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Honda GC135 Owner's Manual

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  • Page 2 The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever.
  • Page 3 Congratulations on your selection of a Honda engine. We are certain you will be pleased with your purchase of one of the finest engines on the market. We want to help you get the best results from your new engine and to operate it safely.
  • Page 4 INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this engine safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.
  • Page 5: Table Of Contents

    CONTENTS ..................ENGINE SAFETY ..........IMPORTANT SAFETY INFORMATION ................. & CONTROLS FEATURES ..........& COMPONENT CONTROL LOCATIONS ..................... CONTROLS ................... Choke Rod ........Throttle Lever (adjustable-speed engines) ......... Ignition Switch Lever (fixed-speed engines) ................Recoil Starter Grip .................... FEATURES ........Oil Alert@ System (applicable engine types) ................
  • Page 6 ....Carburetor Modification for High Altitude Operation ................Oxygenated Fuels ........... Emission Control System Information .................... Air Index ................... Specifications ................Wiring Diagrams ............... CONSUMER INFORMATION ................Honda Publications ............Warranty Service Information ......QUICK REFERENCE INFORMATION Inside back cover...
  • Page 7: Engine Safety

    Owner Responsibilities Honda engines are designed to give safe and dependable service if o p e r a t e d a c c o r d i n g t o i n s t r u c t i o n s . Read and understand this owner’s manual before operating the engine.
  • Page 8 ENGINE SAFETY Carbon Monoxide Hazard Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run the engine in a closed garage or confined area. Other Equipment Review the instructions provided with the equipment powered by this engine for any additional safety precautions that should be observed i n conjunction with engine startup, shutdown, or operation, or protective apparel that may be needed to operate the equipment.
  • Page 9: Controls & Features

  • Page 10: Controls

    CONTROLS & FEATURES CONTROLS Choke Rod The choke rod opens and closes the choke valve in the carburetor. CLOSED position enriches the fuel mixture for starting a cold engine. The OPEN position provides the correct fuel mixture for operation after starting, and for restarting a warm engine. CHOKE ROD...
  • Page 11: Throttle Lever (Adjustable-Speed Engines)

    CONTROLS & FEATURES Throttle Lever (adjustable-speed engines) The throttle lever controls engine speed and operates the ignition switch for running or stopping the engine. Moving the throttle lever between the FAST and SLOW positions makes the engine run faster or slower. Moving the throttle lever to the STOP position stops the engine.
  • Page 13: Recoil Starter Grip

    CONTROLS & FEATURES Recoil Starter Grip Pulling the starter grip operates the recoil starter to crank the engine.
  • Page 14: Features

    CONTROLS & FEATURES FEATURES Oil Alert@ System (applicable engine types) The Oil Alert@ system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in will the crankcase can fall below a safe limit, the Oil Alert@ system will remain in the automatically stop the engine (the ignition switch ON position).
  • Page 15: Before Operation

    IS YOUR ENGINE READY TO GO? For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate engine to check its condition. Be sure to take care of any problem you find, or have your servicing dealer correct it, before you operate the engine.
  • Page 16: Check The Engine

    BEFORE OPERATION Check the Engine Check the engine oil level (see page 25). Running the engine with a low oil level can cause engine damage. The Oil Alert@ system (applicable engine types) will automatically stop the engine before the oil level falls below safe limits. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup.
  • Page 17: Operation

    OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time, please review the IMPORTANT SAFEN INFORMATION on page 5 and the chapter titled TION. BEFORE OPERA Carbon monoxide gas is toxic. Breathing can cause unconsciousness and even kill you. Avoid any areas or actions that expose you to carbon monoxide.
  • Page 18 OPERATION 2. Adjustable-Speed Engines: Move the throttle lever away from the SLOW position, about 1/3 of the way toward the FAST position. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here. THROTTLE LEVER Fixed-Speed Engines: Move the ignition switch lever to the position.
  • Page 20: Stopping The Engine

