Honda GCV190 Owner's Manual
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.
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 B and one of three words, DANGER, WARNING, or
CAUTION.
These signal words mean:
B DANGER
B WARNING
B 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.
This word means:
NOTICE
The purpose of these messages is to help prevent damage to your
engine, other property, or the environment.
© 2003–2009 American Honda Motor Co., Inc.—All Rights Reserved
Your engine or other property can be
damaged if you don’t follow instructions.
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.
OWNER’S MANUAL
MANUEL DE L’UTILISATEUR
MANUAL DEL PROPIETARIO
GCV160 • GCV190
B WARNING: B
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BEFORE OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFE OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TYPE 1: FLYWHEEL BRAKE/REMOTE THROTTLE . . . . . . . . . . . . . 4
TYPE 2: MANUAL CHOKE/MANUAL THROTTLE . . . . . . . . . . . . . . . 5
TYPE 3: FLYWHEEL BRAKE/REMOTE CHOKE/FIXED THROTTLE. 5
TYPE 4: AUTOMATIC CHOKE RETURN/FIXED THROTTLE. . . . . . . 5
TYPE 5: MANUAL CHOKE/FIXED THROTTLE. . . . . . . . . . . . . . . . . . 6
TYPE 6: REMOTE THROTTLE/BLADE BRAKE CLUTCH . . . . . . . . . 6
TYPE 7: ELECTRIC START WITH ENGINE-MOUNTED STARTER
SWITCH/ MANUAL CHOKE CONTROL/FIXED THROTTLE 6
TYPE 8: AUTOMATIC CHOKE/FIXED THROTTLE. . . . . . . . . . . . . . . 7
TYPE 9: AUTOMATIC CHOKE/REMOTE THROTTLE/
FLYWHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TYPE 10: AUTOMATIC CHOKE/REMOTE THROTTLE/ BLADE
BRAKE CLUTCH (equipment control) . . . . . . . . . . . . . . . . . 7
SERVICING YOUR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REFUELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPARK PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FLYWHEEL BRAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPARK ARRESTER (optional equipment) . . . . . . . . . . . . . . . . . . . . . 11
STORING YOUR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TAKING CARE OF UNEXPECTED PROBLEMS . . . . . . . . . . . . . . . . 12
TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CONSUMER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
International Warranty Information . . . . . . . . . . . . . . . . . . . . . . . last page
ENGLISHFRANÇAIS
ESPAÑOL
31Z8B024
00X31-Z8B-0240
EM5
POM31Z8B024
IPC.170000.2009.08
PRINTED IN U.S.A.
ENGLISH
185854
1
SAFETY INFORMATION
TYPE 2: MANUAL CHOKE/MANUAL THROTTLE
• 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 1 meter (3 feet) away from buildings and other
equipment during operation. Keep flammable materials away, and
do not place anything on the engine while it is running.
IDENTIFICATION:
COMPONENTS AND CONTROLS
COMPONENT LOCATION
[9]
[8]
[7]
[6]
[1]
[5]
[4]
[2]
[3]
CHOKE LEVER
THROTTLE LEVER
FUEL VALVE LEVER
TYPE 3: FLYWHEEL BRAKE/REMOTE CHOKE/FIXED THROTTLE
FLYWHEEL BRAKE
CONTROL CABLE
CHOKE CONTROL CABLE
FUEL VALVE LEVER
TYPE 4: AUTOMATIC RETURN CHOKE/FIXED THROTTLE
CHOKE LEVER
FLYWHEEL BRAKE
CONTROL CABLE
1 Fuel filler cap
2Starter grip
3 Fuel tank
4 Control location*
5 Air cleaner
6 Spark plug
7Muffler
8 Starter motor (if equipped)
9 Oil filler cap/dipstick
The engine control area differs based on the engine type.
*
Refer to the individual diagrams below to determine your
engine control type when reading the Operation section and
other sections in this manual.
CONTROL LOCATION
TYPE 1: FLYWHEEL BRAKE/REMOTE THROTTLE
FLYWHEEL BRAKE
CONTROL LEVER
THROTTLE LEVER
FUEL VALVE LEVER
TYPE 5: MANUAL CHOKE/FIXED THROTTLE
ENGINE STOP SWITCH
CHOKE ROD
FUEL VALVE LEVER
TYPE 6: REMOTE THROTTLE/BLADE BRAKE CLUTCH
(equipment control)
THROTTLE LEVER
FUEL VALVE LEVER
2
ENGLISH
FUEL VALVE LEVER
TYPE 7: ELECTRIC START WITH ENGINE-MOUNTED STARTER
SWITCH/MANUAL CHOKE CONTROL/FIXED THROTTLE
STARTER SWITCH
CHOKE ROD
BEFORE OPERATION CHECKS
IS YOUR ENGINE READY TO GO?
For your safety, 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.
FUEL VALVE LEVER
TYPE 8: AUTOMATIC CHOKE/FIXED THROTTLE
FLYWHEEL BRAKE
CONTROL CABLE
FUEL VALVE LEVER
TYPE 9: AUTOMATIC CHOKE/REMOTE THROTTLE/
FLYWHEEL BRAKE
FLYWHEEL BRAKE
CONTROL LEVER
THROTTLE LEVER
FUEL VALVE LEVER
TYPE 10: AUTOMATIC CHOKE/REMOTE THROTTLE/
BLADE BRAKE CLUTCH (equipment control)
B WARNING
Improperly maintaining this engine, or failure to correct a
problem before operation, can cause a malfunction in
which you can be seriously hurt or killed.
