Honda Power Equipment GC135E Automobile Parts User Manual
Contents
1. 0 53 US gal 0 44 Imp gal Engine oil capacity 0 58 2 0 61 US gt 0 51 Imp qt Engine oil Service classification SF or SG SAE 10W 30 Spark plug BPROES NGK NOTE Specifications may vary according to the types and are subject to change without notice 31 kd 06 12 01 19 17 23 32Z2L600 032 MEMO 32 P Is2. Chec Change O 2 Air cleaner Chec Clean OW Replace Timing belt Chec After every 250 hrs 3 5 Spark plug Check Clean Replace Spark arrester Clean optional part Idle speed Check Adjust 3 Valve clearance Check Adjust O 3 Combustion chamber Clean After every 250 hrs 3 4 Fuel tank and strainer Clean O 2 Fuel line Chec Every 2 years Replace if necessary 3 NOTE 1 Service more frequently when used in dusty areas 2 Change engine oil every 25 hours when used under heavy load or in high ambient temperature 3 These items should be serviced by an authorized Honda dealer unless the owner has the proper tools and is mechanically proficient See the Honda Shop Manual 4 For commercial use log hours of operation to determine proper maintenance intervals 5 Check that there is no crack and abnormal wear out in the belt and replace if it is abnormal 17 06 12 01 19 16 08 32Z2L600 038 1 Oil change Drain the oil while the engine is still warm to assure rapid and complete draining 1 Remove the oil filler cap and drain plug to drain the oil 2 Install the drain plug and tighten it securely 3 with the recommended oil see page 6 and check the oil evel 4 Install the oil filler cap ENGINE OIL CAPACITY 0 58 2 0 61 US gt 0 51 Imp qt OIL FILLER CAP J DRAIN PLUG PLO Wash your hands with so
3. 2 4 in Dry weight 11 2 kg 24 7 Ibs Engine Engine type 4 stroke overhead cam 1 cylinder Displacement 135 cm 8 2 cu in Bore x Stroke 64 x 42mm 2 5 X 1 7 in Max output 2 7 KW 3 7 PS 3 600 rpm Max torque 7 4 N m 0 75 kgf m 2 500 rpm Fuel consumption 1 2 Itr h 3 600 rpm Cooling system Forced air Ignition system Transistor magneto PTO shaft rotation Counterclockwise Fuel tank capacity 1 3 0 0 45 US gal 0 37 Imp gal Engine oil capacity 0 58 2 0 61 US gt 0 51 Imp qt Engine oil Service classification SF or SG SAE 10W 30 Spark plug BPROES NGK NOTE Specifications may vary according to the types and are subject to change without notice 30 KS IN Dimensions 06 12 01 19 17 21 32Z2L600 031 Model GC160E Power equipment description code GCABE Length 337 mm 13 3 in Width 369 mm 14 5 in Height 331 mm 13 0 in Dry weight 11 5 kg 25 4 Ibs Engine Engine type 4 stroke overhead cam 1 cylinder Displacement 160 cm 9 8 cu in Bore x Stroke 64 x 50mm 2 5 X 2 0 in Max output 3 4 kW 4 6 PS 3 600 rpm Max torque 9 4 N m 0 96 kgf m 2 500 rpm Fuel consumption 1 5 Itr h 3 600 rpm Cooling system Forced air Ignition system Transistor magneto PTO shaft rotation Counterclockwise Fuel tank capacity 1 8 2
4. ATION SPARK PLUG CHOKE ROD AIR CLEANER CONTROL LEVER STARTER GRIP FUEL TANK RECOIL STARTER P gt MUFFLER 06 12 01 19 14 52 32Z2L600 006 PRE OPERATION CHECK 1 Engine oil level CAUTION eRunning the engine with insufficient oil can cause serious engine damage e Be sure to check the engine on a level surface with the engine stopped 1 Remove the oil filler cap and check the oil level 2 If the lebel is low add the recommended oil to the edge of the oil filler hole Use Honda 4 stroke 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 TERES Motor oils classified SG SF will show 8 88 this designation on the container Hewe SAE 10W 30 is recommended for gen 20 10 0 10 20 30 40 C eral all temperature use If single vis Ambient temperature N cosity oil is used select the appropri SINGLE VISCOSITY ate viscosity for the average tempera MULTI VISCOSITY ture in your area CAUTION Using nondetergent oil or 2 stroke engine oil could shorten the engine s service life OIL FILLER CAP UPPER LIMIT 6 O K IN 06 12 01 19 14 57 32Z2L600 007 2 Air cleaner CAUTION Never run the engine without the air cleaner Rapid engine wear will result Remove th
5. NGINE e Control lever with engine stop function Move the control lever to the STOP position CONTROL LEVER e Control lever with only engine stop function Move the control lever to the OFF position CONTROL LEVER 15 OFF 06 12 01 19 15 49 32Z2L600 036 MAINTENANCE Shut off the engine before performing any maintenance e To prevent accidental start up disconnect the spark plug cap 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 CAUTION Use only genuine Honda parts or their equivalent The use of replacement parts which are not of equivalent quality may damage the engine 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 are described on the following table 16 Maintenance Schedule gt 06 12 01 19 16 00 32Z2L600 017 REGULAR SERVICE PERIOD 4 each First Every Every Every Every Perform at every indicated use month season season year 2 years ITEM month or operating hours or or or or or interval whichever comes 5hrs 25hrs 50hrs 100 hrs 250 hrs first Engine oil
