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GCV135·GCV160
SERIAL NUMBER AND ENGINE TYPE
OWNER’S MANUAL
Honda Motor Co., Ltd. 2001
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Thank you for purchasing a Honda engine. This manual covers the operation and maintenance of your engine: GCV135·GCV160 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 sh
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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 inspection (page 6 ) before you start the engine. You may prevent an accident or equipment damage. To prevent fire hazards and to provide adequate ventilation, keep the engine at least 1 m
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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. Do not tilt the engine more than 15° from horizontal. Operating
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COMPONENT IDENTIFICATION STARTER GRIP RECOIL STARTER OIL FILLER CAP SPARK PLUG MUFFLER FLYWHEEL BRAKE LEVER FUEL TANK CAP (applicable types) CONTROL LEVER AIR CLEANER FUEL VALVE FUEL TANK 5
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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 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. SAE Viscosity Grades Use Honda 4-stroke, or an equivalent SAE high detergent, premium quality mo- t
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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 ). ELEMENT AIR CLEANER COVER 7
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3. Fuel Use automotive gasoline (Unleaded or lowleaded is preferred to minimize combustion chamber deposits). FOR NEW SOUTH WALES ONLY: Use unleaded fuel only. Never use an oil/gasoline mixture or dirty gasoline. Avoid getting dirt, dust 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. Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is s
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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
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STARTING THE ENGINE 1. Turn the fuel valve to the ON position. ON FUEL VALVE 2. Move the control lever to the CHOKE position. Do not use the choke if the engine is warm or the air temperature is high. CHOKE CONTROL LEVER 10
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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 R RE EL LE EA AS SE ED D 4. Pull the starter grip lightly until resistance is 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. 11
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5. When engine warms up, move the control lever to FAST or SLOW. SLOW FAST CONTROL LEVER 12
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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 Honda dealer perform these carburetor modifications. Even with suitab
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STOPPING THE ENGINE 1. Move the control lever to the SLOW position. SLOW CONTROL LEVER 2. With FLYWHEEL BRAKE LEVER type: Return the flywheel brake lever to the ENGAGED position. The engine switch, which is linked with the flywheel brake lever, is turned off when the flywheel brake lever is moved to the ENGAGED position. FLYWHEEL BRAKE LEVER E EN NG GA AG GE ED D 14
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3. Without FLYWHEEL BRAKE LEVER type: Move the control lever to the STOP position. The engine switch, which is linked with the control lever, is turned off when the control lever is moved to the STOP position. S ST TO OP P CONTROL LEVER 4. Turn the fuel valve to the OFF position. O OF FF F FUEL VALVE 15
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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. Periodic inspection and adjustment of the Honda engine is essential if high level
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Maintenance Schedule REGULAR SERVICE PERIOD (4) Each First Every Every Every Every Every ITEM use month 3 6 year 150 hrs. 2 years 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 Change (2) Air cleaner Check Clean (1) Replace Flywheel brake pad Check (applicable types) Spark plug Check-Adjust Replace Spark arrester Clean (optional part) Idle speed Check-Adjust (3)
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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 15 ). 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 6 ). 4. Install the oil filler cap. ENGINE OIL CAPACITY: 0.55 (0.58 US qt , 0.48 Imp qt) OIL FILLER NECK Wash your hands with soap and water after handl
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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 use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result. 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 to
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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. ELEMENT 20
