Honda Power Equipment GX390 Automobile User Manual
Contents
1. Equipment Owners Manual GXV120 160 Click here to save this ie Ses Oe eee 4 to your computer Ht tf ft ees eo LIT diat XE amp 03 EH DUC 411 4 He 2 0 1215 EE E 20 22 eee 1111 Z cenaro Thank you for purchasing a Honda engine This manual covers the operation and maintenance of GXV120 and GXV 160 engines All information in this publication is based on the latest product information available at the time of printing The illustrations in this mannal are based on the GXV 120 engine 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 manual should be considered a permanent part of the engine and should remain with the engine if it is resoid Pay special attention to statements preceded by the following words Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTE Gives helpful information If a problem should arise or if you have any questions about your en2. to obtain the standard idle speed Standard idle speed GXV120 2 000 150 rpm GXV160 1 700 150 rpm THROTTLE STOP SCREW 21 9 TRANSPORTING STORAGE When transporting the engine turn the fuel valve to the OFF position and keep the engine level to preven fuel spillage Fuel vapor or spilled fuel may ignite Before storing the unit for an extended period 1 Be sure the storage area is free of excessive humidity and dust 2 Drain the fuel tank and carburetor into a suitable gasoline container a Remove the fuel tube and drain the fuel tank b Loosen the carburetor drain bolt to drain the carburetor c Retighten the drain bolt connect the fuel tube and tum the fuel valve OFF Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flames or sparks in the area _ 3 Change the engine oil page 16 4 Remove the spark plug and pour about a tablespoon of clean engine oil into the cylinder Crank the engine several revolutions to distribute the oil then reinstall the spark plug 5 Pull the starter rope slowly until resistance is felt This closes the valves and will help to protect the engine from internal corrosion 22 10 TROUBLESHOOTING Engine will not start using recoil starter P Is the control lever in the CHOKE position 15 the fuel valve ON Is there fuel in the fuel tank 15 gasoline reaching the carburet
3. 7 inj Max output 4 0 HP 3 600 rpm torque 0 82 kg m 5 93 ft Ip 2 700 rpm Fuel consumption 250 g HPh 0 55 Ib HPh Cooling system Forced air Ignition system Transistorized magneto 25 Dimensions GXV160 Power equipment description Go code 435 x 345 x 355 mm 17 1 13 6 x 14 0 inj Dry weight 15 5 kg 134 17 Ib Length x Width x Height Engine Engine type 4 stroke overhead valve single cylinder Displacement 163 9 9 cu in Bore x Stroke 68 x 45 mm 2 7 x 1 8 5 5 HP 3 600 rpm 1 1 kg m 7 96 ft Ib 2 500 rpm Forced air Transistorized magneto Counterclockwise Max output Max torque Fuel consumption Cooling system Ignition system PTO shaft rotation 26 High altitude operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will decrease and fuel consumption will increase High 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 6 000 feet above sea level have your authorized Honda Engine dealer perform these carburetor modifications E Even with suitable carburetor jetting engine horsepower will decrease ap proximately 3 5 for each 1 000 foot increase in altitude The affect of altitude on horsepower will be g
4. Imp qal GXV 160 2 0 0 53 US Gal 0 44 Imp gal GASOLINES CONTAINING ALCOHOL If you decide to use a gasoline containing alcohol gasohol be sure it s oc tane rating is at least as high as that recommended by Honda There are two types of gasohol one containing ethanol and the other containing methanol Do not use gasohol that contains more than 1096 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 NOTE Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete Before buying fuel from an unfamiliar station try to find out if the fuel contains alcohol if it does confirm the type and percentage of alcohol used If you notice any undesirable operating symptoms while using a gasoline that contains alcohol or one that you think contains alcohol Switch to a gasoline that you know does not contain alcohol 10 5 STARTING THE ENGINE 1 Turn the fuel valve to the ON position GXV120 GXV160 2 Move the control lever to the CHOKE position Do not use the choke if the engine is warm or the ambient temp
5. Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station for reclamation Do not throw it in the trash or pour it on the ground 16 2 Air cleaner service A dirty air cleaner will restrict air flow to the carburetor To prevent car buretor malfunction service the air cleaner regularly Service more fre quently when operating the engine in extremely dusty areas Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result CAUTION Never run the engine without the air cleaner Rapid engine wear will result 1 Remove the wing nut and the air cleaner cover Remove the ele ments and separate them Careful ly check both elements for holes or tears and replace if damaged 2 Foam element Wash the element in a solution of household de tergent and warm water then rinse thoroughly or wash in nonflammable or high flash point solvent Allow the element to dry thoroughly Soak the element in clean engine oil and squeeze out the excess oil The engine will smoke during in itial start up if too much oil is left in the foam 3 Paper element Tap the element lightly several times on a hard sur face to remove 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 Repl
