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SAFETY INFORMATION
Understand 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. Do not allow children to operate the engine. Keep children and pets away from the area of operation. Your engines 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 away from buildings and other equipment during operation. Keep flammable materials away, and do not place anything on the engine while it is running.

COMPONENT & CONTROL LOCATIONS

STARTER GRIP RECOIL STARTER

INTRODUCTION
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.

GCV135 GCV160

SAFETY LABEL LOCATION

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 servicing dealer for replacement.
OIL FILLER CAP MUFFLER Manual Choke Type (With CHOKE LEVER type) TOP COVER (applicable types) FUEL TANK CAP SPARK PLUG

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.

CHOKE LEVER

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. The illustration may vary according to the type. 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.
FUEL TANK

CONTENTS
INTRODUCTION ....................1 SAFETY MESSAGES .............1 SAFETY INFORMATION ........1 SAFETY LABEL LOCATION ...1 COMPONENT & CONTROL LOCATIONS ...........................1 BEFORE OPERATION CHECKS..................................2 IS YOUR ENGINE READY TO GO? ...............................2 OPERATION ...........................2 SAFE OPERATING PRECAUTIONS ...................2 STARTING THE ENGINE....2 STOPPING THE ENGINE....3 SERVICING YOUR ENGINE...4 THE IMPORTANCE OF MAINTENANCE..................4 MAINTENANCE SAFETY ...4 SAFETY PRECAUTIONS ....4 MAINTENANCE SCHEDULE .........................4 REFUELING ........................4 ENGINE OIL ........................5 Recommended Oil .........5 Oil Level Check ...............5 Oil Change ......................5 AIRCLEANER. ..................... 5 FLYWHEEL BRAKE.............5 . SPARK PLUG ......................6 . SPARKARRESTER..............6 HELPFUL TIPS & SUGGESTIONS ................... STORING YOUR ENGINE............................. Storage Preparation ..... Cleaning ........................ Fuel................................ Draining the Fuel Tank and Carburetor ............. Engine Oil ..................... Storage Precautions ..... Removal from Storage ......................... TRANSPORTING .............. TAKING CARE OF UNEXPECTED PROBLEMS .......................... TECHNICAL INFORMATION .................... Serial Number Location .. Carburetor Modifications for High Altitude Operation ......................... Specifications ................... CONSUMER INFORMATION .................... DISTRIBUTOR/DEALER LOCATOR INFORMATION................. CUSTOMER SERVICE INFORMATION................. 6 6 6 6 6 6 6 7 7 7

These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you dont follow instructions.

AIR CLEANER

FUEL VALVE LEVER

Manual Choke Type (Without CHOKE LEVER type) FLYWHEEL BRAKE LEVER (applicable types) CONTROL LEVER

You CAN be HURT if you dont follow instructions.

FUEL TANK CAP

Each message tells you what the hazard is, what can happen, and what you can do to avoid or reduce injury. DAMAGE PREVENTION MESSAGES

7 7 7

Read Owners Manual before operation. You will also see other important messages that are preceded by the word NOTICE. The engine emits toxic poisonous carbon monoxide gas. Do not run in an enclosed area. This word means: Your engine or other property can be damaged if you dont follow instructions. The purpose of these messages is to help prevent damage to your engine, other property, or the environment.

Gasoline is highly flammable and explosive. Stop the engine and let cool before refueling.

8 8

AIR CLEANER FUEL TANK FUEL VALVE LEVER

2009 Honda Motor Co., Ltd. 3RZ0M600 00X3R-Z0M-6000

All Rights Reserved

GCV135E GCV160E

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Automatic Choke Type (FIXED THROTTLE type) FLYWHEEL BRAKE LEVER (applicable types)

BEFORE OPERATION CHECKS

IS YOUR ENGINE READY TO GO? 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.

OPERATION
SAFE OPERATING PRECAUTIONS Before operating the engine for the first time, please review the SAFETY INFORMATION section on page 1 and the BEFORE OPERATION CHECKS on page 2 .

[Without CHOKE LEVER type] Move the control lever to the CLOSED (CHOKE) position.

