Honda FG400 Owner's Manual

The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.

Keep this owner’s manual handy,
This owner’s manual is considered a permanent part of the tiller and should
remain with the tiller

The information and specifications included in this publication were in effect
at the time of approval for printing. Honda Motor

however, to discontinue or change specifications or design at any time
without notice and without incurring any obligation whatever.

if

resold.

so

you can refer to it any time.

Co.,

Ltd. reserves the right,

Congratulations on your selection of a Honda tiller. We are certain you will be
pleased with your purchase of one of the finest tillers on the market.

We want to help you get the best results from your new tiller and to operate it
safely. This manual contains all the information on how to do that; please read
it carefully.

As you read this manual, you will find information preceded by a
symbol. That information is intended to help you avoid damage to your tiller,
other property, or the environment.

We suggest you read the warranty policy to fully understand its coverage and
your responsibilities of ownership. The warranty policy is aseparate document
that should have been given to you by your dealer.

When your tiller needs scheduled maintenance, keep in mind that your Honda
servicing dealer is specially trained in servicing Honda tillers and is supported
by the parts and service divisions of American Honda. Your Honda servicing
dealer is dedicated to your satisfaction and will be pleased to answer your
questions and concerns.

Best Wishes,
Honda Motor Co., Ltd.

1-1

1

INTRODUCTION

A

FEW WORDS ABOUT SAFETY

Your safety and the safety of others are very important. And using this tiller
safely is an important responsibility.

To help you make informed decisions about safety, we have provided
operating procedures and other information on labels and in this manual.

This information alerts you to potential hazards that could hurt you or others.
Of course, it is not practical or possible to warn you about all the hazards

associated with operating or maintaining a tiller. You must use your own good
judgment.

You will find important safety information in a variety of forms, including:

Safety Labels - on the tiller.
Safety Messages-preceded by a safety alert symbol

signal 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

You CAN be HURT
follow instructions.

Safety Headings - such as
Safety Chapter - such as

0

Instructions

This entire book is filled with important safety information
carefully.

-

how to use this tiller correctly and safely.

IMPORTANT SAFETY INFORMATION.

TILLER SAFETY.

if

you don’t follow instructions.

A

and one of three

if

you don’t

-

please read it

2

TILLER SAFETY

IMPORTANT SAFETY INFORMATION
SAFETY LABEL LOCATIONS

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5

5

8

CONTROLS

COMPONENT & CONTROL LOCATIONS
CONTROLS

Choke Rod
Engine Switch
Recoil Starter
Throttle Lever
Handlebar Height Adjuster
Main Clutch Lever
Drag Bar
Front Wheel
Gearshift Lever

BEFORE OPERATION

ARE YOU READY TO GET STARTED?

IS

YOUR TILLER READY TO GO?

Check the Engine
Check the Tiller

OPERATION

SAFE OPERATING PRECAUTIONS
STARTING THE ENGINE
OPERATING THE CONTROLS FOR TILLING
STOPPING THE ENGINE

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9

9
10
10
10
10
11
11
11
12
12
12

13

13
13
14
14

15

15
16
19
23

SERVICING

THE IMPORTANCE
MAINTENANCE SAFETY
MAINTENANCE SCHEDULE
REFUELING
FUEL RECOMMENDATIONS
ENGINE OIL LEVEL CHECK
ENGINE OIL CHANGE
ENGINE OIL RECOMMENDATIONS
TRANSMISSION OIL LEVEL CHECK
AIR FILTER INSPECTION
AIR FILTER CLEANING
SPARK PLUG SERVICE

YOUR

HONDA TILLER

OF

MAINTENANCE

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24

24
25
26
27
27
29
30
31
32
33
34
35

3

CONTENTS

SERVICING YOUR HONDA TILLER (continued)

CLUTCH CABLE ADJUSTMENT
THROTTLE CABLE ADJUSTMENT
DRIVE BELT ADJUSTMENT
SPARK ARRESTER SERVICE

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37

37

38

39

STORAGE

STORAGE PREPARATION

STORAGE PRECAUTIONS
REMOVAL FROM STORAGE

TRANSPORTING ..................................................................................... 47

TAKING CARE

ENGINE PROBLEMS

TILLING PROBLEMS

TECHNICAL & CONSUMER INFORMATION

TECHNICAL INFORMATION

CONSUMER INFORMATION

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Cleaning
Fuel
Engine Oil

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OF

UNEXPECTED PROBLEMS

....................................

..........................................................................

Will

Engine
Engine Lacks Power

Poor Tilling Quality

Not Start

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Serial Number Locations
Carburetor Modification for High Altitude Operation
Oxygenated Fuels
Emission Control System Information
Air Index
Specifications

Honda Publications
Customer Service Information

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41

41

41

43

45

46

46

48

48

48

49

50

50

51

51

51

52

53

54

56

57

58

58

59

QUICK REFERENCE INFORMATION

4

..........................

Inside back cover

TILLER SAFETY

IMPORTANT SAFETY INFORMATION

Honda tillers are designed to cultivate earth outdoors. Other uses can result
in injury to the operator or damage to the tiller and other property.

Most accidents can be prevented
and on the tiller. The most common hazards are discussed below, along with

the best way to protect yourself and others.

Operator Responsibility

Know how to stop the tiller quickly in case of emergency.
Understand the use of all tiller controls.
Bevery cautious when operating the tiller in REVERSE

if attachments are being used.
Keep a firm hold on the handlebars. They may tend to lift during clutch

engagement.
Be sure the drag bar is in place and properly adjusted.
Be sure that anyone who operates the tiller receives proper instruction.

Do

not let children operate the tiller. Keep children and pets away from the

area of operation.