6. a dealer perform these carburetor modifications 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 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 12 06 12 01 19 15 32 32Z2L600 013 Oil alert system where equipped 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 NOTICE If the engine stops and will not restart check the engine oil level page 6 before troubleshooting in other areas 13 06 12 01 19 15 38 32Z2L600 034 El OPERATION 1 If the choke 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 CHOKE ROD 2 Control lever with engine stop function A Position the control lever for the desired engine speed FAST 06 12 01 19 15 44 32221600 015 E STOPPING THE E
7. a gasoline that you know does not contain alcohol 9 06 12 01 19 15 19 32Z2L600 030 STARTING THE ENGINE 1 Pull the choke rod to the CLOSED position NOTE Do not use the choke if the engine is warm or the air temperature is high gt no CLOSED CHOKE ROD CLOSED n n 2 Control lever with engine stop function 1 Move the control lever away from the SLOW position about 1 3 of the way toward the FAST position CONTROL LEVER FAST SLOW STOP SLOW STOP 10 06 12 01 19 15 24 32Z2L600 011 e Control lever with only engine stop function Move the control lever to the ON position CONTROL LEVER ON 3 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 N CAUTION Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter 06 12 01 19 15 29 32Z2L600 012 High altitude operation At high altitude the standard carburetor air fuel mixture will be ex cessively 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 1 830 m 6 000 feet above sea level have your authorized Hond
8. ap and water after handling used oil NOTE 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 itin the trash pour it on the ground or down a drain 18 06 12 01 19 16 13 32Z2L600 019 2 Air cleaner service 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 CAUTION Never run the engine without the air cleaner Rapid engine wear will result 1 Press the latch tabs on the fuel tank side of the air cleaner cover and remove the air cleaner cover AIR CLEANER COVER LATCH TABS ELEMENT 06 12 01 19 16 17 32Z2L600 020 2 Remove the element Carefully check the element for holes or tears and replace if damaged 3 Tap the element lightly several times on a hard surface 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 Replace the element if it is excessively irty 4 Install the element and air cleaner cover ELEMENT 20 06 12 01 19 16 23 32Z2L600 021 3 Spark plug service Recommended spark plug BPR6ES NGK CAUTION Never use a spark plug of incorrect heat rang
9. due to spoiled fuel is disallowed from coverage by the warranty To avoid this please strictly follow these recommendations e Only use specified gasoline page 8 e To slow deterioration keep gasoline in a certified fuel container e If long storage more than 1 month is foreseen drain fuel tank and carburetor page 26 GASOLINES CONTAINING ALCOHOL If you decide to use a gasoline containing alcohol gasohol be sure it s octane 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 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 NOTE e Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty Honda can not endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete e 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
10. e 06 12 01 19 14 14 32Z2L600 001 HONDA GC135E lt GC160E SERIAL NUMBER AND ENGINE TYPE Honda Motor Co Ltd 2003 OWNER S MANUAL LD IS 06 12 01 19 14 23 32Z2L600 002 Thank you for purchasing a Honda engine This manual covers the operation and maintenance of your engine GC135E GC160E 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 manual should be considered a permanent part of the engine and should remain with it if itis resold Pay special attention to statements preceded by the following words Cec Indicates a strong possibility of severe personal injury or death if instructions are not followed CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTICE Indicates that equipment or property damage can result if instructions are not followed NOTE Gives helpful information If a problem should arise or if you have any questions about your engine consult an authorized Honda dealer AWARNING The Honda engine is designed to give safe and dependable service if operated according to instructions Read and understand the Owner s Man
11. e To ensure proper engine operation the spark plug must be properly gapped and free of deposits 1 Remove the spark plug cap and use a spark plug wrench to remove each spark plug AWARNING If the engine has been running the muffler will be very hot Be careful not to touch the muffler 21 06 12 01 19 16 27 32Z2L600 022 2 Visually inspect the spark plug Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped Clean the spark plug with a wire brush if itis to be reused 3 Measure the plug gap with a feeler gauge Correct as necessary by bending the side electrode The gap should be 0 70 0 80 mm 0 028 0 031 in 0 70 0 80 mm 0 028 0 031 in 22 06 12 01 19 16 32 32Z2L600 023 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 compress the washer NOTE Oo 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 improperly tightened spark plug can become very hot and may damage the engine 23 06 12 01 19 16 37 32Z2L600 024 4 Spark arrester maintenance optional par
