Honda Power Equipment GCV190 User Manual 2

OWNER’S MANUAL

GCV160 • GCV190

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(Appearance may differ in final application)

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

[2]

[1]

		[3]
[5]				[6]
		[10]
[4]			[8]	[7]
COMPONENT LOCATION
1	Fuel filler cap	6	Spark plug
2	Starter grip	7	Muffler
3	Fuel tank	8	Starter motor (if equipped)
4	Control location *	9	Oil filler cap/ dipstick
5	Air cleaner	10	Engine serial number

* The engine control area differs based on the engine type. Refer to the individual figures on page 2 to determine your engine control type when reading the Operation section and other sections in this manual.

ENGLISH

FRANÇAIS

ESPAÑOL

		434780-Rev 9	POM31Z8B0420
			WPG.300000.2013.04
	00X31-Z8B-0420	EM5	PRINTED IN U.S.A.
		© 2003–2013 American Honda Motor Co., Inc.—All Rights Reserved	1

Type/Tipo 1, 2	Type/Tipo 3	Type/Tipo 4
	[3]
	[2]
	[3]	[3]
[2]
[1]	[1]	[1]

EN	[1] Fuel Valve	EN	[1] Fuel Valve	EN	[1] Fuel Valve
	[2] Remote Choke/Throttle		[2] Automatic Return Choke		[3] Flywheel Brake
	[3] Flywheel Brake		[3] Flywheel Brake, Fixed Throttle		Fixed Throttle
FR	[1] Robinet d’essence	FR	[1] Robinet d’essence	FR	[1] Robinet d’essence
	[2] Levier de Starter/Papillon		[2] Starter À Retour Automatique		[3] Starter Automatique
	[3] Frein de Volant		[3] Frein de Volant, Carburateur Préréglé		Carburateur Préréglé
ES	[1] Valvula de combustible	ES	[1] Valvula de combustible	ES	[1] Valvula de combustible
	[2] Cebador/Aceleración Remota		[2] Retorno Automático Del Cebador		[3] Automático Cebador
	[3] Freno del Volante		[3] Freno del Volante, Aceleración Fija		Aceleración Fija

Type/Tipo 5, 6	Type/Tipo 7		Type/Tipo 8, 9
				[3]
				OFF
				ON
	[2]
			X
[2]
[1]	[3]		[2]	[1]
		[1]

EN	[1] Fuel Valve	EN	[1] Fuel Valve	EN	[1] Fuel Valve
	[2] Remote Choke/Throttle		[2] Manual Choke		[2] Manual Choke
	Blade Brake Clutch		[3] Manual Throttle		[3] Stop Switch
					FIxed Throttle
FR	[1] Robinet d’essence	FR	[1] Robinet d’essence	FR	[1] Robinet d’essence
	[2] Levier de Starter/Papillon		[2] Starter Manuel		[2] Starter Manuel
	Frein-embrayage À Aubes		[3] Papillon Manuel		[3] Bouton d’Arret du Moteur
					Carburateur Préréglé
ES	[1] Valvula de combustible	ES	[1] Valvula de combustible	ES	[1] Valvula de combustible
	[2] Cebador/Aceleración Remota		[2] Control Manual		[2] Manual Choke
	Cebador/Aceleración		[3] Aceleración Manual		[3] Interruptor de Para del Motor
					Aceleración Fija

	[1]	ON
	Fuel valve
		OUVERT
	Robinet d’essence
		ABIERTA
	Valvula de combustible

	OFF
	FERMÉ
X	X CERRADA

2

	Figure/Figura 2							Figure/Figura 3
Figure/Figura 1
		[1]
									[1]
				[3]
				[2]
					30
[1]		5W-30 • 10W-30						[4]	[3]
	0	20		40	60	80	100°F
									[2]
	-20 -10		0	10	20	30	40°C
Figure/Figura 4	Figure/Figura 5							Figure/Figura 6
	[1]							[1]	[2]
	[1]
[4]
								[3]
[5]
[4]									[4]
[3]
[2]
	0.028 ~ 0.030 in
	(0.70 ~ 0.80 mm)						[2]
Figure/Figura 7	Figure/Figura 8
1/8 in				[3]
(3 mm)
minimum		[2]
	[1]
								[5]
								[4]
[5]
									3

INTRODUCTION

Thank you for purchasing a Honda engine! We want to help you get the best results from your new engine and 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 an authorized Honda servicing dealer.

All information in this publication is based on the latest product information available at the time of printing. American Honda Motor Co., Inc. 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.

CONTENTS

SAFETY MESSAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 BEFORE OPERATION CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 STARTING/STOPPING THE ENGINE (ALL TYPES) . . . . . . . . . . . 5 SERVICING YOUR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REFUELING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FLYWHEEL BRAKE INSPECTION (if equipped). . . . . . . . . . . . . . . 8 SPARK ARRESTER (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . 9 STORING YOUR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TAKING CARE OF UNEXPECTED PROBLEMS . . . . . . . . . . . . . . . . 10 TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CONSUMER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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.

