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GC135E • GC160E
SERIAL NUMBER AND ENGINE TYPE
OWNER’S MANUAL
Honda Motor Co., Ltd. 2003
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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 check (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 meter (3 feet) away from buildings
and other equipment during operation. Do not place flammable
objects close to the engine.
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.
Know how to stop the engine quickly, and understand the
operation of all controls. Never permit anyone to operate the
engine without proper instructions.
Do not place flammable objects such as gasoline, matches, etc.,
close to the engine while it is running.
Refuel in a well-ventilated area with the engine stopped.
Gasoline is highly flammable and explosive under certain
conditions.
Do not overfill the fuel tank. There should be no fuel in the filler
neck.
Make sure that the filler cap is closed securely.
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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 20° from horizontal. Operating at excessive angles may
result in fuel spillage.
Do not place anything on the engine, as it may create a fire
hazard.
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.
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.
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COMPONENT IDENTIFICATION
SPARK PLUG
AIR CLEANER
CHOKE ROD
CONTROL LEVER
FUEL TANK CAP
STARTER GRIP
FUEL TANK
MUFFLER
RECOIL STARTER
OIL FILLER CAP
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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. Rem ove the oil filler cap and check the oil level.
2. If the lebel is low, add the recom m ended oil to the edge of the
oil filler hole.
Use Honda 4-stroke, or an equivalent
high detergent, premium quality mo-
tor oil certified to m eet or exceed U.S.
autom obile m anufacturer’s require-
m ents for service classification SG, SF.
Motor oils classified SG, SF 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.
Ambient temperature
SINGLE VISCOSITY
MULTI VISCOSITY
Using nondetergent oil or 2-stroke engine oil could shorten the
engine’s service life.
OIL FILLER CAP
UPPER LIMIT
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2. Air cleaner
Never run the engine without the air cleaner. Rapid engine wear
will result.
Rem ove the air cleaner cover and check the cleaner for dirt or
obstruction of the elem ent (page 19 ).
AIR CLEANER COVER
ELEMENT
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3. Fuel
Use autom otive unleaded gasoline with
a
Research Octane
Num ber of 91 or higher (a Pum p Octane Num ber of 86 or higher).
Never use stale or contam inated gasoline or an oil/gasoline
m ixture. 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. Do not
smoke or allow flames or sparks in the area where the engine is
refueled or where gasoline is stored.
Do not overfill the fuel tank (there should be no fuel above the
upper limit mark). After refueling, make sure the fuel tank cap is
closed properly and securely.
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.
Avoid repeated or prolonged contact with skin or breathing of
vapor.
KEEP OUT OF REACH OF CHILDREN.
UPPER LIMIT MARK
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Gasoline spoils very quickly depending on factors such as light
exposure, tem perature and tim e.
In worst cases, gasoline can be contam inated within 1 m onth.
Using contam inated gasoline can seriously dam age the engine
(carburetor clogged, valve stuck).
Such dam age due to spoiled fuel is disallowed from coverage by
the warranty.
To avoid this please strictly follow these recom m endations:
Only use specified gasoline (page 8 ).
To slow deterioration, keep gasoline in a certified fuel container.
If long storage (m ore than 1 m onth) is foreseen, drain fuel tank
and carburetor (page 26 ).
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 recom m ended by
Honda. There are two types of ‘‘gasohol’’: one containing ethanol,
and the other containing m ethanol. Do not use gasohol that
contains m ore than 10% ethanol. Do not use gasoline containing
m ethanol (m ethyl or wood alcohol) that does not also contain
cosolvents and corrosion inhibitors for m ethanol. Never use
gasoline containing m ore than 5% m ethanol, even if it has
cosolvents and corrosion inhibitors.
Fuel system dam age or engine perform ance problem s resulting
from the use of fuels that contain alcohol is not covered under
the warranty. Honda can not endorse the use of fuels containing
m ethanol since evidence of their suitability is as yet incom plete.
Before buying fuel from an unfam iliar 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 sym ptom s 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.
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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 tem perature
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.
CONTROL LEVER
FAST
SLOW
STOP
SLOW
STOP
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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.
