Honda FG400 Owner's Manual
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Honda FG400 Owner's Manual

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  • Page 2 The information and specifications included in this publication were in effect at the time of approval for printing. Honda Motor Co., Ltd. reserves the right, however, to discontinue or change specifications or design at any time...
  • Page 3 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.
  • Page 4 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.

  • Page 5: Table Of Contents

    ..................... OPERATION ........... SAFE OPERATING PRECAUTIONS ..............STARTING THE ENGINE OPERATING THE CONTROLS FOR TILLING ......................STOPPING THE ENGINE ............SERVICING YOUR HONDA TILLER ..........THE IMPORTANCE OF MAINTENANCE ..............MAINTENANCE SAFETY .............. MAINTENANCE SCHEDULE ..................REFUELING .............. FUEL RECOMMENDATIONS ...............
  • Page 6 CONTENTS SERVICING YOUR HONDA TILLER (continued) ............CLUTCH CABLE ADJUSTMENT ............ THROTTLE CABLE ADJUSTMENT ............... DRIVE BELT ADJUSTMENT ............SPARK ARRESTER SERVICE ....................STORAGE ..............STORAGE PREPARATION Cleaning ..................Fuel ....................Engine Oil ................................. STORAGE PRECAUTIONS ............. REMOVAL FROM STORAGE ..................

  • Page 7: Tiller Safety

    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 if you follow all instructions in this manual and on the tiller.
  • Page 8 TILLER SAFETY Fire and Burn Hazards The exhaust system gets hot enough to ignite some materials. Keep the tiller at least 3 feet (1 meter) away from buildings and other 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.
  • Page 9 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 compo For your safety and the safety of others, keep all shields in place when the engine is running.

  • Page 10: Safety Label Locations

    TILLER SAFETY SAFETY LABEL LOCATONS These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact your Honda servicing dealer for a replacement.

  • Page 11: Controls

    CONTROLS COMPONENT & CONTROL LOCATIONS THROTTLE LEVER AIR CLEANER COVER SERIAL ENGINE V-BELT COVER FRONT WHEEL ROTOR CLUTCHLEVER PARK PLUG CAP HANDLEBAR HEIGHT CHOKE ROD ADJUSTER FRAME SERIAL NUMBE ECOIL STARTER TRANSMISSION OIL...

  • Page 12: Controls

    CONTROLS CONTROLS Choke Rod The choke rod opens and closes the choke valve in the carburetor. The CLOSED position enriches the fuel mixture for starting a cold engine. The OPEN position provides the correct fuel mixture for operation after starting and for restarting a warm engine.

  • Page 13: Throttle Lever

    CONTROLS Throttle Lever The throttle lever controls engine speed. Moving the throttle lever in the di- rections shown makes the engine run faster or slower. Tine speed iscontrolled by adjusting FAST the throttle lever. At maximum throttle position, the tines rotate will at the highest speed.

  • Page 14: Drag Bar

    CONTROLS Gearshift Lever .EVER The transmission on the A2 type offers a choice of two forward 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.

  • Page 15: Before Operation

    ARE YOU READY TO GET STARTED? 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.

  • Page 16: Check The Engine

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

  • Page 17: Operation

    OPERATION SAFE OPERATING PRECAUTIONS Before operating the tiller for the first time, please review both the TlLLER SAFETY chapter and the chapter titled BEFORE OPERATION. For your safety, avoid starting or operating the tiller in an enclosed area such 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.

  • Page 18: Starting The Engine

    OPERATION STARTING THE ENGINE Refer to Safe Operating Precautions on Page 15. 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.
  • Page 19 OPERATION 2. Turn the engine switch to the position 3. Move the throttle lever away from the SLOW position, about 1/3 of the way toward the FAST position. THROTTLE LEVER Pull the starter grip lightly until STARTER GRIP you feel resistance, then pull briskly.
  • Page 20 OPERATION 5. If the choke rod was pulled to the CLOSED position to start CHOKE ROD /-t- the engine, gradually move it OPEN position as the to the engine warms up.

  • Page 21: Operating The Controls For Tilling

    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...
  • Page 22 OPERATION Forward Gear Selection (A2 type only) 1. Return the throttle lever to the slowest position. to disengage the clutch. 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 and move the tiller slightly to reposition the gears.
  • Page 23 OPERATION Reverse Gear Operation (A2 Type) 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.
  • Page 24 ~~~~~~ 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.

  • Page 25: Stopping The Engine

    OPERATION STOPPING THE ENGINE To stop the engine in an emergency, simply turn the engine switch to the OFF 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).

  • Page 26: Servicing Your Honda Tiller

    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...

  • Page 27: Maintenance Safety

    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.

  • Page 28: Maintenance Schedule

    (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.

  • Page 29: Refueling

    SERVICING YOUR HONDA TILLER REFUELING Fuel tank capacity: FG400 0.45 US gal (1.7i?, 0.37 Imp gal) FG500 0.53 US gal (2.0i?, 0.44 Imp gal) With the engine stopped, remove the fuel tank cap and check the fuel level. Refill the tank if the fuel level is low. Do not fill above the fuel level mark.
  • Page 30 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.

  • Page 31: Engine Oil Level Check

    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.

  • Page 32: Engine Oil Change

    SERVICING YOUR HONDA TILLER ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. Place a suitable container below the engine to catch the used oil, then remove the filler cap/dipstick, drain plug and sealing washer.

  • Page 33: Engine Oil Recommendations

    SAE VISCOSITY GRADES 100 ‘F ‘C AMBIENTTEMPERATURE 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.