Carbon Monoxide Hazard

if

you follow all instructions in this manual

(A2

type), especially

Exhaust contains poisonous carbon monoxide, a colorless, odorless gas.

Breathing exhaust can cause

If

you run the tiller in a confined or even partially enclosed area, the air you
breathe could contain dangerous amounts of exhaust gas.
exhaust gas from building up, provide adequate ventilation.

loss

of consciousness and may lead to death.

To

keep

5

TILLER SAFETY

Fire and Burn Hazards

The exhaust system gets hot enough to ignite some materials.

-

Keep the tiller at least 3 feet

equipment during operation.

-

Keep flammable materials away from the tiller.

The muffler becomes very hot during operation and remains hot for a while
after stopping the engine. Be careful not to touch the muffler while it is hot.
Let the engine cool before storing the tiller indoors.

Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode. Allow the
engine to cool
ventilated area with the engine
near gasoline, and keep other flames and sparks away. Always store gasoline
in an approved container. Make sure that any spilled fuel has been wiped up
before starting the engine.

if

the tiller has been in operation. Refuel only outdoors in a well-

(1

meter) away from buildings and other

OFF.

Do

not overfill the fuel tank. Never smoke

Avoid Rotating Tines

Rotating tines can cause serious cuts and even amputate body parts. Keep
away from the tine area whenever the engine is running.
around the tines to clear a object accumulation or for any other reason, always

shut

off

the engine. Disconnect the spark plug cap, and wear heavy gloves

when you need to clean the tine area or handle the tines.

Clear Tilling Area

A

tine can throw rocks and other objects with enough force to cause serious
injury. Before tilling, carefully inspect the area and remove all stones, sticks,
bones, nails, pieces of wire, and other loose objects. Be aware if children are
in the area; stop the tiller. Never operate the tines over gravel.

If

you need to work

TILLER SAFETY

Keep Shields in Place

Guards and shields are designed to protect you from being hit by thrown

objects and to keep you from touching hot engine parts and moving components.

For your safety and the safety of others, keep all shields in place when the

engine is running.

Wear Protective Clothing

Wearing protective clothing will reduce your risk of injury. Long pants and eye

protection reduce the risk of injuries from thrown objects. Sturdy shoes with
aggressive soles provide better traction.

Turn Engine

If

you need to leave the tiller for any reason, even just to inspect the area

ahead, always turn the engine off.

Slope Operation

When tilling on slopes, keep the fuel tank less than half full to minimize fuel
spillage.

Till across the slope (at equally spaced intervals) rather than up and down

it.
Be very careful when changing the direction of the tiller on a slope.
Do

not use the tiller on a slope of more than

check that the tiller is not damaged and is in good condition. For your safety

and safety of others, exercise extreme care when using the tiller on a slope.

Tilling Conditions

Operate tiller only in daylight or good artificial light.
night or under poor light conditions.

Off

When Not Operating the Tiller

10".

Before starting the engine,

Do

not operate the tiller at

7

TILLER SAFETY

SAFETY LABEL LOCATONS

These labels warn you of potential hazards that can cause serious injury. Read

them carefully.

Honda servicing dealer for a replacement.

If

a label comes off or becomes hard to read, contact your

8

CONTROLS

COMPONENT & CONTROL LOCATIONS

THROTTLE LEVER

AIR CLEANER COVER

ENGINE SERIAL HlFT LEVER (A2 TYPE)

FRONT WHEEL

ROTOR

V-BELT COVER

CLUTCHLEVER

HANDLEBAR HEIGHT
ADJUSTER

FRAME SERIAL NUMBE

PARK PLUG CAP

CHOKE ROD

ECOIL STARTER

TRANSMISSION OIL

9

CONTROLS

CONTROLS
Choke

Rod

The choke rod opens and closes
the choke valve in the carburetor.

The

CLOSED

fuel mixture

position enriches the
for

starting a cold

engine.
The

OPEN

position provides the
correct fuel mixture for operation
after starting and for restarting a

warm

engine.

Engine Switch

The engine switch controls the
ignition system.

OFF

-

Stops the engine.

ON

-

Running position.

ENGINE

I

ON

SWITC

Recoil Starter

10

STARTER

GRIP

Throttle Lever

The throttle lever controls engine
speed.

Moving the throttle lever in the di­rections shown makes the engine
run faster or slower.

Tine speed iscontrolled by adjusting
the throttle lever. At maximum
throttle position, the tines

will

rotate
at the highest speed.
Moving the throttle lever toward the
idle position will decrease the tine
speed.

Handlebar Height Adjuster

Handlebar height can be adjusted
to match operator height.

CONTROLS

TLE

/

FAST

For normal tilling, the most
comfortable operator position is with
the handlebars at waist height.

Main Clutch Lever

The main clutch lever engages and
disengages the transmission that
drives the tines.

CLUTCH

DISENGAGED

LEVER

11

CONTROLS

Gearshift Lever

The transmission on the
offers a choice

of

speeds and one reverse speed.

Shift lever positions are indicated

on the Change Lever Bracket.

Drag Bar

The drag bar controls tilling depth
and should always be used when
tilling. It enables you to compensate
for the hardness

of

drag bar height will depend on the

type

of

soil being tilled and soil
conditions at the time of tilling. In
general, the drag bar should be
adjusted

so

that the tiller is tilted

slightly backward.

A2

type

two forward

the soil. Ideal

/

PIN

HITCH

.EVER

Front Wheel

The front wheel is used to help

move the tiller from one place to
another. Lift the tiller by the
handlebars to roll the tiller on the

front wheel. Return the wheel to the

raised position before tilling. Always
stop the engine before lowering or
raising the wheel.

