Honda - GXV160 - Parts Catalogue - 2005 - 2005

07/05/01 15:42:38 32Z4P600_001 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. ENGLISH INTRODUCTION OWNER’S MANUAL MANUEL DE L’UTILISATEUR MANUAL DEL PROPIETARIO 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. FRANÇAIS GXV160 This manual should be considered a permanent part of the engine and should remain with the engine if resold. United States, Puerto Rico, and U.S. Virgin Islands: 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. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. SAFETY MESSAGES 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. ESPAÑOL 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. CONTENTS 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. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. Each message tells you what the hazard is, what can happen, and what you can do to avoid or reduce injury. DAMAGE PREVENTION MESSAGES You will also see other important messages that are preceded by the word NOTICE. This word means: Your engine or other property can be damaged if you don’t follow instructions. The purpose of these messages is to help prevent damage to your engine, other property, or the environment. INTRODUCTION ........................1 SAFETY MESSAGES .................1 SAFETY INFORMATION ...........2 SAFETY LABEL LOCATION ......2 COMPONENT & CONTROL LOCATION .................................2 BEFORE OPERATION CHECKS .....................................3 OPERATION ...............................4 SAFE OPERATING PRECAUTIONS ......................4 STARTING THE ENGINE .......4 SETTING ENGINE SPEED......5 STOPPING THE ENGINE .......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...................8 Oil Change ..........................9 AIR CLEANER.........................9 Inspection ...........................9 Cleaning .............................9 SPARK PLUG .......................10 SPARK ARRESTER ..............10 HELPFUL TIPS & SUGGESTIONS .......................11 STORING YOUR ENGINE ....11 TRANSPORTING .................13 TAKING CARE OF UNEXPECTED PROBLEMS .....13 TECHNICAL INFORMATION ...14 Serial Number Location ......14 Remote Control Linkage......14 Carburetor Modifications for High Altitude Operation ......14 Emission Control System Information ..........................15 Air Index ...............................16 Specifications ......................16 Tuneup Specifications.........16 Quick Reference Information ..........................17 Wiring Diagrams .................17 CONSUMER INFORMATION ..18 Distributor/Dealer Locator Information ..........................18 Customer Service Information ..........................18 2005 Honda Motor Co., Ltd. −All Rights Reserved GXV160UH2 37Z4P602 00X37-Z4P-6020 ENGLISH 1 07/05/01 15:43:15 32Z4P600_002 SAFETY INFORMATION COMPONENT & CONTROL LOCATION 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 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. FUEL FILLER CAP OIL FILLER CAP/DIPSTICK MUFFLER FUEL TANK OIL DRAIN PLUG FLYWHEEL BRAKE LEVER (applicable types) 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 dealer for replacement. For Canadian types only: French label comes with the engine. STARTER GRIP RECOIL STARTER AIR CLEANER SPARK PLUG Gasoline is highly flammable and explosive. Turn engine off and let cool before refueling. ENGINE CONTROLS The engine emits toxic poisonous carbon monoxide gas. Do not run in an enclosed area. Read Owner’s Manual before operation. 2 ENGLISH FUEL VALVE LEVER CONTROL LEVER 07/05/01 15:43:31 32Z4P600_003 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. 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 the engine switch is in the OFF position. 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 8 ). Starting with a full tank will help to eliminate or reduce operating interruptions for refueling. 2. Check the engine oil level (see page 8 ). Running the engine with a low oil level can cause engine damage. 3. Check the air filter element (see page 9 ). 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. ENGLISH 3 07/05/01 15:43:55 32Z4P600_004 OPERATION STARTING THE ENGINE SAFE OPERATING PRECAUTIONS 1. Move the fuel valve lever to the ON position. Before operating the engine for the first time, please review the SAFETY INFORMATION section on page 2 and the BEFORE OPERATION CHECKS on page 3 . FUEL VALVE LEVER ON Carbon monoxide gas is toxic. Breathing it can cause unconsciousness and even kill you. ON 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. 