These signal words mean:

DANGER

WARNING

CAUTION

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.

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.

This word means:

		Your engine or other property can be damaged
	NOTICE
		if you don’t follow instructions.

The purpose of these messages is to help prevent damage to your engine, other property, or the environment.

SAFETY INFORMATION

•Understand the operation of all controls and learn how to stop the engine quickly in case of emergency. Make sure the operator receives adequate instruction before operating the equipment.

•Do not allow children to operate the engine. Keep children and pets away from the area of operation.

•Your engine’s exhaust contains poisonous carbon monoxide. Do not run the engine without adequate ventilation, and never run the engine indoors.

•The engine and exhaust become very hot during operation. Keep the engine at least 3 feet (1 meter) away from buildings and other equipment during operation. Keep flammable materials away, and do not place anything on the engine while it is running.

SAFETY LABEL LOCATION

The label shown on page 1 contains important safety information. Please read it carefully. See page 1.

This label is considered a permanent part of your engine. So if the label comes off or becomes hard to read, contact your dealer for a replacement.

BEFORE OPERATION CHECKS

IS YOUR ENGINE READY TO GO?

For your safety, to ensure compliance with environmental regulations, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the engine to check its condition. Be sure to take care of any problem you find, or have your servicing dealer correct it, before you operate the engine.

WARNING

Improperly maintaining this engine, or failing to correct a problem before operation, could cause a malfunction in which you could be seriously injured.

Always perform a pre-operation inspection before each operation, and correct any problem.

Before beginning your preoperation checks, be sure the engine is level and the flywheel brake lever, throttle lever, or engine stop switch is in the STOP or OFF position.

Always check the following items before you start the engine:

1.Fuel level (page 7).

2.Oil level (page 8).

3.Air cleaner (page 8).

4.General inspection: Check for fluid leaks and loose or damaged parts.

5.Check the equipment powered by this engine.

Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine startup.

4

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the engine for the first time, please review the

SAFETY MESSAGES and the BEFORE OPERATION CHECKS page 4.

For your safety, do not operate the engine in an enclosed area such as a garage. Your engine's exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death.

WARNING

Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas. Breathing carbon monoxide can cause unconsciousness or death.

Never run the engine in a closed or even partially closed area where people may be present.

Review the instructions provided with the equipment powered by this engine for any safety precautions that should be observed with engine startup, shutdown, or operation.

Do not operate the engine on slopes greater than 20°.

STARTING/STOPPING THE ENGINE (ALL TYPES)

See the figures on page 2 to identify the type of control used on your equipment. Type specific starting and stopping information can be found after the general information shown below.

•Fuel valve ON: Turn the fuel valve [1] to the ON position before starting the engine.

•Manual choke (if equipped): Place the choke lever/rod [2] in the CHOKE position when starting a cold engine.

Move the choke lever/rod to the OFF position as soon as the engine fully warms up and runs smoothly without use of the choke, or for restarting a warm engine.

•Engine speed: For best engine performance, it is recommended the engine be operated with the throttle in the FAST (or high) position.

•Starter grip: Pull the starter grip lightly until resistance is felt, and then pull briskly.

NOTICE

Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.

To ensure easy restarting and maximum performance from the Auto Choke System™ types, allow the engine to run for at least three minutes after starting a cold engine before shutting down. This minimum run time will be longer if the temperature is below 70°F (21°C).

•Fuel valve OFF: After stopping the engine, turn the fuel valve [1] to the OFF position.

If your equipment will not be used for 3 to 4 weeks, we recommend running the engine’s carburetor out of fuel. You can do this by leaving the fuel valve OFF, restarting the engine, and running it out of fuel. Running time should be less than 3 minutes.

Refer to the Type number for your engine, and the corresponding graphic on page 2.

Type 1: Flywheel Brake, Remote Choke/Throttle

STARTING THE ENGINE

1.Move the choke/throttle lever* [2] to the CHOKE position.

2.Move the flywheel brake lever* [3] to the RUN position.

3.Pull the starter grip lightly until resistance is felt; then pull briskly.

4.Move the choke/throttle lever* [2] to the FAST position.

STOPPING THE ENGINE

1.Move the choke/throttle lever* [2] to the SLOW position.

2.Release the flywheel brake lever* [3] to stop the engine.

Type 2: Flywheel Brake, Automatic Choke,

Remote Throttle

STARTING THE ENGINE

1.Move the remote throttle lever* [2] to the FAST position.

2.Move the flywheel brake lever* [3] to the RUN position.

3.Pull the starter grip lightly until resistance is felt; then pull briskly.

STOPPING THE ENGINE

1.Move the remote throttle lever* [2] to the SLOW position.

