Honda Power Equipment FR650 Tiller User Manual
Contents
1. 7 When engine warms up move the control lever to FAST or SLOW FAST SLOW CONTROL LEVER 13 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 specific modifica tions to the carburetor If you always operate the engine at altitudes higher than 1 500 m 5 000 feet above sea level have your authorized Honda dealer perform these carburetor modifi cations 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 14 STOPPING THE ENGINE 3 Without FLYWHEEL BRAKE LEVER type Move the control lever to the STOP position 1 Move the control lever to the SLOW position The engine switch which is linked with the control lever is turned off when the control lever is moved to the STOP position SLOW STOP CONTROL LEVER CONTROL LEVER 2 With FLYWHEEL BRAKE LEVER type Return the flywheel brake lever to the ENGAGED position The engine switch which is2. applicable types FLYWHEEL BRAKE LEVER applicable types FUEL TANK CAP CONTROL LEVER AIR CLEANER FUEL VALVE FUEL TANK PRE OPERATION CHECK 1 Engine oil level CAUTION eRunning the engine with insufficient oil can cause serious engine damage Be sure to check the engine on a level surface with the engine stopped 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 If the level is low add the recommended oil to the upper limit on the dipstick 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 SH Motor oils classified SG SH 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 area SAE Viscosity Grades SAE TEMP 30 AMBIENT TEMPERATURE CAUTION Using nondetergent oil or 2 stroke engine oil could shorten the engine s service life SO kX OIL FILLER CAP DIPSTICK UPPER LIMIT LOWER LIMIT 2 Air cleaner CAUTION Never run the engine without the air cleaner Rapid engine wear will result Remove the air cleaner cover and check the cleaner for dirt or obstruction of the
3. element page 20 ELEMENT AIR CLEANER COVER 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 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 there should be no fuel in the filler neck After refueling make sure the 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 LEVEL FUEL FILLER NECK 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 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
4. linked with the flywheel brake lever 4 Turn the fuel valve to the OFF position is turned off when the flywheel brake lever is moved to the ENGAGED position FUEL VALVE 16 OB MAINTENANCE e 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 CAUTION 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 17 Maintenance Schedule REGULAR SERVICE PERIOD 4 Each First Every Every Every Every ITEM use month 3 6 year 2years Perform at every indicated month or or months months or or operating hours interval whichever 5hrs or or 100 hrs 250 hrs comes first 25 hrs 50 hrs Engine oil Check
5. plug or starting the engine Fuel vapor or spilled fuel may ignite DRAIN BOLT FUEL VALVE 4 Is the control lever positioned properly page 11 5 Is the flywheel brake lever positioned to the RELEASED position page 12 applicable types 6 Is the spark plug in good condition page 24 7 If the engine still does not start take the engine to an authorized Honda dealer 31 E SPECIFICATIONS Dimensions GCV135E GCV160E Power equipment description code GJAFE GJAAE Length 351 mm 13 8 in 367 mm 14 4 in Width 331 mm 13 0 in 331 mm 13 0 in Height 353 mm 13 9 in 360 mm 14 2 in Dry weight 10 4 kg 22 9 Ibs 10 5 kg 23 1 Ibs Engine Engine type 4 stroke overhead cam 1 cylinder Displacement 135 cm 8 2 cu in 160 cm 9 8 cu in Bore x Stroke 64 x 42 mm 64 x 50 mm 2 5 x 1 7 in 2 5 x 2 0 in Max output 3 3 kW 4 5 PS 4 1 kW 5 5 PS 3 600 rom 3 600 rpm Max torque 9 7 N m 0 99 kgf m 11 4 N m 1 16 kgf m 2 500 rpm 2 500 rpm Fuel consumption 313 g kWh 230 g PSh Cooling system Forced air Ignition system Transistor magneto PTO shaft rotation Counterclockwise Fuel tank capacity 0 9 2 0 24 US gal 0 20 Imp gal 1 12 0 29 US gal 0 24 Imp gal Engine oil capacity 0 55 2 0 58 US qt 0 48 Imp qt Engine oil Service classification SG or SH SAE 10W 30 Spark plug BPR6ES
6. 9 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 29 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 cannot 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 a gasoline that you know does not contain alcohol 10 STARTING THE ENGINE 1 Turn the fuel valve to the ON position FUEL VALVE 2 e Without C
7. HOKE LEVER type Move the control lever to the CLOSE position e With CHOKE LEVER type AUTOMATIC RETURN CHOKE type Move the choke lever to the CLOSE position NOTE Do not use the choke if the engine is warm or the air temperature is high WITH CHOKE LEVER TYPE CHOKE LEVER WITHOUT CHOKE LEVER TYPE oo CONTROL LEVER OPEN CLOSE 2 A 11 3 With FLYWHEEL BRAKE LEVER type only Move the flywheel brake lever to the RELEASED position 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 FLYWHEEL BRAKE LEVER 4 Pull the starter grip lightly 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 With CHOKE LEVER type AUTOMATIC RETURN CHOKE type Operate the recoil starter as soon as you move the flywheel brake lever to the RELEASED position The choke lever automatically begins moving to the OPEN position when the flywheel brake lever is moved to the RELEASED position 5 If the 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 6 Move the flywheel brake lever to the RELEASED position and immediately begin operating the recoil starter Without CHOKE LEVER type
8. HON DA GCV135E GCV160E SERIAL NUMBER AND ENGINE TYPE ECOLOGY CONSCIOUS TECHNOLOGY OWNER S MANUAL 32Z0M600 00X32 ZOM 6000 PRINTED IN ITALY 1 CE Honda Motor Co Ltd 2003 130000 2004 10 Thank you for purchasing a Honda engine This manual covers the operation and maintenance of your engine GCV135E GCV160E 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 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 it is resold Pay special attention to statements preceded by the following words Cie 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 acco
