Honda Power Equipment FL5540K0 Lawn Mower User Manual
Contents
1. TING diae nasa Preparation for StOFJQ8 ci everti pP SER UR EN REMIS NU a otorage Removal from Storage ccccccacececaccescecetcocssvvespeecsnecteataneureesurersecees 1 TILLER SAFETY IMPORTANT SAFETY INFORMATION For your safety and the safety of others pay special attention to these precautions Operator Responsibility Keep the tiller in good operating condition Operating a tiller in poor or questionable condition could result in serious injury Be sure all safety devices are in working order and warning labels are in place These items are installed for your safety Be sure the safety covers V belt cover chain case cover and recoil starter cover are in place Know how to stop the engine and tines quickly in case of emergency Understand the use of all controls Be very cautious when operating the tiller in REVERSE especially if attachments are being used Keep a firm hold on the handlebars They may tend to lift during clutch engagement Allowing anyone to operate this tiller without proper instruction may result in injury Wear sturdy full coverage footwear Operating this tiller barefoot or with open toe shoes or sandals increases your risk of injury Dress sensibly Loose clothing may get caught in moving parts increasing your risk of injury alert Operating this tiller when you are tired2. Power Equipment Owners Manual TILLER FR600 FR800 as RESET RT RES a EE TUR We SF i Click here to save this EE DS es ue s ES 25 manual to your computer DLE NENNEN a M E d En A s ME Um ewes EX LI Ix cooctidg cl 2 200 WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Keep this owner s manual handy so you can refer to it at any time This owner s manual is considered a permanent part of the tiller and should remain with the tiller if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations are based on the FR800 Honda Motor Co Ltd reserves the right however to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever No part of this publication may be reproduced without written permission INTRODUCTION Congratulations on your selection of a Honda tiller We are certain you will be pleased with your purchase of one of the finest tillers on the market We want to help you get the best results from your new tiller and to operate it safely This manual contains the information on how to do that p
3. 2 Remove the oil filler cap dipstick and drain bolt 3 Tilt the tiller forward and allow all of the oil to drain 4 Reinstall and tighten the oil drain bolt Refill with the recommended oil page 11 e113 to the top of the oil OILDRAINBOLT ENGINE OIL FILLER 2m CAP DIPSTICK OIL CAPACITY FR600 0 6 US qt 0 60 0 5 Imp qt FR800 1 2 US qt 1 12 1 0 Imp at 5 Reinstall the oi filler cap dipstick Wash your hands with soap and wa ter after handling used oil Please dispose of used motor oil and containers in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local service station for reclamation Do not throw it in the trash or pour it on the ground Running the engine with low oil level will cause serious engine damage 32 TRANSMISSION OIL CHANGE Drain the oil while the engine is OIL FILLER CAP DIPSTICK warm to assure rapid and complete draining 1 Place a suitable container under the transmission to catch the used Oll 2 Remove the oil filler cap and the drain bolt to drain the used oil Reinstali the drain bolt and fill the transmission case up to the tip of the filler cap dipstick with the recommended oil See page 11 OIL CAPACITY 2 5 US qt 2 40 2 1 Imp qt 4 Reinstall and tighten the filler cap Wash your hands with soap and wa ter after handling used oil Please dispose of used motor oil
4. 9 axo Handlebar Height Adjustment sse mee 20 Tiling Depth 20 Main Clutch 20 Gear Selection 2 Tine Clutch G M Tm High Altitude 24 he Importance of Maintenance 26 Maintenance Safety Emission Control System Information cesses 28 PA MOO TU I Maintenance Schedule mmm 7 EV Ede or ino NITET T D 32 Transmission Oil Air Filter ski Fastener Tightness Check OO Spark Plug Service Mi Spark Arrester Service optional part OF Sediment CUD Main Clucth Cable Adjustment ues dU 5 Tine Cable Adjustment esee Throttle Cable mme Drive ntaa Upper Chain
5. However we cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task A WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in the owner s manual Safety precautions Make sure the engine is off before you begin any maintenance repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts 27 EMISSION CONTROL SYSTEM INFORMATION Source of Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not re
6. ill or under the influence of alcohol or drugs may result in serious injury Keep all persons and pets away from the tilling area Be sure the drag bar is in place and properly adjusted Child Safety Keep children indoors and supervised at all times when any outdoor power equipment is being used nearby Young children move quickly and are attracted especially to the tiller and the tilling activity Never assume children will remain where you last saw them alert and turn the tiller off if children enter the area Children should never be allowed to operate the tiller even under adult supervision Rotating Tines Hazard The rotating tines are sharp and they turn at high speed Accidental contact can cause serious injury Keep your hands and feet away from the tines while the engine Is running Stop the engine and disengage the tine clutch before inspection maintenance of tines Disconnect the spark plug cap to prevent any possibility of accidental starting Wear heavy gloves to protect your hands when cleaning the tines or when inspecting or replacing the tines Thrown Object Hazard Objects hit by the rotating tines can be thrown from the tiller with great force and may cause serious injury Before tilling clear the tilling area of sticks large stones wire glass etc Till only in daylight Always inspect the tiller for damage after striking a foreign object Repair or replace
