Honda GX160 Operational Manual
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Honda GX160 Operational Manual

Gasoline engine
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Summary of Contents for Honda GX160

  • Page 2 Thank you for choosing HONDA gasoline engine. This manual contains the operation & maintenance of GX160 gasoline engine. All the contents of this manual are accomplished by newest information when printed. Do not copy any contents of this operation manual, unless agreed by us in writing.

  • Page 3: Table Of Contents

    Contents Chapter 1 Safety rules ……………………………………………………………………… 4 Warning…………………………………………………………………………………………..4 Chapter 2 Operation parts & its characteristic ……………………………………….. 6 Spare parts/its operation…………………………………………………………………………...6 Operation parts…………………………………………………………………………………….7 Fuel valve……………………………………………………………………………………….7 ON/OFF Switch………………………………………………………………………………...7 Chock handle……………………………………………………………………………………8 Throttle switch handle…………………………………………………………………………..8 Starter grip………………………………………………………………………………………9 Characteristic………………………………………………………………………………………9 Fuel alarm system………………………………………………………………………………….9 Chapter 3 Inspection before operation …………………………………………………..10 Inspect the engine under general condition……………………………………………………….10 Inspect gasoline engine……………………………………………………………………………11...
  • Page 4 Replace the fuel…………………………………………………………………………………..23 Recommend using the oil…………………………………………………………………………24 Air cleaner inspection…………………………………………………………………………….25 Air cleaner maintenance………………………………………………………………………….25 Clean the sediment chamber……………………………………………………………………..29 Spark plug maintenance………………………………………………………………………….30 Idle adjustment……………………………………………………………………………………31 Spark eliminator maintenance (optional)…………………………………………………………32 Chapter 6 Trouble-shooting ………………………………………………………………...33 Gasoline engine can’t start……………………………………………………………………….33 Gasoline engine have not enough power…………………………………………………………33 Chapter 7 Technical/consume information ……………………………………………..34 Technical information…………………………………………………………………………….34...

  • Page 5: Chapter 1 Safety Rules

    Chapter 1 Safety rules Make sure fully understand all the safety tips as follows: If used in accordance with this manual, it will be run safely and reliably. Please read carefully and understand all of them before operation, or it may cause body damage or machine damage.

  • Page 6: Warning

    Safety rules warning location Please read carefully as these warnings express the unsafe factor that may cause damage. If the labels drop off or the contents are not clear, please contact the dealer authorized by HONDA...

  • Page 7: Chapter 2 Operation Parts& Its Characteristic

    Chapter 2 Operation parts& its characteristic Spare parts/operation...

  • Page 8: Operation Parts

    Operation parts Fuel valve Fuel valve is used in the alleyway between controlling oil tank and carburetor. Fuel valve shall be adjusted to ON when the engine runs. Fuel valve shall be adjusted to OFF in case that the oil spill from the carburetor, reducing the possibility of oil spillage when the engine is stopped.

  • Page 9: Chock Handle

    Chock Handle Chock Handle controls the chock of carburetor. Adjusting the chock handle to OFF could provide high concentrations of fuel materials to make the engine start. After starting the engine, adjust the chock handle to ON will not only provide proper fuel materials for running but also supply proper fuel materials for restarting.

  • Page 10: Starter Grip

    Starter Grip Pulling the starter grip will make crank run. Characteristic Fuel alarm system In case of engine damage due to scanty fuel of crankcase, some models design the fuel alarm system. When the lube oil under the safe fuel level, the alarm system will shut off the engine automatically, but the ON/OFF Switch will be still ON.

  • Page 11: Chapter 3 Inspection Before Operation

    Chapter 3 Inspection before operation For your safe and extend the lifespan to longest of this engine as well, it’s very important to take your time to inspect the engine before starting. Make sure all the problems you found have been solved before starting. WARNING!!! It may cause engine trouble, result in serious injuries if incorrectly repair or not correct all the...

  • Page 12: Inspect Gasoline Engine

    Inspect gasoline engine · Inspect the fuel (Refer to Page22), scanty fuel may cause engine damage. When the fuel level is lower than safe level, fuel alarm system will shut off the engine automatically. In order to avoid the inconvenience caused by sudden stop, please inspect the fuel level before starting.

  • Page 13: Chapter 4 Running

    Chapter 4 Operation Safety tips If you are the first time to operate gasoline engine, please refer to the important safety rules on Page 4. In order to make this engine fully use, we suggest run the new engine about 15 minutes before use.
  • Page 14 2. Start the engine, then adjust the chock handle to OFF Restart the engine which is at a hot state, then adjust the chock handle to ON. Some engines adopt distant chock controlling, not controlled by chock handle as the below illustration.
  • Page 15 4. Turn the ON/OFF Switch to ON. 5. Lightly pull the starter grip until feeling of resistance, then quickly pull it with force, and slowly release handle finally. 6. Start the engine. If the chock handle is adjusted to OFF, turn it to ON, and preheat the engine at the same time.