CLOSED (CHOKE)

Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you. 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 pre-operation inspection before each operation, and correct any problem. Before beginning your pre-operation checks, be sure the engine is level and stopped.
Automatic Choke Type (MANUAL THROTTLE type) FLYWHEEL BRAKE LEVER (applicable types) CONTROL LEVER

CONTROL LEVER

Avoid any areas or actions that expose you to carbon monoxide. 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. Do not operate the engine on slopes greater than 15. STARTING THE ENGINE 3. With FLYWHEEL BRAKE LEVER type: Move the flywheel brake lever to the RELEASED position. The engine switch, which is linked with the flywheel brake lever, is turned on when the flywheel brake lever is moved to the RELEASED position.
FLYWHEEL BRAKE LEVER

FUEL VALVE LEVER

Always check the following items before you start the engine: Check the General Condition of the Engine 1. Look around and underneath the engine for signs of oil or gasoline leaks. 2. Remove any excessive dirt or debris, especially around the muffler and recoil starter. 3. Look for signs of damage. 4. Check that all shields and covers are in place, and all nuts, bolts, and screws are tightened. Check the Engine 1. Check the fuel level (see page 4 ). Starting with a full tank will help to eliminate or reduce operating interruptions for refueling.
ON

Do not use the choke if the engine is warm or the air temperature is high. Manual Choke Type 1. Turn the fuel valve lever to the ON position.

RELEASED

FUEL VALVE LEVER

2. Check the engine oil level (see page 5 ). Running the engine with a low oil level can cause engine damage. 3. Check the air filter element (see page 5 ). A dirty air filter element will restrict air flow to the carburetor, reducing engine performance. 4. 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.
OPEN

FUEL VALVE LEVER

4. Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown below. Return the starter grip gently.
STARTER GRIP

2. [With CHOKE LEVER (automatic return choke) type] Move the choke lever to the CLOSED position.
Direction to pull

CLOSED

CLOSED

Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.
CHOKE LEVER

ENGLISH

CONFORMITY

7 8

WARRANTY

ITALIANO

You CAN be KILLED or SERIOUSLY HURT if you dont follow instructions.

NEDERLANDS

ESPAOL

FLYWHEEL BRAKE LEVER (applicable types)

SAFETY MESSAGES

DEUTSCH

We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership.

FRANAIS

OWNERS MANUAL MANUEL DE LUTILISATEUR BEDIENUNGSANLEITUNG MANUAL DEL PROPIETARIO INSTRUKTIEHANDLEIDING MANUALE DELLUTENTE

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5. [With CHOKE LEVER (automatic return choke) type] STOPPING THE ENGINE Without FLYWHEEL BRAKE LEVER type: 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.
STOP

Automatic Choke Type 1. Turn the fuel valve lever to the ON position (see page 2 ). 1. [MANUAL THROTTLE type] Move the control lever to the SLOW position.
SLOW

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. 2. Move the flywheel brake lever to the RELEASED position (see page 2 ). 3. [MANUAL THROTTLE type] Move the control lever to the FAST position.
SLOW FAST CONTROL LEVER CONTROL LEVER

If the engine does not start within several consecutive pulls of the recoil starter, move the flywheel brake lever to the ENGAGED position and move the choke lever to the CLOSED position. Move the flywheel brake lever to the RELEASED position and immediately begin operating the recoil starter. 6. [Without CHOKE LEVER type] When the engine warms up, move the control lever to FAST or SLOW position.
SLOW CONTROL LEVER FAST

2. With FLYWHEEL BRAKE LEVER type: Return the flywheel brake lever to the ENGAGED position. The engine switch, which is linked with the flywheel brake lever, is turned off when the flywheel brake lever is moved to the ENGAGED position.
OFF FLYWHEEL BRAKE LEVER

3. Turn the fuel valve lever to the OFF position.

4. Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown on page 2 .
CONTROL LEVER

5. [MANUAL THROTTLE type] Position the control lever for the desired engine speed.

