Honda GS160 Owner's Manual
OWNER’S MANUAL
GS160 • GS190
[1]
[2]
[3]
[5]
[9]
[8]
[6]
[7]
[4]
COMPONENT LOCATION
1 Fuel filler cap 7 Muffler
2 Starter grip 8 Muffler deflector (optional)
3 Fuel tank 9 Oil filler cap/ dipstick
4 Control location * 10 Oil drain bolt
5 Air cleaner 11 Engine serial number and type
6Spark plug
* 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.
[11]
[10]
California Proposition 65
This product contains or emits chemicals
known to the state of California to cause cancer,
birth defects or other reproductive harm.
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
ENGLISHFRANÇAISESPAÑOL
Click to Save As
00X31Z2C A110
EM5
© 2003–2014 American Honda Motor Co., Inc.—All Rights Reserved
HPE.2014.02
PRINTED IN U.S.A.
1
[2]
[1]
[2]
[1]
[2]
[1]
[1]
[1]
CLOSED
OPEN
SLOW
FAST
[2]
STOP
FAST
[3]
[4]
ON
OFF
[4]
ON
[1]
OFF
Type/Tipo 1 Type/Tipo 2 Type/Tipo 3
Type/
Tipo 1
Manual Choke [1],
Manual Throttle (gray) [2]
Étrangleur Manuel [1],
Accélérateur Manuel [2]
Choke Manual [1],
Acelerador Manual [2]
Figure/Figura 1
Type/
Tipo 2
Manual Choke [1], Ignition Switch
Lever (red) [2], Fixed Throttle
Étrangleur Manuel [1], Levier de
Commande D’allumage [2],
Accélérateur Fixe
Choke Manual [1], Palanca del
Interruptor de Encendido [2],
Acelerador Fijo
Figure/Figura 2
Type/
Tipo 3
Manual Choke [1], Engine Stop Switch
[2], Fixed Throttle
Étrangleur Manuel [1], Interrupteur
d’arrêt du Moteur [2], Accélérateur Fixe
Choke Manual [1], Interruptor de
Parada del Motor [2], Acelerador Fijo
Figure/Figura 3
Figure/Figura 4
2
Figure/Figura 5
Figure/Figura 6
Figure/Figura 7 Figure/Figura 8
[1]
[1]
[3]
[2]
-20 20 30 40°C-10 0 10
40 60 100°F80020
30
5W-30 • 10W-30
[1]
[2]
[3]
[5]
[4]
[3]
[2]
[1]
[6]
[7]
[1]
0.028 ~ 0.030 in
(0.70 ~ 0.80 mm)
[2]
[2]
[1]
[3]
[5]
[4]
[1]
Figure/Figura 9
Figure/Figura 10
Figure/Figura 11 Figure/Figura 12
Figure/Figura 13
3
ENGLISH
NOTICE
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
SAFE OPERATING PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . 5
STARTING/STOPPING THE ENGINE (ALL TYPES) . . . . . . . . . . . 5
SERVICING YOUR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REFUELING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AIR CLEANER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPARK ARRESTER (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STORING YOUR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TAKING CARE OF UNEXPECTED PROBLEMS . . . . . . . . . . . . . . . . . 9
TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONSUMER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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
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
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
CAUTION.
These signal words mean:
Each message tells you what the hazard is, what can happen, and
what you can do to avoid or reduce injury.
4
and one of three words, DANGER, WARNING, or
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.
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 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 6).
2. Oil level (page 7).
®
The Oil Alert
stop the engine before the oil level falls below safe limits. However,
to avoid the inconvenience of an unexpected shutdown, always
check the engine oil level before startup.
3. Air cleaner (page 7).
4. General inspection: Check for fluid leaks and loose or damaged
parts.
5. Check the equipment powered by this engine.
ENGLISH
system (applicable engine types) will automatically
Review the instructions provid ed with the equipment powered by
NOTICE
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 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°.
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 8) for additional information regarding fuel
deterioration.
STARTING/STOPPING THE ENGINE (ALL TYPES)
See the figures on the top of 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.
