Honda Automobiles GCV160 User Manual
INTRODUCTION
Thank you for purchasing a Honda engine. We want to help you to get
the best results from your new engine and to 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
and one of three words, DANGER, WARNING, or CAUTION.
These signal words mean:
DANGER
WARNING
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.
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.
• 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.
© 2003–2007 American Honda Motor Co., Inc.—All Rights Reserved
31Z8B010
00X31-Z8B-0100
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.
IPC POM52684-L
EM5
XXX.2007.02
PRINTED IN U.S.A.
ENGLISH
OWNER’S MANUAL
MANUEL DE L’UTILISATUER
MANUAL DEL PROPIETARIO
GCV160 • GCV190
WARNING:
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
DAMAGE PREVENTION
MESSAGES . . . . . . . . . . . . . . 1
SAFETY INFORMATION . . . . 1
COMPONENT & CONTROL
LOCATION . . . . . . . . . . . . . . . . 2
BEFORE OPERATION CHECKS2
IS YOUR ENGINE READY TO
GO? . . . . . . . . . . . . . . . . . . . . 2
OPERATION. . . . . . . . . . . . . . . 2
SAFE OPERATING
PRECAUTIONS . . . . . . . . . . . 2
Type 1 Operation . . . . . . . . . 2
Type 2 Operation . . . . . . . . . 3
Type 3 Operation . . . . . . . . . 3
Type 4 Operation . . . . . . . . . . 4
Type 5 Operation . . . . . . . . . . 4
Type 6 Operation . . . . . . . . . . 4
Type 7 Operation . . . . . . . . . . 5
Type 8 Operation . . . . . . . . . . 5
SERVICING YOUR ENGINE . . 5
THE IMPORTANCE OF
MAINTENANCE . . . . . . . . . . . 5
MAINTENANCE SAFETY . . . 6
MAINTENANCE SCHEDULE. 6
REFUELING. . . . . . . . . . . . . . 6
ENGINE OIL. . . . . . . . . . . . . . 7
AIR CLEANER . . . . . . . . . . . . 7
SPARK PLUG . . . . . . . . . . . . 7
FLYWHEEL BRAKE
INSPECTION . . . . . . . . . . . . . 8
SPARK ARRESTER (optional
equipment) . . . . . . . . . . . . . . . 8
FRANÇAISESPAÑOL ENGLISH
HELPFUL TIPS &
SUGGESTIONS . . . . . . . . . . . . 8
STORING YOUR ENGINE. . . 8
ADDING A GASOLINE
STABILIZER TO EXTEND
FUEL STORAGE LIFE. . . . . . 9
DRAINING THE FUEL TANK
AND CARBURETOR . . . . . . . 9
TRANSPORTING. . . . . . . . . . 9
TAKING CARE OF
UNEXPECTED PROBLEMS . . 9
TECHNICAL INFORMATION . 10
SERIAL NUMBER AND TYPE
LOCATION. . . . . . . . . . . . . . 10
HIGH ALTITUDE
OPERATION . . . . . . . . . . . . 10
EMISSION CONTROL
SYSTEM INFORMATION . . 10
AIR INDEX . . . . . . . . . . . . . . 11
SPECIFICATIONS . . . . . . . . 11
BATTERY CONNECTIONS . 12
WIRING DIAGRAMS . . . . . . 12
CONSUMER INFORMATION. 13
HONDA PUBLICATIONS. . . 13
DISTRIBUTOR’S LIMITED
WARRANTIES . . . . . . . . . . . 13
EMISSION CONTROL
SYSTEM
WARRANTY. . . . . . . . . . . . . 14
DISTRIBUTOR/DEALER
LOCATOR INFORMATION . 13
CUSTOMER SERVICE
INFORMATION . . . . . . . . . . 13
INTERNATIONAL WARRANTY
INFORMATION . . . . . last page
1
COMPONENT & CONTROL LOCATION
E
BEFORE OPERATION CHECKS
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.