7. air cooled overhead valve Displacement 9 9 cu in 163 cm 14 8 cu in 242 cm Bore and stroke 2 7 X 1 8in 68 X 45 mm 2 9 X 2 3in 73 X 58 mmj Engine oil capaci 0 6 US qt 0 6 2 0 5 Imp qt 1 59 US gal 6 0 0 1 32 Imp gal BPR6ES NGK W20EPR U DENSO Main clutch Belt tension Three speeds forward and one reverse speed Transmission oil capaci 2 5 US qt 2 42 2 1 Imp qt Model J FR600 0 Mi Adjustable drag bar 6 on each side 0 37 US qt 0 35 2 0 31 Imp qt SPECIFICATION MAINTENANCE Spark plua aar 0 028 0 031 in 10 70 0 80 mm Referto page 36 Valve clearance IN 0 15 0 22 mm cold See your authorized 0 20 0 02 mm cold Honda dealer Other specification No other adiustments needed NOTE Specifications may vary according to the types and are subject to change without notice 49 11 SERVICE INFORMATION Honda power equipment 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 or General Manager can help Almost all probiems are solved in this way If you are dissatisfied with the decision made by the dealership s management contact the Honda Power Equipment Customer Helations Office You can write to Ameri
8. and containers in a manner that is compatible with the enviromment We suggest you take used oil in a sealed container to your local service station for reclamation Do not throw it in the trash or pour it on the ground 33 AIR FILTER SERVICE dirty air filter 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 Never run the engine without the air filter Rapid engine wear will result 1 Remove the cover wing nut then remove the air cleaner cover 2 Remove the filter wing nut then remove and separate the air filter elements Carefully check both elements for holes or tears and replace the filter if damaged 3 Foam element Clean in warm soapy water rinse and allow to dry thoroughly Or clean in nonflammable solvent and allow to dry Dip the element in clean engine oil and squeeze out all excess oil The engine will smoke during initial running if too much oil is left in the foam AWARNING Using gasoline or flammable solvent to clean the filter element can lead to a fire or explosion Use only soapy water or nonflammable solvent 4 Paper element Tap the element several times on a hard surface to remove excess dirt or blow compressed air not exceeding 30 psi 207 kPa 2 1 through the filter from the inside Never try to brush the dirt off brushing will force dirt i
9. fuel valve OFF and keep the tiller level to prevent fuel spillage Fuel vapor or spilled fuel may ignite Before storing the unit for an extended period 4 Be sure the storage area is free of excessive humidity and dust Drain the fuel a With the fuel valve turned OFF remove and empty the sediment cup b Turn the fuel valve and drain the gasoline in the fuel tank into a suitable container 44 DRAIN c Replace the sediment cup and tighten securely d Drain the carburetor by loosening the drain knob Drain the gasoline into a suitable container Tighten the drain Knob 5 Change the engine 32 C us incer Remove the spark plug ipage 36 b Pour a tablespoon of clean engine oil into the cylinder Pull the start er grip several times to distribute the oil in the cylinder Reinstall the spark plug NOTE While the spark plug is removed inspect the plug and clean gap or replace it if necessary Pull the starter grip until you feel resistance This closes the valves which helps to protect the cylinder from corrosion 45 STORAGE Select a storage area away from appliances water heater or clothes dryer that use an open flame as a heat source Power tools and some battery operated toys have electric motors that produce sparks that can ignite gasoline vapors AWARNING Gasoline is highly flammable and explosive You can be burned or seriously
10. injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediatery Avoid storing the tiller where it will be exposed to high humidity and dust Place the tiller with its tines and wheels on a level surface Tilting the tiller may result in fuel leakage Cover the tiller to keep out dust NOTE Plastic sheets should not be used as dust covers they trap moisture under the covers promoting rust and corrosion 46 REMOVAL FROM STORAGE Check all items described in the PRE OPERATION CHECK section of this manual pages 11 16 NOTE Fill the fuel tank with fresh gasoline If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline Gasoline oxidizes and deteriorates over time resulting in bad fuel that may cause hard starting Linie Gasoline 15 highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame avvay Handle fuel only outdoors Wipe up spills immediatery elf the cylinder was coated with oil during storage preparation the engine will smoke briefly at start up This is normal 47 9 TROUBLESHOOTING When the engine will not start 1 15 there enough fuel 2 15 the fuel valve ON 3 15 the engine switch ON 4 15 gasoline reaching the carburetor To check loosen the drain knob with the fuel valve on Fuel should flow o
