Honda FJ500 Owner's Manual
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Honda FJ500 Owner's Manual

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36V426020.book Page -1 Tuesday, June 25, 2013 10:43 AM
Honda FJ500
OWNER'S MANUAL
Original instructions
MANUEL DE L'UTILISATEUR
Notice originale
BEDIENUNGSANLEITUNG
Originalbetriebsanleitung
MANUAL DE EXPLICACIONES
Manual original
MANUALE DELL'UTENTE
Istruzioni originali
The ''e-SPEC'' mark symbolizes environmentally
responsible technologies applied to Honda power
equipment, which contains our wish to ''preserve
nature for generations to come.''

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  • Page 1 Original instructions MANUEL DE L’UTILISATEUR Notice originale BEDIENUNGSANLEITUNG Originalbetriebsanleitung MANUAL DE EXPLICACIONES Manual original MANUALE DELL’UTENTE Istruzioni originali The ‘‘e-SPEC’’ mark symbolizes environmentally responsible technologies applied to Honda power equipment, which contains our wish to ‘‘preserve nature for generations to come.’’...
  • Page 2 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.
  • Page 3 36V426020.book Page 1 Tuesday, June 25, 2013 10:43 AM Disposal To protect the environment, do not dispose of this product, battery, engine oil, etc. carelessly by leaving them in the waste. Observe the local laws and regulations or consult your authorized Honda dealer for disposal.

  • Page 4: Table Of Contents

    Carburetor Modification for High Altitude Operation....26 6.TILLER OPERATION ..............27 7.STOPPING THE ENGINE ............37 8.MAINTENANCE..............40 9.TRANSPORTING/STORAGE ............. 61 10.TROUBLESHOOTING............. 64 11.SPECIFICATIONS..............65 MAJOR Honda DISTRIBUTOR ADDRESSES ....Inside back cover ‘‘EC Declaration of Conformity’’ CONTENT OUTLINE..Inside back cover...

  • Page 5: Safety Instructions

    To ensure safe operation– For your safety and the safety of others, pay special attention to these precautions: • Honda tiller is designed to give safe and dependable service if operated according to instructions. Read and understand the Owner’s Manual before operating the tiller.
  • Page 6 36V426020.book Page 4 Tuesday, June 25, 2013 10:43 AM • Gasoline is extremely flammable and is explosive under certain conditions. • Do not smoke or allow flames or sparks in the area where the tiller is refueled or where gasoline is stored. •...
  • Page 7 36V426020.book Page 5 Tuesday, June 25, 2013 10:43 AM To ensure safe operation– Operator responsibility • Read the owner’s manual carefully. Be familiar with the controls and their proper use of the tiller. • Use the tiller for the purpose it is intended that is, cultivating the soil. Any other use could be dangerous or damage the equipment, especially never use it to cultivate soil containing rocks, stones, wires and any other hard materials.
  • Page 8 36V426020.book Page 6 Tuesday, June 25, 2013 10:43 AM To ensure safe operation– Operator responsibility • Stop the engine in the following cases: – Whenever you leave the tiller unattended. – Before refueling • When stopping the engine, move the throttle lever to the LOW position, then turn the engine switch OFF.
  • Page 9 36V426020.book Page 7 Tuesday, June 25, 2013 10:43 AM To ensure safe operation– Fire and burn hazard Gasoline is extremely flammable, and gasoline vapor can explode. Use extreme care when handling gasoline. Keep gasoline out of reach of children. • Add fuel before starting the engine. Never remove the cap of the fuel tank or add gasoline while the engine is running or when the engine is hot.
  • Page 10 36V426020.book Page 8 Tuesday, June 25, 2013 10:43 AM To ensure safe operation– Carbon monoxide poisoning hazard Exhaust contains poisonous carbon monoxide, a colorless and odorless gas. Breathing exhaust can cause loss of consciousness and may lead to death. • If you run the engine in an area that is confined or even partially enclosed, the air you breathe could contain a dangerous amount of exhaust gas.

