Honda Engines GCV135E, GCV160E Owners Manual

							21
ELEMENT
Taptheelement lightly several times on a hard surface to
remove excess dirt, or blow compressed air through the filter
from the inside out. Never try to brush the dirt off; brushing will
force dirt into the fibers. Replace the element if it is excessively
dirty.
Install the element and air cleaner cover. 3.
4.
22
Flywheel brake inspection 3. (applicable types)
[WITH TOP COVER TYPE]
Remove the top cover by removing the three tapping screws
(with top cover type only).
Remove the recoil starter by removing the three 6 mm nuts.
Remove the fuel tank taking care not to disconnect the fuel tube
from the fuel tank and fuel valve, and keeping the fuel tank to a
level. 1.
2.
3.
6mmNUTS
FUEL TANK
FUEL TUBERECOIL STARTER TOP COVER TAPPING SCREWS
[ALL TYPES] 
						

							23
B BR
RA
AK
KE
ES
SH
HO
OE
ET
TH
HI
IC
CK
KN
NE
ES
SS
S
BRAKE SHOE
Check the brake shoe thickness. If it is less than 3 mm (0.12 in),
replace it with newone.
Installthe fuel tank and recoil starter, and tighten the three 6 mm
nutssecurely.
Install the top cover, and tighten the three tapping screws
securely (with top cover type only). 4.
5.
6.
24
Spark plug service
Recommended spark plug:
Never use a spark plug of incorrect heat range.
Iftheengine has been running, the muffler will be very hot. Be
careful not to touch the muffler. 4.
BPR6ES (NGK)
To ensure proper engine operation, the spark plug must be
properly gapped and free of deposits.
Remove the spark plug cap and use a spark plug wrench to
remove each spark plug. 1. 
						

							µµ
µ
µ
25
0.70 0.80 mm
(0.028 0.031 in)
Visually inspect the spark plug.Discard the spark plug if there is
apparent wear, or if the insulator is cracked or chipped. Clean
the spark plug with a wire brush if it is tobereused.
0.70 0.80 mm (0.028 0.031 in) Measure the plug gap with a feeler gauge. Correct as necessary
by bending the side electrode.
The gap should be: 2.
3.
µ
26
The spark plug must be securely tightened. An improperly
tightened spark plug can become very hot and may damage the
engine.Checkthat the spark plug washer is in good condition and
thread the spark plug in by hand to prevent cross-threading.
When installing a new spark plug, tighten 1/2 turn after the spark
plugseats to compress the washer. When reinstalling a used spark
plug, tighten 1/8 1/4 turn after the spark plug seats to compress
the washer.Afterthespark plug is seated, tighten with a spark plug wrench
tocompress the washer. 5. 4. 
						

							27
Spark arrester maintenance (optional part)
Iftheengine has been running, the muffler will be very hot. Allow
it to cool before proceeding.
Thespark arrester must be serviced every 100 hours to maintain
its efficiency. 5.
MUFFLER PROTECTOR SPARK ARRESTER
SCREW
6mmBOLTSMUFFLER SCREW
Remove the muffler protector by removing the three 6 mm bolts.
Remove the spark arrester from the muffler by removing the
two screws. (Taking care not to damage the wire mesh.)
Checkfor carbon deposits around the exhaust port and the spark
arrester, and clean if necessary. 1.
2.
28
Be careful not to damage the spark arrester screen.
SCREEN
Use a brush to remove carbon deposits from the spark arrester
screen.
The spark arrester must be free of breaks and holes. Replace, if
necessary.
Install the spark arrester and the muffler in the reverse order of
disassembly. 3.
4. 
						

							29 TRANSPORTING/STORAGE
When transporting theengine, turn the fuel valve OFF and keep
the engine level to prevent fuel spillage. Fuel vapor or spilled fuel
may ignite.
Gasolineisextremelyflammable and is explosive under certain
conditions. Do not smoke or allow flames or sparks in the area.
DRAIN BOLTFUEL VALVE O ON
NO OF
FF
F
Before storing the unit for an extended period;
Be sure the storage area is free of excessive humidity and dust.
Drain the fuel tank and carburetor into a suitable gasoline
container:
Turn the fuel valve to the OFF position.
Remove the carburetor drain bolt and drain the carburetor.
Turn the fuel valve to the ON position and drain the fuel in the
fueltank into the container.
Retighten the carburetor drain bolt so that the float chamber
and washer cannot be warped, and turn the fuel valve to the
OFFposition. 1.
2.
A.
B.
C.
D.
30
Coat areas that may rust with a light film of oil. Cover theengine
and store it on a level surface in a dry, dust free area. Change the engine oil (page 19 ).
Pull the starter rope slowly until resistance is felt. This closes the
valves, and protects them from dust and corrosion.
5. 3.
4. 
						

							31 TROUBLESHOOTING
If any fuel is spilled, make sure the area is dry before testing the
spark plug or starting the engine. Fuel vapor or spilled fuel may
ignite.
DRAIN BOLTFUEL VALVEO OF
FF
F
O ON
N
Whenthe engine will not start:
Is the fuel valve ON?
Is there fuel in the fuel tank?
Is gasoline reaching the carburetor?
To check, loosen the drain bolt with the fuel valve ON.
Is the control lever positioned properly (page 11 )?
Is the flywheel brake lever positioned to the RELEASED position
(page 12 )? (applicable types)
Isthe spark plug in good condition (page 24 )?
Ifthe engine still does not start, take the engine to an authorized
Honda dealer. 1.
2.
3.
4.
5.
6.
7.
32 SPECIFICATIONS
Engine
4-stroke, overhead cam, 1 cylinder Dimensions
Power equipment
description code
Length
Width
Height
Dry weightGJAAE
367 mm (14.4 in)
331 mm (13.0 in)
360 mm (14.2 in)
10.5 kg (23.1 lbs)
160 cm
(9.8 cu-in)
Counterclockwise Transistor magnetoForced air 313 g/kWh (230 g/PSh)11.4 N·m (1.16 kgf-m)/
2,500 rpm 4.1 kW (5.5 PS)/
3,600 rpm 64x50mm
(2.5 x 2.0 in)
1.1
(0.29 US gal ,
0.24 Imp gal)GCV160E GCV135E
GJAFE
351 mm (13.8 in)
331 mm (13.0 in)
353 mm (13.9 in)
10.4 kg (22.9 lbs)
135 cm
(8.2 cu-in)
3.3 kW (4.5 PS)/
3,600 rpm
0.55
(0.58 US qt , 0.48 Imp qt)
Service classification SG or SH; SAE 10W-30
BPR6ES (NGK) Engine type
Displacement
BorexStroke
Max. output
Max. torque
Fuel consumption
Cooling system
Ignition system
PTO shaft rotation
Fuel tank capacity
Engine oil capacity
Engine oil
Spark plug64x42mm
(2.5 x 1.7 in)
0.9
(0.24 US gal ,
0.20 Imp gal) 9.7 N·m (0.99 kgf-m)/
2,500 rpm
Specifications may vary according to the types, and are subject to
change without notice.