11. the tiller from surging forward when the tines hit hard ground Select reverse R to maneuver the tiller backward The tine clutch lever must be in the DISENGAGE position before you can move the gear shift lever into reverse Avoid using excessive force on the gear shift lever If gear engagement is difficult push and release the main clutch lever to move the tiller slightly this will reposition the gears to facilitate engagement GEAR SHIFT LEVER GEAR SHIFT GATE 21 TINE CLUTCH OPERATION The tine clutch engages and disengages the tine drive Release the main clutch lever before operating the tine clutch lever Move the tine clutch lever forward to engage the tine drive for tilling The tines will start to rotate when you push the main clutch lever down against the handlebar The tines will stop when you release the main clutch lever Move the tine clutch lever back to disengage the tine drive for propelling the tiller to and from the work area the tines will not rotate when the main clutch is operated Engage the tine clutch with the transmission in any forward gear 1 2 Do not engage the tine clutch with the transmission in neutral N The tines and wheels must both be driven for good tilling control Wheel traction helps to prevent the tiller from surging forward when the tines hit hard ground The tine clutch lever cannot be moved to the engaged position while the gear shift lever is in reverse DIS
12. to start the engine turn it to the OPEN CHOKE LEVER position as soon as the engine warms up enough to run smoothly 18 CLEARING FLOODED ENGINE If the engine won t start after you have operated the starter several times the engine may be flooded with excess fuel Use the following procedure to clear and start a flooded engine 1 Turn the engine switch to the OFF position SS 2 Remove the spark plug dry it then reinstall it NOTE Install the spark plug carefully by hand to avoid cross threading After the spark piug is seated tighten 1 8 to 1 4 turn with a spark plug wrench to compress the washer 3 Turn the engine switch to the ON position 4 Move the throttle lever to the FAST 49 position 5 Turn the choke lever to the position Correction Turn the choke lever to the OPEN position 6 Pull the starter grip lightly until you feel resistance then pull briskly Return the starter grip gently don t let it snap back against the engine STARTER GRIP 19 5 TILLER OPERATION Dr e ADJUSTING THE HANDLEBAR BE SURE THE ENGINE IS F HANDLEBAR HEIGHT ADJUSTMENT NOTICE Before adjusting the handlebar place the tiller on firm level qround to prevent the handle from collapsing accidentally Stop the engine before adjusting handlebar height To adjust handlebar height loosen the adjuster knob select HEIGHT ADJUSTER KNOB N the appropriate holes in the ha
13. ENGAGED TINE CLUTCH LEVER 22 HANDLING TIPS Adjust the handlebar height to a comfortable position waist height for norma tilling The drag bar should always be used when tilling It enables you to compensate for the hardness of the soil The ideal height of the drag bar will depend on the type of soil being tilled and soil conditions at the time of tilling In general however the drag bar should be adjusted so that the tiller is tilted slightly backward elf the machine jerks forward while tilling press down the handlebars This will cause the drag bar to dig more deeply into the soll elf tines dig in but the machine will not move forward move the handlebars from side to side When turning push down on the handlebars to bring the tiller s weight to the rear this will make turning easier Stop the tines before crossing gravel drives walks or roads Stay alert for hidden hazards or trafic e Stop the engine immediately if the tiller vibrates abnormally Check the tiller for damage or loose parts and repair or replace them before using the tiller again Vibration is usually a sign of trouble 23 HIGH ALTITUDE OPERATION At high altitude the standard carburetor air fuel mixture will be too rich Performance will decrease and fuel consumption will increase very rich mixture will also foul the spark plug and cause hard starting High altitude performance can be improved by spec
14. ER SIDE COVER MUD GUARD ENGINE OIL FILLER CAP DIPSTICK TINE CLUTCH ROTARY TINES CENE WHEEL WEIGHT FR800 ONLY GEAR SHIFT LEVER AIR CLEANER ENGINE SERIAL NUMBER 9 p HANDLE HEIGHT M SK 4 ADJUSTER 7 e i FRONT WEIGHT B FR600 ONLY M c ERU MED EF FRAME SERIAL NUMBER 72 SE WA LA e d FUEL VALVE STARTER GRIP Record the frame and engine serial numbers for your reference Refer to the serial numbers when ordering parts and when making technical or warranty inquiries see page 50 Frame seria number Engine serial number 10 3 PRE OPERATION CHECK ENGINE OIL Check the engine oil level with the engine stopped and in a level position 1 Remove the oil filler cap dipstick and wipe it clean 2 Insert and remove the dipstick without screwing it into the filler neck Check the oil level shown on the dipstick 3 If the oil level is low fill to the edge of the oil filler hole with the rec ommended oil ENGINE OIL E FILLER CAP DIPSTICK Running the engine with a low oil level will cause serious engine damage Use 4 stroke motor oil that meets or exceeds the requirements for SAE VISCOSITY GRADES service classification SJ Always check the API SERVICE labei on the container to be sure it includes the letters SJ SAE 10W 30 is recommended for general use Other viscosities 20 0 20 40 60 80 100F shown