  • Page 11: Safety Label Locations

    These labels warn you of potential hazards that can cause serious injury. Read the labels and safety notes and precautions described in this manual carefully. If a label comes off or becomes hard to read, contact your Honda dealer for a replacement. READ OWNER’S MANUAL...

  • Page 12: Ce Mark Location

    36V426020.book Page 10 Tuesday, June 25, 2013 10:43 AM CE Mark Location CE MARK Name and address of manufacturer Name and address of authorized representative Description code Year of manufacture Engine net power Machine mass (standard specification) Name and address of manufacturer and authorized representative are written in the “EC Declaration of Conformity”...

  • Page 13: Serial Number Locations

    36V426020.book Page 11 Tuesday, June 25, 2013 10:43 AM Serial Number Locations ENGINE SERIAL NUMBER FRAME SERIAL NUMBER Record the frame serial number and engine serial number in the space below. You will need these numbers when ordering parts. Frame serial number: Engine serial number:...

  • Page 14: Component Identification

    36V426020.book Page 12 Tuesday, June 25, 2013 10:43 AM 3. COMPONENT IDENTIFICATION SE and SER types: HANDLEBAR HEIGHT ADJUSTER THROTTLE LEVER SHIFT LEVER ENGINE SWITCH MUFFLER CLUTCH LEVER FUEL TANK CAP HANDLEBAR FIXING LEVER SHIFT LEVER BELT COVER FRONT GUARD ENGINE OIL DRAIN BOLT ROTARY (SER and DER types)
  • Page 15 36V426020.book Page 13 Tuesday, June 25, 2013 10:43 AM HANDLE GRIP AIR CLEANER SPARK PLUG CHOKE LEVER STARTER GRIP HITCH PIN FUEL VALVE SEDIMENT CUP HITCH ATTACHMENT TRANSMISSION OIL FILLER CAP HITCH BOX DRAG BAR B DRAG BAR A...

  • Page 16: Pre-Operation Check

    • Check that the engine stops securely by operating the engine switch. (See pages 37 through 39 for stopping procedure.) • If you notice any other abnormal symptoms, consult with your authorized Honda dealer promptly. 5.Bolts and nuts Check for looseness in fastened parts. Securely tighten all loose parts.
  • Page 17 36V426020.book Page 15 Tuesday, June 25, 2013 10:43 AM 6.Engine oil CAUTION: Running the engine with insufficient oil can cause serious engine damage. 1.DE and DER types: Set the front wheel to the UP position (see page 34). 2.Park on level ground, stop the engine, put proper mounting under the front frame and put wood block under the drag bar as shown, to keep the tiller horizontal.
  • Page 18 36V426020.book Page 16 Tuesday, June 25, 2013 10:43 AM Recommended oil Use 4-stroke motor oil that meets or exceeds the requirements for API service category SE or later (or equivalent). Always check the API service label on the oil container to be sure it includes the letters SE or later (or equivalent).
  • Page 19 36V426020.book Page 17 Tuesday, June 25, 2013 10:43 AM 7.Transmission gear oil Place the tiller on a level surface and remove the oil filler cap. The oil should be level with the lower edge of the oil filler hole. Add recommended oil if the level is low. Recommended oil Use 10W-30 4-stroke motor oil that meets or exceeds the requirements for API service classification SE or later (or equivalent).
  • Page 20 36V426020.book Page 18 Tuesday, June 25, 2013 10:43 AM 8.Air cleaner CAUTION: Never run the engine without the air cleaner. Rapid engine wear will result. Remove the air cleaner cover. Check the air cleaner elements for dirt or obstruction. Clean if necessary (see page 43).
  • Page 21 36V426020.book Page 19 Tuesday, June 25, 2013 10:43 AM 9.Fuel Check the fuel level, and refill the tank if the fuel level is low. Use unleaded gasoline with a Research Octane Number of 91 or higher (a Pump Octane Number of 86 or higher). Never use stale or contaminated gasoline or an oil/gasoline mixture.
  • Page 22 Gasolines containing alcohol If you decide to use a gasoline containing alcohol (gasohol), be sure its octane rating is at least as high as that recommended by Honda. There are two types of ‘‘gasohol’’: one containing ethanol, and the other containing methanol.
  • Page 23 36V426020.book Page 21 Tuesday, June 25, 2013 10:43 AM 10.Clutch lever Before the operation check, make sure that there are no foreign objects (such as sand, soil, twigs, etc.) caught around the clutch lever, lock lever and/or lock lever arm. Check that the lock lever and the clutch lever operate smoothly by pushing the lock lever, and squeezing the clutch lever.
  • Page 24 11.Tools and Attachments To install a tool or attachment on the tiller, follow the instructions furnished with the tool or attachment. Ask your Honda dealer for advice if you encouter any problem or difficulty in installing a tool or attachment.