TILLING

POSITION

TRANSPORT

POSITION

ARE

YOU

READY

Your safety is your responsibility. A little time spent in preparation will

significantly reduce your risk of injury.

Knowledge

Read and understand this manual. Know what the controls do and how to
operate them.

Familiarize yourself with the tiller and its operation before you begin using it.

Know how to quickly shut off the tiller in case of an emergency.

IS

YOUR TILLER READY

For your safety, and to maximize the service life of your equipment, it is very
important
condition. Be sure to take care of any problem you find, or have your servicing
dealer correct it, before you operate the tiller.

to

take a few moments before

Improperly maintaining this tiller, or failing to
correct a problem before operation, could cause
a malfunction in which you could be seriously
injured.

TO

GET STARTED?

TO

GO?

you

operate the tiller to check its

Always perform a preoperation inspection before
each operation, and correct any problem.

13

BEFORE OPERATION

Do

not place flammable objects close to the engine.

Before beginning your preoperation checks, be sure the tiller is on a level

surface and the engine switch is in the

Check the Engine

Check the oil level (see page 29).
Check the air filter (see page 33).

carburetor, reducing engine and tiller performance.

OFF

position.

A

dirty air filter will restrict air flow to the

Check the fuel level (see page

or reduce operating interruptions for refueling.

Check the Tiller

Check the transmission oil (see page 32).

27).

Starting with a full tank will help to eliminate

14

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the tiller for the first time, please review both the

SAFETY

For

as a garage. Your tiller's exhaust contains poisonous carbon monoxide gas

which can collect rapidly in an enclosed area and cause illness or death.

chapter and the chapter titled

your safety, avoid starting or operating the tiller in an enclosed area such

Carbon monoxide gas is toxic. Breathing it can
cause unconsciousness and even kill you.

Avoid any enclosed areas or activities that expose
you to carbon monoxide.

BEFORE

OPERATION.

TlLLER

15

OPERATION

STARTING THE ENGINE

Refer to

Safe Operating Precautions

Tines are sharp and spin fast.
Spinning tines can cut you severely and can

amputate body parts.

Wear protective footwear.
Keep your hands and feet away from the

tines while the engine is running.
Stop the engine before performing any

adjustment, inspection, or maintenance.

1

.

Pull the choke rod to the CLOSED
position to start a cold engine.

on Page

15.

/,-----

Leave the choke rod in the

OPEN

position to restart a warm engine.

16

CHOKE

ROD

2.

Turn the engine switch to the
position

3.

Move the throttle lever away from

the

SLOW

the way toward the

position, about

1/3

FAST

position.

ON

of

THROTTLE LEVER

OPERATION

ON

4.

Pull the starter grip lightly until
you feel resistance, then pull
briskly.

Do

not allow the starter grip to
snap back against the engine.
Return it gently to prevent

damage to the starter.

STARTER

ow

GRIP

17

OPERATION

5.

If

the choke rod was pulled to

the

CLOSED
the engine, gradually move it
to the
engine warms up.

OPEN

position to start

position

as

the

/-t-

CHOKE

ROD

18

~~ ~~~

OPERATION

OPERATING THE CONTROLS FOR TILLING

If

the tines dig in but the machine will not move forward, move the handlebars
from side-to-side. When turning, push down on the handlebars to bring the
tiller's weight to the rear; this will make turning easier.

Handlebar Height Adjustment

Stop the engine before adjusting
the handlebar height.

To

adjust the handlebar height,

loosen the handlebar height

adjuster, select the appropriate

holes and tighten it.

Clutch

When the main clutch lever is
squeezed, the clutch is engaged,
and power

is

transmitted to the

transmission.
When the lever

clutch

is

disengaged, and power is

is

released, the

not transmitted.

HE

CLUTCH

LEVER

111

I

DISENGAGED

19

OPERATION

~~

Forward Gear Selection

1.

Return the throttle lever to the slowest position.

2.

Release the clutch lever

3.

Move the shift lever to the desired gear position.

If

the shift lever will not engage the desired gear, squeeze the clutch lever

(A2

type

only)

to

disengage the clutch.

and move the tiller slightly to reposition the gears.

HANGE LEVER
RACKET

I

NEUTRAL

20

OPERATION

Reverse Gear Operation

Use the reverse gear only when it is necessary to move the tiller away from
an obstacle.

The tiller tines propel the tiller toward the
operator when operated in reverse.

Contact with rotating tines will cause serious
injury.

Be prepared to quickly release the clutch
lever when operating the tiller in reverse.

1.

Check the area behind you and make sure it is clear of any obstacles.

2.

Verify the transport wheel is raised.

(A2

Type)

3.

Move the throttle to the

4.

Raise the handlebar up

This raises the drag bar out of the soil to allow easy revers gear operation.

5.

Make sure the clutch lever is released. Move the shift lever to the

REVERSE position.

6.

Engage the clutch lever and carefully walk the tiller backwards. Be

prepared to release the clutch lever quickly.

7.

Release the clutch lever, lower the handlebar, and move the shift lever
out of the REVERSE position when done.

SLOW

so

position.

the transport wheel contacts the ground.