15. act in the same way but it is toxic Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons The U S and California Clean Air Acts EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emis sion control systems The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters 28 Problems That Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring under load Afterburning backfiring Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your Honda engine were designed built and certified conform with EPA and California emission regulations We recommend the use of g
16. al words DANGER WARNING or CAUTION These signal words mean A DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions WARNING You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow CAUTION instructions Safety Headings such as IMPORTANT SAFETY INFORMATION Safety Section such as TILLER SAFETY Instructions how to use this tiller correctly and safely This entire book is filled with important safety information please read it carefully 2 5 mportant Safety Information Safety lE tea uS OMPONENT IDENTIFICATION 1 10 CHECK 1 mH Hmmm 117 Transmissiolt Ilo Ie Lower Chain Case Olli ccccsccccceccceetessccessensersteusrantsssesersenstttasteceaa 12 Tire 1G E 4 STARTING IHE ENGINE tartin M Clearing a Flooded Engine eee
17. any damaged parts before continuous use Pieces thrown from worn or damaged tines can cause serious injury Always inspect the tines before using the tiller Fire and Burn Hazard Gasoline is extremely flammable and gasoline vapor can explode Use extreme care when handling gasoline Keep gasoline out of reach of children Refuel in a well ventilated area with the engine stopped Allow the engine to cool before refueling Fuel vapor or spilled fuel may ignite The engine and exhaust system become very hot during operation and remain hot for a while after stopping Contact with hot engine components can cause burn injuries and can ignite some materials Avoid touching a hot engine or exhaust system Allow the engine to cool before performing maintenance or storing the tiller indoors Carbon Monoxide Poisoning Hazard Exhaust contains poisonous carbon monoxide a colorless and odorless gas Breathing exhaust can cause loss of consciousness and may lead to death If you run the engine in an area that is confined or even partially enclosed the air you breathe could contain a dangerous amount of exhaust gas keep exhaust gas from building up provide adequate ventilation Operation Slope When tilling on slopes keep the fuel tank less than half full to minimize fuel spillage Till across the slope at equally spaced intervals rather than up and down it Be very careful when c
18. can Honda Motor Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia 30005 8847 Or telephone 770 497 6400 When you write or call please give us this information Model and serial number see page 10 Name of dealer who sold the tiller to you Name and address of dealer who services your tiller Date of purchase Your name address and telephone number detailed description of the problem 50 51 31770620 EM 280 Go 3002000
19. e belt tensioner 4 If adjustment is necessary loosen the engine and engine stay mount ing bolts and move the engine back and forth until the correct distance is obtained 5 After adjusting the distance tighten the engine and engine stay mounting bolts securely FR600 V belt 5840 FR800 dede NOTE Align the surface of the drive pulley with the surface of the driven pulley when adiusting the belt tension 6 Adjust the belt to belt stopper clearances as shown FR600 0 12 0 16 in 3 0 5 0 mm 2 0 4 0 mm 7 adjust loosen the stopper mounting bolt and move the stopper up or down as necessary 8 After adjusting the clearance tighten the stopper mounting bolt securely 9 Reinstall the belt cover FR600 2 6 2 8 in 65 70 mm FR800 2 0 2 2 52 57 mm ENGIME STAY MOUNTING BOLT Ley EL AA AR Ome 4 4 r ENGINE MOUNTING BOLT After adjustment be sure to reinstall the belt cover Failure to follow this instruction may cause your clothing to be caught in moving parts resulting in serious accident or injury 40 UPPER CHAIN ADJUSTMENT 1 2 Remove the primary chain case Check chain slack midway between the sprockets It should be 0 20 0 59 in 5 0 15 0 mm To adjust tension loosen the tensioner adjusting bolts and move the tensioner up or do
20. enuine Honda parts whenever you have maintenance done These original design replacement parts are manufactured to the same standards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations Maintenance Follow the maintenance schedule page 31 Remember that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature operation or use in unusually wet or dusty conditions will require more frequent service 29 AIR INDEX An Air Index Information hang tag iabel was applied to this engine accordance with the requirements of the California Air Resources Board The bar graph is intended to provide you our customer the ability to compare the emissions performance of available engines The lower the Air Index the less pollution The durability description is intended to provide you with information relating to the engine s emission durability period The descriptive term indicates the useful life period for the engine