2. Release the flywheel brake lever* [3] to stop the engine.

Type 3: Flywheel Brake, Automatic Return Choke,

Fixed Throttle

STARTING THE ENGINE

1.Move the automatic return choke [2] to the CHOKE position.

The choke lever automatically returns to the OFF position 3 - 4 seconds after the flywheel brake is moved to the RUN

position. Reset the choke if the engine does not start within this time frame.

2.Move the flywheel brake lever* [3] to the RUN position.

3.Pull the starter grip lightly until resistance is felt; then pull briskly. The throttle is preset on this type.

STOPPING THE ENGINE

Release the flywheel brake lever* [3] to stop the engine.

Type 4: Flywheel Brake, Automatic Choke, Fixed Throttle

STARTING THE ENGINE

1.Move the flywheel brake lever* [3] to the RUN position.

2.Pull the starter grip lightly until resistance is felt; then pull briskly.

STOPPING THE ENGINE

Release the flywheel brake lever* [3] to stop the engine.

Type 5: Blade Brake Clutch, Remote Choke/Throttle

STARTING THE ENGINE

1.Move the choke/throttle lever* [2] to the CHOKE position.

2.Make sure the blade control lever* is released.

3.Pull the starter grip lightly until resistance is felt; then pull briskly.

4.Move the choke/throttle* [2] to the FAST position as the engine warms, and then engage the blade control lever*.

STOPPING THE ENGINE

1.Release the blade control lever*.

2.Move the choke/throttle lever* [2] to the SLOW position, and then the STOP position.

* See the equipment manual for control location.

5

Type 6: Blade Brake Clutch, Automatic Choke,

Remote Throttle

STARTING THE ENGINE

1.Move the remote throttle lever* [2] to the FAST position.

2.Make sure the blade control lever* is released.

3.Pull the starter grip lightly until resistance is felt; then pull briskly.

4.Allow the engine to warm to operating temperature, and then engage the blade control lever*.

STOPPING THE ENGINE

1.Release the blade control lever*.

2.Move the remote throttle lever* [2] to the SLOW position, and then to the STOP position.

Type 7: Manual Choke, Manual Throttle

STARTING THE ENGINE

1.Move the choke lever [2] to the CHOKE position.

2.Move the throttle control [3] to the FAST position.

3.Pull the starter grip lightly until resistance is felt; then pull briskly.

4.Move the choke lever [2] to the OFF position as the engine warms.

STOPPING THE ENGINE

Move the throttle control [3] to the SLOW position, and then to the STOP position.

Type 8: Manual Choke, Engine Stop Switch, Fixed Throttle

STARTING THE ENGINE

1.Pull the choke rod [2] to the CHOKE position.

2.Turn the engine stop switch [3] to the ON position.

3.Pull the starter grip lightly until resistance is felt; then pull briskly. The engine speed is preset on this type.

4.Move the choke rod to the OFF position as the engine warms.

STOPPING THE ENGINE

Turn the engine stop switch [3] to the OFF position.

Type 9: Manual Choke, Engine Stop Switch, Auto Throttle

STARTING THE ENGINE

1.Pull the choke rod [2] to the CHOKE position.

2.Turn the engine stop switch [3] to the ON position.

3.Pull the starter grip lightly until resistance is felt; then pull briskly.

4.Move the choke rod [2] to the OFF position as the engine warms.

The auto throttle feature only functions when the engine is fully warm.

STOPPING THE ENGINE

1.Remove the load from the engine so that the auto throttle returns the engine to idle.

2.Turn the engine stop switch [3] to the OFF position.

* See the equipment manual for control location.

FREQUENCY OF USE

If your equipment will be used on an infrequent or intermittent basis (more than 4 weeks between usage), refer to the Fuel section of the STORAGE chapter (page 9) for additional information regarding fuel deterioration.

SERVICING YOUR ENGINE

THE IMPORTANCE OF MAINTENANCE

Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce pollution.

WARNING

Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.

Always follow the inspection and maintenance recommendations and schedules in this Owner’s Manual.

To help you properly care for your engine, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions. If you operate your engine under severe conditions, such as sustained high-load or high-temperature operation, or use in unusually wet or dusty conditions, consult your servicing dealer for recommendations applicable to your individual needs and use.

Remember that an authorized Honda servicing dealer knows your engine best and is fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new Honda Genuine parts or their equivalents for repair and replacement.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are “certified” to EPA standards.

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.

WARNING

Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.

Always follow the procedures and precautions in this Owner’s Manual.

SAFETY PRECAUTIONS

•Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:

–Carbon monoxide poisoning from engine exhaust.

Be sure there is adequate ventilation whenever you operate the engine.

–Burns from hot parts.

Let the engine and exhaust system cool before touching.

–Injury from moving parts.

Do not run the engine unless instructed to do so.

•Read the instructions before you begin, and make sure you have the tools and skills required.