21

~~~~~~

Tiling Depth Adjustment

The drag bar is used to control the tilling depth, which can be adjusted by
removing the pin and retainer and sliding the drag bar up and down as
necessary.

During operation,

if

the machine jerks forward while tilling, press down on the

handlebars. This will cause the drag bar to dig more deeply into the soil.

Front Wheel

After getting to the tilling site, move the front wheel to the raised position before
tiling. Always stop the engine before lowering or raising the wheel.

To raise or lower the wheel, pull out the wheel assembly, move the wheel, then

release the wheel assembly.

22

TILLING POSITION

TRANSPORT POSITION

OPERATION

STOPPING

To

stop the engine in an emergency, simply turn the engine switch to the

position. Under normal conditions, use the following procedure.

1.

Release the main clutch lever to

the DISENGAGED position, and

move the shift lever to the neutral

position (A2 type).

2.

Move the throttle lever to the

slowest position.

THE

ENGINE

OFF

3.

Turn the engine switch to the

OFF

position.

OFF

/-

ENGINE SWITCH

OFF

23

THE IMPORTANCE

Good maintenance isessential for safe, economical, and trouble-free operation.
It will also help reduce air pollution.

To help you properly care for your tiller, the following pages include a

maintenanceschedule, routine inspection procedures, and simple maintenance
procedures using basic hand tools. Other service tasks that are more difficult,
or require special
performed by a Honda technician or other qualified mechanic.

OF

MAINTENANCE

tools,

are best handled by professionals and are normally

The maintenance schedule applies to normal operating conditions.

operate your tiller under unusual conditions, (such as sustained high-load or
high-temperature operation, or use in dusty conditions), consult your servicing

dealer for recommendations applicable to your individual needs and use.

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.

Remember that your servicing dealer knows your tiller 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.

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.

If

you

24

SERVICING YOUR HONDA TILLER

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.

Failure to properly follow maintenance
instructions and precautions can cause you
to be seriously hurt or killed.

Always follow the procedures and
precautions in the 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

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 nonflammable solvent, not gasoline, to clean
parts. Keep cigarettes, sparks, and flames away from all fuelrelated parts.

Disconnect the spark plug cap and wear heavy gloves when working near

the tine blades.

so.

SERVICING YOUR HONDA TILLER

MAINTENANCE SCHEDULE

I

Fuel tank and filter Clean

Valve clearance

I

Combustion chamber Clean

I

Fuel tube

Check-Adjust

Check

I

Every

months

or

25 hrs.

6

3

I

--t--t-

First tlme

25

hrs.

(3)

First

time

25

hrs.

(3)

L

Mer every

1

Every

2

years (Replace if necessary)

or

hrs.

Every

2

years

or

250 hrs.

Every Every

months

50

or

hrs.

year

100

Io

0

Io

0

I

0

hrs.

(3)

(3)

~.

(3)

250

0

Emission related items.

(1)

Service more frequently when used in dusty areas.

(2)

Change engine oil every

25

hours when used under heavy load or in high

ambient temperatures.

(3)

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.

(4)

Log hours of operation to determine proper maintenance intervals.

26

REFUELING

SERVICING YOUR HONDA TILLER

Fuel tank capacity: FG400

FG500

With the engine stopped, remove the fuel tank cap and check the fuel level.

Refill the tank

Refuel in a well-ventilated area before starting the engine.
been running, allow it to cool. Refuel carefully to avoid spilling fuel.
the fuel tankabove the fuel level mark. After refueling, tighten the fuel tankcap
securely.

if

the fuel level is low.

Gasoline is highly flammable and explosive.

You can be burned or seriously injured when

handling fuel.

Stop the engine and keep heat, sparks, and
flame away.

Refuel only outdoors.
Wipe up spills immediately.

0.45 US gal (1.7i?, 0.37 Imp gal)

0.53 US gal

Do

(2.0i?,

0.44 Imp gal)

not fill above the fuel level mark.

If

the engine has

Do

not fill

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.

FUEL RECOMMENDATIONS

of

86

or

Use unleaded gasoline with a pump octane rating

This engine is certified to operate on unleaded gasoline. Unleaded gasoline

produces fewer engine and spark plug deposits and extends exhaust system

life.

higher.

27

SERVICING YOUR HONDA TILLER

Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid
getting dirt or water in the fuel tank.

Occasionally you may hear light “spark knock’ or “pinging” (metallic rapping
noise) while operating under heavy loads. This is no cause for concern.

If

spark knock or pinging occurs at a steady engine speed, under normal load,
change brands
authorized Honda servicing dealer.

I

NOTICE

Running the engine with persistent spark knock or pinging can cause engine
damage.

Running the engine with persistent spark knock or pinging is misuse, and the

Distributor’s Limited Warranty

I

of

gasoline.

If

spark knock or pinging persists, see an

does not cover parts damaged by misuse.

28

SERVICING YOUR HONDA

TILLER

ENGINE OIL LEVEL CHECK

Check the engine oil level with the tiller on a level surface and the engine
stopped.

1. Remove the oil filler cap/dipstick and wipe it clean.

2.

Insert and remove the dipstick without screwing it into the filler neck.
Check the oil level shown on the dipstick.

3.

If

the oil level is low, fill to the top of the oil filler neck with the

recommended oil (see page 31).

4.

Screw in the filler cap/dipstick securely.

OIL

FILLER

CAPlDlPSTlCK

NECK

tl+

LOWER

LlMT

29

SERVICING YOUR HONDA TILLER

ENGINE