2. To start a cold engine, move the control lever to the CHOKE position. Control Lever MAX. CHOKE CONTROL LEVER The control lever operates the engine switch (Types without FLYWHEEL BRAKE), throttle, and choke. OFF ––––––––Stop the engine by switching off the ignition system. All other control lever positions leave the ignition (Without FLYWHEEL system switched on. BRAKE types) MIN. –––––––For running the engine at idle speed. MAX. ––––––For restarting a warm engine, and for running the engine at maximum speed. To restart a warm engine, leave the control lever in the MAX. position. CHOKE –––––Enriches the fuel mixture for starting a cold engine. The control lever shown here will be connected to a remote control on the equipment powered by this engine. Refer to the instructions provided by the equipment manufacturer. The control lever shown here will be connected to a remote control on the equipment powered by this engine. Refer to the instructions provided by the equipment manufacturer. OFF MIN. MAX. CHOKE 3. FLYWHEEL BRAKE types: 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. ENGAGED CONTROL LEVER RELEASED FLYWHEEL BRAKE LEVER 4 ENGLISH 07/05/01 15:44:06 32Z4P600_005 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. SETTING ENGINE SPEED Position the control lever for the desired engine speed. Direction to pull CONTROL LEVER MIN. MAX. STARTER GRIP The control lever shown here will be connected to a remote control on the equipment powered by this engine. Refer to the instructions provided by the equipment manufacturer for remote control information and engine speed recommendations. Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter. 5. If the control lever was moved to the CHOKE position to start the engine, gradually move it to the MAX. or MIN. position as the engine warms up. CONTROL LEVER MIN. MAX. CHOKE The control lever shown here will be connected to a remote control on the equipment powered by this engine. Refer to the instructions provided by the equipment manufacturer. 6. FLYWHEEL BRAKE types: Continue to hold the flywheel brake lever in the released position. The engine will stop if you move the flywheel brake lever to the engaged position. ENGLISH 5 07/05/01 15:44:18 32Z4P600_006 4. Turn the fuel valve lever to the OFF position. STOPPING THE ENGINE To stop the engine in an emergency, simply turn the control lever to the OFF position. Under normal conditions, use the following procedure. Refer to the instructions provided by the equipment manufacturer. OFF 1. Move the control lever to the MIN. position. CONTROL LEVER OFF MIN. FUEL VALVE LEVER The control lever shown here will be connected to a remote control on the equipment powered by this engine. Refer to the instructions provided by the equipment manufacturer. 2. With FLYWHEEL BRAKE types Release 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. FLYWHEEL BRAKE LEVER ENGAGED 3. Without FLYWHEEL BRAKE types: Move the control lever to the OFF position. The engine switch, which is linked with the control lever, is turned off when the control lever is moved to the OFF position. CONTROL LEVER OFF The control lever shown here will be connected to a remote control on the equipment powered by this engine. Refer to the instructions provided by the equipment manufacturer. 6 ENGLISH 07/05/01 15:44:45 32Z4P600_007 SERVICING YOUR ENGINE MAINTENANCE SCHEDULE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical and troublefree operation. It will also help reduce pollution. REGULAR SERVICE PERIOD (3) Each Use Perform at every indicated month or operating hour interval, First Every 3 Every 6 Every Refer Month Months Months Year or or or to or Page 20 Hrs 50 Hrs 100 Hrs 200 Hrs whichever comes first. ITEM 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 Air cleaner Check level 8 Change 9 Check 9 Clean Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. 9 (1) ＊ Replace Flywheel brake Check-adjust (2) (2) Shop manual pad (applicable types) 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. Spark plug Check-adjust 10 Replace Spark arrester Clean 10 (applicable types) Idle speed (2) Check-adjust Shop manual Valve clearance 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. (2) Check-adjust Shop manual Combustion Clean Shop After every 250 Hrs. (2) manual chamber Fuel tank & (2) Clean Fuel tube 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. Shop manual filter Check Every 2 years Shop (Replace if necessary) (2) manual ＊ Replace paper element type only. (1) Service more frequently when used in dusty areas. 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. (2) These items should be serviced by your Honda servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures. (3) For commercial use, log hours of operation to determine proper maintenance intervals. Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Failure to follow this maintenance schedule could result in nonwarrantable failures. Always follow the procedures and precautions in this owner’s manual. SAFETY PRECAUTIONS Make sure the engine is off before you begin any maintenance or repairs. 