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Thank you for purchasing a Honda engine.
This manual covers the operation and maintenance of your engine:
GCV135E·GCV160E
Allinformation in this publication is based on the latest product
information available atthe 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
GCV135EGCV160E time without notice and without incurring any obligation.
No part of this publication may be reproduced without written
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SAFETY INSTRUCTIONS Safety Instruction To ensure safe operation 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 Honda engine is designed to give safe and refueled or where gasoline is stored. dependable service if operated according Exhaust gas contains poisonous carbon monoxide. Avoid to instructions. Read and understand the inhalation of exha
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COMPONENT IDENTIFICATION STARTER GRIP RECOIL STARTER FLYWHEEL BRAKE LEVER FUEL TANK CAP (applicable types) CONTROLLEVER AIR CLEANER OIL FILLER CAP FUEL VALVE FUEL TANK SPARK PLUG MUFFLER TOP COVER (applicable types) CHOKELEVER (applicable types) 5 6
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PRE-OPERATION CHECK 2. Aircleaner 1. Engine oil level Never run the engine without the air cleaner. Rapid engine wear will result. Running the engine with insufficient oil can cause serious engine damage. Remove the air cleaner cover and check the cleaner for dirt or Be sure to check the engine on a level surface with the engine stopped. obstruction of the element (page 20 ). 1. Remove the oil filler cap and wipe the dipstick clean. 2. Insert the dipstick into the oil filler neck, but do not scr
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3. Fuel Gasoline spoils very quickly depending on factors such as light Useautomotive unleaded gasoline with a Research Octane exposure, temperature and time. Number of 91 or higher (a Pump Octane Number of 86 or higher). In worst cases, gasoline can be contaminated within 1 month. Never use stale or contaminated gasoline or an oil/gasoline Using contaminated gasoline can seriously damage the engine mixture. Avoid getting dirt or water in the fuel tank. (carburetor clogged, valve stuck). Such da
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3. With FLYWHEEL BRAKE LEVER type only: STARTING THE ENGINE Move the flywheel brake lever to the RELEASED position. The engine switch, which is linked with the flywheel brake lever, 1. Turn the fuel valve to the ON position. is turned on when the flywheel brake lever is moved to the RELEASED position. ON FLYWHEEL BRAKE LEVER FUEL VALVE 2. Without CHOKE LEVER type: Move the control lever to the CLOSE position. R RE EL LE EA AS SE ED D With CHOKE LEVER type (AUTOMATIC RETURN CHOKE type): 4. Pull t
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[With CHOKE LEVER type (AUTOMATIC RETURN CHOKE type)] High altitude operation Operate the recoil starter as soon as you move the flywheel At high altitude, the standard carburetor air-fuel mixture will be ex- brake lever to the RELEASED position. The choke lever cessively rich. Performance will decrease, and fuel consumption automatically begins moving to the OPEN position when the will increase. flywheel brake lever is moved to the RELEASED position. 5. If the engine does not start within sever
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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 CONTROLLEVER S S ST T TO O OP P P CONTROLLEVER 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, 4. Turn the
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Maintenance Schedule MAINTENANCE REGULAR SERVICE PERIOD (4) Each First Every Every Every Every ITEM use month 3 6 year 2 years Shut off the engine before performing any maintenance. Perform at every indicated month or or months months or or To prevent accidental start-up, disconnect the spark plug cap. operating hours interval, whichever 5hrs. or or 100 hrs. 250 hrs. comes first. 25 hrs. 50 hrs. The engine should be serviced by an authorized Honda dealer Engine oil Check level unless the owner
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1. Oil change 2. Aircleaner service Drain the oil while the engine is still warm to assure rapid and Adirty air cleaner will restrict air flow to the carburetor. To prevent complete draining. carburetor malfunction, service the air cleaner regularly. Service 1. Turnthe fuel valve to the OFF position (see page ). more frequently when operating the engine in extremely dusty 16 2. Remove the oil filler cap and drain the oil into the oil container areas. by inclining the engine toward the oil filler
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3. Tapthe 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 cle
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4. Check the brake shoe thickness. If it is less than 3 mm (0.12 in), 4. Spark plug service replace it with new one. Recommended spark plug: BPR6ES (NGK) B BR RA AK KE E S SH HO OE E T TH HIIC CK KN NE ES SS S 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. BRAKE SHOE 5. Installthe fuel tank and recoil starter, and tig
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2. Visually inspect the spark plug. Discard the spark plug if there is 4. Checkthat the spark plug washer is in good condition and apparent wear, or if the insulator is cracked or chipped. Clean thread the spark plug in by hand to prevent cross-threading. the spark plug with a wire brush if it is tobereused. 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) 5. Afterthe
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3. Use a brush to remove carbon deposits from the spark arrester 5. Spark arrester maintenance (optional part) screen. If theengine has been running, the muffler will be very hot. Allow Be careful not to damage the spark arrester screen. it to cool before proceeding. 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. (Taki
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TRANSPORTING/STORAGE 3. Change the engine oil (page 19 ). 4. Pull the starter rope slowly until resistance is felt. This closes the When transporting theengine, 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 gas
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TROUBLESHOOTING SPECIFICATIONS Dimensions GCV135E GCV160E When the engine will not start: Power equipment GJAFE GJAAE 1. Is the fuel valve ON? description code 2. Is there fuel in the fuel tank? Length 351 mm (13.8 in) 367 mm (14.4 in) 3. Is gasoline reaching the carburetor? Width 331 mm (13.0 in) 331 mm (13.0 in) To check, loosen the drain bolt with the fuel valve ON. Height 353 mm (13.9 in) 360 mm (14.2 in) Dry weight 10.4 kg (22.9 lbs) 10.5 kg (23.1 lbs) Engine If any fuel is spilled, make su