Drain the oil while the engine is warm

1.

Place a suitable container below the engine to catch the used
remove the filler cap/dipstick, drain plug and sealing washer.

2.

Allow the used oil to drain completely, then reinstall the drain plug and
sealing washer. Tighten the plug securely.

OIL

CHANGE

to

assure rapid and complete draining.

oil,

lxEia

Improper disposal of engine oil can be harmful to the environment. If you

change your own oil, please dispose

sealed container and take it to a recycling center.

bin or dump it on the ground.

3.

With the tiller in a level position, fill to the outer edge of the oil filler hole

with the recommended

Oil

Capacity:

0.61

US

oil

(see page

qt

(0.58

4)

of

the used oil properly. Put it in

Do

not discard it in a trash

29).

-1

Running the engine with a low oil level can cause engine damage.

then

a

4.

Screw in the filler cap securely.

OIL

FILLER

CAP/DIPSTICK

DRAIN

30

NECK

-

11

UPPER

LlMT

r-y

LOWER

LlMT

SERVICING YOUR HONDA TILLER

ENGINE

OIL

RECOMMENDATIONS

Oil is a major factor affecting performance and service life. Use a 4-stroke
automotive detergent oil.

1

SAE

’

chart may be used when the average temperature in your area is within the

OW-30

is recommended for general use. Other viscosities shown in the

recommended range.

SAE

VISCOSITY

-20

-30

0

I I

-20

20

-10

AMBIENTTEMPERATURE

0

40

GRADES

60

10

20

80

30

100

40

‘F

‘C

The

SAE

oil

viscosit!

and service classification are in the API label on the oil

container. Honda recommends that you use API SERVICE category

SJ

oil.

31

SERVICING

YOUR

HONDA

TILLER

TRANSMISSION

Check the transmission oil level with the tiller

OIL

LEVEL

CHECK

on

a level surface and the engine

stopped.

1.

Remove the transmission oil filler cap. The oil should be level with the lower
edge of the oil filler hole.

2.

Add the same oil as recommended for the engine (see page

is

low.

3.

Screw in the filler cap securely.

,$

TRANSMISSION

FILLER CAP

.--

OIL FILLER HOLE

31),

if

the level

OIL

1

<

32

LOWER EDGE OF
THE OIL FILLER HOLE

I

SERVICING YOUR HONDA TILLER

AIR FILTER INSPECTION

Press the latch tabs on the fuel tank side of the air cleaner cover, remove the
air cleaner cover, and remove the filter.
Check the filter to be sure it is clean and in good condition.
remove the filter and clean it as described on page

'

is damaged.
Reinstall the filter and air cleaner cover. Make sure the latch tabs are secured.

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
covered

by

the

Distributor's Limited Warranty.

34.

If

the filter is dirty,

Replace the filter

of

damage is not

if

it

AIR

/

TABS

FILTER

e

AIR

CLEANER COVER

LATCH TABS

33

SERVICING YOUR HONDATILLER

AIR FILTER CLEANING

A

dirty air filter will restrict air flow to the carburetor, reducing engine
performance.
more frequently than specified in the

If

you operate the engine in very dusty areas, clean the air filter

Maintenance Schedule.

1.

Tap the air filter element several times on a hard surface to remove dirt, or

blow compressed air [not exceeding

30

psi

(207

kPa,

2.1

kgf/cm2)] through
the air filter from the air cleaner housing side. Never try to brush off dirt;
brushing will force dirt into the fibers. Replace the air filter if it is excessively
dirty.

2.

Wipe dirt from the air cleaner housing and cover using a moist rag. Be
careful to prevent dirt from entering the air duct that leads to the carburetor.

I

,

34

SPARK PLUG SERVICE

SERVICING YOUR HONDA TILLER

Recommended spark plug: BPR6ES

Incorrect spark plugs can cause engine damage.

1. Disconnect the spark plug cap, and remove any dirt from around the spark
plug area.

2.

Remove the spark plug with a 13/16-inch spark plug wrench.

I'

\-

3. Inspect the spark plug. Replace it
electrodes are worn, or
is cracked or chipped.

if

the insulator

(NGK)

1

If

if

the

PULG

/

(0.70 - 0.80

WRENCH

mm)

4.

Measure the spark plug electrode gap
with a suitable gauge. The gap should
be

0.028

-

0.031 in
Correct the gap, if necessary, by care­fully bending the side electrode.

5.

Install thesparkplug carefully, by hand,

to avoid cross-threading.

6.

After the spark plug seats, tighten with
a 13/16
compress the washer.

-

inch spark plug wrench to

(0.70 - 0.80

mm).

35

SERVICING YOUR

If

reinstalling a used spark plug, tighten

seats.

If

installing a new spark plug, tighten

A

loose spark plug can overheat and damage the engine.

Overtightening the sparkplug can damage the threads in the cylinder head.

7

Attach the spark plug cap.

HONDA

TILLER

1/8 - 1/4

1/2

turn after the spark plug seats.

turn after the spark plug

36

SERVICING YOUR HONDA TILLER

CLUTCH CABLE ADJUSTMENT

There should be 3/16 - 3/8 inches

If

lever adjustment is incorrect, loosen the lock nut and turn the adjusting bolt

in or out just enough to eliminate free play.

LOCK

ADJUSTING
NUT

THROlTLE CABLE

ADJUSTMENT

NUT

(5

-

10

rnm) of free play at the lever end.

Do

not overtighten.

Measure the free play at the lever tip.

:

Free play

If

the free play is incorrect, turn the adjusting nut in or out as required.

1 -3/16 - 1 -9/16 in (30

-

40

rnm)

1-3/16 - 1-9/16

(30

-

40 mm)

in

37

SERVICING

YOUR

HONDA

TILLER

DRIVE

1.

2.

BELT ADJUSTMENT

Adjust the clutch cable (page

Belt tension is correct when the
distance form the top of the belt
to the top of the tension roller is

1-3/4
when the clutch is engaged.

TO

mounting bolts and the three inner
belt cover tightening bolts and move

the engine forward or backward to get
proper tension on the belt.

After adjusting the tension, use a
straight edge
outside face
with the outside face of the driven
pulley.

-

1-15/16 in (45 - 49 mm)

adjust, loosen the four engine

to

make sure that the

of

the drive pulley is flush

37).

INNER BELT COVER TIGHTENING BOLTS