9. NGK NOTE Specifications may vary according to the types and are subject to change without notice 32
10. NSPORTING STORAGE 3 Change the engine oil page 19 4 Pull the starter rope slowly until resistance is felt This closes the When transporting the engine turn the fuel valve OFF and keep valves and protects them from dust and corrosion 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 Turn the fuel valve to the OFF position B Remove the carburetor drain bolt and drain the carburetor C Turn the fuel valve to the ON position and drain the fuel in the fuel tank into the container D Retighten the carburetor drain bolt so that the float chamber and washer cannot be warped and turn the fuel valve to the OFF position 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 DRAIN BOLT FUEL VALVE AWARNING Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flames or sparks in the area 29 30 E TROUBLESHOOTING When the engine will not start 1 Is the fuel valve ON 2 Is there fuel in the fuel tank 3 Is gasoline reaching the carburetor To check loosen the drain bolt with the fuel valve ON AWARNING If any fuel is spilled make sure the area is dry before testing the spark
11. fuel tube from the fuel tank and fuel valve and keeping the fuel tank to a level WITH TOP COVER TYPE TAPPING SCREWS TP COVER ELEMENT ALL TYPES 6 mm NUTS RECOIL STARTER FUEL TANK 21 22 4 Check the brake shoe thickness If it is less than 3 mm 0 12 in replace it with new one gt BRAKE SHOE THICKNESS BRAKE SHOE 5 Install the fuel tank and recoil starter and tighten the three 6 mm nuts securely 6 Install the top cover and tighten the three tapping screws securely with top cover type only 23 4 Spark plug service Recommended spark plug BPR6ES NGK CAUTION Never use a spark plug of incorrect heat range 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 24 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 it is 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 l 0 028 0 031 in t 25 4 Check that the spark plug washer is in good condition and thread t
12. he 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 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 26 5 Spark arrester maintenance optional part 3 Use a brush to remove carbon deposits from the spark arrester screen AWARNING If the engine has been running the muffler will be very hot Allow CAUTION it to cool before proceeding Be careful not to damage the spark arrester screen CAUTION SCREEN 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 NOTE SCREW The spark arrester must be free of breaks and holes Replace if necessary SPARK ARRESTER 4 Install the spark arrester and the muffler in the reverse order of disassembly MUFFLER SCREW MUFFLER PROTECTOR 6 mm BOLTS 27 28 TRA
13. level Change O O 2 Air cleaner Check Clean on Replace O Flywheel brake pad Check O applicable types Spark plug Check adjust O Replace O Spark arrester Clean O optional part Idle speed Check adjust O 3 Fuel tank and filter Clean O 3 Valve clearance Check adjust O 3 Combustion chamber __ Clean After every 250 hrs 3 Fuel tube Check 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 your servicing dealer unless you have the proper tools and are mechanically proficient Refer to Honda Shop Manual for service procedures 4 For commercial use log hours of operation to determine proper maintenance intervals 18 1 Oil change Drain the oil while the engine is still warm to assure rapid and complete draining 1 Turn the fuel valve to the OFF position see page 16 2 Remove the oil filler cap and drain the oil into the oil container by inclining the engine toward the oil filler neck 3 Refill with the recommended oil and check the oil level see page 7 4 Install the oil filler cap ENGINE OIL CAPACITY 0 55 2 0 58 US qt 0 48 Imp qt OIL FILLER NECK Wash your hands with soap and water after handling used oil NOTE Please dispose of used motor oil in a manner that is compatible with the environment We suggest
14. ller neck Make sure that the filler cap is closed securely 3 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 15 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 COMPONENT IDENTIFICATION STARTER GRIP SPARK PLUG MUFFLER TOP COVER applicable types CHOKE LEVER
15. rding 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 2 El 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 inspection page 7 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 e 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 e Do not overfill the fuel tank There should be no fuel in the fi
16. you take it in 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 19 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 AWARNING 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 air cleaner cover by unhooking the two upper tabs on the top of the air cleaner cover and the two lower tabs ELEMENT AIR CLEANER COVER UPPER TABS LOWER TABS 2 Remove the element Carefully check the element for holes or tears and replace if damaged 20 3 Tap the element lightly several times on a hard surface to 3 Flywheel brake inspection applicable types remove excess dirt or blow compressed air through the filter from the inside out Never try to brush the dirt off brushing will 1 Remove the top cover by removing the three tapping screws force dirt into the fibers Replace the element if it is excessively with top cover type only dirty 2 Remove the recoil starter by removing the three 6 mm nuts 4 Install the element and air cleaner cover 3 Remove the fuel tank taking care not to disconnect the
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