• Manual choke: Place the choke lever/rod [1] 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.
Do not allow the starter grip to snap back against the engine.
Return it gently to prevent damage to the starter.
OIL ALERT® SYSTEM (APPLICABLE ENGINE TYPES)
The Oil Alert system is designed to prevent engine damage caused
by an insufficient amount of oil in the crankcase. Before the oil level in
the crankcase can fall below a safe limit, the Oil Alert system will
automatically stop the engine [the throttle lever (ignition switch lever)
will remain in a run position].
If the engine stops and will not restart, check the engine oil level
(page 7) before troubleshooting in other areas.
Type 1: Manual Choke, Manual Throttle
ST ARTING THE ENGINE
1. Move the choke rod [1] to the CLOSED position (cold engine)
(see Figure 1, page 2).
2. Move the throttle lever (gray) [2] to the SLOW position, about 1/3
of the way toward the FAST position (see Figure 2, page 2).
Some engine applications use a remotely-mounted throttle control
rather than the engine-mounted throttle lever shown.
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
4. If the choke rod was pulled to the CLOSED position to start the
engine, push it to the OPEN position as soon as the engine warms
up enough to run smoothly.
5. Position the throttle control lever (gray) for the desired engine
speed.
STOPPING THE ENGINE
1. Move the throttle control lever (gray) to the SLOW position.
2. Allow the engine to idle for a few seconds; then move the throttle
control lever to the STOP position.
Type 2: Manual Choke, Ignition Switch Lever,
Fixed Throttle
ST ARTING THE ENGINE
1. Move the choke rod [1] to the CLOSED position (cold engine)
(see Figure 1, page 2).
2. Move the ignition switch lever (red) [4] to the ON position (see
Figure 4, page 2).
Some engine applications use a remote-mounted ignition switch
rather than the engine-mounted lever shown.
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
4. If the choke rod was pulled to the CLOSED position to start the
engine, push it to the OPEN position as soon as the engine warms
up enough to run smoothly.
The engine speed is preset on this type.
STOPPING THE ENGINE
Move the ignition switch lever (red) to the OFF position
(see Figure 5, page 2).
Type 3: Manual Choke, Engine Stop Switch, Fixed Throttle
Some engine applications use a remote-mounted engine stop
switch rather than the engine-mounted engine stop switch shown.
Refer to the instructions provided by th e eq u i pment manufacturer .
ST ARTING THE ENGINE
1. Move the choke rod [1] to the CLOSED position (cold engine)
(see Figure 1, page 2).
2. Move the engine stop switch [2] to the ON position (see Figure 6,
page 2).
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
4. If the choke rod was pulled to the CLOSED position to start the
engine, push it to the OPEN position as soon as the engine warms
up enough to run smoothly.
The engine speed is preset on this type.
STOPPING THE ENGINE
Move the engine stop switch to the OFF position (see Figure 6,
page 2).
ENGLISH
5
SERVICING YOUR ENGINE
THE IMPORTANCE OF MAINTENANCE
Good maintenance is essential for safe, economical, and trouble-free
operation. It will also help reduce pollution.
MAINTENANCE SCHEDULE
Perform at every indicated month/year or operating hour interval,
whichever comes first.
Regular
Service Period
(1)
Item Page
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
EP A 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.
Before each
use
First month
Check: Engine oil level
Check: Air filter
page 7
page 7
Change: Engine oil page 7
or 5 hours
Every 3 months
Clean: Air filter
(2)
page 7
or 25 hours
Every 6 months
or 50 hours
Every year
or 100 hours
Change: Engine oil
Clean: Air filter
6 month items above plus:
Check-adjust: Spark plug
Clean: Spark arrester (if equipped)
Check-adjust: Idle speed
Clean: Fuel tank and filter
Check-adjust: Valve clearance
Every 2 years
or 200 hours
Yearly items above plus:
Replace: Air filter
Replace: Spark plug
Every 2 years Check: Fuel lines
(2)
(4)
(3)
(4)
(4)
(replace if
page 7
page 7
page 8
page 8
(4)
page 7
page 8
necessary)
(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. See “Honda
PUBLICATIONS” on
page 11 for ordering information.