MOUNTING

BOLTS

in

r

3.

Loosen the belt stopper attaching bolts. Adjust the clearance between the

belt stopper and the belt as illustrated with the clutch lever squeezed.

1132 - 118

I1

318

(10- 13

-3

-

mm)

112

in

in

mm)

+

1132 - 118

(1

-

3

38

in

mm)

SERVICING

SPARK ARRESTER SERVICE

Your engine is not factory-equipped with a spark arrester. In some areas, it is
illegal to operate an engine without
regulations. A spark arrester

The spark arrester must be serviced every
designed.

If

the engine has been running, the muffler will be very hot. Allow the muffler

to cool before servicing the spark arrester.

1.

Remove the three 6 mm bolts from the muffler protector, and remove the

muffler protector.

2.

Remove the two special screws from the spark arrester, and remove the

spark arrester from the muffler.

is

a

available from Honda servicing dealers.

YOUR

spark arrester. Check local laws and

100

hours to keep it functioning as

HONDA TILLER

MUFFLER

PROTECTOR

BOLTS

39

SERVICING YOUR HONDA TILLER

3.

Use a brush to remove carbon deposits from the spark arrester screen. Be
careful to avoid damaging the screen.
The spark arrester must be free
arrester

4.

Install the spark arrester and muffler protector, in the reverse order

if

it

is

damaged.

SPARK

ARRESTER

disassembly.

of

breaks and holes. Replace the spark

SCREEN

of

40

STORAGE PREPARATION

Proper storage preparation is essential for keeping your tiller trouble free and
looking good. The following steps will help
impairing your tiller’s function and appearance, and will make the engine
easier to start when you use tiller again.

Cleaning

1.

Wash the tiller, including the underside.

Engine

Wash the engine by hand, and be careful to prevent water from entering the

air cleaner.

1

NOTICE

Using a garden hose or pressure washing equipment can force water
into the air cleaner. Water
and can enter the carburetor or engine cylinder, causing damage.

Water contacting a hot engine can cause damage. If the engine has

been running, allow it to cool for at least half an hour before washing.

1

in

the air cleaner will soak the filter elements

to

keep rust and corrosion from.

Tiller

If

using a garden hose or pressure washing equipment to clean the tiller, be

careful to avoid getting water

Spraying water
from cooling too quickly.

on

hot tine shaft bearings can cause them to be damaged

on

the belts.

41

STORAGE

2.

After washing the tiller, wipe dry all accessible surfaces.

3.

Start the engine outdoors, and let it run until it reaches normal operating
temperature to evaporate any water remaining on the engine.

4.

While the engine is running, operate the clutch lever to expel water from the
pulleys, belts, and other moving items.

5.

Stop the engine and allow it to cool.

6.

After the tiller is clean and dry, touch up any damaged paint and coat other
areas with a light film of oil. Lubricate the throttle cable core with a silicone
spray lubricant.

42

STORAGE

Fuel

Gasoline will oxidize and deteriorate in storage. Old gasoline will cause hard
starting, and it leaves gum deposits that clog the fuel system.
in your tiller 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 a few months, or even less
gasoline was not fresh when you filled the fuel tank.

The Distributor’s Limited Warranty does not cover fuel system damage or
engine performance problems resulting from neglected storage preparation.

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.

If

the gasoline

if

the

Adding a Gasoline Stabilizer to Extend Fuel Storage Life

When adding a gasoline stabilizer, fill the fuel tank with fresh gasoline.
partially filled, air in the tank will promote fuel deterioration during storage.
you

keepacontainerofgasolineforrefueling,

gasoline.

1.

Add gasoline stabilizer following manufacturer’s instructions.

2.

After adding a gasoline stabilizer, run the engine outdoors for
to be sure that treated gasoline has replaced the untreated gasoline in the
carburetor.

3.

Stop the engine.

besurethatitcontainsonlyfresh

10

minutes

If

only

43

If

STORAGE

Draining the

1.

Remove the fuel filler cap, and empty the fuel tank into an approved
gasoline container using a commercially available hand siphon. Reinstall
the fuel filler cap.

2.

Place an approved gasoline container below the carburetor, and use a
funnel to avoid spilling fuel.

3.

Loosen the carburetor drain screw to drain the carburetor.

Fuel

Tank and Carburetor

Gasoline is highly flammable and explosive.
You can be burned or seriously injured.
Never use gasoline to clean engine parts.

Use a nonflammable solvent.

'

CARBURETOR

4.

After all the fuel has drained into the container, tighten the drain screw
securely.

44

STORAGE

'

Engine

1.

2.

3.

4.

5.

6.

Oil

Change the engine oil (page

Remove the spark plug (page
Pour a tablespoon

Pull

the starter rope several times to distribute the oil in the cylinder.
Reinstall the spark plug.
Pull the starter rope slowly until resistance is felt. This will close the valves,

so

moisture cannot enter the engine cylinder. Return the starter rope

gently.

(5

-

10

cc)

30).

35).

of

clean engine oil into the cylinder.

45

STORAGE

STORAGE PRECAUTIONS

If

your tiller 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.
spark-producing 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, leave the fuel valve in the

OFF

position to reduce the possibility of fuel leakage.

Place the tiller on a level surface. Tilting can cause fuel or oil leakage.

With the engine and exhaust system cool, cover the tiller to keep out dust.

A

hot engine and exhaust system can ignite or melt some materials.
sheet plastic as
tiller, promoting rust and corrosion.

a

dust cover. A nonporous cover will trap moisture around the

Also

avoid any area with a

Do

not use

.

REMOVAL FROM STORAGE