•To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks, and flames away from all fuel related parts.

6

MAINTENANCE SCHEDULE

Perform at every indicated month/year or operating hour interval, whichever comes first. (1)

	Regular	Item	Page
	Service Period
	Before each	Check: Engine oil level	page 8
	use	Check: Air filter	page 8
	First month	Change: Engine oil	page 7
	or 5 hours
	Every 3 months	Clean: Air filter (2)	page 8
	or 25 hours
	Every 6 months	Change: Engine oil (3)	page 7
	or 50 hours	Clean: Air filter (2)	page 8
		Check: Flywheel brake pad	page 8
		(if equipped)
	Every year	6 month items plus:
	or 100 hours	Check-adjust: Spark plug	page 8
		Clean: Spark arrester (if equipped)	page 9
		Check: Blade brake clutch	(5)
		(if equipped)
		Check-adjust: Idle speed	(4)
		Clean: Fuel tank and filter	(4)
		Check-adjust: Valve clearance	(4)
	Every 2 years	Yearly items plus:
	or 200 hours	Replace: Air filter	page 8
		Replace: Spark plug	page 8
	Every 2 years	Check: Fuel lines (replace if necessary)	(4)

(1)For commercial use, log hours of operation to determine proper maintenance intervals.

(2)Service more frequently when used in dusty areas.

(3)Change engine oil every 25 hours when used under heavy load or in high ambient temperatures.

(4)These items should be serviced by an authorized Honda servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures.

(5)See your equipment manual or Honda engine shop manual.

Failure to follow this maintenance schedule could result in non-warrantable failures.

REFUELING

This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher.

We recommend refueling after each use to minimize the air present in the fuel tank.

Refuel in a well-ventilated area with the engine stopped. If the engine has been running, allow it to cool first. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks.

You may use regular unleaded gasoline containing no more than 10% ethanol (E10) or 5% methanol by volume. In addition, methanol must contain cosolvents and corrosion inhibitors. Use of fuels with content of ethanol or methanol greater than shown above may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system. In addition, ethanol is hygroscopic, which means it attracts and retains water in the fuel system. Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered by warranty.

If your equipment will be used on an infrequent or intermittent basis (more than 4 weeks between usage), refer to the Fuel section of the STORAGE chapter (page 9) for additional information regarding fuel deterioration.

Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.

WARNING

Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling.

•Stop engine and keep heat, sparks, and flame away.

•Refuel only outdoors.

•Wipe up spills immediately.

Adding Fuel

See Figure 1, page 3.

1.Remove the fuel tank cap.

2.Add fuel to the bottom of the fuel level gauge [1] in the neck of the fuel tank. Do not overfill. Wipe up spilled fuel before starting the engine.

3.Install the fuel tank cap and tighten it until it clicks.

Move at least 10 feet (3 meters) away from the fueling source and site before starting the engine.

NOTICE

Fuel can damage paint and some types of plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under your Distributor’s Limited Warranty.

Fuel Storage Container

Store your gasoline in a clean, plastic, sealed container designed for fuel storage. Close the vent (if equipped) when not in use, and store the container away from direct sunlight. If it takes more than 3 months to use the fuel in the container, we suggest adding a fuel stabilizer to the fuel when you fill the container. If you have some fuel left in the storage container at the end of the season, the Environmental Protection Agency (EPA) suggests adding the gasoline to your vehicle’s gas tank (http://epa.gov/reg5oair/mobile/winter.html).

ENGINE OIL

Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. Always change the oil in accordance with the maintenance schedule (page 7).

Recommended Oil

See Figure 2, page 3.

Use 4-stroke motor oil that meets or exceeds the requirements for API service category SJ or later. Always check the API service label on the oil container to be sure it includes the letters SJ or later.

SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range.

7

Oil Level Check

See Figures 2, 3, page 3.

1.Check the oil with the engine stopped and level.

2.Remove the oil filler cap/dipstick [1] and wipe it clean.

3.Insert the oil filler cap/dipstick into the oil filler neck as shown, but do not screw it in, and then remove it to check the oil level.

4.If the oil level is near or below the lower limit mark [2] on the dipstick, remove the oil filler cap/dipstick, and fill with the recommended oil to the upper limit mark [3]. Do not overfill.

5.Reinstall the oil filler cap/dipstick [1].

Oil Change

See Figure 3, page 3.

Drain the engine oil when the engine is warm. Warm oil drains quickly and completely.

1.Turn the fuel valve to the OFF position to reduce the possibility of fuel leakage.

2.Place a suitable container next to the engine to catch the used oil.

3.Remove the oil filler cap/dipstick [1] and drain the oil into the container by tipping the engine toward the oil filler neck [4].

Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash, pour it on the ground, or pour it down a drain.

4.With the engine in a level position, fill to the upper limit mark [3] on the dipstick with the recommended oil.