ENGAGED FUEL VALVE LEVER

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SERVICING YOUR ENGINE

MAINTENANCE SCHEDULE
REGULAR SERVICE PERIOD (4) ITEM 3 months months or 25 hrs. 50 hrs. or 100 hrs. 250 hrs. or or Perform at every indicated or 5 hrs. month or operating hours interval, whichever comes first. use month 6 year 2 years Each First Every Every Every Every

REFUELING Recommended Fuel Unleaded gasoline Research octane rating 91 or higher Pump octane rating 86 or higher This engine is certified to operate on unleaded gasoline with a research octane rating of 91 or higher (a pump octane rating of 86 or higher). Refuel in a well ventilated area with the engine stopped. If the engine has been running, allow it to cool first. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks. You may use unleaded gasoline containing no more than 10% ethanol (E10) or 5% methanol by volume. In addition, methanol must contain cosolvents and corrosion inhibitors. Use of fuels with content of ethanol or methanol greater than shown above may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system. Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under the Warranty.
(3) (3) (3) After every 250 hrs. (3) Every 2 years (Replace if necessary) (3)

THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical and troublefree operation. It will also help reduce pollution.

1. 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. 2. Add fuel to the upper level of the fuel tank. Wipe up spilled fuel before starting the engine.
FUEL TANK CAP UPPER LEVEL FUEL FILLER NECK

Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.
Engine oil Check level Change Air cleaner Check Clean Replace Timing belt Check After every 250 hrs. (3) (5) Flywheel brake Check pad (applicable types) Spark plug Check-adjust Replace Spark arrester (applicable types) Clean Check-adjust Clean Check-adjust Clean Check Idle speed Fuel tank and filter Valve clearance Combustion chamber Fuel tube (1) (2)

Always follow the inspection and maintenance recommendations and schedules in this owners 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 Honda servicing dealer for recommendations applicable to your individual needs and use. Use only Honda Genuine parts or their equivalent. The use of replacement parts which are not of equivalent quality may damage the engine. MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

3. Refuel carefully to avoid spilling fuel. Do not overfill the fuel tank (there should be no fuel in the fuel filler neck). It may be necessary to lower the fuel level depending on operating conditions. After refueling, tighten the fuel tank cap securely. 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.

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 owners manual. SAFETY PRECAUTIONS Make sure the engine is off before you begin any maintenance or repairs. To prevent accidental startup, disconnect the spark plug cap. This will eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate the engine. Burns from hot parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. Read the instructions before you begin, and make sure you have the tools and skills required. To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a non-flammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and flames away from all fuel related parts. Remember that an authorized Honda servicing dealer knows your engine best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new Honda Genuine parts or their equivalents for repair and replacement.

Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling. (1): Service more frequently when used in dusty areas. (2): Change engine oil every 25 hours when used under heavy Stop the engine and keep heat, sparks, and flame load or in high ambient temperatures. away. (3): These items should be serviced by an authorized Honda Refuel only outdoors. dealer, unless the owner has the proper tools and is Wipe up spills immediately. mechanically proficient. See the Honda Shop Manual. (4): For commercial use, log hours of operation to determine proper maintenance intervals. (5): Check that there is no crack and abnormal wear-out in the belt, Fuel can damage paint and some types of plastic. Be careful not to and replace if it is abnormal. spill fuel when filling your fuel tank. Damage caused by spilled To perform maintenance on the lower part of the engine (Machine), fuel is not covered under the Warranty. turn it 90 and lay it down with the carburetor/air cleaner always at Never use stale or contaminated gasoline or an oil/gasoline the top. mixture. Avoid getting dirt or water in the fuel tank. Refer to the instructions provided with the equipment powered by this engine for refuelling.

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ENGINE OIL Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. Recommended Oil Use 4-stroke motor oil that meets or exceeds the requirements for API service category SE or later (or equivalent). Always check the API service label on the oil container to be sure it includes the letters SE or later (or equivalent). 3. Refill with the recommended oil and check the oil level. Engine oil capacity: 0.55 L (0.48 lmp qt)
[With TOP COVER type] [ALL types] 6 mm NUT (3)

Oil Change Drain the used oil when the engine is warm. Warm oil drains quickly and completely. 1. Turn the fuel valve lever to the OFF position (see page 3 ). 2. Remove the oil filler cap and drain the oil into the oil container by inclining the engine toward the oil filler neck. 2. Remove the recoil starter by removing the three 6 mm nuts. Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear. 3. 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 This type of damage is not covered under the Warranty. level. Inspection Remove the air cleaner cover and inspect the filter element. Clean or replace a dirty filter element. Always replace a damaged filter element.
TAPPING SCREW (3) TOP COVER