21. hanging the direction of the tiller on a slope Do not use the tiller on a slope of more than 10 The maximum safe grade angle mentioned above is for reference purpose only and should be determined according to the type of attachments Before starting the engine check that the tiller is not damaged and is in good condition For your safety and safety of oth ers exercise extreme care when using the tiller on a slope SAFETY LABEL LOCATIONS These labels warn you of potential hazards that can cause serious inju ry Read them carefully label comes off or becomes hard to read contact your Honda tiller dealer for a replacement CONTACT WITH ROTATING TINES WILL CAUSE SERIOUS INJURY Keep hands and feet away while the gngine 19 running E Rotary tillers can be hazardous If operated improperly to avoid sericus injury read all safety instructions carefully E Read Owner s Manual before operation the Owrier s Manual has important safety and operation information GASOLINE 15 FLAMMABLE AND EXPLOSIVE B Stop angine Avold heat sparks and open flame when refuellmg o AWARNING amp DRIVE BELT AND PULLEYS INJURE YOU Keep guard in place during operation CAUTION HOT MUFFLER CAN BURN YOU Stay away if engine has been running 2 COMPONENT IDENTIFICATION MAIN CLUTCH LEVER THROTTLE LEVER MUFFLER FUEL TANK CAP ENGINE SWITCH FUEL TANK V BELT COV
22. heat and damage the engine Overtightening the spark plug can damage the threads in the cylinder head If installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats 7 Instail the spark plug cap on the spark plug 0 028 0 031 in 13 16 inch SPARK PLUG WRENCH 0 70 0 80 mm uii 36 SPARK ARRESTER SERVICE optional Your engine is not factory equipped with a spark arrester In some areas it is illegal to operate an engine without a spark arrester Check local laws and regulations spark arrester is available from authorized Honda servicing dealers The spark arrester must be serviced every 100 hours to keep it functioning as designed If the engine has been running the muffler will be very hot Allow the muffler to cool before servicing the spark arrester 1 Remove the two 8 mm nuts D and remove the muffler from the cyl inder 2 Remove the three 4 mm screws from the exhaust deflector D and remove the deflector 3 Remove the four 5 mm screws from the muffler protector and remove the muffler protector 4 Remove the 4 mm screw 6 from the spark arrester D and remove the spark arrester from the muffler 3 FR600j FR800 5 Use a brush to remove carbon deposits from the spark arrester screen Be careful to avoid damaging the screen SCREEN The
23. ific modifications to the carburetor If you always operate your engine at altitudes above 1 500 meters 5 000 feet have your servicing dealer perform this car buretor modification Even with carburetor modification engine horsepower will decrease about 3 5 for each 300 meter 1 000 foot increase in altitude The ef fect of altitude on horsepower will be greater than this if no carburetor modification is made When the carburetor has been modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 1 500 meters 5 000 feet with a modified carburetor may cause the engine to overheat and result in serious engine dam age For use at low altitudes have your servicing dealer return the car buretor to original factory specifications 24 6 STOPPING THE ENGINE To stop the engine in an emergency release the main clutch lever and turn the engine switch to the OFF position To stop the engine under normal conditions use the following steps 1 Release the main clutch lever MAIN CLUTCH LEVER DISENGAGED 2 Move the throttle lever to the idle m position THROTTLE LEVER 3 Turn the engine switch to the OFF position ENGINE SWITCH 4 Turn the fuel valve to the OFF position 7 MAINTENANCE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe economical and trouble free operation It will also help reduce air pollutio
24. ilicone spray lubricant 43 For storage of a month longer perform these additional steps 3 Fill the fuel tank with fresh gasoline and add a gasoline conditioner such as HONDA FUEL STABILIZER which is formulated to extend fuel storage life Be sure the fuel tank is completely filled If partially filled air in the tank will promote fuel oxidation and deterioration resulting in bad fuel that may cause hard starting Deteriorated fuel may also clog carbure tor passages requiring carburetor repair or replacement Fuel oxidation problems can also be prevented by completely draining the fuel tank and carburetor Carburetor draining is recommended if storage time will exceed two months However a drained fuel tank may rust from the effects of moisture condensation is best to leave the fuel tank completely filled unless you are preparing the tiller for shipment or other special circumstances NOTE The Distributor s Limited Warranty does not cover fuel system damage of engine performance problems resulting from neglected storage preparation If storage time will not exceed two months it is not necessary to drain the carburetor Add gasoline conditioner before starting the engine page 44 step 3 that will ensure that treated gasoline replaces the untreated gasoline in the carburetor For storage of two months or longer perform these additional steps A WARNING When transporting or storing the tiller turn the