Failure to follow this maintenance schedule could result in
non-warrantable failures.
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
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.
Y ou 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 8) for additional information regarding fuel
deterioration.
ENGLISH
Never use stale or contaminated gasoline or oil/gasoline mixture.
NOTICE
NOTICE
NOTICE
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 7, page 3.
1. Remove the fuel tank cap.
2. Add fuel to the bottom of the fuel level limit [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 an d
site before starting the engine.
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.
Oil Change
See Figure 9, page 3.
Drain the engine oil when the engine is warm. Warm oil drains quickly
and completely.
1. Place a suitable container next to the engine to catch the used oil.
2. Remove the oil filler cap/dipstick [1], and the oil drain plug [2] and
washer [3].
3. Allow the used oil to drain completely; then reinstall the drain plug
and new washer. Tighten the drain plug securely.
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
(bottom edge of the oil fill hole) on the dipstick with the
recommended oil. Do not overfill.
Capacity: 20 oz (0.58 L)
Running the engine with a low oil level can cause engine damage.
This type of damage is not covered by the Distributor’s Limited
Warranty.
5. Reinstall the oil filler cap/dipstick [1] securely .
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. Always
change the oil in accordance with the maintenance schedule
(page 6).
Recommended Oil
See Figure 8, 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.
Oil Level Check
See Figure 8, 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, fill with the recommended oil to the upper limit mark [3].
Do not overfill.
5. Reinstall the oil filler cap/dipstick [1].
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.
Operating the engine without an air filter, or with a 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
See Figure 10 on page 3.
1. Press the latch tabs [1] on the top of the air cleaner cover [2], and
remove the cover.
2. Remove the foam element [3] from the air cleaner cover.
3. Remove the grid [4] from the paper element [5].
4. Check both elements to be sure they are clean and in good
condition.
5. Reinstall the grid over the paper element. Make sure that the grid
completely surrounds the paper pleats.
6. Reinstall the foam element in the air cleaner cover.
7. Set the paper element and screen grid in the air cleaner body, and
then install the air cleaner cover.
Cleaning
1. Tap the filter [5] 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.
ENGLISH
7
2. Foam Element [3]: Wash the element in a solution of household
NOTICE
NOTICE
NOTICE
NOTICE
detergent and warm water, then rinse thoroughly, or wash in
nonflammable or high flash point solvent. Allow the element to dry
thoroughly.
Soak the element in clean engine oil and squeeze out the excess
oil. The engine will smoke during initial start-up if too much oil is left
in the foam, or the oil could saturate the paper element making the
engine inoperable.
3. Wipe dirt from the air cleaner body [7] and cover using a moist rag.
Be careful to prevent dirt from entering the air duct [6] that leads to
the carburetor.
SPARK PLUG
See Figure 11, page 3.
Recommended Spark Plug: NGK - BPR6ES
The recommended spark plug is the correct heat range for normal
engine operating temperatures.
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 ~ 0.031 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.
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.
SPARK ARRESTER (IF EQUIPPED)
See Figure 12, 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 4 mm 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.
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
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.
8
ENGLISH
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.
Long Term or Seasonal Storage (greater than 90 days)
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.
WARNING
Gasoline is highly flammable and explosive, and you can
be burned or seriously injured when handling fuel.
• Stop engine and keep heat, sparks, and flame away.
• Refuel only outdoors.
• Wipe up spills immediately.
1. Use a siphon pump (commercially available) and siphon the fuel
out of the fuel tank into an approved gasoline container. (see
Figure 13, page 3)
2. Place an approved gasoline container below the carburetor, and
use a funnel to avoid spilling fuel.
3. Loosen the carburetor drain screw [1] and drain the carburetor into
an approved gasoline container. After draining is completed,
tighten the carburetor drain screw.
ENGINE OIL
1. Change the engine oil (see page 7).
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.
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.
TAKING CARE OF UNEXPECTED PROBLEMS
Engine will not start
POSSIBLE CAUSE CORRECTION
Choke is OFF. Unless the engine is warm, move
the choke lever to the CHOKE
position.
