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Honda GC160 Owner's Manual

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Honda GC160 Owner's Manual

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  • Page 1 Click SAVE to save this manual to your computer. Thank you for choosing Honda.
  • Page 2 OWNER’S MANUAL GC160 31ZL8A03 © 2000, 2001 American Honda Motor Co., Inc. 00X31-ZL8-A030 All Rights Reserved...
  • Page 3: Table Of Contents

    Fuel Recomendations ..14 CONSUMER INFORMATION ENGINE OIL ... .15 Honda Publications ..33 Recommended Oil ..15 Distributor’s Limited Oil Level Check .
  • Page 4: Introduction

    INTRODUCTION Thank you for purchasing a Honda engine. We want to help you to get the best results from your new engine and to operate it safely. This manual contains information on how to do that; please read it carefully before operating the engine.
  • Page 5 DAMAGE PREVENTION MESSAGES You will also see other important messages that are preceded by the word NOTICE. This word means: Your engine or other property can be NOTICE damaged if you don’t follow instructions. The purpose of these messages is to help prevent damage to your engine, other property, or the environment.
  • Page 6: Location

    COMPONENT & CONTROL LOCATION THROTTLE CHOKE ROD SPARK PLUG LEVER (gray) Used on engines with an adjustable throttle lever. IGNITION SWITCH FUEL LEVER (red) FILLER Used on engines with a non-adjustable throttle lever. QHAF TYPES (no throttle lever) ENGINE CHOKE STOP FUEL SWITCH...
  • Page 7: Is Your Engine Ready To Go

    BEFORE OPERATION CHECKS 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 the 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 8: Operation

    OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time, please review the SAFETY INFORMATION on 4 and the BEFORE OPERATION CHECKS on 6.  WARNING Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you. Avoid any areas or actions that expose you to carbon monoxide.
  • Page 9 2. ADJUSTABLE-SPEED THROTTLE LEVER (gray) ENGINES: FAST Move the throttle lever (gray) away from the SLOW position, about 1/3 of the way toward the FAST position. Some engine applications use a remotely-mounted throttle control SLOW rather than the engine-mounted throttle lever shown here. 3.
  • Page 10: Setting Engine Speed

    4. Pull the starter grip lightly until resistance is felt, then pull briskly. NOTICE Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter. STARTER GRIP 5. If the choke rod was pulled CHOKE to the CLOSED position to start the engine, push it to...
  • Page 11: Stopping The Engine

    STOPPING THE ENGINE THROTTLE LEVER (gray) 1. ADJUSTABLE-SPEED ENGINES: FAST Move the throttle lever (gray) to the STOP position. 2. FIXED-SPEED ENGINES: STOP Move the ignition switch lever (red) lever to the OFF position. QHAF types: Move the engine stop switch to the OFF position. QHAF types ENGINE STOP...
  • Page 12: Servicing Your Honda 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. If...
  • Page 13: Maintenance Safety

    Remember that an authorized Honda 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 14: Maintenance Schedule

    (2) Change engine oil every 25 hours when used under heavy load or in high ambient temperatures. (3) These items should be serviced by an authorized Honda servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures.
  • Page 15: Refueling

    REFUELING Use unleaded gasoline with a pump octane rating of 86 or higher. This engine is certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life.  WARNING Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling.
  • Page 16: Engine Oil

    ENGINE OIL Recommended Oil Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SH, SJ, or equivalent. Always check the API service label on the oil container to be sure it includes the letters SH, SJ, or equivalent.
  • Page 17: Oil Change

    Oil Change Drain the engine oil when the engine is warm. Warm oil drains quickly and completely. 1. Place a suitable container next to the engine to catch the used oil. OIL FILLER 2. Remove the oil filler cap/ CAP/ dipstick and the oil drain DIPSTICK plug.
  • Page 18: Air Cleaner

    AIR CLEANER A dirty air cleaner will restrict air flow to the carburetor and cause poor engine performance. Inspect the filter each time the engine is operated. You will need to clean the filter more frequently if you operate the engine in very dusty areas. NOTICE Operating the engine without an air filter, or with a damaged filter, will allow dirt to enter the engine, causing rapid engine wear.
  • Page 19: Spark Plug

    SPARK PLUG Recommended Spark Plugs: NGK BPR6ES The recommended spark plug is the correct heat range for normal engine operating temperatures. NOTICE Incorrect spark plugs can cause engine damage. For good performance, the SPARK PLUG spark plug must be properly WRENCH gapped and free of deposits.
  • Page 20 5. Install the spark plug carefully, by hand, to avoid cross-threading. 6. After the spark plug is seated, tighten with the proper size spark plug wrench to compress the washer. 7. When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer.
  • Page 21: Spark Arrester