AIR CLEANER 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 (see page 4 ). 1. Remove the top cover by removing the three tapping screws (with top cover type only). Inspection

FLYWHEEL BRAKE (applicable types)

4. Install the oil filler cap/dipstick securely.

Cleaning
RECOIL STARTER

1. Remove the air cleaner cover by unhooking the two upper tabs on the top of the air cleaner cover and the two lower tabs.
AMBIENT TEMPERATURE AIR DUCT FUEL TANK ELEMENT AIR CLEANER COVER

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.
FUEL TUBE

UPPER TABS

Oil Level Check

OIL FILLER NECK

1. Remove the oil filler cap/dipstick and wipe it clean. 2. Insert the dipstick into the oil filler neck, but do not screw it in. 3. If the level is low, add the recommended oil to the upper limit on the dipstick.
OIL FILLER CAP/DIPSTICK

Wash your hands with soap and water after handling used oil.

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 pour it down a drain.
AIR CLEANER CASE LOWER TABS

4. Check the brake shoe thickness. If it is less than 3 mm (0.12 in), take the engine to an authorized Honda dealer.

2. Remove the element. Carefully check the element for holes or tears and replace if damaged.
BRAKE SHOE THICKNESS UPPER LIMIT LOWER LIMIT

3. Tap the element 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.

OIL FILLER NECK

4. Install the oil filler cap/dipstick.

BRAKE SHOE

Running the engine with a low oil level can cause engine damage. This type of damage is not covered under the Warranty.
ELEMENT

5. Install the fuel tank and recoil starter, and tighten the three 6 mm nuts securely. 6. Install the top cover, and tighten the three tapping screws securely (with top cover type only).

4. Wipe dirt from the inside of the air cleaner case and cover using a moist rag. Be careful to prevent dirt from entering the air duct that leads to the carburetor. 5. Install the element and the air cleaner cover.

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SPARK PLUG Recommended Spark Plug: GCV135E: BPR4ES (NGK) GCV160E: BPR5ES (NGK) For Hover Lawn mower: GCV135E/GCV160E: BPR6ES (NGK) In some areas, it is illegal to operate an engine without a spark arrester. Check local laws and regulations. A spark arrester is available from authorized Honda servicing dealers. STORING YOUR ENGINE Storage Preparation The spark arrester must be serviced every 100 hours to keep it functioning as designed. If the engine has been running, the muffler will be hot. Allow it to cool before servicing the spark arrester. Spark Arrester Removal Cleaning 1. Remove the muffler protector by removing the three 6 mm bolts. 2. Remove the spark arrester from the muffler by removing the two screws. (Taking care not to damage the wire mesh.) The recommended spark plug has the correct heat range for normal engine operating temperatures.

SPARK ARRESTER (applicable types)

HELPFUL TIPS & SUGGESTIONS

1. Drain the fuel tank and carburetor into an approved gasoline container. 2. Turn the fuel valve lever to the OFF position. Loosen the carburetor drain bolt 1 1 1/2 turn and drain the carburetor. 3. Turn the fuel valve lever to the ON position and drain the fuel in the fuel tank into the container. 4. Retighten the carburetor drain bolt so that the float chamber cannot be warped, and turn the fuel valve lever to the OFF position.
FLOAT CHAMBER OFF ON ON

Proper storage preparation is essential for keeping your engine trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your engines function and appearance, and will make the engine easier to start when you use it again.

An incorrect spark plug can cause engine damage.

If the engine has been running, let it cool before servicing the spark plug. For good performance, the spark plug must be properly gapped and free of deposits. 1. Disconnect the spark plug cap, and remove any dirt from around the spark plug area.
SPARK ARRESTER

If the engine has been running, allow it to cool for at least half an hour before cleaning. Clean all exterior surfaces, touch up any damaged paint, and coat other areas that may rust with a light film of oil.