    OPERATION STOPPING THE ENGINE Adjustable-Speed Engines: Move the throttle lever to the STOP position. THROlTLE LEVER Fixed-Speed Engines: Move the ignition switch lever to the position. IGNITION SWITCH LEVER...
  • Page 22: Servicing Your Engine

    Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic. The maintenance schedule applies to normal operating conditions.
  • Page 23: Maintenance Safety

    Remember that your servicing dealer knows your engine best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new, genuine Honda parts or their equivalents for repair and replacement.
  • Page 25: Refueling

    SERVICING YOUR ENGINE REFUELING Fuel tank capacity GC135: 0.45 gal (1.7 ,0.37 Imp gal) GC160: 0.53 gal (2.0 ,0.44 Imp gal) With the engine stopped, remove the fuel tank cap and check the fuel level. Refill the tank if the fuel level is low.
  • Page 26: Fuel Recommendations

    If spark knock normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda servicing dealer. Running the engine with persistent spark knock or pinging cause engine damage.
  • Page 27: Engine Oil Level Check

    SERVICING YOUR ENGINE ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position. 1. Remove the oil filler cap/dipstick and wipe it clean. 2. Insert and remove the dipstick without screwing it into the filler neck. Check the oil level shown the dipstick.
  • Page 28: Engine Oil Change

    ENGINE SERVICING YOUR ENGINE O I L CHANGE Drain the used oil while the engine is warm. Warm oil drains quickly and completely. 1. Place a suitable container below the engine to catch the used oil, then remove the oil filler cap/dipstick and the drain plug. 2.Allow the used oil to drain completely, then reinstall the drain plug, and tighten it securely.
  • Page 29 SERVICING YOUR ENGINE With the engine in a level position, fill to the outer edge of the oil filler hole with the recommended oil (see page 28). capacity: 0.61 US qt (0.58 Engine 0.51 Imp qt) Running the engine with a low oil level can cause engine damage. The Oil Alert@ system (applicable engine types) will automatically stop the engine before the oil level falls below the...
  • Page 30: Engine Oil Recommendations

    SAE VISCOSITY GRADES 100°F - & l 40°C AMBIENT TEMPERATURE The SAE oil viscosity and service classification are in the API label on the oil container. Honda recommends that you use API SERVICE category SJ oil.
  • Page 31: Air Filter Inspection

    SERVICING YOUR ENGINE AIR FILTER INSPECTION Press the latch tabs on the fuel tank side of the air cleaner cover, and remove the cover. Check the filter to be sure it is clean and in good condition. If the filter is dirty, clean it as described on page 30. Replace the filter if is damaged.
  • Page 33: Spark Plug Service

    SERVICING YOUR ENGINE SPARK PLUG SERVICE Recommended spark plug: BPR6ES (NGK) piEK An incorrect spark plug can cause engine damage. 1. Disconnect the spark plug cap, and remove any dirt from around the spark plug area. 2. Remove the spark plug with a 13/16-inch spark plug wrench. PLUG SPARK WRENCH...
  • Page 34 SERVICING YOUR ENGINE 6. After the spark plug seats, tighten with a 13/16-inch spark plug wrench to compress the washer. If reinstalling the used spark plug, tighten 1/8-1/4 turn after the spark plug seats. If installing a new spark plug, tighten 1/2 turn after the spark plug seats.
  • Page 35: Spark Arrester Service (Optional Equipment)

    Check local laws and regulations. A spark arrester is available from authorized Honda servicing dealers. The spark arrester must be serviced every 100 hours to keep it functioning as designed.
  • Page 36 SERVICING YOUR ENGINE 3. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen. The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged. SPARK ARRESTER SCREEN 4.
  • Page 37: Helpful Tips & Suggestions

    HELPFUL TIPS & STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine steps will help to keep troublefree and looking good. The following rust and corrosion from impairing your engine's function and appearance, and will make the engine easier to start when you use it again.
  • Page 38 HELPFUL TIPS &SUGGESTIONS The Distributor’s Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation. You can extend fuel storage life by adding a fuel stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor.
  • Page 40 HELPFUL TIPS & SUGGESTIONS 2. Loosen the carburetor drain screw, and drain the carburetor into an approved gasoline container. After draining is completed, tighten the carburetor drain screw. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
  • Page 41: Storage Precautions