STARTER GRIP
OIL FILLER CAP/
DIPSTICK
ENGINE CONTROL TYPES
TYPE 1: FLYWHEEL BRAKE/
REMOTE THROTTLE
THROTTLE
LEVER
TYPE 2: MANUAL CHOKE/
TYPE 2: MANUAL CHOKE/
MANUAL
MANUAL THROTTLE
CHOKE LEVER
STARTER MOTOR
(if equipped)
FLYWHEEL BRAKE
CONTROL LEVER
FUEL FILLER CAP
AIR CLEANER
SPARK
PLUG
MUFFLER
ENGINE
CONTROL
AREA
TYPE 5: MANUAL CHOKE/FIXED THROTTL
ENGINE
STOP
SWITCH
FUEL VALVE
LEVER
TYPE 6: REMOTE THROTTLE/BLADE
BRAKE CLUTCH
(equipment control)
THROTTLE
LEVER
CHOKE ROD
FUEL TANK
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.
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 pre-operation inspection before each
operation, and correct any problem.
Before beginning your pre-operation 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 (see page 6).
2. Oil level (see page 7).
3. Air cleaner (see page 7).
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 1 and the BEFORE
OPERATION CHECKS above.
THROTTLE
LEVER
TYPE 3: FLYWHEEL BRAKE/REMOTE
FLYWHEEL
BRAKE
CONTROL
CABLE
CHOKE
CONTROL
CABLE
FUEL VALVE
LEVER
TYPE 4: AUTOMATIC CHOKE RETURN/
CHOKE
LEVER
FLYWHEEL
BRAKE
CONTROL
CABLE
FUEL VALVE
LEVER
FUEL VALVE LEVER
CHOKE/FIXED THROTTLE
FIXED THROTTLE
FUEL VALVE
LEVER
TYPE 7: ELECTRIC START (WITH
ENGINE-MOUNTED STARTER SWITCH)/
MANUAL CHOKE/PRESET THROTTLE
STARTER
SWITCH
CHOKE
ROD
FUEL VALVE
LEVER
TYPE 8: AUTOMATIC CHOKE/
FIXED THROTTLE
FLYWHEEL
BRAKE
CONTROL
CABLE
FUEL VALVE
LEVER
WARNING
Carbon monoxide gas is toxic. Breathing it can cause
unconsciousness and even kill you.
Avoid any areas or actions that expose you to carbon
monoxide.
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.
TYPE 1: FLYWHEEL BRAKE/REMOTE THROTTLE
Starting The Engine
1. Turn the fuel valve to the ON
position.
ON
FUEL
VALVE
OFF
2
ENGLISH
2. See equipment manual and
position the throttle control
so the choke/throttle lever
moves to the CHOKE
position (cold engine).
SLOW
CHOKE/
THROTTLE
LEVER
FAST
CHOKE
TYPE 2: MANUAL CHOKE/MANUAL THROTTLE
Starting The Engine
1. Turn the fuel valve to the ON position (see TYPE 1 Step 1 on
page 2).
2. Move the choke lever to the ON position (cold engine).
3. Move the throttle lever to the FAST position.
SLOW
STOP
FAST
CHOKE LEVER
3. See equipment manual
and position the flywheel
FLYWHEEL
BRAKE LEVER
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.
NOTICE
Do not allow the starter grip to snap
back against the engine. Return it
STARTER
GRIP
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
CHOKE/
THROTTLE
LEVER
FAST
CHOKE
enough to run smoothly without
use of the choke.
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
SLOW
FAST
the SLOW position.
THROTTLE
LEVER
2. Release the flywheel
brake lever to stop the
engine.
FLYWHEEL
BRAKE LEVER
3. Turn the fuel valve to
the OFF position (see
TYPE 1 Step 1 on
page 2).
ENGLISH
OFF
FUEL
VALVE
THROTTLE
LEVER
ON
ON
4. Pull the starter grip lightly until resistance is felt, then pull briskly
(see TYPE 1 Step 4 on page 3).