25. in the following chart may 30 20 10 0 10 20 30 40 C be used when the average temper Ambient temperature ature in your area is within the in dicated range Using nondetergent oil can shorten the engine s service life and using 2 stroke oil will damage the engine 11 TRANSMISSION OIL With the tiller on level ground remove the oil filler cap and check to see if oil is up to the tip of the dipstick Add engine oil if necessary see page 11for recommended oil AM FILLER CAP DIPSTICK LEVEL GAUGE LOWER CHAIN CASE OIL Place the tiller on level ground and remove the oil level check boit Remove the oil filler cap The oil level should be up to the lower edge of the check bolt hole If the level is low add oil until it begins to flow out of the hole see page 11 for recommended oil OIL LEVEL CHECK BOLT 12 Refueling Stop the engine Remove the fuel tank cap and check the fuel level Refill the tank if the fuel level is low Fuel tank capacity FR600 0 95 US gal 3 6 0 0 78 Imp FR800 1 59 US gal 6 0 2 1 32 Imp gal Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately After refueling tighten the fuel tank cap securely If any fuel was spilled make sure the area is dry bef
26. ing rapid engine wear This type of damage is not covered by the Distributor s Limited Warranty TIRE PRESSURE Excessive tire pressure will reduce traction and underinflation may IT result in abnormal or accelerated tire wear For best performance keep the tires inflated to 17 psi 118 kPa 1 20 kgf cm s TINES ASL VALVE Jp dc the tines and replace them are worn or damaged page 41 Be sure all nuts and bolts are tight 16 4 STARTING THE ENGINE Be sure the main clutch is disengaged and the shift lever is in the neutral position to prevent sudden uncontrolled movement when the engine starts The clutch is engaged by squeezing the clutch lever and disengaged by releasing the lever 1 Turn the fuel valve to the ON position Be sure that the drain knob is tightened securely FUEL VALVE DRAIN KNOB 2 Turn the engine switch to the ON j position ENGINE SWITCH 3 Turn the choke lever to the CLOSED position NOTE Do not use the choke if the engine is warm or the outside air temperature is warm 17 4 the throttle lever to the position marked with a dot THROTTLE LEVER START 5 Pull the starter grip lightly until resistance 15 felt then pull briskly Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the starter STARTER GRIP 6 if the choke lever has been turned to the CLOSED position
27. lease read it carefully you read this manual you will find information preceded by a symbol That information is intended to help you avoid damage to your tiller other property or the environment We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership The warranty policy Is a separate document that should have been given to you by your dealer When your tiller needs scheduled maintenance keep in mind that your Honda servicing dealer is specially trained in servicing Honda tillers Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns Best Wishes Honda Motor Co Ltd INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important And using this tiller safely is an important responsibility To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all the hazards associated with operating or maintaining a tiller You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels on the tiller Safety Messages preceded by a safety alert symbol AN and one of three sign
28. lutch lever in the DISENGAGE position measure free play at the tip of the lever Free play should be 0 1 25 in 0 1 0 mm Just enough to ensure that the cable does not remain under tension in the DISENGAGE position 2 If adjustment is necessary loosen the lock nuts with a 12 mm wrench and move the adjuster by turning both nuts 3 Tighten the lock nuts and recheck free play THROTTLE CABLE ADJUSTMENT 1 With the throttle lever in the idle wim position measure free play at the tip of the lever You can feel the free play if you loosen the throttle lever tension bolt on top of the throttle lever housing Or you can determine free play by watching for throttle arm movement at the carburetor 2 adjustment is necessary hold one of the cable adjusters with an 8 mm wrench and loosen the lock nut with a 10 mm wrench Turn the adjusters to obtain the correct free play 3 Tighten the lock nut and recheck free play FREE PLAY TINE CLUTCH 0 1 25 0 1 0 mm LEVER NZD FREE PLAY Y 3 16 3 8 in 5 0 10 0 mm L ADJUSTERS NUT 39 DRIVE BELT ADJUSTMENT Correct drive belt tension ts for tiller performance and belt service life slipping belt will cause loss of power and premature belt wear T Adiust the main clutch cable 3 With the main clutch lever in the ENGAGED position check the distance between the upper and lower sections of the drive belt at th
29. n Improperly maintaining this tiller or failure to correct a problem before operation can cause a malfunction in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual To help you properly care for your tiller the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your tiller under severe conditions such as sustained high load or high temperature operation or use in unusually wet or dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use Hemember that your servicing dealer knows your tiller best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair or replacement Maintenance replacement or repair of the emission control devices and systems may be performed by any engine repair establishment or individual using parts that are certified to EPA standards 26 MAINTENANCE SAFETY Some of the most important safety precautions follow
