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Honda GCV135 Problem Solving And Maintenance Manual

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Engine Model: Honda GCV135
SELF-HELP PROBLEM SOLVING and
PETROL LAWNMOWERS
These engines are fitted to the following recent products:
422HP
SP535
SP535 HW
1. Safety Precautions ........................................ 2
3. Routine Engine Maintenance ........................... 7
4. Starting the Engine .......................................
10. Transportation and Handling ...........................
11. Maintenance and Storage ............................... 27
If, after reading this guide, you feel you are either unsure of what is
required, or that you do not have the correct tools to undertake a job
yourself, please contact:
• Our Helpline service, telephone 0845 600 2912 (Monday to
Saturday 9am - 5pm, and Sunday 10am - 4pm), or
• Our local ServiceLink centre who can undertake any remedial
work requested (work that is not covered by the guarantee will be
chargeable)
Your local ServiceLink centre can be found at
www.servicelink.org.uk
Page
1 of 32
and
Honda GCV160
MAINTENANCE
for
462 PD
SP555
Honda Engines Selfhelp
512 PD
Cooper 532PD
10
15
19
23
26
28
Guide 2011, Issue 1.0

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  Also See for Honda GCV135

  Summary of Contents for Honda GCV135

  • Page 1: Table Of Contents

    Engine Model: Honda GCV135 Honda GCV160 SELF-HELP PROBLEM SOLVING and MAINTENANCE PETROL LAWNMOWERS These engines are fitted to the following recent products: • • • 422HP 462 PD 512 PD • • • SP535 SP555 Cooper 532PD • SP535 HW 1.
  • Page 2: Safety Precautions

    Engine Model: Honda GCV135 Honda GCV160 1 Safety Precautions Your lawnmower should be used with due care and attention. Symbols have therefore been placed on various parts of the machine to remind you of the main precautions to be taken. Their meaning is explained below. You are also asked to read the safety precautions listed below.
  • Page 3 Engine Model: Honda GCV135 Honda GCV160 the engine is switched off. PREPARATION: 1. While mowing, always wear sturdy footwear and long trousers. Do not operate the equipment when bare foot or wearing open sandals. Avoid loose clothing that may snag on moving parts.
  • Page 4 Engine Model: Honda GCV135 Honda GCV160 16. Do not put your hands or feet near or under rotating parts. Keep clear of the discharge opening at all times. 17. Never pick up or carry a lawnmower while the engine is running.
  • Page 5 Engine Model: Honda GCV135 Honda GCV160 • Wear strong working gloves; • Grasp the machine at the points that offer a safe grip, taking account of the weight and its distribution; • Use an appropriate number of people for the weight of the machine and the characteristics of the vehicle or the place where it has to be placed or collected.
  • Page 6: Fuel, Oil, Air Filter And Spark Plug Requirements

    Honda GCV160 2 Fuel, Oil, Air Filter and Spark Plug Requirements FUEL – these mowers have a Honda GCV135 4-stroke petrol engine. The correct fuel is the ordinary grade of unleaded petrol. The Honda GCV135 holds 0.9 litres of petrol, and the Honda GCV165 holds 1.1 litres of petrol.
  • Page 7: Routine Engine Maintenance

    Engine Model: Honda GCV135 Honda GCV160 3 Routine Engine Maintenance Regular and careful maintenance is essential to preserve the original performance and safety level of the engine. Always store the mower in a dry place. TESTING FOR A SPARK (this job requires 2 people) 1.
  • Page 8 Engine Model: Honda GCV135 Honda GCV160 CHANGING ENGINE OIL Check the engine oil before each use. Engine Oil • Mountfield MX855 These small four stroke engines hold up to 0.55 litres • SAE30 lawnmower oil of oil (0.9 Pints). Any oil shortages can cause •...
  • Page 9 Engine Model: Honda GCV135 Honda GCV160 ENGINE MANUFACTURER’S RECOMMENDATIONS: As a guide, the table and notes below have been copied from the engine manufacturer’s user manual: NB: Please refer to the engine manufacturer’s manual for specific information. Page 9 of 32 Honda Engines Selfhelp Guide 2011, Issue 1.0...
  • Page 10: Starting The Engine

    Engine Model: Honda GCV135 Honda GCV160 4 Starting the Engine The engine oil should be checked before each use. Check there is sufficient petrol in the fuel tank, and that it is clean and fresh. Old, stale fuel may cause poor starting.
  • Page 11 Engine Model: Honda GCV135 Honda GCV160 A: Spark Plug: Check the H.T. lead (spark plug cap) is correctly fitted to the spark plug. To check the state of the plug, u nscrew the spark plug with a genuine spark plug spanner. Oil can be cleaned from it (the result of the machine having been overfilled with oil or tipped incorrectly) with a clean rag.
  • Page 12 Engine Model: Honda GCV135 Honda GCV160 B: Fuel: Ensure there is fresh unleaded petrol in the fuel tank. The fuel is fed by gravity. Stale fuel or build-ups in the fuel tank are We advise that the engine should be drained of fuel most common when before storage for more than 30 days.
  • Page 13: Engine Starts And Smokes Heavily

    Engine Model: Honda GCV135 Honda GCV160 5 Engine Starts and Smokes Heavily QUICK TROUBLESHOOTING GUIDE: Problem: Likely Cause: Solution: • • White, blue or Over-filled with oil Reduce oil (see A) • • grey smoke from Mower has been tipped incorrectly...
  • Page 14 Engine Model: Honda GCV135 Honda GCV160 This is a general indication that the mower has been over-filled with oil, or tipped incorrectly (perhaps inadvertently). It can be resolved without the intervention of a service dealer. The filter is located on the right hand side of the engine (viewed from the front).
  • Page 15: Engine Cutting Out Or Running Unevenly