Always perform a preoperation inspection before each
operation, and correct any problem.
Before beginning your preoperation checks, be sure the engine is
level and the flywheel brake lever (type 2: throttle lever, type 5: engine
stop switch) is in the STOP or OFF position.
Always check the following items before you start the engine:
1. Fuel level (page 8).
2. Oil level (page 9).
3. Air cleaner (page 9).
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.
OPERATION
SAFE OPERATING PRECAUTIONS
Before operating the engine for the first time, please review the
SAFETY INFORMATION section on page 2 and the BEFORE
OPERATION CHECKS above.
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.
B WARNING
THROTTLE LEVER
FUEL VALVE LEVER
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°.
ENGLISH
3
TYPE 1: FLYWHEEL BRAKE/REMOTE THROTTLE
Starting the Engine
1. Turn the fuel valve to the ON
position.
ON
FUEL
VALVE
OFF
Throttle Setting
Position the throttle control for the desired engine speed. For best
engine performance, it is recommended the engine be operated with
the throttle in the FAST (or high) position.
Stopping the Engine
1. Move the choke/throttle control
to the SLOW position.
SLOW
FAST
THROTTLE
LEVER
2. See equipment manual and
position the throttle control
so the choke/throttle lever
moves to the CHOKE
position (cold engine).
3. See equipment manual
and position the flywheel
brake control so the
flywheel brake lever is in
the RUN position.
4. Pull the starter grip lightly
until resistance is felt, then
pull briskly.
SLOW
CHOKE/
THROTTLE
LEVER
FAST
FLYWHEEL
BRAKE LEVER
CHOKE
2. Release the flywheel
brake lever to stop the
engine.
3. Turn the fuel valve to
the OFF position.
STOP
FUEL
VALVE
FLYWHEEL
BRAKE LEVER
OFF
ON
NOTICE
Do not allow the starter grip to
snap back against the engine.
Return it gently to prevent
damage to the starter.
5. If the choke was used to start the
engine, move the choke/throttle
lever to the FAST (or high)
position as soon as the engine
warms up enough to run
smoothly without use of the
choke.
4
STARTER
GRIP
CHOKE/
THROTTLE
LEVER
FAST
CHOKE
ENGLISH
TYPE 2: MANUAL CHOKE/MANUAL THROTTLE
Starting the Engine
1. Turn the fuel valve to the ON position.
2. Move the choke lever to the ON position (cold engine).
3. Move the throttle lever to the FAST position.
SLOW
STOP
FUEL VALVE ON
FAST
THROTTLE
LEVER
CHOKE LEVER
OFF
ON
4. Pull the starter grip lightly until resistance is felt, then pull briskly
(see TYPE 1 step 4 on page 4).
5. If the choke was used to start the engine, move the choke lever to
the OFF position as soon as the engine warms up enough to run
smoothly without use of the choke.
6. Position the throttle lever for the desired engine speed. For best
engine performance, it is recommended the engine be operated
with the throttle in the FAST (or high) position.
Stopping the Engine
1. Move the throttle lever to the SLOW position and allow the engine
to idle for a few seconds.
2. Move the throttle lever to the STOP position.
3. Turn the fuel valve to the OFF position.
TYPE 3: FLYWHEEL BRAKE/REMOTE CHOKE/FIXED
THROTTLE
Starting the Engine
1. Turn the fuel valve to the
ON position.
2. Move the choke control
cable (see equipment
manual) so that the
choke arm moves to the
choke ON position (cold
engine).
3. Move the flywheel brake
lever to the RUN position.
4. Pull the starter grip lightly until
resistance is felt, then pull
briskly (see TYPE 1 step 4 on
page 4).
5. If the choke was used to start
the engine, move the choke
control cable so that the choke
arm moves to the OFF position
as soon as the engine warms
up enough to run smoothly
without use of the choke.
The engine speed is preset on this type.
CHOKE
ARM
CHOKE CONTROL
CABLE
FUEL VALVE ON
OFF
FLYWHEEL BRAKE LEVER
STOP
RUN
ON
Stopping the Engine
1. Release the flywheel brake lever to stop the engine.
2. Turn the fuel valve to the OFF position.
TYPE 4: AUTOMATIC CHOKE RETURN/FIXED THROTTLE
Starting the Engine
1. Turn the fuel valve to the ON
position.
ON
FUEL
VALVE
2. Move the choke lever to
the choke position (E)
(cold engine).
OFF
3. Move the flywheel brake
lever to the RUN position.
The choke lever
automatically begins
moving to the OFF
position when the flywheel
CHOKE
LEVER
ON
brake lever is moved to
the RUN position.
4. Start the engine.
STOP
RUN
Recoil Starter Types
Pull the starter grip lightly until resistance is felt, then pull briskly
(see TYPE 1 Step 4 on page 4). Begin pulling the recoil starter as
soon as you move the flywheel brake lever to the RUN position
and the choke starts moving to the OFF position.
If the engine does not start before the choke moves to the OFF
position, repeat steps 2 and 3, then continue starting.
Electric Starter Types
Turn the starter switch (located on equipment) to the START
position, and hold it there until the engine starts. When the engine
starts, allow the engine switch to return to its normal position.
NOTICE
Do not use the starter for more than 5 seconds or starter motor
damage may occur. If the engine fails to start, release the switch
and wait 10 seconds before operating the starter again.