Refill amount: 12.0 ~ 13.5 oz (0.35 ~ 0.40 ) Always check the oil level with the dipstick after filling.

NOTICE

Running the engine with a low oil level can cause engine damage.

5. Reinstall the oil filler cap/dipstick [1] securely.

AIR CLEANER

A properly maintained air filter will help prevent dirt from entering your engine. Dirt entering the carburetor can be drawn into small passages in the carburetor and cause premature engine wear. These small passages can become blocked, causing starting or running problems. You will need to clean the filter more frequently if you operate the engine in very dusty areas.

NOTICE

Operating the engine without a filter, or with damaged filter, will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered under your Distributor’s Limited Warranty.

We recommend the use of a Honda Genuine air filter to ensure it seals and performs as designed. Using a non-Honda air filter can result in dirt bypassing the filter, causing damage to the engine or fuel system.

Inspection

See Figure 4, page 3.

1.Press the latch tabs [1] on the top of the air cleaner cover [2], and remove the cover. Check the filter [3] to be sure it is clean and in good condition.

2.Reinstall the filter and air cleaner cover.

Cleaning

See Figure 4, page 3.

1.Tap the filter several times on a hard surface to remove dirt, or blow compressed air not exceeding 30 psi (207 kPa) through the filter from the clean side that faces the engine. Never try to brush off dirt. Brushing will force dirt into the fibers.

2.Wipe dirt from the air cleaner body [4] and cover using a moist rag. Be careful to prevent dirt from entering the air duct [5] that leads to the carburetor.

SPARK PLUG

See Figure 5, page 3.

Recommended Spark Plug:

NGK - BPR6ES	Pressure washer applications
NGK - BPR5ES	All other applications

The recommended spark plug is the correct heat range for normal engine operating temperatures.

NOTICE

Incorrect spark plugs can cause engine damage.

For good performance, the spark plug must be properly gapped and free of deposits.

1.Disconnect the cap from the spark plug, and remove any dirt from the spark plug area.

2.Use the proper size spark plug wrench [1] to remove the spark plug.

3.Inspect the spark plug. Replace it if damaged, badly fouled, if the sealing washer [2] is in poor condition, or if the electrode is worn.

4.Measure the electrode gap with a suitable gauge. The correct gap is 0.028 ~ 0.030 in (0.70 ~ 0.80 mm). If adjustment is needed, correct the gap by carefully bending the side electrode.

5.Install the spark plug carefully, by hand, to avoid cross-threading.

6.After the spark plug is seated, tighten with the proper size spark plug wrench to compress the washer.

When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer.

When reinstalling the original spark plug, tighten 1/8 ~ 1/4 turn after the spark plug seats to compress the washer.

NOTICE

Properly tighten the spark plug. A loose spark plug can become very hot and can damage the engine. Overtightening the spark plug can damage the threads in the cylinder head.

7. Attach the spark plug cap to the spark plug.

FLYWHEEL BRAKE INSPECTION (if equipped)

See Figures 6, 7, page 3.

Start the engine outdoors. Move the throttle lever to the FAST position and release the flywheel brake lever; the engine should stop quickly.

1.Remove the three flange nuts [1] from the recoil starter [2], and remove the recoil starter from the engine.

2.Remove the fuel tank [3] from the engine without disconnecting the fuel tube [4]. If the fuel tank contains fuel, keep it level as you remove it and set it beside the engine in a level position.

3.Check the brake shoe [5] thickness. If it is less than 3 mm, take the engine to your authorized Honda servicing dealer.

4.Install the fuel tank and recoil starter, and tighten the three nuts securely.

8

SPARK ARRESTER (if equipped)

See Figure 8, page 3.

The spark arrester may be standard or an optional part, depending on the engine type. 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 authorized Honda servicing dealers.

The spark arrester must be serviced every 100 hours to keep it functioning as designed.

If the engine has been running, the muffler will be hot. Allow it to cool before servicing the spark arrester.

Removal

1.Remove the three 6 mm bolts [1] from the muffler protector [2], and remove the muffler protector.

2.Remove the special screw [3] from the spark arrester [4], and remove the spark arrester from the muffler [5].

Cleaning & Inspection

1.Use a brush to remove carbon deposits from the spark arrester screen. Be careful not to damage the screen. Replace the spark arrester if it has breaks or holes.

2.Install the spark arrester in the reverse order of removal.

STORING YOUR ENGINE

STORAGE PREPARATION

Proper storage preparation is essential for keeping your engine trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your engine’s function and appearance, and will make the engine easier to start when you use it again.

Cleaning

If the engine has been running, allow it to cool for at least half an hour before cleaning. Clean all exterior surfaces, touch up any damaged paint, and coat other areas that may rust with a light film of oil.