  • Page 25: Starting The Engine

    36V426020.book Page 23 Tuesday, June 25, 2013 10:43 AM 5. STARTING THE ENGINE CAUTION: Be sure the clutch is disengaged and the shift lever is in the neutral position to prevent sudden uncontrolled movement when the engine starts. The clutch is engaged by pulling in the clutch lever and disengaged by releasing the lever.
  • Page 26 36V426020.book Page 24 Tuesday, June 25, 2013 10:43 AM 3.Turn the engine switch to the ON position. ENGINE SWITCH 4.Align the mark ‘‘ △ ’’ on the throttle lever with the mark ‘‘ ● ’’ (START position) as shown. START THROTTLE LEVER...
  • Page 27 36V426020.book Page 25 Tuesday, June 25, 2013 10:43 AM 5.Pull the starter grip lightly until resistance is felt, then return the starter grip once. STARTER GRIP Hold the handlebar with your left hand and pull the starter grip briskly in the direction of the arrow as shown.

  • Page 28: Carburetor Modification For High Altitude Operation

    36V426020.book Page 26 Tuesday, June 25, 2013 10:43 AM 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.

  • Page 29: Tiller Operation

    36V426020.book Page 27 Tuesday, June 25, 2013 10:43 AM 6. TILLER OPERATION 1.Handlebar height adjustment CAUTION: Before adjusting the handlebar, place the tiller on the firm level ground to prevent the handle from collapsing accidentally. SE and SER types: To adjust the handlebar height, loosen the handlebar height adjuster, select the appropriate hole and tighten it.
  • Page 30 36V426020.book Page 28 Tuesday, June 25, 2013 10:43 AM 2.Handlebar angle adjustment DE and DER types: If the handlebar angle adjustment is needed, loosen the handlebar fixing lever, move the handlebar to a required position and tighten the lever. The handlebar can swing within the sweep of 30° from the center to the right and left each.
  • Page 31 36V426020.book Page 29 Tuesday, June 25, 2013 10:43 AM 3.Tilling depth adjustment Install the hitch attachment in the hitch box with a hitch pin. The tilling depth adjustment can be made as follows: Remove the lock pin and pin, loosen the lock nuts and bolts securing the drag bars A and B, and slide the drag bars up or down as necessary.
  • Page 32 36V426020.book Page 30 Tuesday, June 25, 2013 10:43 AM 4.Clutch operation The clutch engages and disengages the power from the engine to the transmission. CAUTION: Reduce engine rpm before operating clutch operation. Engage: 1.Push and hold the lock lever. 2.Squeeze the clutch lever. 3.The clutch is engaged, release the lock lever.
  • Page 33 36V426020.book Page 31 Tuesday, June 25, 2013 10:43 AM 5.Gear selection CAUTION: Return the throttle lever to the Low position and disengage the clutch before moving the shift lever. Avoid using excessive force on the shift lever. Select a gear position in accordance withe the contents of the Gear Selection Table.
  • Page 34 36V426020.book Page 32 Tuesday, June 25, 2013 10:43 AM DE and DER types: GEAR SHIFTING PLATE FORWARD 1 REVERSE FORWARD 2 NEUTRAL NEUTRAL SHIFT LEVER Gear Selection Table (When engine speed is 3,600 rpm) Gear position Speed of rotary part Suitable work SE, SER DE, DER...
  • Page 35 36V426020.book Page 33 Tuesday, June 25, 2013 10:43 AM 6.Use of the hitch box Install the hitch attachment in the hitch box with a hitch pin. (Hitch pin clip snaps into relief in hitch pin to retain pin.) HITCH BOX HITCH PIN HITCH PIN CLIP...
  • Page 36 36V426020.book Page 34 Tuesday, June 25, 2013 10:43 AM 7.Front wheel (DE and DER types) After getting to the tiller site, move the front wheel to the raised position before tilling. 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.
  • Page 37 36V426020.book Page 35 Tuesday, June 25, 2013 10:43 AM 8.Handling tips • If the tiller tends to move forward rapidly, push down on the handlebars to allow the drag bar to penetrate the soil and slow the forward motion on the tiller. Continue to press down until the tiller tines have dug to a desired depth that allows easy tiller handling.
  • Page 38 36V426020.book Page 36 Tuesday, June 25, 2013 10:43 AM 9.Normal operating angle Lower the handle slightly so the front of the machine is raised about 5~7°. HORIZONTAL LINE 5~7° ATTACHMENT LINE OF ENGINE To get the maximum advantage from the tiller, try to hold the machine at the angle shown while you are tilling the ground: CAUTION: •...