If the engine does not start before the choke moves to the OFF
position, repeat steps 2 and 3, then continue starting.
The throttle is preset on this type.
OFF
FLYWHEEL
BRAKE LEVER
Stopping the Engine
1. Release the flywheel brake lever to activate the flywheel brake and
stop the engine.
2. Turn the fuel valve to the OFF position.
ENGLISH
5
TYPE 5: MANUAL CHOKE/FIXED THROTTLE
Starting the Engine
1. Turn the fuel valve to the ON
position.
2. Pull the choke rod to the ON
position (cold engine).
3. Turn the engine stop switch
to the ON position.
4. Pull the starter grip lightly
until resistance is felt, then
pull briskly (see TYPE 1 Step
4 on page 4).
5. If the choke was used to start the engine, move the choke rod to
the OFF position as soon as the engine warms up enough to run
smoothly without use of the choke.
The engine speed is preset on this type.
ENGINE STOP SWITCH
OFF
ON
FUEL VALVE ON
CHOKE
ROD
ON
Stopping the Engine
1. Move the engine switch to the OFF position.
2. Turn the fuel valve to the OFF position.
TYPE 6: REMOTE THROTTLE/BLADE BRAKE CLUTCH
(equipment control)
Starting the Engine
1. Turn the fuel valve to the ON position.
2. Move the
choke/throttle/stop
STOP
SLOW
lever to the CHOKE
position (cold engine)
or FAST (warm
engine).
Make sure the blade
control lever is
CHOKE/
THROTTLE/
STOP
LEVER
disengaged (see
equipment manual).
3. Start the engine.
Recoil Starter Types
Pull the starter grip
lightly until resistance
is felt, then pull briskly
FUEL VALVE ON
(see TYPE 1 Step 4
on page 4).
Electric Starter Types
Turn the starter switch (located on equipment) to the START
position, and hold it there until the engine starts. When the engine
starts, allow the engine switch to return to its normal position.
FAST
CHOKE
Throttle Setting
Position the choke/throttle/stop lever for the desired engine speed.
For best engine performance, it is recommended the engine be
operated with the choke/throttle/stop lever in the FAST (or high)
position.
Stopping the Engine
1. Disengage the blade brake clutch control lever (see equipment
manual).
2. Move the choke/throttle/stop lever to the SLOW position and allow
the engine to idle for a few seconds.
3. Move the choke/throttle/stop lever to the STOP position.
4. Turn the fuel valve to the OFF position.
TYPE 7: ELECTRIC START WITH ENGINE-MOUNTED
STARTER SWITCH/ MANUAL CHOKE
CONTROL/FIXED THROTTLE
Starting the Engine
1. Turn the fuel valve to the ON
position.
2. Pull the choke rod to the ON
position (see TYPE 5 Step 2
on page 6) (cold engine).
3. Start the engine.
Electric Starter Types
Turn the starter switch to the
START position and hold it
there until the engine starts. When the engine starts, allow the
starter switch to return to the ON position.
NOTICE
Do not use the starter for more than 5 seconds or starter motor
damage may occur. If the engine fails to start, release the switch
and wait 10 seconds before operating the starter again.
Recoil Starter Types
a. Turn the starter switch to the RUN position.
b. Pull the starter grip lightly until resistance is felt, then pull briskly
(see TYPE 1 Step 4 on page 4).
4. If the choke was used to start the engine, move the choke rod to
the OFF position as soon as the engine warms up enough to run
smoothly without use of the choke.
The engine speed is preset on this type.
STARTER
SWITCH
FUEL VALVE ON
STOP
ON
START
Stopping the Engine
1. Move the starter switch to the STOP position.
2. Turn the fuel valve to the OFF position.
NOTICE
Do not use the starter for more than 5 seconds or starter motor
damage may occur. If the engine fails to start, release the switch
and wait 10 seconds before operating the starter again.
4. As soon as the engine starts, slowly move the choke/throttle/stop
lever to the FAST position.
5. Allow the engine to warm to operating temperature, then engage
the blade control lever (see equipment manual).
6
ENGLISH
TYPE 8: AUTOMATIC CHOKE/FIXED THROTTLE
Starting the Engine
1. Turn the fuel valve to the ON
position.
2. Move the flywheel brake
lever to the RUN position.
3. Pull the starter grip lightly
until resistance is felt, then
pull briskly (see TYPE 1 Step
4 on page 4).
FLYWHEEL BRAKE CONTROL CABLE
FUEL VALVE
ON
Stopping the Engine
1. Release the flywheel brake lever to activate the flywheel brake and
stop the engine.
2. Turn the fuel valve to the OFF position.
TYPE 9: AUTOMATIC CHOKE/REMOTE THROTTLE/
FLYWHEEL BRAKE
Starting the Engine
1. Turn the fuel valve to the
ON position.
2. Position the throttle control
so the throttle lever moves
to the FAST position (see
the equipment manual).
THROTTLE
LEVER
SLOW
FAST
Throttle Setting
Position the throttle control for the desired engine speed. For best
engine performance, it is recommended the engine be operated with
the throttle in the FAST (or high) position.
Stopping The Engine
1. Move the throttle control to the
SLOW position.
2. Release the flywheel
brake lever to stop the
engine.
3. Turn the fuel valve to
the OFF position.
SLOW
FLYWHEEL
BRAKE LEVER
FAST
THROTTLE
LEVER
FUEL VALVE
ON
3. Position the flywheel
brake control so the
FLYWHEEL
BRAKE LEVER
flywheel brake lever is in
the RUN position (see
the equipment manual).
