Honda Engines GCV135E, GCV160E Owners Manual

							1
GCV135EGCV160E
Honda Motor Co., Ltd. 2003
130000.2004.10 PRINTED IN ITALY32Z0M600
00X32-Z0M-6000
OWNER’S MANUAL
SERIAL NUMBER AND ENGINE TYPE
2
The Honda engine is designed to give safe and dependable service
ifoperated according to instructions. Read and understand the
Owner’s Manual beforeoperating the engine. Failure to do so
could result in personal injury or equipment damage.Indicates that equipment or property damage can
result if instructions are not followed.Indicates a possibility of personal injury or equipment
damage if instructions are not followed.Indicates a strong possibility of severe personal
injury or death ifinstructions arenot followed. Thank you for purchasing a Honda engine.
This manual covers the operation and maintenance of your engine:
Allinformation in this publication is based on the latest product
information available atthetime of printing.
Theillustrations may vary according to the with top cover type.
Ifaproblem should arise, or if you have any questions about your
engine, consult an authorized Honda dealer.Gives helpful information. Pay special attention to statements preceded by the following
words: This manual should be considered a permanent part of the engine
andshould remain with it if it is resold. Nopart of this publication may be reproduced without written
permission. Honda Motor Co., Ltd. reserves the right to make changes at any
time without notice and without incurring any obligation. GCV135E·GCV160E 
						

							µ
3 SAFETY INSTRUCTIONS
To ensure safe operation
Honda engine is designed to give safe and
dependable service if operated according
toinstructions. 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. You may prevent an accident or equipment
damage.
Toprevent fire hazards and to provide adequate ventilation,
keep the engine at least 1 meter (3 feet) away from buildings
and other equipment during operation. Do not place flammable
objects close to the engine.
Children andpets must be kept away from the area of
operation due to a possibility of burns from hot engine
components or injury from any equipment the engine may be
used to operate.
Know how to stop the engine quickly, and understand the
operation of all controls. Never permit anyone to operate the
engine without proper instructions.
Do not place flammable objects such as gasoline, matches, etc.,
close to the engine while it is running.
Refuel in a well-ventilated area with the engine stopped.
Gasolineishighly flammable and explosive under certain
conditions.
Do not overfill the fuel tank. There should be no fuel in the filler
neck.
Make sure that the filler cap is closed securely.7µ
4 Safety Instruction
SAFETY INDICATION LOCATION
If any fuel is spilled, clean it up completely and allow petroleum
vapours to dissipate before starting the engine. To ensure safe operation
Do not smoke or allow flames or sparks where the engine is
refueled or where gasoline is stored.
Exhaust gas contains poisonous carbon monoxide. Avoid
inhalation of exhaust gases. Never run the engine in a closed
garage or confined area.
Do not place anything on the engine, as it may create a fire
hazard.
Asparkarrester is available as an optional part for this engine. It
is illegal in some areas to operate an engine without a spark
arrester. Check local laws andregulations before operating.
The muffler becomes very hot during operation and remains hot
for a while after stopping the engine. Be careful not to touch the
muffler while it is hot. To avoid severe burns or fire hazards, let
theengine cool before transporting it or storing it indoors. Place the engine on a stable surface. Do not tilt the engine more
than 15° from horizontal. Operating at excessive angles may
result in fuel spillage.
READ OWNER’S MANUAL BEFORE OPERATION.
This indication warns you of potential hazards that can cause
serious injury. Read it carefully. 
						

							FUEL TANKFUEL VALVEFUEL TANK CAP FLYWHEEL BRAKE LEVER
(applicable types)
AIR CLEANERCONTROLLEVER
5 COMPONENT IDENTIFICATION
OIL FILLER CAP
MUFFLERSPARK PLUG STARTER GRIP RECOIL STARTER
CHOKELEVER
(applicable types)TOP COVER
(applicable types)
6 
						

							7 PRE-OPERATION CHECK
Engine oil level
Be sure to check the engine on a level surface with the engine
stopped. Running the engine with insufficient oil can cause serious
engine damage.
Usingnondetergent oil or 2-stroke engine oil could shorten the
engine’s service life. 1.
UPPER LIMIT
LOWER LIMITOIL FILLER CAP/
DIPSTICK
SAE Viscosity Grades
AMBIENT TEMPERATURESAE
TEMP
If the level is low, add the recommended oil to the upper limit on
thedipstick. Remove the oil filler cap and wipe the dipstick clean.
Insert the dipstick into the oil filler neck, but do not screw it in.
UseHonda 4-stroke, or an equivalent
highdetergent, premium quality mo-
toroil certified to meet or exceed U.S.
automobile manufacturer’s require-
ments for service classification SG, SH.
Motoroils classified SG, SH will show
this designation on the container.
SAE10W-30 is recommended for gen-
eral, all temperature use. If single vis-
cosity oil is used,select theappropri-
ateviscosity for the average tempera-
ture in your area. 1.
2.
3.
8
Aircleaner
Never run the engine without the air cleaner. Rapid engine wear
will result. 2.
ELEMENT
AIR CLEANER COVER
Remove the air cleaner cover and check the cleaner for dirt or
obstruction of the element (page 20 ). 
						