  • Page 16: Switch Off The Gasoline Engine

    Stop the gasoline engine Stop the engine when happen to emergency, only need turn the ON/OFF Switch to OFF. Usually, please stop the engine by the below step. 1. Turn the throttle switch handle to low speed position Some engine adopt distant throttle switch controlling, not controlled by throttle switch as the below illustration.

  • Page 17: Adjustment The Running Speed

    3.Turn the fuel valve to OFF Adjust speed Turn the throttle switch handle to the speed what the engine need. Some engine adopt distant throttle switch controlling, not controlled by throttle switch as the below illustration. Regarding the recommendation of speed, please refer to power equipment instruction matched with the engine...

  • Page 18: Chapter 5 Maintenance

    Usually, it is repaired by HONDA technician or the service store authorized by HONDA. The maintenance sheet is only apply to regular running condition. If start the engine under abnormal condition, like overload or high temperature, use in wet or dusty circumstance, please consult the service store, and design the maintenance sheet as per your need.

  • Page 19: Safety Tip Of Maintenance

    Keep in mind that your supplier who learn more about the engine and have the power to maintain. In order to assure highest quality and most reliable performance., please repair and replace the engine with the spare parts supplied by HONDA, or the spare parts whose quality won’t be inferior to HONDA.
  • Page 20 (1) operation in the place of big dust, you have to increase the maintenance time (2) if the user have suitable tools or maintenance capacity, otherwise, these items have to ask the Honda service department to maintain. (3) if this machine is used for business function, please record the operation time to make sure the maintenance time.

  • Page 21: Inject The Fuel

    When the engine is stopped, unscrew the fuel tank cap to check the fuel level. If it is too low, please fill in the gasoline. DANGER!!! The gasoline is flammable and explosive It may be burnt when dealing with the gasoline Shut off the engine, keep away from the heat and fuel material.
  • Page 22 If you hear the noise of striking cylinder when the engine is normally loading, we suggest you replace it with qualified gasoline. If the problem still occurs, please contact the special service department authorized by JIALING-HONDA. Remark If there is still the noise of the spark striking cylinder or “bang” noise when loading, it may result in engine damage.

  • Page 23: Oil Level Inspection

    Check fuel oil level Stop the engine when checking fuel oil level, and make the engine on a surface level. 1. Dismantle the oil dipstick, and clean it. 2. Insert the fuel oil level to fill-in hole. But don’t screw it and read the correct fuel oil level from the oil dipstick.

  • Page 24: Replace The Fuel

    Drain out fuel oil when the engine is still hot, it will assure the fuel oil drain completely and quickly. 1. Put a proper vessel under the engine, and unscrew oil dipstick, release oil drain cock, then drain the fuel oil into the vessel. 2.

  • Page 25: Recommend Using The Oil

    Lube oil is an important factor of operation and maintenance of this engine. We suggest use JIALING-HONDA specific lube oil (SJ 10W-30) SE 10W-30 is lowest general lube oil. If the average temperature belongs to relevant recommended scopes, other viscous lube oil as below illustration will be also available.

  • Page 26: Air Cleaner Inspection

    Check the air cleaner Take off the air cleaner cover, and check the air cleaner. Clean or replace the air filter-elements. If the air cleaner is oil-bath type, you have to check the oil level. The maintenance of air cleaner A dirty air filter-element will stop the air go into the carburetor, then reduce the capacity of gasoline engine, if the gasoline engine running under a condition full with dust, then you have to increase the maintenance times.
  • Page 27 5. Clean the air filter-element. Paper filter-element: tap the filter element to make the dust off , or blow the filter element from inside to outside by using high-pressure air flow (not excess 207kPa, 2.1kgf/cm2). Never use brush to clean the filter element, as the brush will make the dust go into the fiber of paper filter element.
  • Page 28 Dust collect type 1. take off the butterfly nuts and the air cleaner cover, and remove and separate the filter element, check the 2 filter element carefully. If there is hole or tearing, please replace it. 2. Foam filter-element: use soap with warm water to clean, rinse and dry the foam filter-element. Or using non-flammable solvent to clean and dry the foam filter-element.
  • Page 29 Oil-bath type 1. take off the butterfly nuts and the air cleaner cover, and remove and separate the filter element, check the 2 filter element carefully. If there is hole or tearing, please replace it. 2. Foam filter-element: use soap with warm water to clean, rinse and dry the foam filter-element. Or using non-flammable solvent to clean and dry the foam filter-element.

  • Page 30: Clean The Sediment Chamber

    Clean the sediment chamber 1. put the fuel valve to Off, then install the sediment chamber and O-ring. Dangerous !!! The fuel is easy to burn and easy to explosion Treatment the fuel have to be careful  Far away to the flog, spark , fire, and so on. ...