Ignition switch or engine stop
switch is OFF.
Engine oil level is low (oil alert
models)
Out of fuel. Refuel
Bad fuel; engine stored
without treating gasoline, or
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 throttle lever to the
SLOW or FAST position
• Move th e ig n i ti on switch lever to
the ON position
• Move th e en gine stop switch to
the ON position
Fill with the recommended oil to
the proper level (page 7).
Drain the fuel tank and carburetor.
Refuel with fresh gasoline.
Adjust or replace the spark plug
(page 8).
Dry and reinstall the spark plug.
Start the engine with the choke in
the OFF position and the throttle
lever in the FAST 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 7).
Drain the fuel tank and carburetor.
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.
ENGLISH
9
TECHNICAL INFORMATION
NOTICE
EMISSION CONTROL SYSTEM INFORMATION
SERIAL NUMBER AND TYPE LOCATION
See figures on page 1.
Record the engine serial number and type in the space below. Y ou will
need this information when ordering parts and when making technical
or warranty inquiries.
MODEL SERIAL NUMBER TYPE
GS160 or GS190
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 operate d 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 using auto throttle type engines in high altitude applications,
the ability to idle down to 2500 rpm could be diminished. See your
servicing dealer for information on adjustme nt s if your au to throttle
unit does not idle down with the load released or has trouble returning
to full rpm with the load applied.
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.
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.
U.S. and California Clean Air Acts, and Canadian
Environment Protection Act
U.S. EPA, California, and Canadian regulations require all
manufacturers to furnish written instructions describing the operation
and maintenance of emissions control systems.
The following instructions and procedures must be followed in order to
keep the emissions from your Honda engine within the emissions
standards.
Tampering and Altering
Tampering is a violation of Federal and California law.
Tampering with or altering the emissions 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 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, backfiring under load, or afterburning
• Black exhaust smoke or high fuel consumption
Replacement Parts
The emissions control systems on your new Honda engine were
designed, built, and certified to conform with EPA, California, and
Canadian emissions 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 emissions
control system.
A manufacturer of an aftermarket part assumes the responsibility that
the part will not adversely affect emissions 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 emissions
regulations.
10
Maintenance
Follow the MAINTENANCE SCHEDULE on page 10. Remember 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.
ENGLISH
Air Index
[1]
[2] [3]
[4]
[5]
WITH OIL ALERT
An Air Index Information 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.
Quick Reference Information
Fuel Type Unleaded gasoline with a pump octane
rating of 86 or higher (
Engine Oil Type SAE 10W-30, API SJ or later, for general
use. Refer to page 7.
Carburetor Idle Speed 1,400 ± 150 rpm
Spark plug Type BPR6ES (NGK)
Maintenance Before each
use
First 5 hours
Subsequent Refer to the maintenance schedule on
Check engine oil level. Refer to
Check air filter. Refer to
Change engine oil. Refer to
page 6.
page 7).
page 7.
page 7.
page 7.
DESCRIPTIVE
TERM
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)
APPLICABLE TO EMISSION
DURABILITY PERIOD
Specifications
GS160
Length x Width x Height 13.3 x 14.5 x 13.0 in
(337 x 369 x 331 mm)
Dry weight 29.9 lb (13.6 kg)
Engine type 4-stroke, overhead cam, single cylinder
Displacement
[Bore x Stroke]
Oil capacity 20 oz (0.58 L)
Fuel tank capacity 0.52 gal (2.0 L)
Cooling system Forced air
Ignition system Transistorized magneto
PTO shaft rotation Counterclockwise
9.8 cu-in (160 cm
[2.5 x 2.0 in (64 x 50 mm)]
GS190
Length x Width x Height 13.6 x 14.5 x 13.0 in
(345 x 369 x 331 mm)
Dry weight 30.4 lb (13.8 kg)
Engine type 4-stroke, overhead cam, single cylinder
Displacement
[Bore x Stroke]
Oil capacity 20 oz (0.58 L)
Fuel tank capacity 0.52 gal (2.0 L)
Cooling system Forced air
Ignition system Transistorized magneto
PTO shaft rotation Counterclockwise
11.4 cu-in (187 cm
[2.7 x 2.0 in (69 x 50 mm)]
Tuneup Specifications
ITEM SPECIFICATION MAINTENANCE
Spark plug gap 0.028 ~ 0.031 in
(0.7 ~ 0.8 mm)
Valve clearance
(cold)
Other specifications No other adjustments needed.
