06/12/01 19:14:14 32Z2L600_001 GC135E • GC160E SERIAL NUMBER AND ENGINE TYPE OWNER’S MANUAL Honda Motor Co., Ltd.
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.
06/12/01 19:14:31 32Z2L600_003 SAFETY INSTRUCTIONS To ensure safe operation− 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. Always make a pre-operation check (page 6 ) before you start the engine. You may prevent an accident or equipment damage.
06/12/01 19:14:39 32Z2L600_004 Safety Instruction To ensure safe operation− If any fuel is spilled, clean it up completely and allow petroleum vapours to dissipate before starting the engine. Do not smoke or allow flames or sparks where the engine is refueled or where gasoline is stored. Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gases. Never run the engine in a closed garage or confined area. Place the engine on a stable surface.
06/12/01 19:14:44 32Z2L600_005 COMPONENT IDENTIFICATION SPARK PLUG CHOKE ROD AIR CLEANER CONTROL LEVER FUEL TANK CAP STARTER GRIP FUEL TANK RECOIL STARTER MUFFLER OIL FILLER CAP 5
06/12/01 19:14:52 32Z2L600_006 PRE-OPERATION CHECK 1. Engine oil level Running 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 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 motor oil certified to meet or exceed U.S.
06/12/01 19:14:57 32Z2L600_007 2. Air cleaner 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 element (page 19 ).
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. Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped.
06/12/01 19:15:12 32Z2L600_009 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: Only use specified gasoline (page 8 ).
06/12/01 19:15:19 32Z2L600_010 STARTING THE ENGINE 1. Pull the choke rod to the CLOSED position. Do not use the choke if the engine is warm or the air temperature is high. CLOSED CHOKE ROD CLOSED 2. Control lever with engine stop function: Move the control lever away from the SLOW position, about 1/3 of the way toward the FAST position.
06/12/01 19:15:24 32Z2L600_011 Control lever with only engine stop function: Move the control lever to the ON position. CONTROL LEVER ON 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. 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 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.
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). If the engine stops and will not restart, check the engine oil level (page 6 ) before troubleshooting in other areas.
06/12/01 19:15:38 32Z2L600_014 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. OPEN OPEN CHOKE ROD 2. Control lever with engine stop function: Position the control lever for the desired engine speed.
06/12/01 19:15:44 32Z2L600_015 STOPPING THE ENGINE Control lever with engine stop function: Move the control lever to the STOP position. STOP STOP CONTROL LEVER Control lever with only engine stop function: Move the control lever to the OFF position.
06/12/01 19:15:49 32Z2L600_016 MAINTENANCE Shut off the engine before performing any maintenance. To prevent accidental start-up, disconnect the spark plug cap. 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. Use only genuine Honda parts or their equivalent. The use of replacement parts which are not of equivalent quality may damage the engine.
06/12/01 19:16:00 32Z2L600_017 Maintenance Schedule REGULAR SERVICE PERIOD (4) each First Every Every Every Every Perform at every indicated use month season season year 2 years or or ITEM month or operating hours or or or interval, whichever comes 5 hrs. 25 hrs. 50 hrs. 100 hrs. 250 hrs. first. Engine oil Check Change Air cleaner (2) Check Clean (1) Replace Timing belt Check Spark plug Check−Clean After every 250 hrs.
06/12/01 19:16:08 32Z2L600_018 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. Refill with the recommended oil (see page 6 ) and check the oil level. 4. Install the oil filler cap. ENGINE OIL CAPACITY: 0.58 (0.61 US qt , 0.51 Imp qt) OIL FILLER CAP DRAIN PLUG Wash your hands with soap and water after handling used oil.
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. 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.
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 dirty. 4. Install the element and air cleaner cover.
06/12/01 19:16:23 32Z2L600_021 3. Spark plug service Recommended spark plug: BPR6ES (NGK) 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. If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.
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 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 (0.028−0.
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. 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. The spark plug must be securely tightened.
06/12/01 19:16:37 32Z2L600_024 4. Spark arrester maintenance (optional part) If the engine has been running, the muffler will be very hot. Allow it to cool before proceeding. 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.
06/12/01 19:16:43 32Z2L600_025 3. Use a brush to remove carbon deposits from the spark arrester screen. Be careful not to damage the spark arrester screen. SCREEN 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.
06/12/01 19:16:49 32Z2L600_026 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.
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.
06/12/01 19:16:57 32Z2L600_028 TROUBLESHOOTING When the engine will not start: 1. Is there fuel in the fuel tank? 2. Is gasoline reaching the carburetor? To check, loosen the drain screw. 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.
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.
06/12/01 19:17:11 32Z2L600_030 SPECIFICATIONS Dimensions Model Power equipment description code Length Width Height Dry weight Engine Engine type Displacement Bore x Stroke Max. output Max. torque Fuel consumption Cooling system Ignition system PTO shaft rotation Fuel tank capacity Engine oil capacity Engine oil Spark plug GC135E GCAAE 330 mm (13.0 in) 369 mm (14.5 in) 315 mm (12.4 in) 11.2 kg (24.7 lbs) 4-stroke, overhead cam, 1 cylinder 135 cm (8.2 cu-in) 64 × 42 mm (2.5 × 1.7 in) 2.7 kW (3.
06/12/01 19:17:21 32Z2L600_031 Dimensions Model Power equipment description code Length Width Height Dry weight Engine Engine type Displacement Bore x Stroke Max. output Max. torque Fuel consumption Cooling system Ignition system PTO shaft rotation Fuel tank capacity Engine oil capacity Engine oil Spark plug GC160E GCABE 337 mm (13.3 in) 369 mm (14.5 in) 331 mm (13.0 in) 11.5 kg (25.4 lbs) 4-stroke, overhead cam, 1 cylinder 160 cm (9.8 cu-in) 64 × 50 mm (2.5 × 2.0 in) 3.4 kW (4.6 PS)/3,600 rpm 9.
06/12/01 19:17:23 32Z2L600_032 MEMO 32