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 (see TYPE 1 Step 1 on
page 2).
TYPE 3: FLYWHEEL BRAKE/REMOTE CHOKE/FIXED
THROTTLE
Starting The Engine
1. Turn the fuel valve to the
ON position (see TYPE 1
CHOKE
ARM
OFF
Step 1 on page 2).
2. Move the choke control
cable (see equipment
manual) so that the choke
arm moves to the choke
CHOKE CONTROL
CABLE
FUEL VALVE
ON position (cold engine).
3. Move the flywheel brake lever
to the RUN position.
FLYWHEEL BRAKE LEVER
4. Pull the starter grip lightly until
resistance is felt, then pull
STOP
briskly (see TYPE 1 Step 4 on
page 3).
RUN
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.
Stopping The Engine
1. Release the flywheel brake lever to stop the engine.
2. Turn the fuel valve to the OFF position (see TYPE 1 Step 1 on
page 2).
ON
ON
3
TYPE 4: AUTOMATIC CHOKE RETURN/FIXED THROTTLE
Starting The Engine
1. Turn the fuel valve to the ON
position (see TYPE 1
Step 1 on page 2).
2. Move the choke lever to the
choke position () (cold
engine).
3. Move the flywheel brake
lever to the RUN position.
The choke lever
automatically begins moving
to the OFF position when the flywheel brake lever is moved to the
RUN position.
4. Start the engine.
Recoil Starter Types
Pull the starter grip lightly until resistance is felt, then pull briskly
(see TYPE 1 Step 4 on page 3). Begin pulling the starter grip 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.
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 (see TYPE 1 Step 1 on
page 2).
OFF
CHOKE
LEVER
STOP
RUN
ON
FLYWHEEL
BRAKE LEVER
TYPE 5: MANUAL CHOKE/FIXED THROTTLE
Starting The Engine
1. Turn the fuel valve to the ON
position (see TYPE 1
Step 1 on page 2).
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 3).
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.
Stopping The Engine
1. Move the engine switch to the OFF position.
2. Turn the fuel valve to the OFF position (see TYPE 1 Step 1 on
page 2).
ENGINE STOP SWITCH
OFF
ON
CHOKE
ROD
ON
TYPE 6: REMOTE THROTTLE/BLADE BRAKE CLUTCH
Starting The Engine
1. Turn the fuel valve to the ON position (see TYPE 1 Step 1 on
page 2).
2. Move the choke/
throttle/stop lever to
STOP
SLOW
the CHOKE position
(cold engine).
Make sure the blade
control lever is
disengaged (see
equipment manual).
CHOKE/
THROTTLE/
STOP
LEVER
3. Start the engine.
Recoil Starter Types
Pull the starter grip
lightly until
resistance is felt,
then pull briskly (see
TYPE 1 Step 4 on
page 3).
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
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).
4
ENGLISH
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 OFF (see TYPE 1 Step 1 on page 2).
TYPE 7: ELECTRIC START WITH ENGINE-MOUNTED
STARTER SWITCH/MANUAL CHOKE CONTROL/
PRESET THROTTLE
Starting The Engine
1. Turn the fuel valve to the ON
position (see TYPE 1
Step 1 on page 2).
2. Pull the choke rod to the ON
position (see TYPE 5 Step 2
on page 4) (cold engine).
3. 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 3).
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.
Stopping The Engine
1. Move the starter switch to the STOP position.
2. Turn the fuel valve to the OFF position (see TYPE 1 Step 1 on
page 2).
STARTER
SWITCH
STOP
ON
START
TYPE 8: AUTOMATIC CHOKE/FIXED THROTTLE
Starting The Engine
1. Turn the fuel valve to the ON
position (see TYPE 1
Step 1 on page 2).
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 3).
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 (see TYPE 1 Step 1 on
page 2).
