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Honda GCV135 Service Manual

Honda GCV135
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Engine Model:
Honda GCV135
and
Honda GCV160
Page
1 of 32 Honda Engines Selfhelp Guide 2011, Issue 1.0
SELF-HELP PROBLEM SOLVING and
MAINTENANCE
for
PETROL LAWNMOWERS
These engines are fitted to the following recent products:
422HP 462 PD 512 PD
SP535 SP555 Cooper 532PD
SP535 HW
1. Safety Precautions ………………………………….
2
2. Fuel, Oil, Air Filter and Spark Plug Requirements.
6
3. Routine Engine Maintenance ……………………...
7
4. Starting the Engine …………………………………
10
5. Engine Starts and Smokes Heavily ……………….
13
6. Engine Cutting Out or Running Unevenly ………..
15
7. Pull Cord Not Pulling or Snatching Back …………
17
8. Cutting and Collecting Grass, Vibration …….……
19
9. Loss of Drive on Self-Propelled Mowers …………
10. Transportation and Handling ………………………
23
26
11. Maintenance and Storage ………………………….
27
12. Guarantee, Spare Parts, Repairs .………………
28
If, after reading this guide, you feel you are either unsure of what is
required, or that you do not have the correct tools to undertake a job
yourself, please contact:
Our Helpline service, telephone 0845 600 2912 (Monday to
Saturday 9am – 5pm, and Sunday 10am – 4pm), or
Our local ServiceLink centre who can undertake any remedial
work requested (work that is not covered by the guarantee will be
chargeable)
Your local ServiceLink centre can be found at
www.servicelink.org.uk

Other manuals for Honda GCV135

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Honda GCV135 Specifications

General IconGeneral
Compression Ratio8.0:1
PTO Shaft RotationCounterclockwise (from PTO shaft side)
Cooling SystemForced air
Ignition SystemTransistorized magneto
Starting SystemRecoil starter
Fuel SystemCarburetor
Lubrication SystemSplash
Displacement135 cm3
Net Power Output3.6 HP (2.7 kW) at 3, 600 rpm
Oil Capacity0.55 liters
Air CleanerDual element
Engine Type4-stroke, overhead cam, single-cylinder

Summary

Safety Precautions

General Safety Precautions and Warnings

Covers safety symbols, reading instructions, proper use, and general safety advice.

Preparation and Operation Safety

Details on safe preparation before mowing and operational safety guidelines.

Continued Safety Advice and Handling

Further safety points for operation, maintenance, and transportation.

Handling and Transportation Safety

Specific guidelines for safely handling, raising, and transporting the lawnmower.

Fuel, Oil, Air Filter and Spark Plug Requirements

Fuel, Oil, Air Filter, and Spark Plug Specifications

Details on correct fuel, oil types, air filter, and spark plug for the engine.

Routine Engine Maintenance

Spark Testing and Fuel Draining

Procedures for testing for a spark and draining fuel from the engine.

Engine Oil Change Procedure

Instructions on how to check and change the engine oil.

Engine Manufacturer's Maintenance Schedule

Recommended maintenance intervals for engine oil, air cleaner, spark plug, etc.

Starting the Engine

Starting Procedure and Troubleshooting

Steps for starting the engine and a guide for common starting problems.

Spark Plug and Air Filter Checks

Detailed checks for the spark plug and air filter as part of starting.

Fuel System Checks and Draining

Ensuring fresh fuel and procedures for draining the fuel tank.

Engine Starts and Smokes Heavily

Diagnosing and Rectifying Smoke Issues

Troubleshooting white, blue, or grey smoke from the exhaust due to oil or tipping.

Clearing Cylinder Residue

Procedure to clear residual oil from the cylinder after overfilling or tipping.

Engine Cutting Out or Running Unevenly

Troubleshooting Engine Stalling and Uneven Running

Addresses problems like low revs, uneven running, or engine hunting.

Fuel Draining for Storage and Blockages

Advice on draining fuel for storage and handling fuel supply blockages.

Pull Cord Not Pulling or Snatching Back

Pull Cord Operation and Troubleshooting

Explains OPC engagement and issues with pull cord not pulling or snatching back.

Blade and Mounting Checks for Pull Cord Issues

Checks related to blade security and mounting that can affect the pull cord.

Cutting and Collecting Grass, Vibration

Mower Performance Issues: Cutting and Vibration

Addresses problems like poor cutting, excessive vibration, and collection issues.

Optimizing Cutting Technique and Blade Care

Tips on cutting grass effectively, mulching, and blade sharpness.

Diagnosing Vibration: Blade and Engine Mounting

Checks for blade, blade mounting, and engine mounting to resolve excessive vibration.

Clearing Grass Buildup and Airflow

Procedures for clearing grass clippings from underneath the mower for better airflow.

Loss of Drive on Self-Propelled Mowers

Clutch Cable Adjustment for Drive Issues

Guidance on adjusting the clutch cable tension to restore drive.

Belt Replacement for Drive Loss

Instructions for replacing the drive belt to fix loss of self-propelled drive.

Belt Replacement Procedure Details

Further steps and notes on replacing the drive belt, including common issues.

Transportation and Handling

Safe Mower Handling and Access

Procedures for accessing mower underside and safe handling during transport.

Maintenance and Storage

Routine Maintenance and Storage Guidelines

Key maintenance points and advice for storing the lawnmower, especially long-term.

Long-Term Storage Preparation

Specific instructions for preparing the mower for storage longer than 30 days.

Guarantee, Spare Parts, Repairs

Warranty Information and Conditions

Details on the guarantee period, coverage, and conditions for domestic use.

Spare Parts Information

Information on obtaining spare parts and using the ServiceLink network for parts.

Repair Services and Network

Details on repair services available through the ServiceLink network.

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