30. ndle column and handlebar ERR bracket and tighten the knob GL TILLING DEPTH ADJUSTMENT ONE as BEFORE ADJUSTING THE AS A TILLING DEPTH BE SURE THE md ENGINE IS OFF HANDLEBAR BRACKET Tilling depth can be adjusted by removing the retainer and sliding the drag bar up or down as necessary If breaking ground for the first time lower the drag bar all the way the soil becomes softer the drag bar can be raised If not sure about soil conditions start with the drag bar in the lowest position see HANDLING Toa TIPS on page 23 MAIN CLUTCH OPERATION DRAG BAR MAIN CLUTCH LEVER The main clutch disengages and engages the power from the engine to the transmission Push the clutch lever down against the handlebar to engage the main clutch Release the lever to disengage the main clutch a ISSENGAGED ENGAGED y 20 GEAR SELECTION The transmission has three forward speeds neutral and reverse The gear shift pattern 15 marked on the shift gate at the base of the gear shift lever Release the main clutch lever before operating the gear shift lever Select one of the forward speeds 1 or 2 for tilling or 3 for propelling the tiller to and from the work area Select neutral N to move the tiller when the engine is not running NOTE Do not select neutral for tilling The tines and wheels must both be driven for good tilling control Wheel traction helps to prevent
31. nto the fibers 5 Wipe dirt from the inside of the air cleaner housing and cover using a moist rag Be careful to avoid dropping dirt into the air cleaner duct that leads to the carburetor 6 Reinstall the air filter and cover 34 co COVER WING NUT AIR CLEANER COVER g FILTER WING NUT AIR CLEANER HOUSING FASTENER TIGHTNESS CHECK Check to be sure all the fasteners are tight H not retighten them Tightening points are as follows Upper chain case to rotary case ransmission to rotary frame Rotary cover to rotary frame Swing base to transmission 35 SPARK PLUG SERVICE Recommended spark plug BPR6ES NGK NOTICE W20EPR U DENSO An incorrect spark plug can cause engine damage 1 Clean any dirt from around the spark plug base 2 Remove the spark plug cap Use a 13 16 inch spark plug wrench to remove the spark plug 3 Inspect the spark plug Replace it if the electrodes are worn or if the insulator is cracked or chipped Clean the spark plug with a wire brush if you are going to reuse it 4 Measure the spark plug electrode gap with a suitable gauge The gap should be 0 028 0 031 in 0 70 0 80 mm Correct the gap if necessary by carefully bending the side electrode 5 Install the spark plug carefully by hand to avoid cross threading 6 After the spark plug is seated tighten with a 13 16 inch spark plug wrench to compress the washer loose spark plug can over
32. o people should lift the tiller on and off the vehicle while holding the tiller level Position the tiller so the tines and wheels are on the bed of the vehicle Tie the tiller down with rope or straps and block the wheels Keep the tie down rope or straps away from controls cables governor linkage carburetor and the fuel line 42 PREPARATION FOR STORAGE When the tiller will not be used for one month or longer proper stor age preparation will help to prevent rust and corrosion and will make it easier to start the engine when the tiller is removed from storage 1 Clean all surfaces of the tiller including the area underneath the tine cover Wear heavy gloves to protect your hands If you use a garden hose to wash the tiller observe the following precautions f the tiller has been running allow the engine to cool for at least half an hour before spraying water on it Never spray water on hot engine Wash the tiller using low vvater pressure and keep water away from controls cable ends and all other places that are difficult to dry if water enters After washing start the engine outdoors and let it run until it reaches normal operating temperature to evaporate any water remaining on the engine Stop the engine turn the fuel valve OFF and allow the engine to cool before placing the tiller in storage 2 Coat areas that may rust with a light film of oil Lubricate ail contro cable cores with a s
33. ore starting the engine LEVEL MARK 13 Use unleaded gasoline with a pump octane rating of 86 or higher This engine is certified to operate on unleaded gasoline Unleaded gas oline produces fewer engine and spark plug deposits and extends ex haust system life Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in the fuel tank Occasionally you may hear light spark knock or pinging metallic rapping noise while operating under heavy loads This is no cause for concern If spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline If spark knock or pinging persists see an authorized Honda tiller dealer Running the engine with persistent spark knock or pinging can cause engine damage NOTE Running the engine with persistent spark knock or pinging is considered misuse and the Distributor s Limited Warranty does not cover parts damaged by misuse 14 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are collectively referred to as oxy enated fuels To meet clean air standards some areas of the United tates and Canada use oxygenated fuels to help reduce emissions If you use an oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confilm the fuel s contents Some states
34. provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 1076 ethanol by volume Gasoline containing ethanol may be mar keted under the name Gasohol MTBE methyl tertiary butyl ether 15 by volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fu el system Gasoline containing more than 5 methanol by volume may cause starting and or per formance problems It may also damage metal rub ber and plastic parts of your fuel system If you notice any undesirable operating Symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxy genates mentioned above are not covered under warranty 15 AIR FILTER Hemove the cover wing nut then remove the air cleaner cover Inspect the air filter elements If the elements are dirty clean them as described on page 34 Replace the elements if they are damaged cm Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine caus