4. Pull the starter grip lightly until resistance is felt, then pull briskly
(see TYPE 1 Step 4 on page 4).
TYPE 10: AUTOMATIC CHOKE/REMOTE THROTTLE/
BLADE BRAKE CLUTCH (equipment control)
Starting the Engine
1. Turn the fuel valve to the ON position.
2. Position the throttle
control so the throttle
lever moves to the
FAST position (see the
equipment manual).
3. Make sure the blade
THROTTLE/
STOP
LEVER
STOP
SLOW
FAST
control lever is
disengaged (see
equipment manual).
4. Pull the starter grip
FUEL VALVE
ON
lightly until resistance is
felt, then pull briskly (see TYPE 1 Step 4 on page 4).
Throttle Setting
Position the throttle/stop control for the desired engine speed. For
best engine performance, it is recommended the engine be operated
with the throttle/stop lever in the FAST (or high) position.
Stopping the Engine
1. Disengage the blade brake clutch control lever (see equipment
manual).
2. Move the throttle/stop control to the SLOW position and allow the
engine to idle for a few seconds.
3. Move the throttle/stop lever to the STOP position.
4. Turn the fuel valve to the OFF position.
ENGLISH
7
SERVICING YOUR ENGINE
THE IMPORTANCE OF MAINTENANCE
Good maintenance is essential for safe, economical and trouble-free
operation. It will also help reduce pollution.
B 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.
B 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.
8
MAINTENANCE SCHEDULE
First
Before
Item (1) Action
Engine oil
Air cleaner
Spark plug
Blade brake
clutch
Flywheel
brake pad
Spark arrester
(optional)
Idle
speed
Fuel tank and
filter
Valve
clearance
Fuel line Check Every 2 years (4)
Combustion
chamber
(1) For commercial use, log hours of operation to determine proper
(2) Service more frequently when used in dusty areas.
(3) Change engine oil every 25 hours when used under heavy load or in high
(4) These items should be serviced by an authorized Honda servicing dealer,
* See your equipment manual or Honda engine shop manual.
Failure to follow this maintenance schedule could result in non-warrantable
failures.
Check O9
Change OO (3) 9
Check OO
Clean O (2)
Replace
Check-
Adjust
Replace
Check
Check O10
Clean O11
Adjust O (4)
Check O (4)
Check-
Adjust
Clean After every 250 hours (4)
maintenance intervals.
ambient temperatures.
unless you have the proper tools and are mechanically proficient. Refer
to the Honda shop manual for service procedures.
Each
Use
Month
or
5 Hrs.
Every Season
or
or
25
50
Hrs.
Hrs.
O
Every
Every
100
150
Hrs.
Hrs.
(200
Hrs
(200
Hrs
O*
O (4)
REFUELING
This engine is certified to operate on unleaded gasoline with a pump
octane rating of 86 or higher.
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. Engine damage or performance
problems that result from using a fuel with percentages of ethanol or
methanol greater than shown above are not overed by warranty.
If your equipment will be used on an infrequent or intermittent basis,
please refer to the fuel section of the STORAGE chapter (page 11) for
additional information regarding fuel deterioration.
B 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.
ENGLISH
Page
9
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manual
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manual
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manual
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manual
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manual
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.
Never use stale or contaminated gasoline or oil/gasoline mixture.
Avoid getting dirt or water in the fuel tank.
Adding Fuel
1. Remove the fuel tank
cap.
2. Add fuel to the bottom of
the fuel level limit in the
neck of the fuel tank. Do
not overfill. Wipe up
spilled fuel before starting
the engine.
MAXIMUM FUEL LEVEL
3. Install the fuel tank cap
and tighten it until it clicks.
4. Move at least 10 feet
(3 meters) away from the
fueling source and site
before starting the engine.
FUEL TANK
CAP
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 8).
Recommended Oil
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.
5W-30 • 10W-30
40 60 100°F80020
-20 20 30 40°C-10 0 10
AMBIENT TEMPERATURE
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.
30
Oil Level Check
1. Check the oil with the engine stopped and level.
2. Remove the oil filler cap/dipstick and wipe it clean.
OIL FILLER CAP/DIPSTICK
(Optional
oil filler
extension)
UPPER
LIMIT
LOWER
LIMIT
3. Insert the oil filler cap/dipstick into the oil filler neck as shown, but
do not screw it in, then remove it to check the oil level.
4. If the oil level is near or below the lower limit mark on the dipstick,
remove the oil filler cap/dipstick, and fill with the recommended oil
to the upper limit mark. Do not overfill.
5. Reinstall the oil filler cap/dipstick.
Oil Change
Drain the engine oil when the engine is warm. Warm oil drains quickly
and completely.
OIL FILLER NECK
OIL FILLER
CAP/DIPSTICK
UPPER
LIMIT
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 and drain the oil into the container
by tipping the engine toward the oil filler neck.
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 on the
dipstick with the recommended oil.
NOTICE
Running the engine with a low oil level can cause engine damage.
5. Reinstall the oil filler cap/dipstick securely.
AIR CLEANER
A dirty air cleaner will restrict air flow to the carburetor and cause poor
engine performance. Inspect the filter each time the engine is
operated. 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.
Inspection
1. Press the latch
tabs on the top of
the air cleaner
cover, and
remove the cover.
Check the filter to
be sure it is clean
and in good
condition.
