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GCV135·GCV160

SERIAL NUMBER AND ENGINE TYPE

OWNER’S MANUAL

Honda Motor Co., Ltd. 2001

1

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Summary of Contents for Honda GCV135

  • Page 1
    GCV135·GCV160 SERIAL NUMBER AND ENGINE TYPE OWNER’S MANUAL Honda Motor Co., Ltd. 2001…
  • Page 2
    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.
  • Page 3: Safety Instructions

    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 ) before you start the engine.

  • Page 4
    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.
  • Page 5: Component Identification

    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…

  • Page 6: Pre-Operation Check

    PRE-OPERATION CHECK 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. Remove the oil filler cap and wipe the dipstick clean. Insert the dipstick into the oil filler neck, but do not screw it in.

  • Page 7: Air Cleaner Cover

    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…

  • Page 8
    Avoid repeated or prolonged contact with skin or breathing of vapor. KEEP OUT OF REACH OF CHILDREN. Fuel tank capacity: GCV135: 0.9 (0.24 US gal , 0.20 Imp gal) GCV160: 1.1 (0.29 US gal , 0.24 Imp gal) UPPER LEVEL…
  • Page 9: Gasolines Containing Alcohol

    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.

  • Page 10: Starting The Engine

    STARTING THE ENGINE Turn the fuel valve to the ON position. FUEL VALVE 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…

  • Page 11
    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 Pull the starter grip lightly until resistance is felt, then pull briskly.
  • Page 12
    When engine warms up, move the control lever to FAST or SLOW. SLOW FAST CONTROL LEVER…
  • Page 13
    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.
  • Page 14: Stopping The Engine

    STOPPING THE ENGINE 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.

  • Page 15
    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. CONTROL LEVER Turn the fuel valve to the OFF position. FUEL VALVE…
  • Page 16: Maintenance

    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.

  • Page 17: Maintenance Schedule

    Maintenance Schedule REGULAR SERVICE PERIOD (4) Each First Every Every Every Every Every ITEM month year 150 hrs. 2 years Perform at every indicated month or months months operating hours interval, whichever 5 hrs. 100 hrs. 250 hrs. comes first. 25 hrs.

  • Page 18: Engine Oil Capacity

    Oil change Drain the oil while the engine is still warm to assure rapid and complete draining. Turn the fuel valve to the OFF position (see page Remove the oil filler cap and drain the oil into the oil container by inclining the engine toward the oil filler neck.

  • Page 19
    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.
  • Page 20
    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.
  • Page 21: Recoil Starter

    Flywheel brake inspection (applicable types) Remove the recoil starter by removing the three 6 mm nuts. Remove the fuel tank taking care not to disconnect the fuel tube from the fuel tank and fuel valve, and keeping the fuel tank to a level.

  • Page 22
    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. Remove the spark plug cap and use a spark plug wrench to remove each spark plug.
  • Page 23
    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. Measure the plug gap with a feeler gauge. Correct as necessary by bending the side electrode.
  • Page 24
    Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross-threading. 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.
  • Page 25
    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. Remove the muffler protector by removing the three 6 mm bolts. Remove the spark arrester from the muffler by removing the two screws.
  • Page 26
    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. Install the spark arrester and the muffler in the reverse order of disassembly.
  • Page 27
    TRANSPORTING/STORAGE When transporting the engine, turn the fuel valve OFF and keep the engine level to prevent fuel spillage. Fuel vapor or spilled fuel may ignite. Before storing the unit for an extended period; Be sure the storage area is free of excessive humidity and dust. Drain the fuel tank and carburetor into a suitable gasoline container: Turn the fuel valve to the OFF position.
  • Page 28
    Change the engine oil (page 18 ). Pull the starter rope slowly until resistance is felt. This closes the valves, and protects them from dust and corrosion. 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.
  • Page 29: Troubleshooting

    TROUBLESHOOTING When the engine will not start: Is the fuel valve ON? Is there fuel in the fuel tank? Is gasoline reaching the carburetor? To check, loosen the drain bolt with the fuel valve ON. If any fuel is spilled, make sure the area is dry before testing the spark plug or starting the engine.

  • Page 30
    Is the control lever positioned properly (page 10 )? Is the flywheel brake lever positioned to the RELEASED position (page 11 )? (applicable types) Is there a spark at the spark plug? Remove the spark plug cap. Clean any dirt from around the spark plug base, then remove the spark plug.
  • Page 31: Specifications

    SPECIFICATIONS Dimensions GCV135 Power equipment GJAF description code Length 351 mm (13.8 in) Width 331 mm (13.0 in) Height 353 mm (13.9 in) Dry weight 9.5 kg (20.9 lbs) Engine Engine type 4-stroke, overhead cam, 1 cylinder Displacement 135 cm (8.2 cu-in) Bore x Stroke 64 x 42 mm (2.5 x 1.7 in)

  • Page 32
    Dimensions GCV160 Power equipment GJAE description code Length 367 mm (14.4 in) Width 331 mm (13.0 in) Height 360 mm (14.2 in) Dry weight 9.8 kg (21.6 lbs) Engine Engine type 4-stroke, overhead cam, 1 cylinder Displacement 160 cm (9.8 cu-in) Bore x Stroke 64 x 50 mm (2.5 x 2.0 in) Max.