  • Page 39: Stopping The Engine

    36V426020.book Page 37 Tuesday, June 25, 2013 10:43 AM 7. STOPPING THE ENGINE In an emergency: • Turn the engine switch to the OFF position. ENGINE SWITCH In normal use: 1.Release the clutch lever to the DISENGAGED position. DISENGAGED CLUTCH LEVER DISENGAGED 2.Move the throttle lever fully to the right.
  • Page 40 36V426020.book Page 38 Tuesday, June 25, 2013 10:43 AM 3.Set the shift lever in the NEUTRAL position. SE and SER types: NEUTRAL SHIFT LEVER DE and DER types: NEUTRAL NEUTRAL SHIFT LEVER 4.Turn the engine switch to the OFF position. ENGINE SWITCH...
  • Page 41 36V426020.book Page 39 Tuesday, June 25, 2013 10:43 AM 5.Turn the fuel valve to the OFF position. FUEL VALVE...

  • Page 42: Maintenance

    If the engine must be run, make sure the area is well ventilated. CAUTION: Use only genuine Honda parts or their equivalent for maintenance or repair. Replacement parts which are not of equivalent quality may damage the tiller.
  • Page 43 36V426020.book Page 41 Tuesday, June 25, 2013 10:43 AM REGULAR SERVICE PERIOD (1) First Every Every Every Perform at every indicated month or month year After Each operating hour interval, whichever months months storage comes first. 20 hrs 300 hrs 50 hrs 100 hrs ITEM...
  • Page 44 36V426020.book Page 42 Tuesday, June 25, 2013 10:43 AM 1.Changing oil Change the oil when the engine is warm to assure rapid and complete draining. 1.Place a suitable container below the engine to catch the used oil, and then remove the oil filler cap, drain bolt, and sealing washer. 2.Tilt the tiller slightly forward and allow all of the oil to drain.
  • Page 45 36V426020.book Page 43 Tuesday, June 25, 2013 10:43 AM 2.Air cleaner service A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the engine in extremely dusty areas. Never use gasoline or low flash point solvents for cleaning the air cleaner element.
  • Page 46 36V426020.book Page 44 Tuesday, June 25, 2013 10:43 AM 2.Clean both filter elements if they are to be used. Foam element: Clean in warm soapy water, rinse and allow to dry thoroughly. Or clean in high flash-point solvent and allow to dry. Dip the element in clean engine oil and squeeze out all the excess.
  • Page 47 36V426020.book Page 45 Tuesday, June 25, 2013 10:43 AM 3.Sediment cup cleaning Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in the area. 1.Turn the engine switch to the OFF position. 2.Turn the fuel valve to the OFF position so that it touches the stopper button.
  • Page 48 36V426020.book Page 46 Tuesday, June 25, 2013 10:43 AM 4.Spark plug service Recommended spark plug: BPR5ES (NGK) W16EPR-U (DENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. 1.Remove the spark plug cap. Use the spark plug wrench to remove the spark plug.
  • Page 49 36V426020.book Page 47 Tuesday, June 25, 2013 10:43 AM 4.Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross-threading. SPARK PLUG WRENCH 5.After the spark plug is seated, tighten with a spark plug wrench to compress the washer.
  • Page 50 36V426020.book Page 48 Tuesday, June 25, 2013 10:43 AM 5.Throttle cable adjustment Measure the freeplay at the lever tip. Freeplay: 5–10 mm (0.2–0.4 in) THROTTLE LEVER FREEPLAY: 5–10 mm (0.2–0.4 in) If the freeplay is incorrect, loosen the lock nut and turn the adjusting bolt in or out as required.
  • Page 51 36V426020.book Page 49 Tuesday, June 25, 2013 10:43 AM 6.Clutch cable adjustment With the clutch disengaged, measure the freeplay between the handle bracket stopper and lock lever arm stopper. Freeplay: 2.0–4.0 mm (0.08–0.16 in) If the freeplay is incorrect, loosen the lock nut and turn the adjusting bolt in or out as required.