Check your tiller as described in the
manual.

If

the fuel was drained during storage preparation,
gasoline.
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 may

smoke briefly at start-up. This is normal.

If

you keep a container of gasoline for refueling, be sure that it

BEFORE OPERATlON

fill

the tank with fresh

chapter of this

46

BEFORE

If

the engine has been running, allow it to cool for at least

loading the tiller on the transport vehicle.

LOADING

A

burn you and can ignite some materials.

*

Always turn the ignition switch to the

OFF

LOADING AND UNLOADING

If

asuitable loading ramp is not available,

off the transport vehicle while holding the tiller level.

15

minutes before

hot engine and exhaust system can

position.

two

people should lift the tiller on and

Position the tiller

down with rope

so

it sits flat on the bed of the transport vehicle. Tie the tiller

or

straps. Keep the tie-down rope

or

straps away from the

controls, adjustment levers, cables, and the carburetor.

47

ENGINE

PROBLEMS

Engine

1.

Check control
positions.

2. Check fuel.

I

3.

Checkengineoil level.

4. Remove and inspect
spark plug.

5.

Take tiller
rized Honda servicing
dealer, or refer

Will

to

an autho-

Not

to

Possible

Choke OPEN.

Engine switch OFF
Out of fuel.

Bad fuel; tiller stored with­out treating or draining
gasoline, or refueled with
bad gasoline.

Low oil level caused Oil Add oil (p.29).
Alert

to

Spark plug faulty, fouled,
or improperly gapped.

Spark plug wet with fuel
(flooded engine).

Fuel filter clogged, carbu­retor malfunction, ignition

the

malfunction,valvesstuck,
etc.

stoD

Cause

enaine.

I

Move to CLOSED unless
engine is warm.

Turn engine switch

Refuel (p.27).

Drain fuel tank and carbu­retor (p.44).
Refuel with fresh gasoline

(P.27).

Clean, gap, or replace

spark plug (p.35).

Dry and reinstall spark
plug. Start engine with

throttle lever in
sition.

Replace or repair faulty

components as neces­sary.

Correction

FAST

to

ON.

po-

TAKING CARE

OF

UNEXPECTED PROBLEMS

Engine

I

Power

I

1.

Check air filter.

2.

Check fuel.

rized Honda servicing
dealer, or refer to the
shop manual.

Lacks

Possible Cause

Air filter clogged.

Bad fuel; tiller stored

without treating or drain-

ing gasoline, or refueled

with bad gasoline.

Fuel filter clogged,

carburetor malfunction,

ignition malfunction,

valves stuck, etc.

Correction

Clean or replace air filter
(P.34).

Drain fuel tankand carbu­retor (p.44).

Refuel with fresh gasoline

(P.27).

Replace or repair faulty

as

components
sary.

neces-

49

TAKING CARE

TILLING PROBLEMS

I

Poor Tilling Quality

1.

Check that the throttle
lever is in the FAST
position.

OF

UNEXPECTED PROBLEMS

Possible Cause

Engine speed is too slow

to till well.

I

Move the throttle to the
FAST position (p.11).

Correction

2. Reduce forward
speed.

I

3.

Check drag bar depth

setting.

4.

Check tines.

Tiller is movingtoo fast for to slower speed

soil

conditions.

Drag bar adjustment set
to high.

Tines dull, worn, or dam- tines if neces­aged.

Wrong tines installed.
Tines installed incorrectly. I Install tines correctly.

Lower drag bar adjust­ment (p.22).

I

Install correct

tines.

50

TECHNICAL & CONSUMER INFORMATION

Serial Number Location

TECHNICAL INFORMATION Serial Number

Loc

FRAME

Record the engine and frame serial numbers in the spaces below. You will
need this serial number when ordering parts, and when making technical or
warranty inquires. (see page

Engine serial number:

Frame serial number:

59.)

51

TECHNICAL & CONSUMER INFORMATION

Carburetor Modification for High Altitude operation

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 a specific modifications to the

carburetor.

meters) 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.

Even with carburetor modification, engine horsepower will decrease about

3.5%for each 1,000-foot (300-meter) increase in altitude. The effect of altitude
on horsepower will be greater than this

If

you always operate your tiller at altitudes above 5,000feet

if

no carburetor modification is made.

(1,500

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
feet (1,500 meters) 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 specification.

5,000

TECHNICAL & CONSUMER INFORMATION

Oxygenated

Some conventional gasolines are being blended with alcohol or an ether
compound. These gasolines are collectively referred to as oxygenated fuels.
To meet clean air standards, some areas of the United States and Canada use
oxygenated fuels to help reduce emissions.

If

you use an oxygenated fuel, be sure it is unleaded and meets the minimum

octane rating requirement.

Before using an oxygenated fuel, try to confirm the fuel’s contents. Some

states/provinces require this information to be posted on the pump.
The following are the

ETHANOL

MTBE

Fuels

EPA

approved percentages of oxygenates:

-

(ethyl or grain alcohol)
You may use gasoline containing up to
volume. Gasoline containing ethanol may be marketed
under the name “Gasohol”.

(Methyl Tertiary Butyl Ether)
You may use gasoline containing up
volume.

10%

by volume

15%

by volume

to

10%

15%

ethanol by

MTBE by

METHANOL - (methyl or wood alcohol)

You may use gasoline containing up to
volume, as long as it also containscosolvents and corrosion
inhibitors to protect the fuel system. Gasoline containing
more than
or performance problems.
ber, and plastic parts of your fuel system.

If

you notice any undesirable operating symptoms, try another service station,

or switch to another brand of gasoline.
Fuel system damage or performance problems resulting from the use of an

oxygenated fuel containing more than the percentages of oxygenates men-

tioned above are not covered under warranty.

5%

methanol by volume may cause starting and/

5%

by volume

5%

methanol by

It