  • Page 34: Transmission Oil Level Check

    SERVICING YOUR HONDA TILLER TRANSMISSION OIL LEVEL CHECK Check the transmission oil level with the tiller a level surface and the engine stopped. Remove the transmission oil filler cap. The oil should be level with the lower edge of the oil filler hole.

  • Page 35: Air Filter Inspection

    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. If the filter is dirty, remove the filter and clean it as described on page 34.

  • Page 36: Air Filter Cleaning

    SERVICING YOUR HONDATILLER AIR FILTER CLEANING A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If you operate the engine in very dusty areas, clean the air filter more frequently than specified in the Maintenance Schedule. 1.

  • Page 37: Spark Plug Service

    SERVICING YOUR HONDA TILLER SPARK PLUG SERVICE Recommended spark plug: BPR6ES (NGK) 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.
  • Page 38 SERVICING YOUR HONDA TILLER If reinstalling a used spark plug, tighten 1/8 1/4 turn after the spark plug seats. If installing a new spark plug, tighten turn after the spark plug seats. A loose spark plug can overheat and damage the engine.

  • Page 39: Clutch Cable Adjustment

    SERVICING YOUR HONDA TILLER CLUTCH CABLE ADJUSTMENT There should be 3/16 3/8 inches - 10 rnm) of free play at the lever end. If lever adjustment is incorrect, loosen the lock nut and turn the adjusting bolt in or out just enough to eliminate free play. Do not overtighten.

  • Page 40: Drive Belt Adjustment

    SERVICING YOUR HONDA TILLER DRIVE BELT ADJUSTMENT 1. Adjust the clutch cable (page 37). Belt tension is correct when the form distance belt of the to the top of the tension roller is 1-3/4 - 1-15/16 (45 - 49 when the clutch is engaged.

  • Page 41: Spark Arrester Service

    Your engine is not factory-equipped with a spark arrester. In some areas, it is illegal to operate an engine without a spark arrester. Check local laws and regulations. A spark arrester is available from Honda servicing dealers. The spark arrester must be serviced every 100 hours to keep it functioning as designed.
  • Page 42 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 of breaks and holes. Replace the spark arrester if it is damaged.

  • Page 43: Storage

    STORAGE PREPARATION Proper storage preparation is essential for keeping your tiller trouble free and looking good. The following steps will help to keep rust and corrosion from. impairing your tiller’s function and appearance, and will make the engine easier to start when you use tiller again. Cleaning 1.
  • Page 44 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. While the engine is running, operate the clutch lever to expel water from the pulleys, belts, and other moving items.

  • Page 45: Fuel

    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. If the gasoline in your tiller deteriorates during storage, you may need to have the carburetor and other fuel system components serviced or replaced.
  • Page 46 STORAGE Draining the Fuel Tank and Carburetor 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.

  • Page 47: Engine Oil

    STORAGE Engine Oil 1. Change the engine oil (page 30). Remove the spark plug (page 35). 3. Pour a tablespoon (5 10 cc) of clean engine oil into the cylinder. 4. Pull the starter rope several times to distribute the oil in the cylinder. 5.

  • Page 48: Storage Precautions

    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.

  • Page 49: Transporting

    BEFORE LOADING If the engine has been running, allow it to cool for at least 15 minutes before loading the tiller on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials. Always turn the ignition switch to the OFF position. LOADING AND UNLOADING If asuitable loading ramp is not available, two people should lift the tiller on and off the transport vehicle while holding the tiller level.

  • Page 50: Engine Problems

    Start engine with (flooded engine). FAST throttle lever in sition. 5. Take tiller to an autho- Fuel filter clogged, carbu- Replace or repair faulty rized Honda servicing retor malfunction, ignition components as neces- dealer, or refer to the malfunction,valvesstuck, sary. etc.

  • Page 51: Taking Care Of Unexpected Problems

    Refuel with fresh gasoline with bad gasoline. (P.27). Fuel filter clogged, Replace or repair faulty components as neces- rized Honda servicing carburetor malfunction, ignition malfunction, dealer, or refer to the sary. shop manual. valves stuck, etc.

  • Page 52: Tilling Problems

    TAKING CARE OF UNEXPECTED PROBLEMS TILLING PROBLEMS Poor Tilling Quality Possible Cause Correction Check that the throttle Engine speed is too slow Move the throttle to the lever is in the FAST to till well. FAST position (p.11). position. 2. Reduce forward Tiller is movingtoo fast for to slower speed speed.

  • Page 53: Technical & Consumer Information

    TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Loc Serial Number Location 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 59.) Engine serial number: Frame serial number:...

  • Page 54: Carburetor Modification For High Altitude Operation

    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.

  • Page 55: Oxygenated Fuels

    TECHNICAL & CONSUMER INFORMATION Oxygenated Fuels 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.

  • Page 56: Emission Control System Information

    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 nitrogen, and hydrocarbons.
  • Page 57 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 mainte- nance done.

  • Page 58: Air Index

    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.

  • Page 59: Specifications

    0.031 in 0.028 (0.70 Spark Plug Gap Refer to page: 0.80 mm) IN: 0.1 1 0.19 mm cold See your authorized Valve Clearance Honda dealer 0.24 mm cold Other Specification other adjustments needed. NOTE: Specifications are subject to change without notice.

  • Page 60: 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 Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician.

  • Page 61: Customer Service Information

    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.
  • Page 63 Unleaded gasoline with a pump octane rating of 86 or higher (page 27) Fuel FG400 : 0.45 US gal (1.71) Capacity FG500 : 0.53 US gal (2.01) SAE 10 W - 30, API SJ, for general use TY Pe (page 31) Engine Oil 0.51 US qt (0.581) Capacity...

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