air cleaner make sure the washer is under the air cleaner then tightening the b...

Page 28: ... smoke during first start 3 Paper filter element tap the filter element to make the filter element off the dust Or blow the filter element from inside to outside by using high pressure air flow not excess 207kPa 2 1kgf cm2 Never use brush to clean the filter element as the brush will make the dust go into the fiber of paper filter element If the filter element is too dirty please replace it clean ...

Page 29: ...an and dry the foam filter element 3 Make the filter element Soaked the clean fuel then squeezing out the extra fuel If there have extra fuel in the foam filter element box it will case the gasoline engine smoke during first start 4 Discharge out the fuel of air cleaner Using non flammable or high lit solvent to clean the dust Then dry the air clean box 5 inject the same oil lubricate of the gasol...

Page 30: ...3 Put the O ring back to the fuel pipe then install the sediment chamber back and fixed 4 put the fuel valve to On check whether there is oil leakage if yes please replace the O ring 29 Dangerous The fuel is easy to burn and easy to explosion Treatment the fuel have to be careful Far away to the flog spark fire and so on Treatment the fuel in outdoor Clean the spill fuel immediately ...

Page 31: ...ional spark plug wrench to take off the spark plug 3 Check the spark plug if you find it has wore or has gas in insulator or broken please replace it or clean it by wire brush 4 Use thickness measurement to measure the gap of spark plug if the spark plug need adjust bending the side electrode and adjustment the correct gas between 0 70 to 0 80mm 5 To prevent the thread waterloo please install back...

Page 32: ...ore 1 2 circle Important matters The unscrewed spark plug may too hot and damage the gasoline engine 7 Unload the spark plug cap Adjust the idle 1 Start the gasoline engine outdoor and preheating the gasoline engine to normal running temperature 2 Put the throttle switch handle to the lowest speed 3 Adjustment the throttle switch stopper nuts to get the standard idle Standard idle 1440 r min 31 ...

Page 33: ... to maintenance every 100 hours to keep is effective If you has been running the gasoline engine the eliminator is very hot you have to cool it then maintenance the spark plug eliminator 1 Unload the 3pcs of 4mm and 4pcs of 5mm bolts from the muffler and take off the cover of muffler 2 Unload the 4mm bolts from the spark plug eliminator 3 Using brush to clean the dust of the screen of spark elimin...

Page 34: ...t the gap or replace the spark plug refer to page30 The spark plug is socked on fuel Dried and re loading the spark plug and put the valve handle on high speed 4 Take the machine to Honda special maintenance office or distributor Fuel air cleaner is clogged or carburetor default or spark default oil pipe is stuck Replace or repair the parts No enough power Cause Solution 1 check the air cleaner Fi...

Page 35: ...nique information Series Number Please fill the series number of gasoline engine under the underline it will be useful when you order the spare parts or consult the technique information and claim Series number ______________________________ 34 ...

Page 36: ...holes can assemble the fixed cable movable cable and collective cable If assemble the movable and collective cable it need add a reset spring as the follow diagram Using the far distance operating the throttle switch please loose the lock nuts of throttle switch handle Far distance control connection 35 ...

Page 37: ...n the plateau region higher than 1 800mm please ask the Honda distributor adjustment the carburetor The adjustment gasoline engine using in plateau region would ensure the emissions standard in the warranty period The gasoline engine which has adjusted the carburetor its power will lower 3 5 once the altitude increase 300m if the carburetor did not adjust well the affection will increase Important...

Page 38: ...hin 15 of the volume Methanol Methyl or wood alcohol 5 of the volume You can use the fuel which the Methanol content within 5 of the volume once it contain the Cosolvent and Preservatives to protect the oil pipe The fuel contain more than 5 Methanol which will cause the problem of starting and performance Also it will damage the metal rubber and plastic parts of oil pipe system Important matters D...

Page 39: ...CO have not such interactive it s toxic The Honda company using the lean carburetor and other system to reduce the emission of CO Nitrogen oxides and Hydrocarbons Modified gasoline engine The modified gasoline engine will make the emission increase and excess the legal rules the modified parts as below Move or change the vent which it s belong to one of the fuel system or exhaust system Change the...

Page 40: ...spare parts are products by the same standard design and you can take care its performance If you use difference replace parts it may damage the emission control system The replace parts supplier have to approve the spare parts is meet the emission request rules and have to bear the responsibility of damage the emission system Maintenance According to maintenance table maintenance the gasoline eng...

Page 41: ...able adjust ratio 10 10 Speed adjust feature Running speed volatility 3 Main frame parameter 11 Cylinder Dia Stock mm 68 45 12 Exhaust 163mL 13 Compression Ratio 8 5 1 14 Spark advance BTDC 25 3 300r min 4200r min Air in 0 15 0 02 15 Cooling valve clearance Air out 0 20 0 02 16 Spark plug clearance mm 0 7 0 8 17 Rotation direction Anti clockwise Accessories 18 Model No of spark plug NGK BPR6ES 19 ...

Page 42: ...Chapter 8 Wiring diagram 41 ...

Page 43: ...ill go into the cylinder though filter element and muffler and damage the gasoline engine The water encounter the hot gasoline engine will make the gasoline engine damage if the gasoline engine is just operation please cooling the machine at least half an hour before clean Fuel The fuel will go bad during storage the bad fuel will make the gasoline engine hard to start at the same time the bad fue...

Page 44: ...of the fuel When add a fuel stable controller please inject the fresh fuel to the fuel tank The fuel have to fill full to avoid the air of the fuel tank go bad If you inject the fuel from a tank please make sure the fuel of the tank is fresh 1 Add the fuel stable controller according to the use manual of supplier 2 After add the fuel stable running about 10 minutes in the outdoor to make sure the ...

Page 45: ...n cock of carburetor move the sediment chamber and put the fuel valve on Off 3 After fill the fuel to the fuel tank screw the oil drain cock and return it back to the sediment chamber and fix it 44 Danger The fuel easy to burn and easy explosion Improper handling of fuel may be seriously injured Stay away from flog spark fire and so on Handling outdoor Please clean the oil immediately when spill o...

Page 46: ...od to prevent moisture go into the cylinder and rusty Then release the starter grip back Storage notice If there is fuel in the fuel tank or carburetor when you storage your gasoline engine and it s very important to reduce the burning dangerous choose a good ventilation conditions to storage at the same time far away from fair such as furnaces water heater dryer and so on Also far away to the mot...

Page 47: ...ine engine If the fuel discharge out before storage then inject the fresh oil to the fuel tank If you inject the fuel from a container please make sure the fuel is fresh the bad fuel will make the gasoline engine hard to start If you smear a layer of oil on the gasoline engine once you start the gasoline engine it will produce some flog it is normal Transportation If the gasoline engine has been r...