FLYWHEEL BRAKE CONTROL CABLE
FUEL VALVE
LEVER
SERVICING YOUR ENGINE
THE IMPORTANCE OF MAINTENANCE
Good maintenance is essential for safe, economical and trouble-free
operation. It will also help reduce pollution.
WARNING
Improper maintenance, or failure to correct a problem
before operation, can cause a malfunction in which you
can be seriously hurt or killed.
Always follow the inspection and maintenance
recommendations and schedules in this owner’s manual.
To help you properly care for your engine, the following pages include
a maintenance schedule, routine inspection procedures, and simple
maintenance procedures using basic hand tools. Other service tasks
that are more difficult, or require special tools, are best handled by
professionals and are normally performed by a Honda technician or
other qualified mechanic.
The maintenance schedule applies to normal operating conditions. If
you operate your engine under severe conditions, such as sustained
high-load or high-temperature operation, or use in unusually wet or
dusty conditions, consult your servicing dealer for recommendations
applicable to your individual needs and use.
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.
ENGLISH
5
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.
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.
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
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 covered under warranty.
• 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.
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.
WARNING
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.
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 genuine Honda
parts or their equivalents for repair and replacement.
MAINTENANCE SCHEDULE
Item (1) Action Each
Engine oil Check O7
Change O O (3) 7
Air cleaner Check OO7
Clean O (2)
Replace O
Spark plug Check-Adjust O7
Replace O
Blade brake
clutch
Flywheel
brake pad
Spark
arrester
Idle
speed
Fuel tank
and filter
Fuel line Check Every 2 years (4) Shop
Valve
clearance
Combustion
chamber
(1) For commercial use, log hours of operation to determine proper maintenance
(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
(4) These items should be serviced by an authorized Honda servicing dealer, unless
* See your equipment manual or Honda engine shop manual.
Failure to follow this maintenance schedule could result in non-warrantable failures.
Check O
Check O8
Clean O8
Adjust O (4) Shop
Check O (4) Shop
Check-Adjust O (4) Shop
Clean After every 250 hours (4) Shop
intervals.
temperatures.
you have the proper tools and are mechanically proficient. Refer to the Honda shop
manual for service procedures.
Use
or 5
Hrs.
First
Month
or
5 Hrs.
or
25 Hrs.or50 Hrs.
Every Season Every
100
Hrs.
Every
150
Hrs.
(200 Hrs.)
(200 Hrs.)
Page
*
manual
manual
manual
manual
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 (see
page 13).
Never use stale or contaminated gasoline or oil/gasoline mixture.
Avoid getting dirt or water in the fuel tank.
Move at least 3 meters (10 feet) away from the fueling source and site
before starting the engine.
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.
3. Secure the fuel tank cap.
a. Non-tether type:
Tighten the cap securely.
b. Tether type:
Tighten the cap until it
clicks.
MAXIMUM FUEL LEVEL
FUEL TANK
CAP
TETHER
6
ENGLISH
ENGINE OIL
Recommended Oil
Use 4-stroke motor oil that meets
or exceeds the requirements for
API service classification 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
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
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
(ELECTRIC
STARTER
TYPES)
(ELECTRIC
STARTER
TYPES)
AIR CLEANER
A dirty air filter 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 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 (see page 13).
Inspection
1. Press the latch
tabs on the top of
AIR CLEANER BODY
FILTER
AIR
CLEANER
COVER
the air cleaner
cover and remove
LATCH TABS
the cover. Check
the filter to be sure
it is clean and in
good condition.
2. Reinstall the filter
AIR DUCT
and air cleaner
cover.
Cleaning
1. Tap the filter several times on a hard surface to remove dirt, or
blow compressed air [not exceeding 30 psi (207 kPa, 2.1 kg/cm²)]
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
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.
SPARK PLUG
WRENCH
1. Turn the fuel valve to the OFF position to reduce the possibility of
fuel leakage (see TYPE 1 Step 1 on page 2).
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 (see page 7).
