Honda Gx160 Manual
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µ INTRODUCTION CONTENTS SAFETY MESSAGES ENGLISH FRANÇAIS ESPAÑOL ENGLISH OWNER’S MANUAL MANUEL DE L’UTILISATEUR MANUAL DEL PROPIETARIO DAMAGE PREVENTION MESSAGES GX120 · GX160 · GX200 1 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. If a problem should arise, or if you have any questions about your engine, consult an authorized Honda servicing dealer. All information in this publication is based on the latest product information available at the time of printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. This manual should be considered a permanent part of the engine and should remain with the engine if resold. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. .................. SEDIMENT CUP .12 ...................... SPARK PLUG .12 ............. SPARK ARRESTER .13 ......................... IDLE SPEED .13 HELPFUL TIPS & ...................... SUGGESTIONS .13 ... STORING YOUR ENGINE .13 ................ TRANSPORTING .14 TAKING CARE OF .... UNEXPECTED PROBLEMS .15 ........ FUSE REPLACEMENT .15 TECHNICAL & CONSUMER ....................... INFORMATION .16 ..... Serial Number Location .16 Battery Connections for .................... Electric Starter .16 ..... Remote Control Linkage .16 Carburetor Modifications for ..... High Altitude Operation .16 ............... Oxygenated Fuels .17 Emission Control System ......................... Information .17 .............................. Air Index .18 ..................... Specifications .18 ........ Tuneup Specifications .18 Quick Reference ......................... Information .19 ................ Wiring Diagrams .19 . CONSUMER INFORMATION .20 Distributor/Dealer Locator ......................... Information .20 Customer Service ......................... Information .20 2005 Honda Motor Co., Ltd. All Rights Reserved The purpose of these messages is to help prevent damage to your engine, other property, or the environment.Your engine or other property can be damaged if you don’t follow instructions. This word means: You will also see other important messages that are preceded by the word NOTICE. Each message tells you what the hazard is, what can happen, and what you can do to avoid or reduce injury.You CAN be HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. These signal words mean: A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol and one of three words, DANGER, WARNING, or CAUTION. Your safety and the safety of others are very important. We have provided important safety messages in this manual and on the engine. Please read these messages carefully. Review the instructions provided with the equipment powered by this engine for any additional information regarding engine startup, shutdown, operation, adjustments or any special maintenance instructions. We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership. The warranty policy is a separate document that should have been given to you by your dealer. United States, Puerto Rico, and U.S. Virgin Islands: ....................... INTRODUCTION .1 ................ SAFETY MESSAGES .1 .......... SAFETY INFORMATION .2 ..... SAFETY LABEL LOCATION .2 COMPONENT & CONTROL ................................ LOCATION .2 ................................ FEATURES .3 BEFORE OPERATION .................................... CHECKS .3 .............................. OPERATION .4 SAFE OPERATING ..................... PRECAUTIONS .4 ...... STARTING THE ENGINE .4 ...... STOPPING THE ENGINE .5 ..... SETTING ENGINE SPEED .6 ..... SERVICING YOUR ENGINE .7 THE IMPORTANCE OF .................... MAINTENANCE .7 ...... MAINTENANCE SAFETY .7 ....... SAFETY PRECAUTIONS .7 MAINTENANCE ............................ SCHEDULE .7 ........................... REFUELING .8 ........................... ENGINE OIL .8 ............ Recommended Oil .8 .................. Oil Level Check .9 ......................... Oil Change .9 ......... REDUCTION CASE OIL .9 ............ Recommended Oil .9 .................. Oil Level Check .9 ....................... Oil Change .10 ...................... AIR CLEANER .10 ........................ Inspection .10 .......................... Cleaning .11 37Z4F603 00X37-Z4F-6030 GX120U1·GX160U1·GX200U 06/06/14 16:08:22 32Z4F601_001