2. Reinstall the filter
and air cleaner
cover.
AIR CLEANER BODY
AIR DUCT
FILTER
AIR
CLEANER
COVER
LATCH TABS
ENGLISH
9
Cleaning
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 and cover using a moist rag. Be
careful to prevent dirt from entering the air duct that leads to the
carburetor.
SPARK PLUG
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 to remove
the spark plug.
3. Inspect the spark plug. Replace it if damaged, badly fouled, if the
sealing washer 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.
SPARK PLUG
WRENCH
0.028 ~ 0.030 in
(0.70 ~ 0.80 mm )
SEALING
WASHER
FLYWHEEL BRAKE INSPECTION
1. Remove the three flange
nuts from the recoil
starter, and remove the
recoil starter from the
engine.
2. Remove the fuel tank from
the engine without
disconnecting the fuel
tube. 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
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.
RECOIL
STARTER
FUEL TANK
FLANGE NUTS (3)
SPACER (3)
FUEL
TUBE
BRAKE SHOE
THICKNESS
BRAKE SHOE
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.
10
ENGLISH
SPARK ARRESTER (optional equipment)
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.
Spark Arrester
SPARK ARRESTER
Removal
1. Remove the three 6 mm
bolts from the muffler
protector, and remove
the muffler protector.
2. Remove the special
screw from the spark
arrester, and remove
the spark arrester from
the muffler.
MUFFLER
PROTECTOR
MUFFLER
6 mm BOLT (3)
SPECIAL
SCREW
Spark Arrester
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.
Gasoline will oxidize and deteriorate in storage. Deteriorated gasoline
will cause hard starting, and it leaves gum deposits that clog 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.
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 few months, or even less if the gasoline was not fresh when
you filled the fuel tank.
Fuel system damage or engine performance problems resulting from
neglected storage preparation are not covered under your engine
warranty.
To Prevent Fuel-Related Problems:
1. Add gasoline stabilizer following the manufacturer’s instructions.
When adding a gasoline stabilizer, fill the fuel tank with fresh
gasoline. If only partially filled, air in the tank will promote fuel
deterioration during storage. If you keep a container of gasoline for
refueling, be sure that it contains only fresh gasoline.
2. After adding a gasoline 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 (see diagram, TYPE 1 Step
1 on page 4).
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.
ENGLISH
11
Engine Oil
1. Change the engine oil
(see page 9).
2. Remove the spark plug
(see page 10).
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 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. 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 (see diagram, TYPE 1 Step 1 on page 4).
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.
Removal From Storage
Check your engine as described in the BEFORE OPERATION
CHECKS section of this manual (see page 3).
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
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 ON
position.
Ignition switch or engine stop
switch is OFF.
Electric start types:
Battery under-charged.
Battery cables are loose or
corroded. Fuse is blown.
Out of fuel. Refuel.
Bad fuel; engine stored without
treating gasoline, of refueled with
bad gasoline.
Spark plug faulty, fouled, or
improperly gapped.
Spark plug wet with fuel (flooded
engine).
Fuel filter clogged, carburetor
malfunction, ignition malfunction,
valves stuck, etc.
Engine lacks power
Possible Cause Correction
Air filter clogged. Clean or replace the air filter
Bad fuel; engine stored without
treating the gasoline, of refueled
with bad gasoline.
Fuel filter clogged, carburetor
malfunction, ignition malfunction,
valves stuck, etc.
Move the flywheel brake lever to RUN
position.
(Types 2 & 6: Throttle lever to FAST
position.
Type 5: Engine stop switch to ON)
Refer to the equipment manufacturer’s
instructions for servicing the battery
and related components.
Refuel with fresh gasoline.
Adjust or replace the spark plug
(page 10).
Dry and reinstall the spark plug. Start
the engine with the choke/throttle lever
in the FAST position.
(Types 4 & 5: Choke in the OFF
position).
Take the engine to an authorized
Honda servicing dealer or refer to the
shop manual to replace or repair faulty
components as necessary.
(page 10).
Refuel with fresh gasoline.
Take the engine to an authorized
Honda servicing dealer or refer to the
shop manual to replace or repair faulty
components as necessary.
Keep the engine level when transporting to reduce the possibility of
fuel leakage. Turn the fuel valve to the OFF position (see diagram,
TYPE 1 Step 1 on page 4).
Review the instructions provided with the equipment powered by this
engine for any procedures that should be followed for transporting.
12
ENGLISH
TECHNICAL INFORMATION
Serial Number and Type Location
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 ENGINE TYPE
GCV160
GCV190
DATE OF
PURCHASE
ELECTRIC STARTER TYPES
SERIAL
NUMBER
LOCATION
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.
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 1,500 meters (5,000 feet) 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.
__ __ __ __ __– __ __ __ __ __ __ __ __ __ __
__ __ __ __ __– __ __ __ __ __ __ __ __ __ __
SERIAL NUMBER AND
TYPE LOCATION
TYPE
LOCATION
SERIAL NUMBER
TYPE
ENGLISH
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., California Clean Air Act, and Environment Canada
EPA, California, and Canadian 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
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 8. 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.
13
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 18) for additional information.