12. e air cleaner cover and check the cleaner for dirt or obstruction of the element page 19 AIR CLEANER COVER di E NI 06 12 01 19 15 04 32Z2L600 008 3 Fuel Use automotive unleaded gasoline with a Research Octane Number of 91 or higher a Pump Octane Number of 86 or higher Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in the fuel tank AWARNING e Gasoline is extremely flammable and is explosive under certain conditions 9 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 there should be no fuel above the upper limit mark After refueling make sure the fuel tank cap is closed properly and securely e 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 e Avoid repeated or prolonged contact with skin or breathing of vapor KEEP OUT OF REACH OF CHILDREN UPPER LIMIT MARK 06 12 01 19 15 12 32Z2L600 009 NOTE Gasoline spoils very quickly depending on factors such as light exposure temperature and time In worst cases gasoline can be contaminated within 1 month Using contaminated gasoline can seriously damage the engine carburetor clogged valve stuck Such damage
13. e carburetor drain screw to drain the carburetor C Retighten the drain screw CARBURETOR DRAIN SCREW AWARNING Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flames or sparks in the area 26 e 06 12 01 19 16 52 32Z2L600 027 3 Change the engine oil page 18 4 Pull the starter rope slowly until resistance is felt This closes the valves and protects them from dust and corrosion 5 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 N 27 06 12 01 19 16 57 32Z2L600 028 5 TROUBLESHOOTING When the engine will not start 1 Is there fuel in the fuel tank 2 15 gasoline reaching the carburetor To check loosen the drain screw AWARNING 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 CARBURETOR DRAIN SCREW 28 06 12 01 19 17 01 32Z2L600 029 3 Is the control lever positioned properly page 10 11 4 Is the spark plug in good condition page 21 5 If the engine still does not start take the engine to an authorized Honda dealer 29 06 12 01 19 17 11 32Z2L600_ 030 SPECIFICATIONS Dimensions Model GC135E Power equipment description code GCAAE Length 330 mm 13 0 in Width 369 mm 14 5 in Height 315 mm 1
14. n the filler neck Make sure that the filler cap is closed securely KS IN 06 12 01 19 14 39 32Z2L600 004 Safety Instruction AWARNING To ensure safe operation e If any fuel is spilled clean it up completely and allow petroleum vapours to dissipate before starting the engine e Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stored eExhaust gas contains poisonous carbon monoxide Avoid inhalation of exhaust gases Never run the engine in a closed garage or confined area e Place the engine on a stable surface Do not tilt the engine more than 20 from horizontal Operating at excessive angles may result in fuel spillage e Do not place anything on the engine as it may create a fire hazard e 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 e 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 storing it indoors SAFETY INDICATION LOCATION This indication warns you of potential hazards that can cause serious injury Read it carefully READ OWNER S MANUAL BEFORE OPERATION 06 12 01 19 14 44 32Z2L600 005 COMPONENT IDENTIFIC
15. t AWARNING If the engine has been running the muffler will be very hot Allow it to cool before proceeding CAUTION The spark arrester must be serviced every 100 hours to maintain its efficiency 1 Remove the muffler protector by removing the three 6 mm bolts 2 Remove the spark arrester from the muffler by removing the two screws Taking care not to damage the wire mesh NOTE Check for carbon deposits around the exhaust port and the spark arrester and clean if necessary n q n 5 MUFFLER N SCREW 2 SPARK ARRESTER MUFFLER PROTECTOR 6 mm BOLTS 06 12 01 19 16 43 32Z2L600 025 3 Use a brush to remove carbon deposits from the spark arrester screen CAUTION Be careful not to damage the spark arrester screen SCREEN NOTE n n The spark arrester must be free of breaks and holes Replace if necessary 4 Install the spark arrester and the muffler in the reverse order of disassembly 25 06 12 01 19 16 49 32Z2L600 026 88 TRANSPORTING STORAGE When transporting the engine keep the engine level to prevent 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 Empty the fuel tank into an approved gasoline container using a commercially available hand siphon B Loosen th
16. ual before operating the engine Failure to do so could result in personal injury or equipment damage 2 06 12 01 19 14 31 32Z2L600 003 E SAFETY INSTRUCTIONS To ensure safe operation e Honda engine is designed to give safe and dependable service 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 e Always make a pre operation check page 6 before you start the engine You may prevent an accident or equipment damage e To prevent fire hazards and to provide adequate ventilation keep the engine at least 1 meter 3 feet away from buildings and other equipment during operation Do not place flammable objects close to the engine e 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 e 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 flammable objects such as gasoline matches etc close to the engine while it is running e Refuel in a well ventilated area with the engine stopped Gasoline is highly flammable and explosive under certain conditions Do not overfill the fuel tank There should be no fuel i
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