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Also See for GCV135:

  • Owner’s manual (57 pages)
  • ,

  • User manual (33 pages)
  • ,

  • Problem solving and maintenance manual (32 pages)

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Table Of Contents

85

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    85

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    85

  • Contents

  • Table of Contents

  • Troubleshooting

  • Bookmarks

Table of Contents

  • Contents

  • Index

  • Specifications

  • Dimensions and Weights

  • Performance Curves

  • Dimensional Drawings

  • PTO Dimensional Drawings

  • Wiring Diagrams

  • The Importance of Proper Servicing

  • Important Safety Precautions

  • Service Rules

  • Serial Number Location

  • Maintenance Standards

  • Torque Values

  • Standard Torque Value

  • Special Tools

  • General Symptoms and Possible Causes

  • Hard Starting Troubleshooting

  • Cylinder Compression Check

  • Ignition System Troubleshooting

  • Spark Plug Test

  • Engine Starts but Stalls Soon

  • Engine Lacks Power

  • Engine Speed Does Not Increase

  • Harness Routing

  • Maintenance Schedule

  • Engine Oil

  • Oil Level Check

  • Oil Change

  • Air Cleaner

  • Spark Plug Inspection/Cleaning

  • Valve Clearance Inspection/Adjustment

  • Carburetor
  • Pilot Screw

  • Throttle Stop Screw

  • Governor Adjustment

  • Fuel Tank/Fuel Filter Cleaning

  • Fuel Line Check

  • Flywheel Brake

  • Brake Shoe Thickness Inspection

  • Spark Arrester (Optional Part)

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37

General Symptoms and Possible Causes

75

Valve Clearance Inspection/Adjustment

77

Carburetor

79

Governor Adjustment

See also:
Owner’s Manual, User Manual

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Troubleshooting

  • Hard Starting Troubleshooting
    39

  • Ignition System Troubleshooting
    40

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This manual is also suitable for:

Gcv160

Table of Contents

GCV135·GCV160

SERIAL NUMBER AND ENGINE TYPE

OWNER’S MANUAL

Honda Motor Co., Ltd. 2001

1

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 should remain with it if it is resold.

Pay special attention to statements preceded by the following words:

Indicates a strong possibility of severe personal injury or death if instructions are not followed.

Indicates a possibility of personal injury or equipment damage if instructions are not followed.

Indicates that equipment or property damage can result if instructions are not followed.

Gives helpful information.

If a problem should arise, or if you have any questions about your engine, consult an authorized Honda dealer.

The 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.

2

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 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.

3

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 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.

4

Honda Power Equipment GCV135, GCV160 User Manual

COMPONENT IDENTIFICATION

STARTER GRIP

RECOIL STARTER

OIL FILLER CAP

SPARK PLUG

MUFFLER

FLYWHEEL BRAKE LEVER

FUEL TANK CAP

(applicable types)

CONTROL LEVER

AIR CLEANER

5

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.

Use Honda 4-stroke, or an equivalent high detergent, premium quality motor oil certified to meet or exceed U.S. automobile manufacturer’s requirements for service classification SG, SH. Motor oils classified SG, SH will show this designation on the container.

SAE 10W-30 is recommended for general, all temperature use. If single viscosity oil is used, select the appropriate viscosity for the average temperature in your area.

SAE Viscosity Grades

SAE

TEMP

AMBIENT TEMPERATURE

Using nondetergent oil or 2-stroke engine oil could shorten the engine’s service life.

OIL FILLER CAP/

DIPSTICK

UPPER LIMIT

LOWER LIMIT

6

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

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 stored.

Do not overfill the fuel tank (there should be no fuel in the filler neck). After refueling, make sure the 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.

Fuel tank capacity: GCV135: 0.9 (0.24 US gal , 0.20 Imp gal) GCV160: 1.1 (0.29 US gal , 0.24 Imp gal)

UPPER LEVEL

FUEL FILLER

NECK

8

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 5% methanol, even if it has cosolvents and corrosion inhibitors.

Fuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty. Honda cannot endorse the use of fuels containing methanol since evidence of their suitability is as yet incomplete. Before buying fuel from an unfamiliar 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 symptoms 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.

9

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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