NOTICE

Using a garden hose or pressure washing equipment can force water into the air cleaner or muffler opening. Water in the air cleaner will soak the air filter, and water that passes through the air filter or muffler can enter the cylinder, causing damage.

Fuel

NOTICE

Depending on the region where you operate your equipment, fuel formulations may deteriorate and oxidize rapidly. Fuel deterioration and oxidation can occur in as little as 30 days and may cause damage to the carburetor and/or fuel system. Please check with your servicing dealer for local storage recommendations.

The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline blend, your storage temperatures, and whether the fuel tank is partially or completely filled. The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel problems may occur within a month of inactivity, or even less if the gasoline was not fresh when you filled the fuel tank.

Gasoline will oxidize and deteriorate in storage. Deteriorated gasoline will cause hard starting, and it leaves gum deposits that can clog the small passages in the fuel system. If the gasoline in your engine deteriorates during storage, you may need to have the carburetor and other fuel system components serviced or replaced.

If you keep a container of gasoline for refueling, be sure that it contains only fresh gasoline. If it takes more than 3 months to use the fuel in your storage container, we suggest adding a fuel stabilizer to the fuel when you fill the container.

Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under your engine warranty.

Short Term Storage (30 - 90 days)

If your equipment will not be used between 30 and 90 days, we recommend the following to prevent fuel-related problems:

1.Add fuel stabilizer following the manufacturer’s instructions.

When adding a fuel stabilizer, fill the fuel tank with fresh gasoline. If only partially filled, air in the tank will promote fuel deterioration during storage.

Note:

–All stabilizers have a shelf life and their performance will deteriorate over time.

–Fuel stabilizers will not reconstitute stale fuel.

2.After adding a fuel stabilizer, run the engine outdoors for

10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor.

3.Turn the fuel valve to the OFF position.

4.Continue to run the engine until it stops from the lack of fuel in the carburetor fuel bowl. Running time should be less than 3 minutes.

Long Term or Seasonal Storage (greater than 90 days)

Turn the fuel valve on, start the engine, and allow it to run long enough to empty all the gasoline from the entire fuel system (including the fuel tank). Do not allow gasoline to remain in your engine for more than 90 days of inactivity.

Engine Oil

1.Change the engine oil (see page 8).

2.Remove the spark plug (see page 8).

3.Pour 1 - 2 teaspoons (5 ~ 10 cc) of clean engine oil into the cylinder.

4.Pull the recoil starter several times to distribute the oil.

5.Reinstall the spark plug.

Storage Precautions

If your engine will be stored with gasoline in the fuel tank, 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. Also avoid any area with a spark-producing electric motor, or where power tools are operated.

If possible, avoid storage areas with high humidity, because that promotes rust and corrosion.

If there is gasoline in the fuel tank, leave the fuel valve in the OFF position.

Keep the engine level in storage. Tilting can cause fuel or oil leakage.

With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials. Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture around the engine, promoting rust and corrosion.

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Removal From Storage

Check your engine as described in the BEFORE OPERATION CHECKS section of this manual (see page 4).

If the fuel was drained during storage preparation, fill the tank with fresh gasoline. If you keep a container of gasoline for refueling, be sure it contains only fresh gasoline. Gasoline oxidizes and deteriorates over time, causing hard starting.

If the cylinder was coated with oil during storage preparation, the engine will smoke briefly at startup. This is normal.

TRANSPORTING

Keep the engine level when transporting to reduce the possibility of fuel leakage. Turn the fuel valve to the OFF position.

Review the instructions provided with the equipment powered by this engine for any procedures that should be followed for transporting.

TAKING CARE OF UNEXPECTED PROBLEMS

Engine will not start

POSSIBLE CAUSE	CORRECTION
Fuel valve is OFF.	Move the fuel valve lever to ON.
Choke is OFF.	Unless the engine is warm, move
	the choke/throttle lever, choke rod,
	or choke lever to the CHOKE
	position. (if equipped)
Ignition switch or engine stop	Move the flywheel brake lever to
switch is OFF.	RUN position.
	Throttle lever to FAST position.
	Engine stop switch to ON.
Out of fuel.	Refuel.
Bad fuel; engine stored	Refuel with fresh gasoline.
without treating gasoline, or
refueled with bad gasoline.
Spark plug faulty, fouled, or	Adjust or replace the spark plug
improperly gapped.	(page 8).
Spark plug wet with fuel	Dry and reinstall the spark plug.
(flooded engine).	Start the engine with the
	choke/throttle lever in the FAST
	position.
	Choke in the OFF position.
Fuel filter clogged, carburetor	Take the engine to an authorized
malfunction, ignition	Honda servicing dealer or refer to
malfunction, valves stuck, etc.	the shop manual to replace or
	repair faulty components as
	necessary.
Engine lacks power

POSSIBLE CAUSE	CORRECTION
Air filter clogged.	Clean or replace the air filter
	(page 8).
Bad fuel; engine stored	Refuel with fresh gasoline.
without treating the gasoline,
of refueled with bad gasoline.
Fuel filter clogged, carburetor	Take the engine to an authorized
malfunction, ignition	Honda servicing dealer or refer to
malfunction, valves stuck, etc.	the shop manual to replace or
	repair faulty components as
	necessary.