COMPONENT & CONTROL LOCATION SAFETY INFORMATION SAFETY LABEL LOCATION ENGLISH FUEL FILLER CAP FUEL TANK OIL DRAIN PLUG CHOKE LEVER ELECTRIC STARTER TYPES ENGINE SWITCHAIR CLEANER MUFFLER SPARK PLUG STARTER GRIP THROTTLE LEVER FUEL VALVE LEVERENGINE CONTROL TYPESOIL FILLER CAP/DIPSTICK ENGINE SWITCH CIRCUIT PROTECTORELECTRIC STARTER (applicable types) EXCEPT ELECTRIC STARTER TYPESRECOIL STARTER ENGINE SWITCH CHOKE LEVER (air cleaner low profile type) 2Understand the operation of all controls and learn how to stop the engine quickly in case of emergency. Make sure the operator receives adequate instruction before operating the equipment. Your engine’s exhaust contains poisonous carbon monoxide. Do not run the engine without adequate ventilation, and never run the engine indoors. The engine and exhaust become very hot during operation. Keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Keep flammable materials away, and do not place anything on the engine while it is running. Do not allow children to operate the engine. Keep children and pets away from the area of operation. This label warns you of potential hazards that can cause serious injury. Read it carefully. If the label comes off or becomes hard to read, contact your Honda dealer for replacement. The engine emits toxic poisonous carbon monoxide gas. Do not run in an enclosed area. Gasoline is highly flammable and explosive. Turn engine off and let cool before refueling. Read Owner’s Manual before operation.For Canadian types only: French label comes with the engine. 05/06/17 17:22:17 32Z4F601_002
BEFORE OPERATION CHECKS FEATURES IS YOUR ENGINE READY TO GO? Check the General Condition of the Engine Check the Engine OIL ALERTSYSTEM (applicable types) CIRCUIT PROTECTOR (applicable types) ENGLISH CIRCUIT PROTECTOR ON OFF 3 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. Improperly maintaining this engine, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always perform a preoperation inspection before each operation, and correct any problem. The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert system will automatically stop the engine (the engine switch will remain in the ON position). If the engine stops and will not restart, check the engine oil level (see page ) before troubleshooting in other areas. Before beginning your preoperation checks, be sure the engine is level and the engine switch is in the OFF position. Always check the following items before you start the engine: Look around and underneath the engine for signs of oil or gasoline leaks. Remove any excessive dirt or debris, especially around the muffler and recoil starter. Look for signs of damage. Check that all shields and covers are in place, and all nuts, bolts, and screws are tightened. Check the fuel level (see page ). Starting with a full tank will help to eliminate or reduce operating interruptions for refueling. Check the engine oil level (see page ). Running the engine with a low oil level can cause engine damage. The Oil Alert system (applicable types) will automatically stop the engine before the oil level falls below safe limits. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup. The green indicator inside the circuit protector will pop out to show that the circuit protector has switched off. If this occurs, determine the cause of the problem, and correct it before resetting the circuit protector. Push the circuit protector button to reset. Check the reduction case oil level on applicable types (see page ). Oil is essential to reduction case operation and long life. Check the air filter element (see page ). A dirty air filter element will restrict air flow to the carburetor, reducing engine performance. Check the equipment powered by this engine. Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine startup. The circuit protector protects the battery charging circuit. A short circuit, or a battery connected with reverse polarity, will trip the circuit protector. 1. 2. 3. 4. 5. 1. 2. 3. 4. 9 8 9 9 10 05/06/17 17:22:36 32Z4F601_003
OPERATION SAFE OPERATING PRECAUTIONS STARTING THE ENGINEELECTRIC STARTER TYPES EXCEPT ELECTRIC STARTER TYPES ENGLISH ENGINE SWITCH CHOKE LEVER OFF OONN OOPPEENNCCLLOOSSEEDD OONN CCLLOOSSEEDD MMIINN..MMAAXX.. 1/3 POSITION THROTTLE LEVERENGINE SWITCH ONONON ON ON ENGINE SWITCH ON MMIINN.. FFUUEELLVVAALLVVEELLEEVVEERR 4 Before operating the engine for the first time, please review the SAFETY INFORMATIONsection on page and theBEFORE OPERATION CHECKS on page . Review the instructions provided with the equipment powered by this engine for any safety precautions that should be observed with engine startup, shutdown or operation.Turn the engine switch to the ON position. 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. Move the fuel valve lever to the ON position. Some engine applications use a remote-mounted throttle control rather than the engine-mounted throttle lever shown here. Refer to the instructions provided by the equipment manufacturer.Move the throttle lever away from the MIN. position, about 1/3 of the way toward the MAX. position. Some engine applications use a remote-mounted choke control rather than the engine-mounted choke lever shown here. Refer to the instructions provided by the equipment manufacturer. To restart a warm engine, leave the choke lever in the OPEN position. To start a cold engine, move the choke lever to the CLOSED position. 3.4. 1. 2.2 3 05/06/17 17:22:59 32Z4F601_004