Descriptive Term Applicable to Emission
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
(367 x 331 x 360 mm)
Dry weight 22 lb (9.8 kg) 26 lb (11.6 kg)
Engine type 4-stroke, overhead cam, single cylinder
Displacement
[Bore x Stroke]
* Net power
(in accordance with SAE
J1349)
* Max. net torque
(in accordance with SAE
J1349)
Oil capacity Dry engine: 18.6 oz (0.55 l)
**Refill amount: 12.0 ~ 13.5 oz (0.35 ~ 0.41 l)
Fuel tank capacity 0.25 US gal (0.91 l)
Fuel consumption 1.1 l/h at 3,000 rpm
Cooling system Forced air
Ignition system Transistorized magneto
PTO shaft rotation Counterclockwise
Charging system:
BBC types
Flywheel brake types 12 VDC, 0.20 A min. @ 2,900 rpm
9.8 cu in (160 cm
[2.5 x 2.0 in (64 x 50 mm)]
4.4 hp (3.3 kW) at 3,600 rpm
6.9 ft-lb (9.4 N•m) at 2,500 rpm
12 VDC, 0.15 A min. @ 2,900 rpm
14.4 x 13.9 x 14.2 in
(367 x 354 x 360 mm)
3
)
Quick Reference Information
Fuel Type Unleaded gasoline with a pump octane
Engine Oil Type SAE 10W-30, API SJ or later, for general
Carburetor Idle Speed 1,400 ± 150 rpm
Spark plug Type BPR6ES (NGK) (pressure washer
Maintenance Before each
use
First 5 hours Change engine oil. Refer to page 9.
Subsequent Refer to the maintenance schedule on
** Actual amount will vary due to residual oil remaining in the engine. Always
use the dipstick to confirm the actual level (see page 9)
Tuneup
ITEM SPECIFICATION MAINTENANCE
Spark plug gap 0.028 ~ 0.031 in
Valve clearance (cold) IN: 0.15 ± 0.04 mm
Other specifications No other adjustments needed.
rating of 86 or higher (page 9).
use. Refer to page 9.
** Refill amount: 12.0 ~ 13.5 oz
applications)
BPR5ES (NGK (all other applications)
Check engine oil level. Refer to page 9.
Check air filter. Refer to page 9.
page 8.
(0.7 ~ 0.8 mm)
EX: 0.20 ± 0.04 mm
(0.35 ~ 0.41 l)
Refer to page 10.
See your authorized
Honda dealer
GCV190
Type Recoil start Electric start
Length x Width x Height 14.4 x 13.0 x 14.5 in
Dry weight 27.1 lb (12.3 kg) 29.3 lb (13.3 kg)
Engine type 4-stroke, overhead cam, single cylinder
Displacement
[Bore x Stroke]
* Net power
(in accordance with SAE
J1349)
* Max. net torque
(in accordance with SAE
J1349)
Oil capacity Dry engine: 18.6 oz (0.55 l)
Fuel tank capacity 0.25 US gal (0.91 l )
Fuel consumption 1.3 l/h at 3,000 rpm
Cooling system Forced air
Ignition system Transistorized magneto
PTO shaft rotation Counterclockwise
Charging system:
BBC types
Flywheel brake types 12 VDC, 0.20 A min. at 2,900 rpm
* The power rating of the engine indicated in this document is the net power
output tested on a production engine for the engine model and measured in
accordance with SAE J1349 at 3,600 rpm (net power) and at 2,500 rpm (max
net torque). Mass production engines may vary from this value. Actual power
output for the engine installed in the final machine will vary depending on
numerous factors, including the operating speed of the engine in application,
environmental conditions, maintenance, and other variables.
** Actual amount will vary due to residual oil remaining in the engine. Always
use the dipstick to confirm the actual level (see page 9)
(367 x 331 x 368 mm)
11.4 cu in (187 cm
[2.7 x 2.0 in (69 x 50 mm)]
5.1 hp (3.8 kW) at 3,600 rpm
8.3 ft-lb (11.3 N•m) at 2,500 rpm
** Refill amount: 12.0 ~ 13.5 oz (0.35 ~ 0.41 l)
12 VDC, 0.15 A min. at 2,900 rpm
14.4 x 13.9 x 14.5 in
(367 x 354 x 368 mm)
3
)
14
ENGLISH
Battery Connections
Use the following materials to connect a 12-volt battery to the starter
on type 7 units (with electric start switch/fixed throttle/manual choke):
• Battery – 12-volt lead acid battery with a recommended ampere-hr
rating of 3 Ah or a 14.4-volt NiCd battery with a recommended
ampere-hr rating of 1.7 Ah.
• Wire – 12-gauge (minimum) wire with a maximum length of
10 feet (3 meters).
• Fuse – 40-ampere blade type fuse.
• Term in al – Delphi 56 series male connector and terminal to
connect to the starter motor.
Coat the battery terminals and cable ends with dielectric grease. Be
careful not to connect the battery in reverse polarity.
Wiring Diagrams
RECOIL STARTER
(All Types)
[1]
ELECTRIC STARTER
(Type 4 with Flywheel Brake)
[2]
BLACK
[3]
ENGINE SWITCH
RUN OPEN
STOP CLOSE
CONTACT
B WARNING
A battery can explode if you do not follow the correct
procedure, seriously injuring anyone nearby.
Keep all sparks, open flames, and smoking materials away
from the battery.
WARNING: Battery posts, terminals and related accessories contain
lead and lead compounds. Wash hands after handling.
1. Connect the battery positive (+) cable using the appropriate
connector and insulator to the supplied starter connector.
2. Connect the battery negative (-) cable to an engine mounting bolt,
frame bolt, or the provided ground position on the starter motor
(requires 5 x 8 mm screw).