TECHNICAL INFORMATION

Serial Number and Type Location

See Figure on page 1.

Record the engine serial number and type in the space below. You will need this information when ordering parts and when making technical or warranty inquiries.

MODEL	SERIAL NUMBER	TYPE
GCV160 or 190	__ __ __ __ __– __ __ _ __ __	__ __ _ __
Date of purchase

Radio Frequency Interference Label (Canada)

This engine complies with Canadian radio frequency interference regulations, ICES-002.

Carburetor Modifications 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.

High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above 5,000 feet (1,500 meters), have your servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life.

Even with carburetor modification, engine horsepower will decrease about 3.5% for each 1,000-foot (300-meter) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.

When auto throttle type engines are used in high altitude applications, the ability to idle down to 2500 rpm could be diminished. See your servicing dealer for information on adjustments if your auto throttle unit does not idle down with the load released or has trouble returning to full rpm with the load applied.

NOTICE

When the carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use. Operation at altitudes below 5,000 feet (1,500 meters) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have your servicing dealer return the carburetor to original factory specifications.

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EMISSION CONTROL SYSTEM INFORMATION

Source of Emissions

The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

Honda utilizes appropriate air/fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons. Additionally, Honda fuel systems utilize components and control technologies to reduce evaporative emissions.

The U.S. EPA, CARB, and Environment Canada

EPA, California, and Canadian emissions regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems.

The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards.

Tampering and Altering

NOTICE

Tampering is a violation of Federal and California law.

Tampering with or altering the emission control system may increase emissions beyond the legal limit. Among those acts that constitute tampering are:

•Removal or alteration of any part of the intake, fuel, or exhaust systems.

•Altering or defeating the governor linkage or speed-adjusting mechanism to cause the engine to operate outside its design parameters.

Problems That May Affect Emissions

If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer.

•Hard starting or stalling after starting.

•Rough idle.

•Misfiring or backfiring under load.

•Afterburning (backfiring).

•Black exhaust smoke or high fuel consumption.

Replacement Parts

The emission control systems on your Honda engine were designed, built, and certified to conform with EPA, California, and Canadian emission regulations. We recommend the use of Honda Genuine parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system.

A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.

Maintenance

Follow the maintenance schedule on page 7. Remember that this schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load or high-temperature operation, or use in unusually wet or dusty conditions, will require more frequent service.

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. The lower the Air Index, the less pollution.

The durability description is intended to provide you with information relating the engine’s emission durability period. The descriptive term indicates the useful life period for the engine’s emission control system. See your EMISSION CONTROL SYSTEM WARRANTY

(page 14) for additional information.

DESCRIPTIVE	APPLICABLE TO EMISSION
TERM	DURABILITY PERIOD
Moderate	50 hours (0–80 cc inclusive)
	125 hours (greater than 80 cc)
Intermediate	125 hours (0–80 cc inclusive)
	250 hours (greater than 80 cc)
Extended	300 hours (0–80 cc inclusive)
	500 hours (greater than 80 cc)
	1000 hours (225 cc and greater)

SPECIFICATIONS

GCV160

TYPE	RECOIL START	ELECTRIC START
Length x Width x Height	14.4 x 13.0 x 14.2 in	14.4 x 13.9 x 14.2 in
	(367 x 331 x 360 mm)	(367 x 354 x 360 mm)
Dry weight	22 lb (9.8 kg)	26 lb (11.6 kg)
Engine type	4-stroke, overhead	cam, single cylinder
Displacement	9.8 cu in (160 cm3)
[Bore x Stroke]	[2.5 x 2.0 in (64 x 50 mm)]
Oil capacity	Dry engine: 18.6 oz (0.55 )
	Refill amount: 12.0 ~ 13.5 oz (0.35 ~ 0.41 )*
Fuel tank capacity	0.25 US gal (0.93 )
Fuel consumption **	1.1 /h at 3,000 rpm
Cooling system	Forced air
Ignition system	Transistorized magneto
PTO shaft rotation	Counterclockwise
GCV190

TYPE	RECOIL START	ELECTRIC START
Length x Width x Height	14.4 x 13.0 x 14.5 in	14.4 x 13.9 x 14.5 in
	(367 x 331 x 368 mm)	(367 x 354 x 368 mm)
Dry weight	27.1 lb (12.3 kg)	29.3 lb (13.3 kg)
Engine type	4-stroke, overhead	cam, single cylinder
Displacement	11.4 cu in (187 cm3)
[Bore x Stroke]	[2.7 x 2.0 in (69 x 50 mm)]
Oil capacity	Dry engine: 18.6 oz (0.55 )
	*Refill amount: 12.0 ~ 13.5 oz (0.35 ~ 0.41 )
Fuel tank capacity	0.25 US gal (0.93 )
Fuel consumption **	1.3 /h at 3,000 rpm
Cooling system	Forced air
Ignition system	Transistorized magneto
PTO shaft rotation	Counterclockwise