Direction to pull
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High altitude operation
At high altitude, the standard carburetor air-fuel mixture will be ex-
cessively rich. Perform ance will decrease, and fuel consum ption
will increase.
High altitude perform ance can be im proved by installing a sm aller
diam eter m ain 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 m odifications.
Even with suitable carburetor jetting, engine horsepower will
decrease approxim ately 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 m odification is m ade.
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.
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Oil alert system (where equipped)
The Oil Alert System is designed to prevent engine dam age
caused by an insufficient am ount of oil in the crankcase. Before
the oil level in the crankcase can fall below a safe lim it, the Oil
Alert System will autom atically stop the engine (the engine switch
will rem ain in the ON position).
If the engine stops and will not restart, check the engine oil level
(page 6 ) before troubleshooting in other areas.
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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
warm s up enough to run sm oothly.
OPEN
OPEN
CHOKE ROD
2. Control lever with engine stop function:
Position the control lever for the desired engine speed.
FAST
SLOW
CONTROL LEVER
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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.
OFF
OFF
CONTROL LEVER
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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 adjustm ent of the Honda engine is
essential if high level perform ance is to be m aintained. Regular
m aintenance will also ensure a long service life. The required
service intervals and the kind of m aintenance to be perform ed are
described on the following table.
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Maintenance Schedule
REGULAR SERVICE PERIOD (4)
Perform at every indicated
each
use
First
Every
Every
Every
year
or
Every
2 years
or
m onth season season
ITEM
m onth or operating hours
interval, whichever com es
first.
or
or
or
5 hrs.
25 hrs. 50 hrs. 100 hrs. 250 hrs.
Engine oil
Check
Change
Check
(2)
Air cleaner
Clean
(1)
Replace
Check
Tim ing belt
Spark plug
After every 250 hrs. (3) (5)
Check－Clean
Replace
Clean
Spark arrester
(optional part)
Idle speed
Check－Adjust
Check－Adjust
Clean
(3)
(3)
Valve clearance
Com bustion cham ber
Fuel tank and strainer
Fuel line
After every 250 hrs. (3)
Clean
(3)
Check
Every 2 years (Replace if necessary) (3)
(1):Service m ore frequently when used in dusty areas.
(2):Change engine oil every 25 hours when used under heavy load or in high am bient tem perature.
(3):These item s should be serviced by an authorized Honda dealer, unless the owner has the proper
tools and is m echanically proficient. See the Honda Shop Manual.
(4):For com m ercial use, log hours of operation to determ ine proper m aintenance intervals.
(5):Check that there is no crack and abnorm al wear-out in the belt, and replace if it is abnorm al.
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1. Oil change
Drain the oil while the engine is still warm to assure rapid and
com plete draining.
1. Rem ove the oil filler cap and drain plug to drain the oil.
2. Install the drain plug, and tighten it securely.
3. Refill with the recom m ended 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 Im p qt)
OIL FILLER CAP
DRAIN PLUG
Wash your hands with soap and water after handling used oil.
Please dispose of used m otor oil in a m anner that is com patible
with the environm ent. We suggest you take it in a sealed container
to your local service station for reclam ation. Do not throw it in the
trash, pour it on the ground, or down a drain.
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2. Air cleaner service
A dirty air cleaner will restrict air flow to the carburetor. To prevent
carburetor m alfunction, service the air cleaner regularly. Service
m ore frequently when operating the engine in extrem ely 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 rem ove the air cleaner cover.
AIR CLEANER COVER
LATCH TABS
TABS
ELEMENT
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2. Rem ove the elem ent. Carefully check the elem ent for holes or
tears and replace if dam aged.
3. Tap the elem ent lightly several tim es on a hard surface to
rem ove excess dirt, or blow com pressed air through the filter
from the inside out. Never try to brush the dirt off; brushing will
force dirt into the fibers. Replace the elem ent if it is excessively
dirty.
4. Install the elem ent and air cleaner cover.
ELEMENT
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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 m ust be
properly gapped and free of deposits.
1. Rem ove the spark plug cap and use a spark plug wrench to
rem ove each spark plug.