ENGLISH STOPPING THE ENGINE ELECTRIC STARTER TYPES EXCEPT ELECTRIC STARTER TYPES THROTTLE LEVER OOFFFF ENGINE SWITCH FUEL VALVE LEVER OFF OONN CCHHOOKKEELLEEVVEERR OOPPEENN CCLLOOSSEEDDOOPPEENN MMIINN..MMIINN.. OOFFFF OOFFFF OFF OOFFFF ENGINE SWITCH OOFFFFENGINE SWITCH SSTTAARRTTEERRGGRRIIPP ENGINE SWITCH (applicable types) SSTTAARRTT SSTTAARRTTOOFFFF 5 Turn the engine switch to the OFF position. To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. Refer to the instructions provided by the equipment manufacturer. Move the throttle lever to the MIN. position. Some engine applications use a remote-mounted throttle control rather than the engine-mounted throttle lever shown here. Operate the starter. Pull the starter grip lightly until you feel resistance, then pull briskly. Return the starter grip gently. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter. Turn the key to the START position, and hold it there until the engine starts. If the engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again. Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it. When the engine starts, release the key, allowing it to return to the ON position. Turn the fuel valve lever to the OFF position. ELECTRIC STARTER (applicable types): If the choke lever has been moved to the CLOSED position to start the engine, gradually move it to the OPEN position as the engine warms up. RECOIL STARTER: 1. 2. 3. 6. 5. 05/06/17 17:23:24 32Z4F601_005
ENGLISH SETTING ENGINE SPEED THROTTLE LEVER MMAAXX..MMIINN..MMIINN..MMAAXX.. 6 Position the throttle lever for the desired engine speed. Some engine applications use a remote-mounted throttle control rather than the engine-mounted throttle lever shown here. Refer to the instructions provided by the equipment manufacturer. For engine speed recommendations, refer to the instructions provided with the equipment powered by this engine. 05/06/17 17:23:31 32Z4F601_006
Î ÎÎ µ µ µ µ µÎ ÎÎ ENGLISH MAINTENANCE SCHEDULE THE IMPORTANCE OF MAINTENANCE Maintenance, replacement, or repair of the emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are ‘‘certified’’ to EPA standards. MAINTENANCE SAFETY Injury from moving parts. Burns from hot parts. Carbon monoxide poisoning from engine exhaust. SAFETY PRECAUTIONSSERVICING YOUR ENGINE STANDARD TYPE INTERNAL VENT CARBURETOR TYPE BREATHER TUBE BREATHER TUBE TUBE CLIP 7 Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. To help you properly care for your engine, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. 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 you operate your engine under severe conditions, such as sustained high-load or high-temperature operation, or use in unusually wet or dusty conditions, consult your servicing dealer for recommendations applicable to your individual needs and use. Some of the most important safety precautions follow. However, we cannot warn you ofevery conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. To ensure the best quality and reliability, use only new genuine Honda parts or their equivalents for repair and replacement. Remember that an authorized Honda servicing dealer knows your engine best and is fully equipped to maintain and repair it.To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and flames away from all fuel related parts. Read the instructions before you begin, and make sure you have the tools and skills required.Do not run the engine unless instructed to do so. Let the engine and exhaust system cool before touching. Be sure there is adequate ventilation whenever you operate the engine. Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in this owner’s manual. Good maintenance is essential for safe, economical and trouble- free operation. It will also help reduce pollution. Internal vent carburetor with dual element type only. Cyclone type every 6 months or 150hours. Replace paper element type only. Cyclone type every 2 years or 600hours. Service more frequently when used in dusty areas. 