* Actual amount will vary due to residual oil remaining in the engine. Always use the dipstick to confirm the actual level (see page 8)

**Actual consumption will vary, depending on the load applied to the engine.

Tuneup Specifications

Spark plug gap	0.028	~ 0.030 in	Refer to page 8
	(0.70 ~ 0.80 mm)
Idle speed	1,400 ± 150 rpm		See your authorized Honda
	1,700	± 150 rpm (fixed	dealer.
		throttle types)
	2,500	± 150 rpm (auto
		throttle types)
Valve clearance	IN: 0.006 + 0.001 in
(cold)	(0.15 + 0.02 mm)
	EX: 0.008 + 0.001 in
	(0.20 + 0.02 mm)

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Quick Reference Information

Fuel	Type	Unleaded gasoline with a pump octane
		rating of 86 or higher (page 7).
Engine Oil	Type	SAE 10W-30, API SJ or later, for general
		use. Refer to page 7.
		* Refill amount: 12.0 ~ 13.5 oz.
		(0.35 ~ 0.41 )
Spark plug	Type	BPR6ES (NGK) (pressure washer types)
		BPR5ES (NGK) (all other applications)
Maintenance	Before each	Check engine oil level. Refer to page 8.
	use	Check air filter. Refer to page 8.
	First 5 hours	Change engine oil. Refer to page 8.
	Subsequent	Refer to the maintenance schedule on
		page 7.

*Actual amount will vary due to residual oil remaining in the engine. Always use the dipstick to confirm the actual level (see page 8)

Wiring Diagrams

RECOIL STARTER (all types)

		ENGINE	SWITCH
			CONTACT
BLACK		RUN	OPEN
		STOP	CLOSE

[1]

[2]

[3]

ELECTRIC STARTER

(with flywheel brake) Supplied by equipment manufacturer.

BLACK E

OFF ON

[3]

[4]	[5]

M

WHITE

[1][2]

OFF E ON

STOP

ON

ELECTRIC STARTER (with blade brake clutch)

BLACK

[3]

			M	WHITE	[5]
			[4]
	[1]	[2]		Supplied by equipment
				manufacturer.
[1]	SPARK PLUG		[4]	STARTER MOTOR
[2]	IGNITION COIL		[5]	STARTER SWITCH
[3]	ENGINE STOP SWITCH

CONSUMER INFORMATION

Distributor/Dealer Locator Information

United States, Puerto Rico, and U.S. Virgin Islands:

Visit our website: www.engines.honda.com

Canada:

Call (888) 9honda9 [888 946-6329] or visit our website: www.honda.ca

Honda Publications

These publications will give you additional information for maintaining and repairing your engine.

Shop	This manual covers complete maintenance and overhaul
Manual	procedures. It is intended to be used by a skilled technician.
	Available through your Honda dealer or through Helm Inc. at
	1 888-292-5395 or visit www.Honda-engines.com and click on
	Product Manuals.
Parts	This manual provides complete, illustrated parts lists. Available
Catalog	through your Honda dealer.

Customer Service Information

Servicing 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. The Service Manager, General Manager, or Owner can help. Almost all problems are solved in this way.

If you are dissatisfied with the decision made by the dealership's management, contact the Honda Regional Engine Distributor for your area. You can find their name, address, and phone number using the dealer/distributor locator on our website at www.hond-engines.com

If you are still dissatisfied after speaking with the Regional Engine Distributor, you may contact the Honda Office as shown below.

<Honda’s Office>

When you write or call, please provide this information:

•Equipment manufacturer’s name and model number that the engine is mounted on

•Engine model, serial number, and type (see page 10)

•Name of dealer who sold the engine to you

•Name, address, and contact person of the dealer who services your engine

•Date of purchase

•Your name, address and telephone number

•A detailed description of the problem

United States, Puerto Rico, and U.S. Virgin Islands:

American Honda Motor Co., Inc. Power Equipment Division Customer Relations Dept.

4900 Marconi Drive Alpharetta, GA 30005-8847

Or telephone: [phone], 8:30 a.m. - 7:00 p.m. ET

Canada:

Honda Canada, Inc.

180 Honda Blvd.

Markham, ON L6C OH9 or visit: www.honda.ca

Telephone: (888) 9honda9	Toll free
[phone]
Facsimile: [phone]	Toll free

DISTRIBUTOR’S WARRANTIES

The applicable warranty is the warranty policy in effect in the country where the warranty service is provided.

12