  • Page 52 36V426020.book Page 50 Tuesday, June 25, 2013 10:43 AM 7.Clutch lever cleaning If the lock lever and clutch lever do not operate smoothly, or the clutch engages by squeezing the clutch lever without pushing the lock lever, disassemble and clean the clutch lever. NOTE: Be aware of the spring and collar coming off when you disassemble the clutch lever.
  • Page 53 6.Check the lock lever and clutch lever for smooth operation. If the lock lever and clutch lever do not operate smoothly, or the clutch engages by squeezing the clutch lever without pushing the lock lever, take the tiller to an authorized Honda dealer.
  • Page 54 36V426020.book Page 52 Tuesday, June 25, 2013 10:43 AM 8.Rotary tines inspection and replacement (SER and DER types) • Wear heavy gloves to protect your hands. • Carry out the check or replacement work with the tiller on the level spot and the engine stopped.
  • Page 55 2.Check the rotary setting bolt for looseness, tighten if necessary. 3.Check the rotary pins and retaining pins for damage or missing, replace with new one if necessary (see pages 56 and 57) NOTE: Use genuine Honda parts or equivalent when replacing the rotary tines. ROTARY PIN ROTARY SETTING BOLT...
  • Page 56 36V426020.book Page 54 Tuesday, June 25, 2013 10:43 AM Rotary and side disk removal: • DER type: Set the front wheel to the UP position (see page 34). 1.Pull up the handlebar while holding it to contact the front wheel (DER type) or front end of the tiller to the ground.
  • Page 57 36V426020.book Page 55 Tuesday, June 25, 2013 10:43 AM 3.Remove the retaining pins and rotary pins, then remove the side disk and outer rotaries. 4.Remove the retaining pin and rotary pin, then remove the inner rotary. 5.The opposite side rotary/side disk is similar. RETAINING PIN (4) SIDE DISK INNER ROTARY...
  • Page 58 36V426020.book Page 56 Tuesday, June 25, 2013 10:43 AM Rotary and side disk installation: 1.Install the inner rotary to the axle. • The “G” and “H” mark on the left side inner rotary is visible. • The “G” and “H” mark on the right side inner rotary will be invisible. LEFT INNER ROTARY RIGHT INNER ROTARY (Viewed from outer rotary side)
  • Page 59 36V426020.book Page 57 Tuesday, June 25, 2013 10:43 AM 3.Install the outer rotaries with the “R” (right rotary) mark or “L” (left rotary) mark facing toward the inner rotary as shown. 4.Insert the rotary pins B and set the retaining pins. 5.Install the side disk, then insert the rotary pin B and set the retaining pin.
  • Page 60 36V426020.book Page 58 Tuesday, June 25, 2013 10:43 AM Tine installation: Install the tines properly. Incorrect arrangement of the tines or installing the tines in the wrong direction will cause vibration and hinder proper tilling. Two types of tines (G and H) are provided. Tine G has engraved “G” mark on its face and tine H has “H”...
  • Page 61 36V426020.book Page 59 Tuesday, June 25, 2013 10:43 AM • Outer rotary tines GEAR CASE SIDE DISK “L” MARK “R” MARK RIGHT OUTER ROTARY TINES TINE H TINE G “G” and ”H” mark toward the gear case LEFT OUTER ROTARY TINES TINE G TINE H “G”...
  • Page 62 36V426020.book Page 60 Tuesday, June 25, 2013 10:43 AM • Inner rotary tines GEAR CASE SIDE DISK “L” MARK “R” MARK RIGHT INNER ROTARY TINES TINE H TINE G “G” and ”H” mark toward the gear case LEFT INNER ROTARY TINES TINE H TINE G “G”...