3. Connect the battery positive (+) cable to the battery positive (+)
terminal as shown.
4. Connect the battery negative (-) cable to the battery negative (-)
terminal as shown.
The following diagram only shows connections for type 7 units
(with electric start switch/fixed throttle/manual choke). Connections
are different for the other electric start types (types 4 and 6).
STARTER GROUND (-)
WIRE
BATTERY
NEGATIVE (-)
TERMINAL
STARTER
MOTOR
BLACK
[1]
ELECTRIC STARTER
(Type 6 with Blade Brake Clutch)
[1]
ELECTRIC STARTER
(Type 7 with starter switch on the engine)
[2]
[2]
[8]
[8]
[3]
OFF
E
ON
[4]
STOP
ON
M
WHITE
BLACK
WHITE
[3]
OFF E ON
M
[4]
BAT
OFF
ST
[5]
[7]
Supplied by equipment
manufacturer.
[3]
[7]
[5]
Supplied by equipment
manufacturer.
STARTER MOTOR
POSITIVE (+) CONNECTOR
(from starter switch)
40 AMP FUSE
BATTERY POSITIVE
BATTERY
(+) TERMINAL
If the engine is not equipped with a charge coil, the battery will lose
charge during starter motor operation only. There is no drain on the
battery once the engine is running.
The battery must be charged by an external battery charging system if
the engine is not equipped with a charge coil. Refer to the equipment
manufacturer’s instructions or the battery manufacturer for specific
external battery charging recommendations.
ENGLISH
[1]
[2]
BLACK
IG BAT
[5]
E ST
[8]
[4]
STOP
ON
START
RED
M
WHITE
Supplied by equipment
manufacturer.
[5]
IG E ST BAT
OFF
[6]
BAT
ST
[7]
[1] SPARK PLUG [5] STARTER SWITCH
[2] IGNITION COIL [6] FUSE (40A)
[3] ENGINE STOP SWITCH [7] BATTERY (+)
[4] STARTER MOTOR [8] CHARGE COIL (if equipped)
15
CONSUMER INFORMATION
Distributor/Dealer Locator Information
Distributor’s Warranties
The applicable warranty is the warranty policy in effect in the country where
the warranty service is provided.
United States, Puerto Rico, and U.S. Virgin Islands:
Visit our website: www.honda-engines.com
Canada:
Call (888) 9HONDA9
or visit our website: www.honda.ca
Honda Publications
Shop
Manual
Parts
Catalog
This manual covers complete maintenance and overhaul
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.
This manual provides complete, illustrated parts lists. Available
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.
<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 13)
• 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: (770) 497-6400, 8:30 am - 7:00 pm ET
Canada:
Honda Canada, Inc.
Please visit www.honda.ca for contact information
Telephone: (888) 9HONDA9 Toll free
(888) 946-6329
Facsimile: (877) 939-0909 Toll free
Distributor’s Limited Warranty
United States, Puerto Rico, or the U.S. Virgin Islands
PRODUCTS COVERED
BY THIS WARRANTY:
RESIDENTIAL
GCV Series Engines 24 months 12 months
(1)
Private Residential: Used in maintaining owner’s primary and/or secondary
residence. Any other use, including but not limited to informal “for hire” use, is
considered commercial/rental/institutional.
(2)
Honda GCV general purpose engines are not covered by this warranty
when installed on concession type vehicles.
To Qualify for this Warranty:
The Honda general purpose engine must be purchased from a Honda general
purpose engine dealer or distributor authorized to sell that product in the
United States, Puerto Rico, or the U.S. Virgin Islands. This limited warranty
applies to first retail purchaser and each subsequent owner during the
applicable warranty time period.
What American Honda Will Repair or Replace Under Warranty:
American Honda will repair or replace, at its option, any part that is proven to
be defective in material or workmanship under normal use during the
applicable warranty time period. Warranty repairs and replacements will be
made without charge for parts or labor. Anything replaced under warranty
becomes the property of American Honda Motor Company, Inc. All parts
replaced under warranty will be considered as part of the original product and
any warranty on those parts will expire coincident with the original product
warranty.
To Obtain Warranty Service:
You must take your Honda general purpose engine, or the equipment in which
it is installed, together with proof of original retail purchase date, at your
expense, to a Honda engine dealer or distributor authorized to sell that product
in the United States, Puerto Rico, or the U.S. Virgin Islands, during their
normal business hours. Many Honda engine dealers and distributors are listed
in the yellow pages of the telephone directory under gasoline engines, lawn &
garden equipment & supplies, etc.
If you are unable to obtain warranty service, or are dissatisfied with the
warranty service you receive, take the following steps: First contact the owner
of the dealership or distributor involved. Normally this should resolve the
problem. However, if you should require further assistance, write or call the
Power Equipment Customer Relations Department of American Honda Motor
Co., Inc. listed in the adjacent column.
Exclusions:
This warranty does not extend to parts affected or damaged by the product in
which the engine is installed, or by collision, misuse, neglect, parts worn
beyond service limits due to normal wear/normal service life, parts affected or
damaged by the conversion to or use of fuel other than the fuel(s) which the
engine is originally manufactured to use, poor operation related to fuel
contamination or fuel quality, parts damaged by fuel contamination, the
incorporation of, or use of, unsuitable attachments or parts, the unauthorized
alteration of any part or any causes other than defects in material or
workmanship of the engine. Use of the Honda general purpose engine for
racing or competition will void this warranty. Any engine that is part of a
product that has ever been declared a total loss or sold for salvage by a
financial institution or insurer.