NOTICE
Running the engine with a low oil level can cause engine damage.
5. Reinstall the oil filler cap/dipstick securely.
ENGLISH
1. Disconnect the cap from the
spark plug, and remove any dirt
from the spark plug area.
2. Use a 13/16" 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
0.70 ~ 0.80 mm
(0.028 ~ 0.031 in)
0.70 ~ 0.80 mm (0.028 ~ 0.031 in).
If adjustment is needed, correct the
gap by carefully bending the side
SEALING
WASHER
electrode.
5. Install the spark plug carefully, by
hand, to avoid cross-threading.
6. After the spark plug is seated,
tighten with a spark plug wrench to
compress the washer.
7
When installing a new spark plug, tighten 1/2 turn after the spark
plug seats to compress the washer. When reinstalling the original
spark plug, tighten 1/8 ~ 1/4 turn after the spark plug seats to
compress the washer.
NOTICE
Properly tighten the spark plug. A loose spark plug can become
very hot and can damage the engine. Overtightening the spark
plug can damage the threads in the cylinder head.
7. Attach the spark plug cap to the spark plug.
FLYWHEEL BRAKE INSPECTION
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.
RECOIL
STARTER
FUEL TANK
FLANGE NUT (3)
SPACER (3)
FUEL
TUBE
Spark Arrester Removal
1. Remove the three 6 mm
bolts from the muffler
SPARK ARRESTER
MUFFLER
PROTECTOR
protector, and remove
the muffler protector.
2. Remove the two special
screws from the spark
MUFFLER
arrester, and remove
the spark arrester from
the muffler.
6 mm BOLT (3)
SPECIAL
SCREW (2)
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.
HELPFUL TIPS & SUGGESTIONS
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.
3. Check the brake shoe
thickness. If it is less than
BRAKE SHOE
THICKNESS
3 mm (0.12 in), take the
engine to your authorized
Honda servicing dealer.
4. Install the fuel tank and
recoil starter, and tighten
the three nuts securely.
BRAKE SHOE
SPARK ARRESTER (OPTIONAL EQUIPMENT)
In some areas, it is illegal to operate an engine without a USDA
(United States Department of Agriculture)-qualified spark arrester.
Check local laws and regulations. A USDA-qualified spark arrester is
available from an authorized Honda servicing dealer.
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.
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
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 (see page 13).
You can extend fuel storage life by adding a gasoline stabilizer that is
formulated for that purpose, or you can avoid fuel deterioration
problems by draining the fuel tank and carburetor.
8
ENGLISH
ADDING A GASOLINE STABILIZER TO EXTEND FUEL STORAGE LIFE
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.
1. Add gasoline stabilizer following the manufacturer’s instructions.
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. Stop the engine, and turn the fuel valve to the OFF position (see
TYPE 1 Step 1 on page 2).
DRAINING THE FUEL TANK AND CARBURETOR
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. Place an approved gasoline container below the carburetor, and
use a funnel to avoid spilling fuel.
2. Remove the drain bolt, then move the fuel valve lever to the ON
position (see TYPE 1 Step 1 on page 2).
3. After all the fuel has drained into the container, reinstall the drain
bolt and washer. Tighten the drain bolt securely.
WASHER
FLOAT BOWL
Engine Oil
1. Change the engine oil
(see page 7).
2. Remove the spark plug
(see page 7).
3. Pour a tablespoon (5 ~ 10 cc) of
clean engine oil into the
cylinder.
4. Pull the starter grip 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.
DRAIN BOLT
If there is gasoline in the fuel tank, leave the fuel valve in the OFF
position (see TYPE 1 Step 1 on page 2).
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 2).
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 (see TYPE 1
Step 1 on page 2).
TAKING CARE OF UNEXPECTED PROBLEMS
ENGINE WILL NOT START
Possible Cause Correction
Fuel valve OFF Move lever to ON.
Choke OFF Move the choke/throttle lever, choke rod, or
choke lever to the ON position unless the
engine is warm.