    HELPFUL TIPS & SUGGESTIONS Engine Oil 1. Change the engine oil (see page 26). 2. Remove the spark plug (see page 31). 3. Pour a tablespoon (5- 10 cm3) clean engine oil into the cylinder. 4. Pull the starter rope several times to distribute the oil in the cylinder. 5.
  • Page 42: Transporting

    HELPFUL TIPS & SUGGESTIONS TRANSPORTING If the engine has been running, allow it to cool for a t least 15 minutes before loading the engine-powered equipment on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials.
  • Page 43: Taking Care Of Unexpected Problems

    (flooded engine). plug. Start engine with throttle lever in FAST position. 4. Take engine to an Fuel filter clogged, Replace or repair faulty authorized Honda carburetor malfunction, components as servicing dealer, ignition malfunction, necessary. refer to shop manual. valves stuck, etc.
  • Page 44: Technical & Consumer Information

    TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location SERIAL NUMBER & ENGINE TYPE Record the engine serial number in the space below. You will need this serial number when ordering parts, and when making technical or warranty inquires (see page 52 ). Engine serial number:...
  • Page 45: Remote Control Linkage

    TECHNICAL & CONSUMER INFORMATION Remote Control Linkage Some throttle levers are provided with a hole or cable attachment. SOLID WIRE TYPE 5 mm SCREW CABLE THROTTLE LEVER BRAIDED WIRE TYPE mm SCREW ROTTLE CABLE THROTTLE LEVER...
  • Page 46: Carburetor Modification For High Altitude Operation

    TECHNICAL & CONSUMER INFORMATION Carburetor Modification for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.
  • Page 47: Oxygenated Fuels

    TECHNICAL & CONSUMER INFORMATION Oxygenated Fuels Some conventional gasolines are being blended with alcohol or ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.
  • Page 48: Emission Control System Information

    The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards. Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit.
  • Page 49 Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption. Replacement Parts The emission control systems on your Honda engine were designed, built, and certified to conform with EPA and California emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done.
  • Page 50: Air Index

    TECHNICAL & CONSUMER INFORMATION Index An Air Index Information hang tag/label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines.
  • Page 51: Specifications

    TECHNICAL & CONSUMER INFORMATION Specifications GC135-QHA Type 13.0 14.5 12.4 in Length Width Height (330 315 mm) 24.7 Ibs (1 1.2 kg) Dry weight 4-stroke, overhead cam, single cylinder Engine type 8.2 cu-in (1 35 cm3) Displacement [ 2.5 1.7 in (64...
  • Page 52: Wiring Diagrams

    TECHNICAL & CONSUMER INFORMATION Wiring Diagrams Without Oil Alert Blue Light blue L..- IGNITION SWITCH SPARK IGNITION ENGINE SWITCH (normal position open) PLUG COIL POSITION CLOSED STOP With Oil Alert L..- IGNITION IGNITION SWITCH OIL LEVEL SWITCH SPARK (normal position open) PLUG COIL (normal position open)
  • Page 53: Consumer Information

    Honda Publications These publications will give you additional information for maintaining and repairing your engine. You may order them from your Honda engine dealer. Shop Manual This manual covers complete maintenance and overhaul procedures. is intended to be used b y a skilled technician.
  • Page 54: Warranty Service Information

    General Manager can help. Almost all problems are solved in this way. If you are dissatisfied with the decision made by the dealership's management, contact the Honda Power Equipment Customer Relations Office. You can write to: American Honda Motor Co., Inc.
  • Page 55: Quick Reference Information

    QUICK REFERENCE INFORMATION Fuel TY Pe Unleaded gasoline with a pump octane rating of 86 or higher (page 24) GC135: Capacity 0.45 US gal (1.7 ! 2 , 0.37 Imp gal) GC160: 0.53 US gal (2.0 !2 ,0.44 Imp gal) Engine Oil...

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