Honda GP160 User Manual

1
INTRODUCTION
Thank you for purchasing a Honda engine. We want to help you to
get the best results from your new engine and to operate it safely.
This manual contains information on how to do that; please read it
carefully before operating the engine. If a problem should arise, or
if you have any questions about your engine, consult your servicing
dealer.
All information in this publication is based on the latest product
information available at the time of printing. Honda Motor Co., Ltd.
reserves the right to make changes at any time without notice and
without incurring any obligation. No part of this publication may be
reproduced without written permission.
This manual should be considered a permanent part of the engine
and should remain with the engine if resold.
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.
We suggest you read the warranty policy to fully understand its
coverage and your responsibilities of ownership.
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.
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.
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.
The purpose of these messages is to help prevent damage to your
engine, other property, or the environment.
©2017 Honda Motor Co., Ltd. –All Rights Reserved
GP160H·GP200H
42ZDKX01
00X42-ZDK-X011
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.
This word means:
Your engine or other property can be damaged if you
don’t follow instructions.
OWNER’S MANUAL
GP160 • GP200
The illustrations herein are mainly based on: PTO shaft type S
• The illustration may vary according to the type.
CONTENTS
INTRODUCTION........................ 1
SAFETY MESSAGES................. 1
SAFETY INFORMATION ..........2
SAFETY LABEL LOCATION .........2
COMPONENT & CONTROL
LOCATIONS............................... 3
FEATURES .................................3
BEFORE OPERATION
CHECKS ....................................4
OPERATION...............................4
SAFE OPERATING
PRECAUTIONS .....................4
STARTING THE ENGINE ...... 4
STOPPING THE ENGINE ......5
SETTING ENGINE SPEED .....5
SERVICING YOUR ENGINE ..... 6
THE IMPORTANCE OF
MAINTENANCE .................... 6
MAINTENANCE SAFETY ......6
SAFETY PRECAUTIONS........ 6
MAINTENANCE
SCHEDULE............................. 6
REFUELING............................ 7
Recommended Fuel...........7
ENGINE OIL............................ 7
Recommended Oil ............7
Oil Level Check ...................7
Oil Change..........................8
AIR CLEANER.........................8
Inspection ...........................8
Cleaning ............................. 8
SPARK PLUG........................ 10
HELPFUL TIPS &
SUGGESTIONS ....................... 10
STORING YOUR ENGINE .... 10
TRANSPORTING.................. 11
TAKING CARE OF
UNEXPECTED PROBLEMS.....12
ENGINE WILL NOT
START...................................12
ENGINE LACKS
POWER .................................12
TECHNICAL INFORMATION .....12
SERIAL NUMBER LOCATION ....12
REMOTE CONTROL LINKAGE .... 13
CARBURETOR
MODIFICATIONS FOR
HIGH ALTITUDE OPERATION .... 13
SPECIFICATIONS .................14
TUNE-UP SPECIFICATIONS ....14
WIRING DIAGRAMS............ 14
42ZDKX011.fm Page 1 Friday, March 17, 2017 5:01 PM

Honda GP160 Specifications

General

Engine Type	Air-cooled 4-stroke OHV
Compression Ratio	8.5:1
PTO Shaft Rotation	Counterclockwise (from PTO shaft side)
Ignition System	Transistorized magneto ignition
Starting System	Recoil starter
Air Cleaner	Dual element
Fuel System	Carburetor
Lubrication System	Splash
Displacement	163 cm³
Bore x Stroke	68 mm x 44 mm
Net Power Output	4.8 HP (3.6 kW) at 3, 600 rpm
Net Torque	10.3 Nm (7.6 lb ft) @ 2, 500 rpm
Fuel Tank Capacity	3.1 L (0.82 US gal)
Fuel Consumption	1.4 L/h at 3, 600 rpm
Oil Capacity	0.6 liters
Dry Weight	15.1 kg

Summary

Introduction to Honda Engine Operation

Understanding Safety Messages

Explains safety alert symbols (DANGER, WARNING, CAUTION) and damage prevention messages (NOTICE).

General Safety Precautions

General safety precautions for operating the engine, including ventilation and hot parts.

Safety Label Location and Importance

Describes the warning label and its importance for potential hazards.

Engine Component and Control Identification

Identifies key parts and controls of the engine, including fuel tank, oil filler, etc.

Key Engine Features

Highlights specific features like the Oil Alert system designed to prevent engine damage.

Pre-Operation Checks Checklist

Lists essential checks before starting the engine, including general condition and fluid levels.

Safe Engine Operation Procedures

Covers safe operating precautions and how to start/stop the engine.

Setting Engine Speed

Explains how to position the throttle lever for the desired engine speed.

Engine Servicing and Maintenance

Importance of Regular Maintenance

Emphasizes the necessity of good maintenance for safety, economy, and trouble-free operation.

Maintenance Safety Precautions

Lists critical safety precautions to follow when performing maintenance.

General Safety Measures During Servicing

Provides specific safety measures to prevent hazards during maintenance.

Safe Refueling Procedures and Fuel Types

Covers recommended fuel types and safe refueling procedures.

Engine Oil: Recommendations and Changes

Details recommended oil, oil level check, and oil change procedures.

Air Cleaner Inspection and Cleaning

Explains the importance of the air cleaner and how to inspect and clean it.

Helpful Tips and Storage Guidance

Proper Engine Storage Preparation

Provides steps for proper engine storage preparation to prevent rust and corrosion.

Fuel Deterioration During Storage

Discusses fuel deterioration and its effects during storage.

Fuel System and Storage Procedures

Storage Area Safety Recommendations

Advises on safe storage locations and conditions to prevent fire and corrosion.

Steps for Removing Engine from Storage

Outlines checks and procedures for taking the engine out of storage.

Safe Engine Transport Guidelines

Gives guidance on safely transporting the engine, emphasizing keeping it level.

Troubleshooting Unexpected Engine Problems

Engine Will Not Start: Causes and Solutions

Lists possible causes and corrections for an engine that fails to start.

Engine Lacks Power: Causes and Solutions

Lists possible causes and corrections for an engine that lacks power.

Technical Information and Serial Number Record

Provides space to record serial number, engine type, and purchase date for inquiries.

Engine Adjustments and Specifications

Remote Control Linkage Setup

Describes how to connect remote throttle and choke controls.

High Altitude Carburetor Modifications

Explains carburetor adjustments for high altitude to maintain performance and meet emission standards.

Engine Specifications and Diagrams

Engine Tune-Up Specifications

Lists specific tune-up parameters like spark plug gap and valve clearance for GP160/200.

Engine Wiring Diagrams

Provides wiring diagrams for engines with and without the Oil Alert system.