Ignition switch or engine stop
switch OFF
Electric Starter types only
Battery under-charged.
Battery cables are loose or
corroded.
Fuse is blown.
If starter motor operates but
the engine does not start, go to
Out of fuel (below).
Out of fuel Refuel.
Bad fuel; engine stored without
treating or draining 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 (p. 7).
Bad fuel; engine stored without
treating or draining gasoline, or
refueled with bad gasoline
Fuel filter clogged, carburetor
malfunction, ignition
malfunction, valves stuck, etc.
Move the flywheel brake lever to the 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.
Drain the fuel tank and carburetor (p. 9).
Refuel with fresh gasoline.
Adjust or replace the spark plug (p. 7).
Dry and reinstall spark plug. Start engine
with choke/throttle lever in FAST position.
(TYPES 4 & 5: Choke OFF position).
Replace or repair faulty components as
necessary.
Drain the fuel tank and carburetor (p. 9).
Refuel with fresh gasoline.
Replace or repair faulty components as
necessary.
ENGLISH
9
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 purchased: ____________________
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
1,500 meters (5,000 feet), 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 300-meter (1,000-foot) 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
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 genuine Honda 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 6. 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.
10
ENGLISH
Air Index
An Air Index Information hang tag/label is applied to engines certified
to an emission durability time period in accordance with the
requirements of the California Air Resources Board.
The bar graph is intended to provide you, our customer, the ability to
compare the emissions performance of available engines. The lower
the Air Index, the less pollution.
The durability description is intended to provide you with information
relating the engine’s emission durability period. The descriptive term
indicates the useful life period for the engine’s emission control
system. See your EMISSION CONTROL SYSTEM WARRANTY
(page 14) for additional information.
Descriptive 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)
The Air Index Information hang tag/label must remain on the engine
until it is sold. Remove the hang tag before operating the engine.
Specifications
GCV160
Length x Width x Height
(without electric start)
Length x Width x Height
(with electric start)
Dry weight (without electric start) 9.8 kg (22 lb)
Dry weight (with electric start) 11.6 kg (26 lb)
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)
Fuel tank capacity 0.93 (0.25 gal)
Cooling system Forced air
Ignition system Transistorized magneto
PTO shaft rotation Counterclockwise
367 x 331 x 360 mm
(14.4 x 13.0 x 14.2 in)
367 x 354 x 360 mm
(14.4 x 13.9 x 14.2 in)
3
(9.8 cu in)
161 cm
[64 x 50 mm (2.5 x 2.0 in)]
3.3 kW (4.4 hp) at 3,600 rpm
9.4 N•m (6.9 ft-lb) at 2,500 rpm
GCV190
Length x Width x Height 367 x 331 x 368 mm
Dry weight 12.3 kg (27.1 lb)
Engine type 4-stroke, overhead cam, single
Displacement
[Bore x Stroke]
Net power *
(in accordance with SAE J1349)
Max. net torque
(in accordance with SAE J1349)
Fuel tank capacity 0.93 (0.25 gal)
Cooling system Forced air
Ignition system Transistorized magneto
PTO shaft rotation Counterclockwise
* 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 3600 rpm. 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.
(14.4 x 13.0 x 14.5 in)
cylinder
3
187 cm
[69 x 50 mm (2.7 x 2.0 in)]
3.8 kW (5.1 hp) at 3,600 rpm
11.3 N•m (8.3 ft-lb) at 2,500 rpm
(11.4 cu in)
Tuneup
ITEM SPECIFICATION MAINTENANCE
Spark plug gap 0.7 ~ 0.8 mm
(0.028 ~ 0.031 in)
Valve clearance (cold) IN: 0.15 ± 0.04 mm
EX: 0.20 ± 0.04 mm
Other specifications No other adjustments needed.
Refer to page 7.
See your authorized
Honda dealer.
Quick Reference Information
Fuel Type Unleaded gasoline with a pump octane
rating of 86 or higher (page 6).