  • Page 63: Transporting/Storage

    36V426020.book Page 61 Tuesday, June 25, 2013 10:43 AM 9. TRANSPORTING/STORAGE When transporting the tiller, turn the fuel valve OFF and keep the tiller level to prevent fuel spillage. Fuel vapor or spilled fuel may ignite. Before storing the unit for an extended period: 1.Be sure the storage area is free of excessive humidity and dust.
  • Page 64 36V426020.book Page 62 Tuesday, June 25, 2013 10:43 AM d. Allow the gasoline to drain completely, and turn the fuel valve to the OFF position. e. Turn the fuel valve to the DRAIN position while keeping the stopper button pressed. Drain the gasoline into a suitable con- tainer.
  • Page 65 36V426020.book Page 63 Tuesday, June 25, 2013 10:43 AM 3.Pull the starter grip until resistance is felt. Continue pulling until the notch on the starter pulley aligns with the hole on the recoil starter. At this point, the intake and exhaust valves are closed, and this will help to the engine from internal corrosion.

  • Page 66: Troubleshooting

    5.Is the spark plug in good condition? Remove and inspect the spark plug. Clean, readjust gap and dry the spark plug. Replace it if necessary. 6.If the engine still does not start, take the tiller to an authorized Honda dealer.

  • Page 67: Specifications

    36V426020.book Page 65 Tuesday, June 25, 2013 10:43 AM 11. SPECIFICATIONS Model FJ500-SE FJ500-SER FJ500-DE FJ500-DER Description code FAAC Dimensions and weight Model FJ500-SE FJ500-SER FJ500-DE FJ500-DER Length 1,395 mm (54.9 in) 1,435 mm (56.5 in) Width 610 mm (24.0 in) 925 mm (36.4 in)
  • Page 68 36V426020.book Page 66 Tuesday, June 25, 2013 10:43 AM Noise and vibration Type SE, SER DE, DER Sound pressure level at operator’s ears 81 dB (A) 81 dB (A) (EN ISO 11200: 1995) Uncertainty 2 dB (A) 2 dB (A) Measured sound power level 96 dB (A) 96 dB (A) (Reference to the motor hoe of 2000/14/EC, 2005/88/EC)
  • Page 69 36V426020.book Page 67 Tuesday, June 25, 2013 10:43 AM...
  • Page 70 36V426020.book Page 68 Tuesday, June 25, 2013 10:43 AM...

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