35. s emission control system See your Emission Control Warranty for additional information Applicable to Emissions Durability Period 50 hours 0 65 cc 125 hours greater than 65 cc Intermediate 125 hours 0 65 cc 250 hours greater than 65 cc Extended 300 hours 0 65 cc 500 hours greater than 65 cc The Air Index Information hang tag must remain on the tiller until it is sold Remove the hang tag before operating the tiller Descriptive Term Moderate 30 MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD 3 Perform at every indicated Before ITEM month or operating inter each val whichever comes first Chack Heplace Replace Upper chain Adjust Grease Main clutch cable Adjust Tine clutch cable Adjust Adjust _ Replace Clean After every 500 hrs 2 NENNEN doal Every 2 years Replace if necessa 2 NOTE Emission related items Replace the paper element only 1 Service more frequently when used in dusty areas 2 These items should be serviced by an authorized Honda tiller dealer unless you have the proper tools and are mechanicaily proficient Refer to the Honda shop manual 3 For professional commercial use log hours of operation to determine proper maintenance intervals 31 ENGINE CHANGE Drain the oil while the engine 15 warm to assure rapid and complete draining 1 Place a suitable container in front of the tiller to catch the used
36. spark arrester screen must be free of breaks and holes Replace the spark arrester if it is damaged 6 nstall the spark arrester and muffler in the reverse order of disassembly 37 SEDIMENT CUP CLEANING 1 Turn the fuel valve to the OFF position 2 Remove the sediment cup with a 10 mm wrench 3 Empty the sediment cup and wash it in nonflammable solvent 4 inspect and reinstall the O ring Replace the O ring if it is damaged 5 Install the sediment cup and tighten it securely 6 Turn the fuel valve to the ON position and check for leaks amp WARNING Gasoline is extremely flammable and gasoline vapor can explode Turn the fuel valve to the OFF position after servicing the sediment cup Wipe up any spilled fuel MAIN CLUTCH CABLE ADJUSTMENT Correct main clutch cable adjust ment is important for tiller perfor mance and drive service Misadjustment can cause drive belt slippage with resultant loss of pow er and premature belt wear 1 Measure free play at the top of the lever Free play should be 3 16 3 8 in 5 0 10 0 mm 2 If adjustment is necessary loosen the lock nuts with a 12 mm wrench and move the adjuster by turning both nuts 3 Tighten the lock nuts and recheck free play 38 MAIN CLUTCH LEVER FREE PLAY 3 16 3 8 in 5 0 10 0 mm ra c 2 ADJUSTER MAIN CLUTCH LOCK NUTS CABLE TINE CLUTCH CABLE ADJUSTMENT 1 With the tine c
37. ut freely Retighten drain knob DRAIN KNOB AWARNING If any fuel is spilled make sure the area is dry before testing the spark plug or starting the engine Spilled fuel or fuel vapor may ignite 5 16 there a spark at the spark plug a Remove the spark plug cap Clean any dirt from around the spark plug base then remove the spark plug b Install the spark plug in the plug cap c urn the engine switch on d Grounding the side electrode to any engine ground pull the recoil starter to see if sparks jump across the gap AWARNING Never hold the spark plug lead with wet hands while performing this test Make sure that no fuel has been spilled on the engine and that the plug is not wet with fuel To avoid fire hazards do not allow sparks near the plug hole e If there is no spark replace the plug If OK try to start the engine according to the instructions 6 If the engine still does not start take the tiller to an authorized Honda dealer 48 10 SPECIFICATIONS Model FR600 FR800 Dimensions 57 5 in 1 460 mm 55 9 in 1 420 mm 48 8 in 1 240 mm 48 4 in 1 230 mm 22 0 in 560 mm 27 8 in 705 mm 207 Ibs 94 278 Ibs 126 47 8 in 1 215 mm Length Height Weight Tire size Maximum handle height e J Model FR600 FR800 GX160 K1 GX240 K1 Engine Single cylinder 4 stroke forced
38. wn as necessary 3 Grease the chain TINE REPLACEMENT Use genuine Honda replacement tines or their equivalent Wear heavy gloves to protect your hands Nut and bolt positions Tine positions For rotary tines Rotary tines C D and C D Tighten the bolts from outside in Toward outside Make sure to install the tine plates Others Toward inside For other tines Tighten the bolts from inside out je ji E A d 9 p 4 2 CLA 10 mm ml B D ep 10 mm SPRING WASHERS 41 8 TRANSPORTING STORAGE If the tiller has been running allow the engine to cool for at least 15 minutes before loading the tiller on the transport vehicle or placing it in storage hot engine and exhaust system can burn you and can ignite some materials A WARNING When transporting or storing the tiller keep the tiller leve to prevent fuel spillage Fuel vapor or spilled fuel may ignite Before Loading Turn the fuel valve to the OFF position This will prevent the possibility of carburetor flooding and will reduce the possibility of ipsum fuel leakage FUEL T VALVE er gt LL 46 Let 010 2 orr A h Loading Unloading To reduce the possibility of fuel leakage keep the tiller level while transporting and avoid tilting the tiller excessively when loading and unloading if a suitable loading ramp is not available tw
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