    Engine Model: Honda GCV135 Honda GCV160 6 Engine Cutting Out or Running Unevenly QUICK TROUBLESHOOTING GUIDE: Problem: Likely Cause: Solution: • • Engine revs are Paper air filter may be Replace the air filter very low and contaminated with oil...
  • Page 16 Engine Model: Honda GCV135 Honda GCV160 Turn fuel the valve to the OFF position Remove the float bowl bolt (10mm spanner) and turn fuel valve to the ON position to drain the fuel. After draining, re-install the float bowl while holding it in position, and tighten the float bowl bolt securely.
  • Page 17: Pull Cord Not Pulling Or Snatching Back

    Engine Model: Honda GCV135 Honda GCV160 7 Pull Cord Not Pulling or Snatching Back QUICK TROUBLESHOOTING GUIDE: Problem: Likely Cause: Solution: • • Pull cord will not OPC not engaged Hold OPC in (see A) • • pull Grass caught between...
  • Page 18 Engine Model: Honda GCV135 Honda GCV160 The engine pull cord may snatch back when pulled if the machine is not on a flat and firm surface, or the blade and/or its mounting boss are damaged or fitted insecurely. Ensure the machine is situated on a firm level surface (path, patio or short grass).
  • Page 19: Cutting And Collecting Grass, Vibration

    Engine Model: Honda GCV135 Honda GCV160 8 Cutting and Collecting Grass, Vibration QUICK TROUBLESHOOTING GUIDE: Problem: Likely Cause: Solution: • • Mower will not Technique is incorrect See A • • cut grass Grass is too long or wet See A •...
  • Page 20 Engine Model: Honda GCV135 Honda GCV160 maximum height setting in steps until you reach your ideal height. 1. Remember the one third rule – never remove more than one third of the length of the blade of grass whenever you mow. This is good advice no matter what type of mower you use! 2.
  • Page 21 Engine Model: Honda GCV135 Honda GCV160 Excessive vibration can indicate damage to the Check the blade bolt is tight. blade, or blade mounting, or that the WARNING: Mark the blade before attempting engine is loose to remove it. This will enable you to replace it the correct way up.
  • Page 22 Engine Model: Honda GCV135 Honda GCV160 BUILD-UP OF GRASS CLIPPINGS UNDERNEATH or LACK OF AIRFLOW When cutting grass make sure 1. Ensure there is no build up of grass underneath the you are using the casing. Before checking the underside, make machine on full sure to remove the HT Cap (sparkplug cap).
  • Page 23: Loss Of Drive On Self-Propelled Mowers

    Engine Model: Honda GCV135 Honda GCV160 9 Loss of Drive on Self-Propelled Mowers QUICK TROUBLESHOOTING GUIDE: Problem: Likely Cause: Solution: • • Clutch cable very Cable is detached or broken See A • • slack and mower Cable tension is incorrect...
  • Page 24 Engine Model: Honda GCV135 Honda GCV160 or become detached (see a service dealer). Find your local ServiceLink centre at www.servicelink.org.uk B REPLACING THE BELT To replace the belt on these machines, it will involve tipping the machine to gain access to the belt.
  • Page 25 Engine Model: Honda GCV135 Honda GCV160 4. Raise the stone guard flap, tip the mower BACKWARDS with the handle hanging over the edge of the bench – it will stand upright like this 5. Mark the blade so that after removing it you can replace it the correct way 6.
  • Page 26: Transportation And Handling

    Engine Model: Honda GCV135 Honda GCV160 10 Transportation and Handling The correct way to gain access underneath the mower: Before checking the underside, make sure to remove the HT Cap (sparkplug cap). ALWAYS lift from the front of the mower so that the front wheels are raised, and the handles touch the ground at the rear.
  • Page 27: Maintenance And Storage

    Engine Model: Honda GCV135 Honda GCV160 11 Maintenance and Storage Regular and careful maintenance is essential to preserve original performance and safety levels of the engine. Always store the mower in a dry place. Please also refer to the Engine Routine Maintenance information for additional help.
  • Page 28: Guarantee, Spare Parts, Repairs

    Engine Model: Honda GCV135 Honda GCV160 12 Guarantee, Spare Parts, Repairs Congratulations on the purchase of your lawnmower. This product is guaranteed against faulty parts or manufacture for domestic use as shown below: MOWER MODEL: GUARANTEE PERIOD: 422 HP, 462 PD, 512 PD...
  • Page 29 Engine Model: Honda GCV135 Honda GCV160 Repairs Your local ServiceLink centre can be found at www.servicelink.org.uk Notes: Page 29 of 32 Honda Engines Selfhelp Guide 2011, Issue 1.0...
  • Page 30 Engine Model: Honda GCV135 Honda GCV160 Notes: Page 30 of 32 Honda Engines Selfhelp Guide 2011, Issue 1.0...
  • Page 31 Engine Model: Honda GCV135 Honda GCV160 Notes: Page 31 of 32 Honda Engines Selfhelp Guide 2011, Issue 1.0...
  • Page 32 Engine Model: Honda GCV135 Honda GCV160 Notes: Page 32 of 32 Honda Engines Selfhelp Guide 2011, Issue 1.0...

This manual is also suitable for:

Gcv160