6. ace the paper element if it is ex cessively dirty PAPER ELEMENT FOAM ELEMENT 17 4 Spark plug service Recommended spark plug BP5ES BPRSES NGK W1G6EP U W16EPR U ND CAUTION Never use a spark plug of incorrect heat range To ensure proper engine operation the spark plug must be properly gapped free of deposits 1 Remove the spark plug cap and use a spark plug wrench to remove the plug If the engine has been running the muffler will be very hot Be careful not to touch the muffler Te dh 9 lo 2 Visually inspect the spark plug Discard it if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 3 Measure the plug gap with feeler gauge The gap should be 7 0 8 mm 0 028 0 031 in Correct as necessary by bending the side electrode 0 7 0 8 1 0 028 0 031 in 18 4 Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross threading 5 After the spark plug is seated tighten with a spark plug wrench to com press the washer NOTE 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 CAUTION The spark plug must be securely tightened An
7. ed Exhaust gas contains poisonous carbon monoxide Avoid inhalation of exhaust gases Never run the engine in a closed garage or confined area Operate the engine on a level surface If the engine is tilted fuel spillage may result Do not place anything on the engine as it may create a fire hazard A spark arrester is available as 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 2 COMPONENT IDENTIFICATION GXV120 RECOIL STARTER SPAKE PLUG FUEL FILLER OIL FILLER CAP MUFFLER FUEL TANK OIL DRAIN PLUG 160 RECOL STARTER STARTER GRIP AIR CLEANER SPARK PLUG FUEL FILLER CAP OIL FILLER CAP FUEL TANK MUFFLER DRAIN PLUG 3 BATTERY CONNECTIONS for electric starter Use a 12 volt battery with an ampere hour rating of at least 8 AH Connect the battery positive cable to the starter solenoid terminal as shown Connect the battery negative cable to an engine mounting bolt frame bolt or other good engine ground connection Check the battery cable connections to be sure the cables are secured and free of corrosion Remove any corrosion and coat the terminals and cable ends with grease The battery gives off explosive gases keep sparks flames and cigaret tes away Provide adequate ventilation when charging or using batteries in an enclo
8. ent Customer Relations Department P O Box 50 Gardena California 90247 0805 Telephone 213 604 2400 We still need the following information in order to assist you Your name address and telephone number Engine model and serial number Date of purchase Dealer name and address Product or equipment in which the engine is installed Nature of the problem After reviewing all the facts involved you will be advised of what action can be taken Please bear in mind that your problem will likely be resolved at the dealership using the dealer s facilities equipment and personnel so it is very important that your initial contact be with the dealer Your purchase of a Honda engine is greatly appreciated by both your dealer and American Honda Motor Co Inc We want to assist you in every way possible to assure your complete satisfaction with your purchase 28 Current customer service contact information Servicing dealership personnel are trained professionals They should be able to answer any question you may have If you encounter a problem that your dealer does not solve to your satisfaction please discuss it with the dealership s management The Service Manager General Manager or Owner can help Almost all problems are solved in this way United States Puerto Rico and U S Virgin Islands 1 you are dissatisfied with the decision made by the dealership s management contact the Honda Regional Eng
9. erature is high 11 With recoil starter Pull the starter grip tightly until resistance is felt then pull briskly CAUTION Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter e With electric starter Turn the engine switch to the START position and hold it there until the engine starts NOTE Do not use the electric starter for more than 5 seconds at a time If the engine fails to start release the switch and wait 10 seconds before operating the starter again When the engine starts allow the engine switch to return to the OIN position 12 6 OPERATION When the engine warms up move the control lever fram the CHOKE posi tion to the operating position for the desired engine speed 13 7 STOPPING THE ENGINE 1 Move the control lever to the STOP position 2 Turn the fuel valve to the OFF position GXV120 GXV 160 14 8 MAINTENANCE The purpose of the maintenance and adjustment schedule is to keep the engine in good operating condition Inspect or service as scheduled in the table below Shut off the engine before performing any maintenance If the engine must be run make sure the area is well ventilated The exhaust con tains poisonous carbon monoxide gas CAUTION Use only genuine HONDA parts or their equivalent The use of replacement parts which are not of equivalent quality may damage the engi