  • Page 31: Spark Plug Maintenance

    Spark plug maintenance Recommend spark plug model: BPR6ES(NGK) Important matters The unsuitable spark plug may cause the gasoline engine damage. 1. Take off the cap of spark plug, and clean its around dirty material. 2. Please use the professional spark plug wrench to take off the spark plug. 3.

  • Page 32: Idle Adjustment

    6. After put back the spark plug, please screw it by professional wrench. Install the used spark plug, press the washer , then screw more 1/8 to 1/4 circle. Install the new spark plug, press the washer more 1/2 circle.. Important matters The unscrewed spark plug may too hot and damage the gasoline engine.

  • Page 33: Spark Eliminator Maintenance (Optional)

    You have to check your rule, and if you need the spark plug eliminator, please ask Honda service office to equip it. The spark plug eliminator have to maintenance every 100 hours to keep is effective.

  • Page 34: Chapter 6 Trouble-Shooting

    Dried and re-loading the spark fuel plug, and put the valve handle on high speed 4. Take the machine to Honda Fuel air cleaner is clogged, or Replace or repair the parts special maintenance office or carburetor default, or spark...

  • Page 35: Chapter 7 Technical/Consume Information

    Chapter 7 Technique & user’s information Technique information Series Number Please fill the series number of gasoline engine under the underline, it will be useful when you order the spare parts or consult the technique information and claim. Series number ______________________________...

  • Page 36: Far Away Control The Connection

    Far distance control connection The throttle switch control pole has assemble the hole of cables, these holes can assemble the fixed cable, movable cable and collective cable. If assemble the movable and collective cable, it need add a reset spring, as the follow diagram. Using the far distance operating the throttle switch, please loose the lock nuts of throttle switch handle.

  • Page 37: Adjust The Carburetor To Suitable The Plateau Region Use

    Adjustment the carburetor will improve the performance in the plateau region. If you always use the gasoline engine in the plateau region higher than 1,800mm, please ask the Honda distributor adjustment the carburetor. The adjustment gasoline engine using in plateau region would ensure the emissions standard in the warranty period.

  • Page 38: Alcohol Fuel

    Due to using alcohol fuel, cause fuel system damage or engine performance failure, it’s  not in the warranty. Honda company won’t bear the fuel contain the alcohol, because its applicability still has not been approved . Before purchase the fuel on the oil supplier, first, please try to know whether the fuel ...

  • Page 39: Emission Control System

    CO have not such interactive, it’s toxic. The Honda company using the lean carburetor and other system to reduce the emission of CO, Nitrogen oxides and Hydrocarbons.
  • Page 40 During maintenance the gasoline engine, we suggest you using the true spare parts come from Honda, because the replace spare parts are products by the same standard design, and you can take care its performance. If you use difference replace parts, it may damage the emission control system.

  • Page 41: Specification

    Main technique specification Item Technique parameter Model No. JH168F (GX160) Function Normal use Style Single-cylinder, 4-stroke, Forced air cooling Main specification parameter Max. power and running speed 3.05kW/3600r/min Min. no-load stable running speed ≤1440 Max. torque and running speed 8.6N.m/2500r/min Fuel consume ratio ≤395...

  • Page 42: Chapter 8 Wiring Diagram

    Chapter 8 Wiring diagram...

  • Page 43: Chapter 9 Appendix/Suggestion

    Chapter 9 Appendix/Suggestion Storage Storage preparation Correct storage is necessary for keeping the good performance of gasoline engine, the following steps will avoid the gasoline engine rusty, corrosion, and damage the performance and appearance of the gasoline engine. Correct storage will make the gasoline engine easy to start. Clean Complete operation of the gasoline engine, please allow it at least half and hour to cooling, then clean it.
  • Page 44 The damage of the gasoline engine which is caused by fuel or storage uncorrected are not in warranty. Please use the professional fuel stable controller to prolong the life time of the fuel, or discharge the fuel of the fuel tank and carburetor to avoid the fuel go bad. Add a fuel stable controller to prolong the storage life time of the fuel When add a fuel stable controller, please inject the fresh fuel to the fuel tank.
  • Page 45 Discharge the fuel of the fuel tank and carburetor 1. Put a suitable fuel container under the carburetor, it’s better to use a hopper to discharge the fuel to avoid the fuel spill out. 2. Release the drain cock of carburetor, move the sediment chamber, and put the fuel valve on Off.

  • Page 46: Storage Notice

    Gasoline engine lube oil 1. Replace (Refer to Page23) 2. Dismantle the spark plug 3. Put a spoon (5-10CC) clean fuel to the inside cylinder. 4. Pull up the starter grip several times, to make the oil decentralized. 5. Install back the spark plug 6.

  • Page 47: Move Out

    Install the gasoline engine in level, because the tilt will lead the fuel or oil leakage. After the gasoline engine and fuel system cooling, cover the gasoline engine to avoid the dust. The hot gasoline engine or exhaust system may burn or melt some materials, don’t use plastic film. The gas-tight cover will make the engine gasoline engine moisture, and acceleration the rusty or corrosion.

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