							Fuel
Gasoline is extremely flammable and is explosive under certain
conditions.
Refuel in a well-ventilated area with the engine stopped. Do not
smoke or allow flames or sparks in the area where the engine is
refueled or where gasoline is stored.
Do not overfill the fuel tank (there should be no fuel in the filler
neck). After refueling, make sure the tank cap is closed properly
and securely.
Be careful not to spill fuel when refueling. Spilled fuel or fuel
vapor may ignite. If any fuel is spilled, make sure the area is dry
before starting the engine.
Avoid repeated or prolonged contact with skin or breathing of
vapor.
KEEP OUT OF REACH OF CHILDREN. 3.
Useautomotive unleaded gasoline with a Research Octane
Number of 91 or higher (a Pump Octane Number of 86 or higher).
Never use stale or contaminated gasoline or an oil/gasoline
mixture. Avoid getting dirt or water in the fuel tank.
9
UPPER LEVEL
FUEL FILLER
NECK
10
GASOLINES CONTAINING ALCOHOL
Beforebuying fuel from an unfamiliar station, try to find out if
the fuel contains alcohol, if it does, confirm the type and
percentage of alcohol used. If you notice any undesirable
operating symptoms while using a gasoline that contains
alcohol, or one that you think contains alcohol, switch to a
gasoline that you know does not contain alcohol. Fuel system damage orengine performance problems resulting
from the use of fuels that contain alcohol is not covered under
the warranty. Honda cannot endorse the use of fuels containing
methanol since evidence of their suitability is as yet incomplete. Gasoline spoils very quickly depending on factors such as light
exposure, temperature and time.
In worst cases, gasoline can be contaminated within 1 month.
Using contaminated gasoline can seriously damage the engine
(carburetor clogged, valve stuck).
Such damage due to spoiled fuel is disallowed from coverage by
thewarranty.
To avoid this please strictly follow these recommendations:
Only use specifiedgasoline (page ).
To slow deterioration, keep gasoline in a certified fuel container.
Iflong storage (more than 1 month) is foreseen, drain fuel tank
and carburetor (page ).
Ifyoudecidetouseagasoline containing alcohol (gasohol), be
sureit’soctane rating is at least as high as that recommended by
Honda. There are two types of ‘‘gasohol’’: one containing ethanol,
andthe other containing methanol. Do not use gasohol that
contains more than 10% ethanol. Do not use gasoline containing
methanol (methyl or wood alcohol) that does not also contain
cosolvents and corrosion inhibitors for methanol. Never use
gasoline containing more than 5% methanol, even if it has
cosolvents and corrosion inhibitors. 299 
						

							11 STARTING THE ENGINE
FUEL VALVE
CHOKEON
CONTROL
LEVERCHOKELEVER
CLOSE   OPEN     [WITHOUT CHOKE LEVER TYPE] [WITH CHOKE LEVER TYPE]
Turn the fuel valve to the ON position.
Do not use the choke if the engine is warm or the air temperature
is high.Move the control lever to the CLOSE position.
Move the choke lever to the CLOSE position. 1.
2.Without CHOKE LEVER type:
With CHOKE LEVER type
(AUTOMATIC RETURN CHOKE type):
12
Do not allow the starter grip to snap back against the engine.
Return it gently to prevent damage to the starter.
FLYWHEEL BRAKE LEVER
R RE
EL
LE
EA
AS
SE
ED
D
Pull the starter grip lightly until resistance is felt, then pull
briskly. Theengine switch, which is linked with the flywheel brake lever,
is turned on when the flywheel brake lever is moved to the
RELEASED position. Move the flywheel brake lever to the RELEASED position. 3.
4.With FLYWHEEL BRAKE LEVER type only: 
						