10. gine consult an authorized Honda dealer Honda engines are designed to give safe and dependable ser vice if operated according to instructions Read and understand the Owner s Manual before operating the engine Failure to do so could result in personal injury or equipment damage CONTENTS Tm 3 SEENEN 4 6 7 EE 11 13 14 8 MAINTENANCE 15 9 TRANSPORTING STORAGE 1 23 24 4 SPECIFICA TIONS DE 26 High altitude operation 27 1 2 WARRANIY SERVICE EE 28 1 SAFETY INSTRUCTIONS To ensure safe operation To prevent fire hazards and to provide adequate ventilation keep the engine at least 3 ft away from buildings and other equipment during operation Do not place flammable objects such as gasoline matches etc close to the engine while it is running Refuel a well ventilated area with the engine stopped Gasoline is flammable and explosive under certain conditions Do not overfill the tank There should be no fuel in the filler neck Make sure that the filler cap is closed securely If any fuel is spilled clean it up completely before starting the engine Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stor
11. improperly tightened spark plug can become very hot and may damage the engine 19 5 Spark arrester maintenance optional part If the engine has been running the muffler will be very hot Allow it to cool before proceeding 1 Loosen the three 6 mm nuts and remove the muffler protector iden tification plate muffler and gasket 2 Remove the spark arrestor from the muffler take care not to demage the wire mesh IDENTIFICATION PLATE MUFFLER PROTECTOR OPTIONAL PART MUFFLER GASKET SPARK ARRESTER OPTIONAL PART GASKET OPTIONAL PART 3 Use a brush to remove carbon deposits from the spark arrester screen CAUTION Be careful not to damage the spark arrester screen SPARK ARRESTER SCREEN NOTE The spark arrester must be free of breaks and holes Replace if necessary 4 instal the spark arrester and the muffler in the reverse order of disassembly 20 6 Carburetor adjustment 1 Start the engine and allow it to warm up to normal operating temperature 2 With the engine idling turn the pilot screw in or out to the setting that produces the highest idle rpm The correct setting will usually be ap proximately 3 turns out GXV 120 2 1 8 GXV 160 turns out from the fully closed position CAUTION Do not tighten the pilot screw against its seat this will damage the pilot screw or seat PILOT SCREW 3 After the pilot screw is correctly adjusted turn the throttle stop screw
12. inated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank Use of a lower octane gasoline can cause persistent pinging or heavy spark knock a metallic rapping noise which if severe can lead to engine damage CAUTION If spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline If spark knock or pinging persists consult your authorized Honda dealer Failure to do so is con sidered misuse and damage caused by misuse is not covered by Honda s Limited Warranty Occasionally you may experience light spark knock while operating under heavy loads This is no cause for concern simply means your engine 15 operating efficiently Gasoline is extremely flammable and is explosive under certain conditions e Refuel in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored e Do not overfill the fuel tank thera should be no fuel in the filler neck After refueling 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 11 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 Fuel tank capacity GXV120 1 07 0 26 US Gal 0 22
13. ine Distributor for your area www honda engines com dea htm you are still dissatisfied after soeaking with the Regional Engine Distributor you may contact the Honda Office as shown American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta GA 30005 8847 Or telephone 770 497 6400 M F 8 30 am 7 00 pm EST When you write or call please provide the following information e Equipment manufacturer s name and model number that the engine is mounted on e Engine model serial number and type e Name of the dealer who sold the engine to you e Name address and contact person of the dealer who services your engine e Date of purchase e Your name address and telephone number e Adetailed description of the problem K re e DI EXE IL 4111 1 Re tH E ER 4 EE E EECH Red Can 11 ei aes Se e EIE Ae ea EE See EE e OR 828 MER UNE EET 1 41 4 41 41 2 4 E 101 PRINTED IN JAPAN
14. ne Maintenance Schedule REGULAR SERVICE PERIOD Performed at every indicated month or operating hour interval whichever Check level Engine oil Change Check Clean Check Air cleaner Flywheel brake pad Replace if necessary Spark plug Clean Readiust Spark arrester optional part Clean Valve clearance Check Readjust Fuel tank and Clean strainer Check Fuel fine Replace if Every 3 years 2 necessary NOTE 11 Service more frequently when used in dusty areas 121 These items should be serviced by an authorized Honda dealer unless the owner has the proper 10015 and is mechanically proficient See the Honda Shop Manual 15 1 Oil change Drain the oil while the engine is still warm te assure rapid and complete draning 1 Remove the ail filler cap and drain plug to drain the oil 2 Install the drain plug and tighten it securely 3 Refill with the recommended oil page check the oil level 4 Install the Filler cap ENGINE OIL CAPACITY GXV120 0 6 0 63 US qt 0 53 Imp ait GXV160 0 65 0 69 US qt 0 57 Imp qt OIL FILLER CAP DRAIN PLUG CAUTION Used motor oil may cause skin cancer if repeatedly left in con tact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used NOTE