    In some areas, it is illegal to operate an engine without a USDA (United States Department of Agriculture)-qualified spark arrester. Check local laws and regulations. A USDA-qualified spark arrester is available from an authorized Honda servicing dealer. The spark arrester must be serviced every 100 hours to keep it functioning as designed.
  • Page 22: Helpful Tips & Suggestions

    HELPFUL TIPS & SUGGESTIONS STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine troublefree and looking good. The following steps will help to keep rust and corrosion from impairing your engine’s function and appearance, and will make the engine easier to start when you use it again. Cleaning If the engine has been running, allow it to cool for at least half an hour before cleaning.
  • Page 23 Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under warranty. You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor.
  • Page 24 3. Loosen the carburetor drain screw. and drain the carburetor into an approved gasoline container. After draining is completed, tighten the carburetor drain screw. SYPHON PUMP (COMMERCIALLY AVAILABLE) FLOAT BOWL DRAIN SCREW Engine Oil 1. Change the engine oil (see 16). 2.
  • Page 25: Transporting

    Storage Precautions If your engine will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well-ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer.
  • Page 26: Taking Care Of Unexpected Problems

    Start engine with throttle lever in FAST position (choke in OPEN position). 5. Take engine to an Fuel filter clogged, carburetor Replace or repair faulty authorized Honda malfunction, ignition components as necessary. servicing dealer, or malfunction, valves stuck, refer to shop manual.
  • Page 27: Technical & Consumer Information

    1,500 meters (5,000 feet) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have an authorized Honda servicing dealer return the carburetor to original factory specifications.
  • Page 28: Oxygenated Fuels

    Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an 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.
  • Page 29: Emission Control System Information

    Carbon monoxide does not react in the same way, but it is toxic. Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.
  • Page 30 • 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 31: Air Index

    AIR 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 32: Specifications

    ITEM SPECIFICATION MAINTENANCE Valve clearance IN: 0.15 ± 0.04 mm See your authorized EX: 0.20* ± 0.04 mm Honda dealer Other specifications No other adjustments needed. Quick Reference Information Fuel Type Unleaded gasoline with a pump octane rating of 86 or higher (14).
  • Page 33: Wiring Diagram

    Wiring Diagram With Oil Alert Without Oil Alert...
  • Page 34: Consumer Information Honda Publications

    CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing you engine.You may order them from an authorized Honda servicing dealer. Shop This manual covers complete maintenance and overhaul Manual procedures. It is intended to be used by a skilled technician.
  • Page 35: Distributor's Limited Warranty

    What American Honda Will Repair or Replace Under Warranty: American Honda will repair or replace, at its option, any part that is proven to be defective in material or workmanship under normal use during the applicable warranty time period.
  • Page 36 THE INCORPORATION OF, OR USE OF, UNSUITABLE ATTACHMENTS OR PARTS, THE UNAUTHORIZED ALTERATION OF ANY PART OR ANY CAUSES OTHER THAN DEFECTS IN MATERIAL OR WORKMANSHIP OF THE ENGINE. USE OF THE HONDA GENERAL PURPOSE ENGINE FOR RACING OR COMPETITION WILL VOID THIS WARRANTY.
  • Page 37: Emission Control System Warranty

    Emission Control System Warranty Your new Honda Power Equipment engine complies with both the U.S. EPA and State of California emission regulations. American Honda provides the same emission warranty coverage for engines sold in all 50 states. Your Warranty Rights And Obligations: California The California Air Resources Board and American Honda Motor Co., Inc.
  • Page 38: Warranty Coverage

    To Obtain Warranty Service: You must take your Honda Power Equipment engine or the product on which it is installed, along with your warranty registration card or other proof of original purchase date, at your expense, to any Honda Power Equipment dealer who is authorized by American Honda Motor Co., Inc.
  • Page 39 Disclaimer of Consequential Damage and Limitation of Implied Warranties: AMERICAN HONDA MOTOR CO., INC. DISCLAIMS ANY RESPONSIBILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SUCH AS LOSS OF TIME OR THE USE OF THE POWER EQUIPMENT, OR ANY COMMERCIAL LOSS DUE TO THE FAILURE OF THE EQUIPMENT;...
  • Page 40: Warranty Service Information

    Warranty Service Information Honda engine dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership’s management. The Service Manager or General Manager can help.