Engine Oil Type SAE 10W-30, API SJ 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 Change engine oil. Refer to page 7.
Subsequent Refer to the maintenance schedule on
ENGLISH
Check engine oil level. Refer to page 7.
Check air filter. Refer to page 7.
page 6.
11
Battery Connections
Use the following materials to connect a 12-volt battery to the starter
on TYPE 7 units (electric start with engine-mounted starter switch/
manual choke control/preset throttle):
• 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 ft
(3 meters).
• Fuse – 40-ampere blade type fuse.
• Termin 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.
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
(electric start with engine-mounted starter switch/manual choke
control/preset throttle). Connections are different for the other
electric starter types (TYPES 4 and 6).
STARTER GROUND (-)
CONNECTION
BATTERY
NEGATIVE (-)
TERMINAL
BATTERY
NEGATIVE (-)
CABLE
STARTER
MOTOR
Wiring Diagrams
RECOIL STARTER
(All Types)
SPARK
PLUG
IGNITION
COIL
ELECTRIC STARTER
(TYPE 4 with Flywheel Brake)
ENGINE STOP
SWITCH
IGNITION
COIL
SPARK
PLUG
STARTER
MOTOR
ELECTRIC STARTER
(TYPE 6 with Blade Brake Clutch)
SPARK
PLUG
STARTER
MOTOR
IGNITION
COIL
ELECTRIC STARTER
(TYPE 7 with Starter Switch on the engine)
ENGINE STOP
SWITCH
Supplied by equipment
manufacturer.
STARTER
SWITCH
FUSE
(40A)
BATTERY
Supplied by equipment
manufacturer.
FUSE
(40A)
STARTER
SWITCH
BATTERY
Supplied by equipment
manufacturer.
BATTERY
STARTER MOTOR
POSITIVE (+) CONNECTOR
(from starter switch)
40 AMP FUSE
BATTERY POSITIVE
(+) TERMINAL
BATTERY POSITIVE (+)
CABLE
This engine is not equipped with a charging system to keep the
battery charged during engine operation. The battery will loose
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.
Refer to the equipment manufacturer’s instructions or the battery
manufacturer for specific external battery charging recommendations.
12
ENGLISH
SPARK
PLUG
IGNITION
COIL
STARTER SWITCH
STARTER
SWITCH
STARTER
MOTOR
BATTERY
FUSE
(40A)
CONSUMER INFORMATION
HONDA PUBLICATIONS
Shop
Manual
Parts
Catalog
DISTRIBUTOR/DEALER LOCATOR INFORMATION
United States, Puerto Rico, and U.S. Virgin Islands:
Call (800) 426-7701
or visit our website: www.honda-engines.com
Canada:
Call (888) 9HONDA9
or visit our website: www.honda.ca
CUSTOMER SERVICE INFORMATION
United States, Puerto Rico, and U.S. Virgin Islands:
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.honda-engines.com
or by calling 1-800-426-7701.
If you are still dissatisfied after speaking with the Regional Engine
Distributor, you may contact the Honda Power Equipment Customer
Relations Office for your area. You can write to:
American Honda Motor Co., Inc.
Power Equipment Division
Customer Relations Office
4900 Marconi Drive
Alpharetta, GA 30005-8847
Telephone: (770) 497-6400, 8:30 am - 8:00 pm ET
Honda Canada, Inc.
715 Milner Avenue
Toronto, ON
M1B 2K8
Telephone: (888) 9HONDA9 Toll free
Facsimile: (877) 939-0909 Toll free
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 > product
manuals.
This manual provides complete, illustrated parts lists. Available
through your Honda dealer.