15. or To check loosen the drain screw with the fuel valve on If any fuel is spilled make sure the area is dry before testing the spark plug or starting the engine Fuel vapor or spilled fuel may ignite DRAIN SCREVV 8 there a spark at the spark plug d 0 Remove the spark plug cap Clean any dirt from around the spark plug base then remove the spark plug Install the spark plug in the plug cap Turn the engine switch on Grounding the side electrode to any engine ground and pull the recoil starter to see if sparks jump across the gap there ts no spark replace the plug If OK reinstall the spark plug and try to start the engine again accord ing to the instructions 6 if the engine still does not start take the engine to an authorized Honda dealer 23 Engine will not start using electric starter 1 Are the battery cables securely connected and free of corrosion 2 Is the battery fully charged 3 11 the starter moter operates but the engine will not start follow the troubleshooting procedures described under recoil starter operation 24 11 SPECIFICATIONS Dimensions GXV 1 20021 GAV12Z0D1 375 355 335 mm Length x Width x Height 14 8 x 14 0 x 13 2 in Dry weight gt 12 1 kg 26 7 Ibi 12 6 kg 27 8 Ib Engine Engine type 4 stroke overhead valve single cylinder Displacement 118 cc 7 2 cu in Bore x Stroke BO x 42 mm 2 4 x 1
16. otor oils Oo j classified SE or SF will show this designation on the container SAE 10 40 is recommended for general all temperature use Other viscosities shown in the chart Ambient temperature may be used when the average temperature in your area is within the indicated range 1 1 20 0 40 60 80 WHF 141 4 30 20 10 0 10 20 30 40 1 Remove the oil filler cap and wipe the dipstick clean 2 Insert the dipstick into the oil filler neck but do not screw it in 3 11 the level is low add the recommended oil to the upper mark on the dipstick CAUTION Running the engine with insufficient oil can cause serious engine darnage UPPER OIL LEVEL LOWER OIL LEVEL 2 AIR CLEANER Check the air cleaner elements to be sure they are clean and in good condition Clean or replace the elements if necessary page 17 CAUTION Never run the engine without the air cleaner Rapid engine wear will result PAPER ELEMENT FOAM ELEMENT 3 FUEL Your engine is designed to use any gasoline that has a pump octane number 8 of 86 or higher or that has a research oc tane number of 91 or higher Gasoline pumps at service station normally display the pump octane number We recommend that you use unleaded fuel because it produces fewer engine and spark plug deposits and extends the life of exhaust system components Never use stale or contam
17. reater than this if no carburetor modifica tion is made CAUTION Operation of the engine at an altitude lower than the carburetor is jetted for may result in reduced performance overheating and serious engine damage caused by an excessively lean air fuel mixture 27 12 WARRANTY SERVICE Owner Satisfaction Your satisfaction and goodwill are important to your dealer and to us All Honda warranty details are explained in the Distributor s Limited Warranty Warranty service is available at any dealership displaying the Honda Power Equipment Engines sign To locate dealers in your area look in the yellow pages of your telephone directory under Gasoline Engines Garden amp Lawn Equipment amp Supplies Lawn Mowers etc HONDA Power Equipment a Engines Normally any problem concerning the engine will be handled by the dealer s service department you have a warranty problem that has not been handled to your satisfaction we suggest you take the following action e Discuss your problem with a member of dealership management Often complaints can be quickly resolved at that level If the problem has already been reviewed with the Service Manager contact the owner of the dealership or the General Manager f your problem still has not been resolved to your satisfaction contact the Power Equipment Customer Relations Department of American Honda Motor Co Inc American Honda Motor Co Inc Power Equipm
18. sed space The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns Wear protective clothing and a face shield if electrolyte gets on your skin flush with water 11 electrolyte gets in your eyes flush with water for at least 15 minutes and call a physician immediately e Electrolyte is poisonous swallowed drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician e KEEP OUT OF REACH OF CHILDREN CAUTION Use only distilled water in the battery Tap water will shorten the service life of the battery e Filling the battery above the UPPER LEVEL line may cause the electrolyte to overflow resulting in corrosion to engine or nearby parts Immediate ly wash off any spilled electrolyte Do not connect the battery in reverse polarity as this will short circuit the battery charging system POSITIVE BATTERY CABLE 4 PRE OPERATION CHECK 1 ENGINE OIL CAUTION Engine oil is a major factor affecting engine performance and service life Non detergent oils and vegetable oils are not recommended Be sure to check the engine on a level surface with the engine stopped Use Honda 4 stroke oil or equivalent high detergent premium quality motor oil certified to meet or exceed U S automobile manufac 1 1 1 turer s requirements for Service 10 40 Classification SE or SF M
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