Honda GCV135 User Manual
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Also See for GCV135:
- Service manual (85 pages) ,
- Owner's manual (57 pages) ,
- Problem solving and maintenance manual (32 pages)
Related Manuals for Honda GCV135
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.
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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.
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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...
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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.
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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...
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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.
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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.
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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.
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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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