Disclaimer of Consequential Damage and Limitation of Implied
Warranties:
American Honda disclaims any responsibility for loss of time or use of the
engine, or the equipment in which the engine is installed, transportation,
commercial loss, or any other incidental or consequential damage. Any implied
warranties are limited to the duration of this written limited warranty. Some
states do not allow limitations on how long an implied warranty lasts and/or do
not allow the exclusion or limitation of incidental or consequential damages, so
the above exclusions and limitations may not apply to you. This warranty gives
you specific legal rights, and you may also have other rights which vary from
state to state.
LENGTH OF WARRANTY:
(FROM DATE OF ORIGINAL PURCHASE)
PRIVATE/
COMMERCIAL/RENTAL/
(1)
INSTITUTIONAL
(2)
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ENGLISH
Distributor’s Warranty Canada
Honda Canada Inc., for and on behalf of Honda Motor Co. Ltd., Tokyo, Japan,
gives the following written warranty on each new General Purpose Engine
manufactured by Honda Motor Co. Ltd., Japan, distributed in Canada by
Honda Canada Inc. and sold as part of the original equipment of machinery or
equipment when such machinery or equipment is manufactured in Canada.
Whenever used herein, the word “Honda” refers to Honda Canada Inc. and/or
Honda Motor Co. Ltd. as appropriate from the context.
Honda warrants that each new Honda General Purpose Engine will be free,
under normal use and maintenance, from any defects in material or
workmanship for the relevant warranty period set forth below. If any defects
should be found in a Honda General Purpose Engine within the relevant
warranty period, necessary repairs and replacements with a new part or the
Honda equivalent shall be made at no cost to the consumer for parts and
labour (except for labour charges due to the presence of an attachment), when
Honda acknowledges that such defects are attributable to faulty material or
workmanship at the time of manufacture.
WARRANTY PERIOD
Warranty coverage commences from the original date of sale or when the unit
is first put into use as a demonstrator.
MODEL NON-COMMERCIAL COMMERCIAL RENTAL CONCESSION
GCV160
GCV190
NOTE: Concession use refers to Go Karts, etc.
THIS WARRANTY COVERS:
a) Any Honda General Purpose Engine purchased from a Honda general
purpose engine dealer or distributor authorized to sell that product in
Canada.
b) Any factory installed part (except normal maintenance parts referred to in
“THIS WARRANTY DOES NOT COVER”); and
c) Any General Purpose Engine on which required maintenance services
have been performed as prescribed in the Owner's Manual.
THIS WARRANTY DOES NOT COVER:
a) Any repairs required as a result of collision, striking any object, racing,
misuse or lack of required maintenance.
b) Any repairs required as a result of any attachments, parts or devices
installed by or repairs done by a party other than the Original Equipment
Manufacturer or an authorized Honda Power Products dealer.
c) Any Honda General Purpose Engine modified, altered, disassembled or
remodelled;
d) Normal maintenance services, including tightening of nuts, bolts and
fittings and engine tune-up and the replacement of parts made in
connection with normal maintenance services including filters, spark
plugs and wires, fuses, belts, lubricants and other expendables
susceptible to natural wear.
THE OWNER’S OBLIGATION
In order to maintain the validity of this DISTRIBUTOR'S WARRANTY, the
required maintenance services as set forth in the Owner's Manual must be
performed at the proper intervals and detailed receipts and records retained as
proof.
TO OBTAIN WARRANTY SERVICE
You must take your Honda General Purpose Engine, at your expense, during
normal service hours, to the authorized Honda Power Products dealer or the
dealer designated by the manufacturer of the machinery or equipment
powered by the Honda engine. If you are unable to obtain or are dissatisfied
with the warranty service you receive, first contact the owner of the dealership
involved; this should resolve the problem. If you require further assistance,
contact Honda Canada Inc., at the address shown under Customer Service
Information (page 16).
REPLACEMENT PARTS WARRANTY
New Honda Genuine replacement parts sold to a consumer or installed by an
authorized Honda power equipment dealer which are not covered by the
DISTRIBUTOR'S WARRANTY are warranted for a period of one year from
date of purchase for normal use, or 3 months for rental or concession use
provided, however, that this Replacement Parts Warranty does not apply to
any replacement parts modified, used with, or installed on a power product for
which the replacement parts were not intended. Electrical components that are
not installed by the dealer (sold over the counter) are not covered by warranty.
24 months 3 months 3 months NONE
ENTIRE WRITTEN WARRANTY
This DISTRIBUTOR'S WARRANTY is the only and the entire written warranty
given by Honda for Honda General Purpose Engines. No dealer or his agent or
employee is authorized to extend or enlarge on these warranties on behalf of
Honda by any written or verbal statement or advertisement.
DISCLAIMER
To the extent the law permits, Honda disclaims any responsibility for loss of
time or use of the General Purpose Engine, transportation or towing costs or
any other indirect, incidental or consequential damage, inconvenience or
commercial loss.
NOTICE TO CONSUMER
The provisions contained in these written warranties are not intended to limit,
modify, take away from, disclaim or exclude any warranties set forth in or the
operation of The Consumer Products Warranties Act, 1977 (Saskatchewan),
The Consumer Product Warranty and Liability Act (New Brunswick), The
Consumer Protection Act (Quebec), or any other similar provincial or federal
legislation.
International Warranty
See last pages.
ENGLISH
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