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. For commercial use, log hours of operation to determine proper maintenance intervals. Failure to follow this maintenance schedule could result in non- warrantable failures. (1) (2) (3) REGULAR SERVICE PERIOD (3) ITEMPerform at every indicated month or operating hour interval, whichever comes first. Check level Change Check level Change Check Clean Replace Clean Check-adjust Replace Clean Check-adjust Check-adjust Clean Clean CheckEach UseFirst Month or 20 HrsEvery 3 Months or 50 Hrs (1)Every 6 Months or 100 Hrs (1) (2)Every Year or 300 Hrs (2) (2) After every 500 Hrs. (2) Every 2 years (Replace if necessary) (2) Engine oil Reduction case oil () Air filter Sediment cup Spark plug Spark arrester () Idle speed Valve clearance Combustion chamber Fuel tank & filter Fuel tubeRefer to Page 9 9 910 10 10 11 12 12 12 13 13 Shop manual Shop manual Shop manual Shop manual applicable types applicable types 05/06/17 17:23:57 32Z4F601_007
ENGLISH ENGINE OIL Recommended Oil REFUELING Recommended Fuel AMBIENT TEMPERATURESAE Viscosity Grades (non-strainer type) (strainer type) FUEL TANK TOP 25 mm (1 inch)MAXIMUM FUEL LEVEL MAXIMUM FUEL LEVEL 8Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SJ, SL, or equivalent. Always check the API service label on the oil container to be sure it includes the letters SJ, SL, or equivalent. SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range. Refuel in a well-ventilated area before starting the engine. If the engine has been running, allow it to cool. Refuel carefully to avoid spilling fuel. Do not fill the fuel tank completely. Fill tank to approximately 25 mm (1 inch) below the top of the fuel tank to allow for fuel expansion. It may be necessary to lower the fuel level depending on operating conditions. After refueling, tighten the fuel tank cap securely. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc. Spilled fuel is not only a fire hazard, it causes environmental damage. Wipe up spills immediately. For information regarding oxygenated fuels, please refer to page . Unleaded gasoline Pump octane rating 86 or higher Research octane rating 91 or higher Pump octane rating 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. Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling. Stop engine and keep heat, sparks, and flame away. Refuel only outdoors. Wipe up spills immediately. Add fuel to the bottom of the fuel level limit of the fuel tank. Do not overfill. Wipe up spilled fuel before starting the engine. With the engine stopped and on a level surface, remove the fuel tank cap and check the fuel level. Refill the tank if the fuel level is low. Running the engine with persistent spark knock or pinging is considered misuse, and the Distributor’s Limited Warrantydoes not cover parts damaged by misuse. Running the engine with persistent spark knock or pinging can cause engine damage. If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized Honda servicing dealer. Occasionally you may hear a light ‘‘spark knock’’ or ‘‘pinging’’ (metallic rapping noise) while operatingunder heavy loads. This is no cause for concern. Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid getting dirt or water in the fuel tank. Fuel can damage paint and some types of plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under the Distributor’s Limited Warranty. U.S. Except U.S. 1. 2.17 05/06/17 17:24:16 32Z4F601_008
ENGLISH REDUCTION CASE OIL (applicable types) Recommended Oil Oil Level Check Oil Level Check Oil Change2 : 1 Reduction Case With Centrifugal Clutch WASHER OIL LEVEL DRAIN PLUGOIL FILLER CAP/ DIPSTICK UPPER LIMIT OIL FILLER CAP/DIPSTICK LOWER LIMIT OIL FILL HOLE (bottom edge) LOWER LIMIT UPPER LIMITFILLER CAP/DIPSTICK 9 Install the oil filler cap/dipstick and tighten securely. Use the same oil that is recommended for the engine (see page ). Check the reduction case oil level with the engine stopped and in a level position. Remove the oil filler cap/dipstick and wipe it clean. Insert and remove the oil filler cap/dipstick without screwing it into the filler hole. Check the oil level shown on the oil filler cap/ dipstick. If the oil level is low, add oil to reach theupper limit mark on the dipstick with the recommended oil. Screw in the oil filler cap/dipstick and tighten securely. Check the engine oil level with the engine stopped and in a level position. Remove the oil filler cap/dipstick and wipe it clean. Insert the oil filler cap/dipstick into the oil filler neck as shown, but do not screw it in, then remove it to check the oil level. Reinstall the oil filler cap/dipstick. Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash, pour it on the ground, or down a drain. Allow the used oil to drain completely, then reinstall the oil drain plug and new washer, and tighten the oil drain plug securely. Place a suitable container below the engine to catch the used oil, then remove the oil filler cap/dipstick, oil drain plug and washer. Drain the used oil when the engine is warm. Warm oil drains quickly and completely. The Oil Alert system (applicable types) will automatically stop the engine before the oil level falls below the safe limit. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup. Running the engine with a low oil level can cause engine damage. Running the engine with a low oil level can cause engine damage. The Oil Alertsystem (applicable types) will automatically stop the engine before the oil level falls below the safe limit. However, to avoid the inconvenience of an unexpected shutdown, fill to the upper limit, and check the oil level regularly. With the engine in a level position, fill to theupper limit mark (bottom edge of the oil fill hole) on the dipstick with the recommended oil (see page ). If the oil level is near or below the lower limit mark on the dipstick, fill with the recommended oil (see page ) to the upper limit mark (bottom edge of the oil fill hole). Do not overfill. 1. 2. 3. 4. 3.4. 1. 2. 1. 2. 3. 4. 8 88 05/06/17 17:24:44 32Z4F601_009
µ ENGLISH 6 : 1 Reduction Case 6 : 1 Reduction Case 2 : 1 Reduction Case With Centrifugal Clutch Oil Change AIR CLEANER Inspection UPPER LIMIT LOWER LIMITFILLER CAP/DIPSTICK DRAIN PLUG OIL-LEVEL-CHECK BOLTFILLER BOLT OIL LEVEL OIL-LEVEL-CHECK BOLTFILLER BOLT OIL LEVEL 10Remove the oil-level-check bolt and washer, and see whether the oil level is at the edge of the bolt hole. Place a suitable container below the reduction case to catch the used oil, then remove the filler bolt, oil-level-check bolt and washers. With the engine in a level position, fill oil until it starts to flow out the check bolt hole with the recommended oil (see page ). Reinstall the oil-level-check bolt, filler bolt and new washers, and tighten them securely. Drain the used oil while the engine is warm. Warm oil drains quickly and completely. Drain the used oil completely into the container by tipping the engine toward the oil-level-check bolt hole. Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash or pour it on the ground or down a drain. Running the engine with a low reduction case oil level can cause reduction case damage. If the oil level is below the check bolt hole, remove the filler bolt and washer. Add oil until it starts to flow out the check bolt hole with the recommended oil (see page ). Screw in the filler cap/dipstick securely. Running the engine with a low reduction case oil level can cause reduction case damage. Reduction case oil capacity: 0.50(0.53 US qt , 0.44 Imp qt) With the engine in a level position, fill to theupper limit mark on the dipstick with the recommended oil (see page ). To check the oil level, insert and remove the dipstick without screwing it into the filler hole. Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash or pour it on the ground or down a drain. Allow the used oil to drain completely, then reinstall the drain plug and a new washer, and tighten it securely. Place a suitable container below the reduction case to catch the used oil, then remove the oil filler cap/dipstick, the drain plug and washer. Drain the used oil while the engine is warm. Warm oil drains quickly and completely.Install the oil-level-check bolt, filler bolt and washers. Tighten them securely. A dirty air cleaner will restrict air flow to the carburetor, reducing engine performance. If you operate the engine in very dusty areas, clean the air filter more often than specified in the MAINTENANCE SCHEDULE. Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered by the Distributor’s Limited Warranty. Remove the air cleaner cover and inspect the filter elements. Clean or replace dirty filter elements. Always replace damaged filter elements. If equipped with an oil-bath air cleaner, also check the oil level. Refer to pages for instructions that apply to the air cleaner and filter for your engine type. 1. 2. 3. 4. 1. 2. 3.1. 2. 3. 4.9 9 9 12 11 05/06/17 17:25:07 32Z4F601_010