IN: 0.15 ± 0.04 mm
EX: 0.20 ± 0.04 mm
Refer to
See your authorized
Honda dealer
3
)
3
)
page 8.
Wiring Diagrams
[1] SPARK PLUG [4] OIL LEVEL SWITCH
[2] IGNITION COIL [5] OIL ALERT UNIT
[3] IGNITION 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
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 visit
www.engines.honda.com and click on Product Manuals.
This manual provides complete, illustrated parts lists. Available
through your Honda dealer.
ENGLISH
11
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.engines.honda.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 9)
• 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 a.m. - 7:00 p.m. ET
Canada:
Honda Canada, Inc.
180 Honda Blvd, Markham, ON L6C 0H9
or visit: www.honda.ca
Telephone: (888) 9HONDA9 Toll free
(888) 946-6329
Facsimile: (877) 939-0909 Toll free
DISTRIBUTOR’S WARRANTIES
The applicable warranty is the warranty policy in effect in the country
where the warranty service is provided.
Distributor’s Limited Warranty
United States, Puerto Rico, or the U.S. Virgin Islands
This warranty is limited to Honda general purpose engines distributed by American Hon da
Motor Co., Inc., Power Equipment Division, 4900 Marconi Dr, Alpharetta, GA 30005.
The following warranty applies to engines purchased at retail or placed into rental service
on or after January 1, 2009.
PRODUCTS COVERED BY
THIS WARRANTY:
RESIDENTIAL
GS Series Engines 24 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 GS general purpose engines are not covered by this warranty when inst alled on
concession type vehicles.
LENGTH OF WARRANTY:
(FROM DATE OF ORIGINAL PURCHASE)
PRIVATE/
COMMERCIAL/RENTAL/
(1)
INSTITUTIONAL
3 months
(2)
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 ret ail 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 pu rchase date, at your expense, to a Honda
engine dealer authorized to sell that product in the United S tates, Puerto Rico, or the U.S.
Virgin Islands, during their normal business hours. To locate a dealer near you, visit our
web site at http://engines.honda.com and click on FIND A DEALER.
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 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 engine warranty does not include the following:
1. Any damage or deterioration resulting from the following:
- Neglect of the periodic maintenance as specified in the engine owner’s manual
- Improper repair or maintenance
- Operating methods other than those indicated in the engine owner’s manual
- Damage caused by the product on which the engine is installed
- Damage caused by conversion to, or use of, fuel other than the fuel(s) that the
engine was originally manufactured to use, as se t for th in the engine o wner’s manual and/or warranty booklet
- The use of non-genuine Honda parts and accessories, other than those approved
by Honda (other than recommended lubricants and fluids) (does not apply to the
emissions warranty unless non-genuine part used is not comp arable to Honda part
and was cause of the failure)
- Exposure of the product to soot and smoke, chemical agents, bird droppin gs, sea
water, sea breeze, salt or other environmental phenomena
- Collision, fuel contamination or deterioration, neglect, unauthorized alteration, or
misuse
- Natural wear and tear (natural fading of painted or plated surfaces, sheet peeling
and other natural deterioration)
2. Consumable parts: Honda does not warrant parts deterioration due to normal wear
and tear. The parts listed below are not covered by warranty (unless they are
needed as a part of another warranty repair):
- Spark plug, fuel filter, air cleaner element, clutch disc, recoil starter rope
- Lubricant: oil and grease
3. Cleaning, adjustment, and normal periodic maintenance work (carburetor cleaning
and engine oil draining).
4. Use of the Honda general purpose engine for racing or competition.
5. 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, commercia l 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 in cident al or consequent ial
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
.
PWL50372-O
12
ENGLISH
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