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 genuine Honda parts or their equivalents for repair and replacement. ENGLISH 7 07/05/01 15:45:14 32Z4P600_008 REFUELING ENGINE OIL Recommended Fuel Unleaded gasoline U.S. Except U.S. Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. Pump octane rating 86 or higher Research octane rating 91 or higher Pump octane rating 86 or higher Recommended Oil This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher (a research octane rating of 91 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 regular 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 warranty. Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SJ or later (or equivalent). Always check the API service label on the oil container to be sure it includes the letters SJ or later (or equivalent). AMBIENT TEMPERATURE 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. Oil Level Check Check the engine oil level with the engine stopped and in a level position. 1. Remove the oil filler cap/dipstick and wipe it clean. 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. 2. 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. 3. If the oil level is near or below the lower limit mark on the dipstick, fill with the recommended oil to the upper limit mark. Do not overfill. 4. Screw in the filler cap/dipstick securely. 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. OIL FILLER CAP/DIPSTICK LOWER LIMIT 1. With the engine stopped and on a level surface, remove the fuel filler cap and check the fuel level. Refill the tank if the fuel level is low. 2. 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. UPPER LIMIT MAXIMUM FUEL LEVEL FUEL FILLER NECK Running the engine with a low oil level can cause engine damage. Engine damage caused by running the engine with a low oil level is not covered under the Distributor’s Limited Warranty. FUEL FILLER CAP Refuel carefully to avoid spilling fuel. Do not fill the fuel tank completely. It may be necessary to lower the fuel level depending on operating conditions. After refueling, screw the fuel filler cap back on until it clicks. 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. 8 ENGLISH 07/05/01 15:45:38 32Z4P600_009 Oil Change AIR CLEANER Drain the used oil when the engine is warm. Warm oil drains quickly and completely. 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. 1. Place a suitable container below the engine to catch the used oil, then remove the oil filler cap/dipstick, oil drain plug and washer. 2. Allow the used oil to drain completely, then reinstall the oil drain plug and new washer, and tighten the oil drain plug securely. 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 pour it down a drain. 3. With the engine in a level position, fill to the upper limit mark on the dipstick with the recommended oil (see page 8 ). 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. Inspection Remove the air cleaner cover and inspect the filter elements. Clean or replace dirty filter elements. Always replace damaged filter elements. Cleaning Running the engine with a low oil level can cause engine damage. Engine damage caused by running the engine with a low oil level is not covered under the Distributor’s Limited Warranty. OIL FILLER CAP/DIPSTICK 3. Remove the foam air filter element from the paper air filter element. UPPER LIMIT OIL DRAIN PLUG 1. Remove the wing nuts from the air cleaner cover, and remove the cover. 2. Remove the air filter elements. 4. Screw in the oil filler cap/dipstick securely. SEALING WASHER WING NUT 4. Inspect both air filter elements, and replace them if they are damaged. Always replace the paper air filter element at the scheduled interval (see page 7 ). AIR CLEANER COVER PAPER FILTER ELEMENT FOAM FILTER ELEMENT AIR CLEANER CASE 5. Clean the air filter elements if they are to be reused. Paper air filter element: Tap the filter element several times on a hard surface to remove dirt, or blow compressed air [not exceeding 207 kPa (2.1 kgf/cm , 30 psi)] through the filter element from the inside. Never try to brush off dirt; brushing will force dirt into the fibers. Foam air filter element: Clean in warm soapy water, rinse, and allow to dry thoroughly. Or clean in non-flammable solvent and allow to dry. Dip the filter element in clean engine oil, then squeeze out all excess oil. The engine will smoke when started if too much oil is left in the foam. 6. 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. 7. Place the foam air filter element over the paper element, and reinstall the assembled air filter. 8. Install the air cleaner cover, and tighten the wing nut securely. ENGLISH 9 07/05/01 15:46:07 32Z4P600_010 SPARK PLUG SPARK ARRESTER (applicable types) Recommended Spark Plugs: BPR5ES (NGK) W16EPR-U (DENSO) The spark arrester may be standard or an optional part, depending on the engine type. 