2. Remove the spark plug with the spark plug wrench. 3. 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 to be reused.
SPARK PLUG WRENCH SIDE ELECTRODE MUFFLER PROTECTOR 0.7 0.8 mm (0.028 0.031 in) 6 mm BOLT (3)

Using a garden hose or pressure washing equipment can force water into the air cleaner or muffler opening. Water in the air cleaner will soak the air filter, and water that passes through the air filter or muffler can enter the cylinder, causing damage.
Fuel
FUEL VALVE LEVER DRAIN BOLT

MUFFLER SCREW (2)

4. Measure the spark plug electrode gap with a feeler gauge. Correct as necessary by bending the side electrode. The gap should be: 0.7 0.8 mm (0.028 0.031 in) 5. Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross-threading. 6. After the spark plug is seated, tighten with the spark plug wrench to compress the washer.

Depending on the region where you operate your equipment, fuel formulations may deteriorate and oxidize rapidly. Fuel deterioration and oxidation can occur in as little as 30 days and may cause damage to the carburetor and/or fuel system. Please check with your servicing dealer for local storage recommendations.
Gasoline will oxidize and deteriorate in storage. Deteriorated gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If the gasoline in your engine deteriorates during storage, you may need to have the carburetor and other fuel system components serviced or replaced. The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled. The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel deterioration problems may occur within 30 days from keeping the fuel in the fuel tank, or even less if the gasoline was not fresh when you filled the fuel tank.

5. If you cannot drain from the carburetor, drain the fuel tank into an approved gasoline container using a commercially available hand pump. Do not use an electric pump. Operate the engine until it stops from the lack of fuel. Engine Oil 1. Change the engine oil (see page 5 ). 2. Remove the spark plug (see page 6 ). 3. Pour a teaspoon 5 10 cm of clean engine oil into the cylinder.

Spark Arrester Cleaning & Inspection Check for carbon deposits around the exhaust port and spark arrester, and clean if necessary. 1. Use a brush to remove carbon deposits from the spark arrester screen. Be careful not to damage the screen. Replace the spark arrester if it has breaks or holes.
SCREEN

4. Pull the starter grip several times to distribute the oil in the cylinder. 5. Reinstall the spark plug. 6. Pull the starter grip slowly until resistance is felt. This closes the valves, and protects them from dust and corrosion.
STARTER GRIP

Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under the Warranty.
SPARK PLUG

Draining the Fuel Tank and Carburetor

When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. When reinstalling the original spark plug, tighten 1/8 1/4 turn after the spark plug seats to compress the washer. 2. Install the spark arrester and the muffler in the reverse order of disassembly. Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head.
7. Attach the spark plug cap to the spark plug.

7. Coat areas that may rust with a light film of oil. Cover the engine to keep out dust.

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Storage Precautions

TRANSPORTING

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START 1. Check control positions. Fuel valve OFF. Choke open (applicable types). Control lever is not in proper position (applicable types). Flywheel brake lever in ENGAGED position (applicable types). Engine serial number: __ __ __ __ Refuel (p. 4). Drain fuel tank and carburetor (p. 6). Refuel with fresh gasoline (p. 4). Date Purchased: ______ / ______ / ______ Carburetor Modifications for High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above 1,500 meters, have your servicing dealer perform this carburetor modification. Even with carburetor modification, engine horsepower will decrease about 3.5% for each 300 meters increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made. Engine type: ___ ___ ___ ___ __ __ __ __ __ __ __ 2. Check fuel. Out of fuel. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline. Spark plug faulty, fouled, or improperly gapped. Spark plug wet with fuel (flooded engine). Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc. Replace or repair faulty components as necessary. Possible Cause Filter element restricted. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline. Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc. Replace or repair faulty components as necessary. Drain fuel tank and carburetor (p. 6). Refuel with fresh gasoline (p. 4). Clean or replace filter element (p. 5). Correction Dry and reinstall spark plug. Gap or replace spark plug (p. 6). Move lever to RELEASED position.
SERIAL NUMBER & ENGINE TYPE

TECHNICAL INFORMATION
Serial Number Location Record the engine serial number in the space below. You will need this information when ordering parts and when making technical or warranty inquiries.