may also damage metal, rub-

53

TECHNICAL & CONSUMER INFORMATION

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.

Honda uses lean carburetor settings and other systems to reduce the
emissions of carbon monoxide, oxides

The

U.S.

and California Clean Air Act

EPA

and California regulations require all manufacturers
instruction describing the operation and maintenance of emission control
systems.

The following instructions and procedures must be followed in order to keep
the Honda engine emissions within the emission standards.

of

nitrogen, and hydrocarbons.

to

furnish written

-

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

Altering or defeating the governor linkage or speed-adjusting mechanism

to cause the engine to operate outside its design parameters.

of

intake, fuel, or exhaust system.

54

*

TECHNICAL & CONSUMER INFORMATION

Problems That May Affect Emissions

If

you are aware of any of the following symptoms, have your engine inspected

and repaired by your authorized Honda servicing dealer.

Hard starting or stalling after starting.
Rough idle.
Misfiring or backfiring under load.

0

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

Replacement Parts

The emission control systems on your new Honda engine were designed,

built, and certified to conform with EPA and California emission regulations.
We recommend the use genuine Honda parts whenever you have mainte­nance done. These original-design replacement parts are manufactured to

the same standards as the original parts,

performance. The use of replacement parts that are not of the original design
and quality may impair the effectiveness of your emission control system.

so

you can be confident of their

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 afailure of the engine
to comply with emission regulations.

Maintenance

Follow the Maintenance Schedule on page
is based on the assumption that your machine will be used for its designed
purpose. Sustained high-load or high-temperature operation, or use in unusu­ally wet or dusty conditions, will require more frequent service.

26.

Remember that this schedule

55

TECHNICAL & CONSUMER INFORMATION

Air

Index

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.

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

Control Warranty

Descriptive Term
Moderate

Intermediate

Extended

for additional information.

Applicable to Emissions Durability Period

50

hours

(0

-

65

cc)

125

hours

(greater than

125

hours

(0

-

250

hours (greater

300

hours

(0

-

500

hours (greater than

65

65

cc)

than

cc)

65

65

65

cc)
cc)

cc)

Emission

The Air Index Information hang tag must remain on the tiller until it is sold.

Remove the hang tag before operating the tiller.

TECHNICAL & CONSUMER INFORMATION

Specifications

Model

Power equipment description

I

code

Dry weight
Length

Width

Height

I

Engine Model

Displacement

Bore x Stroke

Ignition System

Spark Plug
Oil Capacity

I

Fuel Tank Capacity
Clutch
Transmission Oil Capacity

FG500-A1 FG400-A1

1

I

I

FZCW

106

99

Ibs

(45

kg)

53.1

25.8 in (655

GC135

Single cylinder, 4-stroke, forced air cooled,

over head valve, gasoline

(1

35

cm3)

mm)

Transistorized magneto

BPR6ES (NGK)

0.61

0.45

US

gal

(1.7

E)

Belt tension type

1

.O

US

qt (0.95

Ibs

in (1,350

I

2.5 X 2.0 in (64 X 50 mm) 2.5X1.7 in (64x42

US

qt (0.58

I

I

e,

FZCY

(48

kg)

108

mm)

mm)

42.9 in (1,090mm) 42.1 in (1,070mm)

GC160

9.8 cu-in

(1

4)

0.53

US

gal

0.84 Imp qt)

FG500-A2

Ibs

(49

60

cm3) 8.2 cu-in

(2.0

E)

~

kg)

Tune-up Specifications

ITEM

I

Spark Plug Gap

Valve Clearance

I

Other Specification

NOTE:

Specifications are subject to change

0.028

0.80
IN: 0.1 1

EX:

I

-

mm)

0.1

6 - 0.24

MAINTENANCE SPECIFICATION

0.031 in

-

0.19

(0.70

-

Refer

to

mm

cold

mm

No other adjustments needed.

without

See your authorized

cold

Honda dealer

notice.

page:

35

I

57

TECHNICAL & CONSUMER INFORMATION

CONSUMER INFORMATION
Honda Publications

These publications will give you additional information for maintaining and

repairing your tiller. You may order them from your Honda tiller dealer.

Shop

This manual covers complete maintenance and overhaul procedures. It is
intended

Parts Catalog

This manual provides complete, illustrated parts lists.

Manual

to

be used by a skilled technician.

58

TECHNICAL & CONSUMER INFORMATION

~

Customer Service Information

Honda Power Equipment 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 or General

*

Manager can help. Almost all problems are solved in this way.

If

you are dissatisfied with the decision made by dealership’s management,

*

contact the Honda Power Equipment Customer Relations Office. You can
write:

American Honda Motor

Co.,

Inc.

Power Equipment Division
Customer Relations Office

4900

Marconi Drive

Alpharetta, Georgia

-

Or telephone: (770) 497

6400

When you write or call, please give

Model and serial numbers (see page

30005

us

-

8847

this information:

51)

Name of the dealer who sold the tiller to you
Name and address of the dealer who services your tiller
Date of purchase

Your name, address, and telephone number

0

A detailed description of the problem

59

60

Fuel

Engine Oil

Capacity

TY Pe
Capacity

Unleaded gasoline with a pump octane
rating

SAE

0.51

of

86 or higher (page 27)

FG400
FG500

(page 31)

:

0.45

:

10

W

US

qt (0.581)

0.53

-

US

gal (1.71)

US

gal (2.01)

30, API

SJ,

for general use

Spark Plug
Carburetor

Maintenance

Type
Gap

Idle speed

Before each
use

First 5 hours
Subsequent

BPR6ES (NGK)

0.028

Check engine oil level.
Check air filter.
Tiller outside

Transmission oil

-

0.031 in (0.7

1,400

f

150 rpm

Each lever function

Bolt

and nut torque
Cables and wires
Engine operation

Change engine oil
Refer to maintenance schedule (page 26)

-

0.8

mm)