Honda Power Equipment GXV160, GXV120 User Manual 2

Thank you for purchasing a Honda engine.
This manual covers the operation and maintenance of GXV120 and

GXVl60 engines. All information in this publication is based on the latest
product information available at the time of printing.
The illustrations in this mannal are based on the GXVl20 engine.

Honda Motor Co., Ltd. reserves the right to make changes at any time
without notice and without incurring any obligation.

No part of this publication may be reproduced without written permission.
This manual should be considered a permanent part of the engine and

should remain with

the

engine if it

is resold.

Pay special attention to statements preceded by the following words:

Ewm

life if instructions are not followed.

CAUTION: Indicates a possibility of personal injury or equipment damage
if instructions are not followed.

Indicates a strong possibility of severe personal injury or loss of

NOTE: Gives helpful information.
If a problem should arise, or if you have any questions about your engine,

consult an authorized Honda dealer.

m

vice if operated according to instructions. Read and understand the

Owner’s Manual before operating the engine. Failure to do so could result

in personal injury or equipment damage.

Honda engines are designed to give safe and dependable ser-

1

,

CONTENTS

1. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. COMPONENT IDENTIFICATION . . . . . . . . ..a...................................

3. BATTERY CONNECTIONS (for electric starter)

4. PRE-OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...’ . . . . . . . . . 7

5. STARTING THE ENGINE

6. OPERATION

7. STOPPING THE ENGINE

8. MAINTENANCE

9. TRANSPORTING/STORAGE

10. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. SPECIFICATIONS

l

High altitude operation

12. WARRANTY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

3’
4
6

11
13
14

15
23
24
26
27
28

2

1. SAFETY INSTRUCTIONS

m

To ensure safe operation -

To prevent fire hazards and to provide adequate ventilation, keep the
engine at least 3 ft away from buildings and other equipment during
operation.

Do not place flammable objects such as gasoline, matches, .etc., close

to the engine while it is running.

Refuel in a well-ventilated area with the engine stopped. Gasoline is

flammable and explosive under certain conditions.

Do not overfill the tank. There should be no fuel in the filler neck. Make
sure that the filler cap is closed securely.
If any fuel is spilled, clean it up completely before starting the engine.
Do not smoke or allow flames or sparks where the engine is refueled or
where gasoline is stored.
Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of
exhaust gases. Never run the engine in a closed garage or confined area.
Operate the engine on a level surface. If the engine is tilted, fuel spillage
may result.
Do not place anything on the engine, as it may create a fire hazard.
A spark arrester is available as an optional part for this engine. It is illegal
in some areas to operate an engine without a spark arrester. Check local
laws and regulations before operating.

3

2. COMPONENT IDENtlFlCATlON

GXVI 20

RECOIL STARTER

SPAKE PLUG

FUEL FILLER CAP

4

.MUFFLER

GXV160

FUEL

SPARK.PLUG

FUEL FILLER CAP

\

RECOL STARTER

STARTER GRIP

OIL FILLER CAP

I

OIL DRAIN PLUG

5

I

/

3. BATTERY CONNECTIONS (for electric starter)

Use a 12 volt battery with an ampere-hour rating of at least 8 AH.
Connect the battery positive (3-j cable to the starter solenoid terminal as

shown.
Connect the battery negative (-1 cable to an engine mounting bolt, frame

bolt, or other good engine ground connection.

Check the battery cable connections to be sure the cables are secured and
free of corrosion. Remove any corrosion and coat the terminals and cable
ends with grease.

l

The battery gives off explosive gases; keep sparks, flames and cigaret­tes away. Provide adequate ventilation when charging or using batteries
in an enclosed space.

l

The battery contains sulfuric acid (electrolyte). Contact with skin or
eyes may cause severe burns. Wear protective clothing and a face
shield.

- If electrolyte gets 6n your skin, flush with water.

- If electrolyte gets in your eyes, flush with water for at least 16
minutes and call a physician immediately.

l

Electrolyte is poisonous.

- If swallowed, drink large quantities of water or milk and follow with
milk of magnesia or vegetable oil and call a physician.

. KEEP OUT OF REACH OF CHILDREN.

CAUTION:

l

Use only distilled water in the battery. Tap water will shorten the service

life of .the battery.

l

Filling the battery above the UPPER LEVEL line may cause the electrolyte
to overflow, resulting in corrosion to engine or nearby parts. Immediate­ly wash off any spilled electrolyte.

l

Do not connect the battery in reverse polarity as this will short circuit
the battery charging system.

POSITIVE (+ 1
BATTERY CABLE

6

4. PRE-OPERATION CHECK

1. ENGINE OIL

CAUTION:

l

Engine oil is a major factor affecting engine performance and service life.
Non-detergent oils and vegetable oils are not recommended.

l

Be sure to check the engine on a level surface with the engine stopped.

Use Honda 4-stroke oil or an
equivalent high-detergent, premium

quality motor oil certified to meet or
exceed U.S. automobile manufac­turer’s requirements for Service

Classification SE or SF. Motor oils

classified SE
designation on the container.

SAE low-40 is recommended for
general, all-temperature use.

Other viscosities shown in the chart

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

indicated range.

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

2. Insert the dipstick into the oil filler neck but do not screw it in.

3. If the level is low, add the, recommended oil to the upper mark on the
dipstick.

or

SF will

show this

_

Ambient temperature

CAUTION: Running the engine with insufficient oil can cause serious

engine damage.

UPPER OIL LEVEL

LOWER OIL LEVEL

7

2. AIR CLEANER

Check the air cleaner elements to be sure they are clean and in good
condition.
Clean or replace the elements if necessary (page 17).

CAUTION: Never run the engine without the air, cleaner. Rapid engine

wear will result.

PAPER ELEMENT

FOAM ELEMENT

8