If your engine will be stored with gasoline in the fuel tank and carburetor, it is important to reduce the hazard of gasoline vapor ignition. Select a well ventilated storage area away from any appliance that operates with a flame, such as a furnace, water heater, or clothes dryer. Also avoid any area with a sparkproducing electric motor, or where power tools are operated. If the engine has been running, allow it to cool for at least 15 minutes before loading the engine-powered equipment on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials. Possible Cause Move lever to ON position. Move lever to CLOSED position unless the engine is warm. Move lever to proper position. Correction Keep the engine level when transporting to reduce the possibility of fuel leakage. Turn the fuel valve lever to the OFF position (see page 3 ). If possible, avoid storage areas with high humidity, because that promotes rust and corrosion. Keep the engine level in storage. Tilting can cause fuel or oil leakage. With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials. Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture around the engine, promoting rust and corrosion. Removal from Storage Check your engine as described in the BEFORE OPERATION CHECKS section of this manual (see page 2 ). If the fuel was drained during storage preparation, fill the tank with fresh gasoline. If you keep a container of gasoline for refueling, be sure it contains only fresh gasoline. Gasoline oxidizes and deteriorates over time, causing hard starting. If the cylinder was coated with oil during storage preparation, the engine will smoke briefly at startup. This is normal. 3. Remove and inspect spark plug.

4. Take engine to an authorized Honda servicing dealer, or refer to shop manual. ENGINE LACKS POWER 1. Check air filter.

Operation of the engine at an altitude lower than the carburetor is jetted for may result in reduced performance, overheating, and serious engine damage caused by an excessively lean air/fuel mixture.

2. Check fuel.

3. Take engine to an authorized Honda servicing dealer, or refer to shop manual.

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2colGCV135_160_297x210_ORIZ_15set09:297x210 (303x216) 25/09/09 14:18 Pagina 8

Specifications Dimensions Model Description code Length Width Height Dry mass [weight] Engine Engine type Displacement Bore Stroke Net power GCV135E GJAFE 351 331 340 mm (13.8 13.0 13.4 in) 10.7 kg (23.6 lbs) Visit our website: http://www.honda-engines-eu.com CUSTOMER SERVICE INFORMATION Servicing dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealerships management. The Service Manager, General Manager, or Owner can help. Almost all problems are solved in this way. If you are dissatisfied with the decision made by the dealerships management, contact the Honda Office as shown. Hondas Office When you write or call, please provide this information: Equipment manufacturers name and model number that the engine is mounted on Engine model, serial number, and type (see page 7 ) Name of dealer who sold the engine to you Name, address, and contact person of the dealer who services your engine Date of purchase Your name, address and telephone number A detailed description of the problem Honda Europe NV. European Engine Center http://www.honda-engines-eu.com Please contact the Honda distributor in your area for assistance. 4-stroke, overhead cam, 1 cylinder 135 cm (8.2 cu-in) 64.0 42.0 mm (2.5 1.7 in) 2.6 kW (3.5 PS)/3,600 rpm 6.9 Nm (0.70 kgfm)/2,500 rpm 0.77 L (0.169 lmp gal) 0.55 L (0.48 lmp qt) Forced air Transistor magneto Counterclockwise
(in accordance with SAE J1349 )

CONSUMER INFORMATION
DISTRIBUTOR/DEALER LOCATOR INFORMATION

Max. Net torque

(in accordance with SAE J1349 )

Fuel tank capacity Engine oil capacity Cooling system Ignition system PTO shaft rotation Dimensions Model Description code Length Width Height Dry mass [weight] Engine Engine type Displacement Bore Stroke Net power GCV160E GJAAE 367 331 347 mm (14.4 13.0 13.7 in) 10.8 kg (23.8 lbs) 4-stroke, overhead cam, 1 cylinder 160 cm (9.8 cu-in) 64.0 50.0 mm (2.5 2.0 in) 3.3 kW (4.5 PS)/3,600 rpm 9.4 Nm (0.96 kgfm)/2,500 rpm 0.91 L (0.20 lmp gal) 0.55 L (0.48 lmp qt) Forced air Transistor magneto Counterclockwise
(in accordance with SAE J1349 )

Max. Net torque

(in accordance with SAE J1349 )

Fuel tank capacity Engine oil capacity Cooling system Ignition system PTO shaft rotation The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine model and measured in accordance with SAE J1349 at 3,600 rpm (Net Power) and at 2,500 rpm (Max. Net Torque). Mass production engines may vary from this value. Actual power output for the engine installed in the final machine will vary depending on numerous factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables.

Specifications may vary according to the types, and are subject to change without notice.

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