If the engine has been running, the muffler will be very hot. Be
careful not to touch the muffler.
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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 m m (0.028－0.031 in)
0.70－0.80 mm
(0.028－0.031 in)
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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 com press the washer.
When installing a new spark plug, tighten 1/2 turn after the spark
plug seats to com press the washer. When reinstalling a used spark
plug, tighten 1/8－1/4 turn after the spark plug seats to com press
the washer.
The spark plug must be securely tightened. An improperly
tightened spark plug can become very hot and may damage the
engine.
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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 m uffler protector by rem oving the three 6 m m bolts.
2. Rem ove the spark arrester from the m uffler by rem oving the
two screws. (Taking care not to dam age the wire m esh.)
Check for carbon deposits around the exhaust port and the spark
arrester, and clean if necessary.
MUFFLER
SCREW (2)
SPARK ARRESTER
MUFFLER PROTECTOR
6 mm BOLTS
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3. Use a brush to rem ove carbon deposits from the spark arrester
screen.
Be careful not to damage the spark arrester screen.
SCREEN
The spark arrester m ust be free of breaks and holes. Replace, if
necessary.
4. Install the spark arrester and the m uffler in the reverse order of
disassem bly.
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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 hum idity and dust.
2. Drain the fuel tank and carburetor into a suitable gasoline
container:
A.Em pty the fuel tank into an approved gasoline container using
a com m ercially available hand siphon.
B.Loosen the carburetor drain screw to drain the carburetor.
C.Retighten the drain screw.
DRAIN SCREW
CARBURETOR
Gasoline is extremely flammable and is explosive under certain
conditions. Do not smoke or allow flames or sparks in the area.
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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 m ay rust with a light film of oil. Cover the engine
and store it on a level surface in a dry, dust free area.
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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.
CARBURETOR
DRAIN SCREW
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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.
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SPECIFICATIONS
Dimensions
Model
GC135E
GCAAE
Power equipm ent
description code
Length
330 m m (13.0 in)
369 m m (14.5 in)
315 m m (12.4 in)
11.2 kg (24.7 lbs)
Width
Height
Dry weight
Engine
Engine type
4-stroke, overhead cam , 1 cylinder
135 cm (8.2 cu-in)
Displacem ent
Bore x Stroke
Max. output
64 × 42 m m (2.5 × 1.7 in)
2.7 kW (3.7 PS)/3,600 rpm
7.4 N·m (0.75 kgf-m )/2,500 rpm
1.2 ltr/h /3,600 rpm
Max. torque
Fuel consum ption
Cooling system
Ignition system
PTO shaft rotation
Fuel tank capacity
Engine oil capacity
Engine oil
Forced air
Transistor m agneto
Counterclockwise
1.3 (0.45 US gal , 0.37 Im p gal)
0.58 (0.61 US qt , 0.51 Im p qt)
Service classification SF or SG; SAE 10W-30
BPR6ES (NGK)
Spark plug
Specifications m ay vary according to the types, and are subject to
change without notice.
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Dimensions
Model
GC160E
GCABE
Power equipm ent
description code
Length
337 m m (13.3 in)
369 m m (14.5 in)
331 m m (13.0 in)
11.5 kg (25.4 lbs)
Width
Height
Dry weight
Engine
Engine type
4-stroke, overhead cam , 1 cylinder
160 cm (9.8 cu-in)
Displacem ent
Bore x Stroke
Max. output
64 × 50 m m (2.5 × 2.0 in)
3.4 kW (4.6 PS)/3,600 rpm
9.4 N·m (0.96 kgf-m )/2,500 rpm
1.5 ltr/h /3,600 rpm
Max. torque
Fuel consum ption
Cooling system
Ignition system
PTO shaft rotation
Fuel tank capacity
Engine oil capacity
Engine oil
Forced air
Transistor m agneto
Counterclockwise
1.8 (0.53 US gal , 0.44 Im p gal)
0.58 (0.61 US qt , 0.51 Im p qt)
Service classification SF or SG; SAE 10W-30
BPR6ES (NGK)
Spark plug
Specifications m ay vary according to the types, and are subject to
change without notice.
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MEMO
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