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. The recommended spark plug has the correct heat range for normal engine operating temperatures. The spark arrester must be serviced every 100 hours to keep it functioning as designed. An incorrect spark plug can cause engine damage. If the engine has been running, the muffler will be hot. Allow it to cool before servicing the spark arrester. 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 PLUG CAP Spark Arrester Removal SPARK PLUG WRENCH 1. Loosen the two 6 mm nuts and remove the muffler protector, identification plate, muffler and gasket. 2. Remove the spark plug with a 13/16-inch spark plug wrench. 2. Remove the spark arrester from the muffler (take care not to damage the wire mesh). 3. Inspect the spark plug. Replace it if damaged or badly fouled, if the sealing washer is in poor condition, or if the electrode is SIDE ELECTRODE worn. 4. Measure the spark plug electrode gap with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode. The gap should be: 0.70−0.80 mm (0.028−0.031 in) 6 mm NUTS PACKING IDENTIFICATION PLATE 0.70−0.80 mm (0.028−0.031 in) GASKET PACKING SEALING WASHER MUFFLER SPARK ARRESTER GASKET 5. Install the spark plug carefully, by hand, to avoid crossthreading. Spark Arrester Cleaning & Inspection 6. After the spark plug is seated, tighten with a 13/16-inch spark plug wrench to compress the sealing washer. 1. Check for carbon deposits around the exhaust port and spark arrester, and clean if necessary. 7. When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. 8. When reinstalling the original spark plug, tighten 1/8−1/4 turn after the spark plug seats to compress the washer. A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head. 2. 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. SPARK ARRESTER SCREEN 3. Install the gasket, spark arrester, muffler, identification plate, packings and muffler protector in the reverse order of disassembly. 9. Attach the spark plug cap to the spark plug. 10 MUFFLER PROTECTOR ENGLISH 07/05/01 15:46:31 32Z4P600_011 HELPFUL TIPS & SUGGESTIONS Draining the Fuel Tank and Carburetor STORING YOUR ENGINE Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel. Stop engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. Storage Preparation 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 engine’s function and appearance, and will make the engine easier to start when you use it again. Cleaning 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. 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. 1. Place an approved gasoline container below the carburetor, and use a funnel to avoid spilling fuel. 2. Remove the drain bolt and gasket, and drain the carburetor bowl fuel into an approved gasoline container. 3. Move the fuel valve lever to the ON position. This will allow the fuel tank to drain through the carburetor bowl. Fuel 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. GASKET 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 a few months, or even less if the gasoline was not fresh when you filled the fuel tank. DRAIN BOLT CARBURETOR BOWL FUEL VALVE LEVER ON OFF Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under the Distributor’s Limited Warranty. ON OFF You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor. 4. After draining the carburetor bowl and fuel tank, move the fuel valve lever to the OFF position. Adding a Gasoline Stabilizer to Extend Fuel Storage Life When adding a gasoline stabilizer, fill the fuel tank with fresh gasoline. If only partially filled, air in the tank will promote fuel deterioration during storage. If you keep a container of gasoline for refueling, be sure that it contains only fresh gasoline. 5. Install the gasket and drain bolt, and tighten securely. 1. Add gasoline stabilizer following the manufacturer’s instructions. 2. After adding a gasoline stabilizer, run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor. 3. Stop the engine. ENGLISH 11 07/05/01 15:46:48 32Z4P600_012 Engine Oil Removal from Storage Check your engine as described in the BEFORE OPERATION CHECKS section of this manual (see page 3 ). 1. Change the engine oil (see page 9 ). 2. Remove the spark plug (see page 10 ). 3. Pour a tablespoon 5−10 cm (5−10 cc) of clean engine oil into the cylinder. 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. 4. Pull the starter rope several times to distribute the oil in the cylinder. If the cylinder was coated with oil during storage preparation, the engine will smoke briefly at startup. This is normal. 