							13
SLOWFAST
CONTROLLEVER
Operate the recoil starter as soon as you move the flywheel
brake lever to the RELEASED position. The choke lever
automatically begins moving to the OPEN position when the
flywheel brake lever is moved to the RELEASED position.
If the engine does not start within several consecutive pulls of
therecoil starter, move the flywheel brake lever to the
ENGAGED position and move the choke lever to the CLOSE
position.
Move the flywheel brake lever to the RELEASED position and
immediately begin operating the recoil starter.
When engine warms up, move the control lever to FAST or
SLOW. [With CHOKE LEVER type (AUTOMATIC RETURN CHOKE type)]
5.
6.
[Without CHOKE LEVER type]
7.
14
High altitude operation
Operation of the engine at an altitude lower than the carburetor is
jetted formay result in reduced performance, overheating, and
serious engine damage caused by an excessively lean air/fuel
mixture. At high altitude, the standard carburetor air-fuel mixture will be ex-
cessively rich. Performance will decrease, and fuel consumption
will increase.
Even with suitable carburetor jetting, engine horsepower will
decrease approximately 3.5% for each 300 m (1,000 feet) increase
inaltitude. The effect of altitude on the horsepower will be greater
than this if no carburetor modification is made. High altitude performance can be improved by specific modifica-
tions to the carburetor. If you always operate the engine at
altitudes higher than 1,500 m (5,000 feet) above sea level, have
your authorized Honda dealer perform these carburetor modifi-
cations. 
						

							STOPPING THE ENGINE
SLOW
CONTROLLEVER
ENGAGED
Move the control lever to the SLOW position.
Theengine switch, which is linked with the flywheel brake lever,
is turned off when the flywheel brake lever is moved to the
ENGAGED position. Return the flywheel brake lever to the ENGAGED position. 1.
2. With FLYWHEEL BRAKE LEVER type:
15
ENGAGED
FLYWHEEL BRAKE LEVER
E EN
NG
GA
AG
GE
ED
D
OFF
S
ST
TO
OP
PCONTROLLEVER
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. 3.Without FLYWHEEL BRAKE LEVER type:
16
OFF STOP
FUEL VALVEO OF
FF
F
Turn the fuel valve to the OFF position. 4. 
						

							17 MAINTENANCE
Shut off the engine before performing any maintenance.
Toprevent accidental start-up, disconnect the spark plug cap.
Useonly genuine Honda parts or their equivalent. The use of
replacement parts which are not of equivalent quality may
damage the engine.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.
To perform maintenance on the lower part of the engine
(Machine), turn it 90° and lay it down with the carburetor/air
cleaner always at the top. Periodic inspection and adjustment of the Honda engine is
essential if high level performance is to be maintained. Regular
maintenance will also ensure a long service life. The required
service intervals and the kind of maintenance to be performed are
described on the following table.
Ó
ÓÓ
Ó
Ó Ó
Ó
Ó
Ó
ÓÓÓ Ó
18
Maintenance Schedule
REGULAR SERVICE PERIOD (4)
Engine oil
Air cleaner
Flywheel brake pad
(applicable types)
Spark plug
Spark arrester
(optional part)
Idle speed
Fuel tank and filter
Valve clearance
Combustion chamber
Fuel tube
Service more frequently when used in dusty areas.
Change engine oil every 25 hours when used under heavy load or in high ambient temperature.
For commercial use, log hours of operation to determine proper maintenance intervals. ITEM
Perform at every indicated month or
operating hours interval, whichever
comes first.
These items should be serviced by your servicing dealer, unless you have the proper tools and
are mechanically proficient. Refer to Honda Shop Manual for service procedures. Check level
Change
Check
Clean
Replace
Check
Check-adjust
Replace
Clean
Check-adjust
Clean
Check-adjust
Clean
Check Every 2 years (Replace if necessary) (3)After every 250 hrs. (3)
(1):
(2):
(3):
(4):Each
useFirst
month
or
5hrs.Every
3
or
25 hrs.Every
year
or Every
6
or
50 hrs.Every
or
(1)(2)
(3)
(3)
(3)
months
100 hrs. months2years
250 hrs. 
						

							19
Oil change
ENGINE OIL CAPACITY: 1.
OIL FILLER NECK
Drain the oil while the engine is still warm to assure rapid and
complete draining.
Please dispose of used motor oil in a manner that is compatible
with the environment. We suggest you take it in a sealed container
to your local service station for reclamation. Do not throw it in the
trash, pour it on the ground, or down a drain. Wash your hands with soap and water after handling used oil.0.55
(0.58 US qt , 0.48 Imp qt) Install the oil filler cap.
Refillwith the recommended oil and check the oil level (see
page ). Remove the oil filler cap and drain the oil into the oil container
byinclining the engine toward the oil filler neck. Turnthefuel valve to the OFF position (see page ). 1.
2.
3.
4.16
7
20
Aircleaner service
Never run the engine without the air cleaner. Rapid engine wear
will result. Never use gasoline or low flash point solvents for cleaning the air
cleaner element. A fire or explosion could result. 2.
LOWER TABS UPPER TABS ELEMENT AIR CLEANER COVER
Adirty 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.
Remove the air cleaner cover by unhooking the two upper tabs
onthetopoftheair cleaner cover and the two lower tabs.
Remove the element. Carefully check the element for holes or
tears and replace if damaged. 1.
2.