Honda Power Equipment GC135E User Manual

06/12/01 19:14:14 32Z2L600_001  
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 anufacturers 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 its 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)  
CheckClean  
Replace  
Clean  
Spark arrester  
(optional part)  
Idle speed  
CheckAdjust  
CheckAdjust  
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:  
0.700.80 m m (0.0280.031 in)  
0.700.80 mm  
(0.0280.031 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 1/81/4 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.  
29  
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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.  
30  
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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.  
31  
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MEMO  
32  

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