5. Reinstall the spark plug. 6. Pull the starter grip slowly to the direction of the arrow as show below until resistance is felt. This will close the valves so moisture cannot enter the engine cylinder. Return the starter rope gently. Direction to pull Storage Precautions 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 possible, avoid storage areas with high humidity, because that promotes rust and corrosion. Unless all fuel has been drained from the fuel tank, turn the fuel valve lever to the OFF position to reduce the possibility of fuel leakage. 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. 12 ENGLISH 07/05/01 15:47:04 32Z4P600_013 TAKING CARE OF UNEXPECTED PROBLEMS TRANSPORTING 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. ENGINE WILL NOT START 1. Check control positions. Possible Cause Fuel valve OFF. Choke OPEN. Keep the engine level when transporting to reduce the possibility of fuel leakage. Turn the fuel valve to the OFF position (see page 6 ). Engine switch OFF. 2. Check fuel. 3. Remove and inspect spark plug. Move lever to ON position. Move the control lever to CHOKE position unless the engine is warm. Move the control lever to MAX. position. (Flywheel brake types: flywheel brake lever to RELEASED position.) Refuel (p. 8). Drain fuel tank and carburetor (p. 11). Refuel with fresh gasoline (p. 8). Gap or replace spark plug (p. 10). Dry and reinstall spark plug. Start engine with control lever in MAX. position. (Flywheel brake types: flywheel brake lever to RELEASED position.) Replace or repair faulty components as necessary. 4. Take engine to an authorized Honda servicing dealer, or refer to shop manual. Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc. ENGINE LACKS POWER 1. Check air filter. Possible Cause Correction Filter element(s) restricted. Clean or replace filter element(s) (p. 9). Drain fuel tank and carburetor (p. 11). Refuel with fresh gasoline (p. 8). 2. Check fuel. 3. Take engine to an authorized Honda servicing dealer, or refer to shop manual. ENGLISH 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). Correction 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. 13 07/05/01 15:47:21 32Z4P600_014 TECHNICAL INFORMATION WIRE CABLE types: CONTROL LEVER Serial Number Location Record the engine serial number, type and purchase date in the space below. You will need this information when ordering parts and when making technical or warranty inquiries. CABLE CLAMP ENGINE SERIAL NUMBER & ENGINE TYPE LOCATION 5 × 16 mm SCREW THROTTLE CABLE Engine serial number: __ __ __ __ − __ __ __ __ __ __ __ THROTTLE CABLE Engine type: ___ ___ ___ ___ Carburetor Modifications for High Altitude Operation Date Purchased: ______ / ______ / ______ Remote Control Linkage The control is provided with a hole for cable attachment. Install a solid wire cable or wire cable as shown below. Do not use braided wire cable. At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions. High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above 1,500 meters (5,000 feet), have your servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life. REMOTE THROTTLE LINKAGE SOLID WIRE CABLE types: CONTROL LEVER Even with carburetor modification, engine horsepower will decrease about 3.5% for each 300-meter (1,000-foot) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made. CABLE CLAMP 5 × 16 mm SCREW THROTTLE CABLE When the carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use. Operation at altitudes below 1,500 meters (5,000 feet) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have your servicing dealer return the carburetor to original factory specifications. THROTTLE CABLE 14 ENGLISH 07/05/01 15:47:40 32Z4P600_015 Emission Control System Information Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Maintenance Follow the maintenance schedule on page 7 . Remember that this schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load or hightemperature operation, or use in unusually wet or dusty conditions, will require more frequent service. Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons. The U.S., California Clean Air Acts and Environment Canada EPA, California and Canadian regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems. The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards. Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. Among those acts that constitute tampering are: Removal or alteration of any part of the intake, fuel, or exhaust systems. Altering or defeating the governor linkage or speed-adjusting mechanism to cause the engine to operate outside its design parameters. Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring). Black exhaust smoke or high fuel consumption. Replacement Parts The emission control systems on your Honda engine were designed, built, and certified to conform with EPA, California and Canadian emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system. A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations. ENGLISH 15 07/05/01 15:48:01 32Z4P600_016 Air Index Specifications An Air Index Information hang tag/label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board. GXV160 (PTO shaft type N1) Length × Width × 418 × 365 × 357 mm Height (16.5 × 14.4 × 14.1 in) Dry mass [weight] 15.1 kg (33.3 lbs) Engine type 4-stroke, overhead valve, single cylinder Displacement 163 cm (9.9 cu-in) [Bore × Stroke] [68.0 × 45.0 mm (2.68 × 1.77 in)] Net power 3.2 kW (4.4 PS, 4.3 bhp) at 3,600 rpm The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution. The durability description is intended to provide you with information relating to the engine’s emission durability period. The descriptive term indicates the useful life period for the engine’s emission control system. See your Emission Control System Warranty for additional information. Descriptive Term Moderate Intermediate Extended Applicable to Emissions Durability Period 50 hours [0−80 cm (0−80 cc) inclusive] 125 hours [greater than 80 cm (80 cc)] 125 hours [0−80 cm (0−80 cc) inclusive] 250 hours [greater than 80 cm (80 cc)] 300 hours [0−80 cm (0−80 cc) inclusive] 500 hours [greater than 80 cm (80 cc)] 1,000 hours [225 cm (225 cc) and greater] The Air Index Information hang tag/label must remain on the engine until it is sold. Remove the hang tag before operating the engine. (in accordance with SAE J1349＊) Max. Net torque (in accordance with SAE J1349＊) Engine oil capacity Fuel tank capacity Cooling system Ignition system PTO shaft rotation 9.6 N·m (0.98 kgf·m, 7.1 lbf·ft) at 2,500 rpm 0.65 (0.69 US qt , 0.57 Imp qt) 1.4 (0.37 US gal , 0.31 Imp gal) Forced air Transistor magneto Counterclockwise ＊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. Tuneup Specifications ITEM SPECIFICATION 0.70−0.80 mm Spark plug gap (0.028−0.031 in) 1,700 ± 150 rpm Idle speed Valve clearance (cold) Other specifications 16 ENGLISH MAINTENANCE Refer to page: 10 Refer to shop manual See your IN: 0.15 ± 0.02 mm authorized EX: 0.20 ± 0.02 mm Honda dealer No other adjustments needed. 07/05/01 15:48:11 32Z4P600_017 Quick Reference Information Fuel Engine oil Spark plug Maintenance Wiring Diagrams Unleaded gasoline (Refer to page 8) U.S. Pump octane rating 86 or higher Except Research octane rating 91 or higher U.S. Pump octane rating 86 or higher SAE 10W-30, API SJ or later, for general use. Refer to page 8. BPR5ES (NGK) W16EPR-U (DENSO) Before each use: Check engine oil level. Refer to page 8. Check air filter. Refer to page 9. First 20 hours: Change engine oil. Refer to page 9. Subsequent: Refer to the maintenance schedule on page 7. (1) (2) (3) Bl ENGLISH ENGINE STOP SWITCH SPARK PLUG IGNITION COIL Black 17 07/05/01 15:48:48 32Z4P600_018 CONSUMER INFORMATION Canada: Honda Canada, Inc. 715 Milner Avenue Toronto, ON M1B 2K8 Distributor/Dealer Locator Information United States, Puerto Rico, and U.S. Virgin Islands: Call (800) 426-7701 or visit our website: www.honda-engines.com Telephone: (888) 9HONDA9 (888) 946-6329 English: (416) 299-3400 French: (416) 287-4776 Facsimile: (877) 939-0909 (416) 287-4776 Canada: Call (888) 9HONDA9 or visit our website: www.honda.ca For European Area: visit our website: http://www.honda-engines-eu.com Toll free Local Toronto dialing area Local Toronto dialing area Toll free Local Toronto dialing area Australia: Honda Australia Motorcycle and Power Equipment Pty. Ltd. 1954−1956 Hume Highway Campbellfield Victoria 3061 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 dealership’s management. The Service Manager, General Manager, or Owner can help. Almost all problems are solved in this way. Telephone: (03) 9270 1111 Facsimile: (03) 9270 1133 For European Area: Honda Europe NV. European Engine Center http://www.honda-engines-eu.com United States, Puerto Rico, and U.S. Virgin Islands: If you are dissatisfied with the decision made by the dealership’s management, contact the Honda Regional Engine Distributor for your area. All Other Areas: Please contact the Honda distributor in your area for assistance. If you are still dissatisfied after speaking with the Regional Engine Distributor, you may contact the Honda Office as shown. All Other Areas: If you are dissatisfied with the decision made by the dealership’s management, contact the Honda Office as shown. 《Honda’s Office》 When you write or call, please provide this information: Equipment manufacturer’s name and model number that the engine is mounted on Engine model, serial number, and type (see page 14 ) 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 United States, Puerto Rico, and U.S. Virgin Islands: American Honda Motor Co., Inc. Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta, GA 30005-8847 Or telephone: (770) 497-6400, 8:30 am - 8:00 pm EST 18 ENGLISH