(888) 946-6329 Toll free
(416) 284-8110 Local Toronto dialing area
(416) 287-4776 Local Toronto dialing area
DISTRIBUTOR’S LIMITED WARRANTY
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
PRODUCTS COVERED BY THIS
PRODUCT APPLICATIONS NONCOMMERCIAL/
GCV Series Engines All 24 months 3 months*
* 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 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.honda-engines.com)
or by calling 1-800-426-7701. If you are still dissatisfied after speaking with the Regional
Engine Distributor, you may contact the Honda Power Equipment Customer Relations
Department of American Honda Motor Co., Inc. Refer to page 13 for contact information.
Exclusions:
This warranty does not extend to parts affected or damaged by the product in which the
engine is installed, or by accident and/or 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.
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.
WARRANTY:
LENGTH OF WARRANTY:
(FROM DATE OF ORIGINAL
PURCHASE)
NONRENTAL
COMMERCIAL/
RENTAL
When you write or call, please provide this information:
• Equipment manufacturer’s name and model number that the
engine is mounted on
• Engine model, serial number, and type (see page 10)
• Name of dealer who sold the engine to you
• Name, address, and contact person of the dealer who services
your engine
• Date of purchase
• Your name, address and telephone number
• A detailed description of the problem
ENGLISH
13
Distributor’s Limited Warranty
Canada
Honda Canada Inc., 715 Milner Avenue, Toronto, Ontario 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, accident, 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 remodeled.
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 LIMITED 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 13).
Replacement parts warranty
New genuine Honda 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.
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.
24 months 3 months 3 months NONE
EMISSION CONTROL SYSTEM WARRANTY
Your new Honda Power Equipment engine complies with the U.S. EPA, Environment
Canada and State of California emission regulations. American Honda Motor Co., Inc.
provides the emission warranty coverage for engines in the United States, and its
territories. Honda Canada Inc. provides the emission warranty for engines in the 13
provinces and territories of Canada. In the remainder of this Emission Control System
Warranty, American Honda Motor Company Inc. and Honda Canada Inc. will be referred
to as Honda.
Your Warranty Rights And Obligations:
California
The California Air Resources Board and Honda are pleased to explain the emission
control system warranty on your Honda Power Equipment engine. In California, new
spark-ignited small off-road equipment engines must be designed, built and equipped to
meet the State's stringent anti-smog standards.
Other States, U.S. Territories, and Canada
In other areas of the United States and in Canada, your engine must be designed, built,
and equipped to meet the U.S. EPA and Environment Canada emission standards for
spark-ignited engines at or below 19 kilowatts.
All of the United States and Canada
Honda must warrant the emission control system on your power equipment engine for the
period of time listed below, provided there has been no abuse, neglect or improper
maintenance of your power equipment engine. Where a warrantable condition exists,
Honda will repair your power equipment engine at no cost to you including diagnosis,
parts and labor.
Your emission control system may include such parts as the carburetor or fuel injection
system, the ignition system, and catalytic converter. Also included may be hoses,
connectors and other emission-related assemblies.
Manufacturer's Warranty Coverage:
The 1995 and later power equipment engines are warranted for two years. If any
emission-related part on your engine is defective, the part will be repaired or replaced by
Honda.
Owner's Warranty Responsibility:
As the power equipment engine owner, you are responsible for the performance of the
required maintenance listed in your owner's manual. Honda recommends that you retain
all receipts covering maintenance on your power equipment engine, but Honda cannot
deny warranty coverage solely for the lack of receipts or for your failure to ensure the
performance of all scheduled maintenance.
As the power equipment engine owner, you should however be aware Honda may deny
you warranty coverage if your power equipment engine or a part has failed due to abuse,
neglect, improper maintenance, or unapproved modifications.
You are responsible for presenting your power equipment engine to a Honda Power
Equipment dealer as soon as a problem exists. The warranty repairs should be completed
in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and responsibilities, you should
contact the Honda Office in your region:
American Honda Motor Co., Inc.
Power Equipment Customer Relations
4900 Marconi Drive
Alpharetta, Georgia 30005-8847
Telephone: (770) 497-6400
Warranty Coverage:
Honda power equipment engines manufactured after January 1, 1995 and sold in the
State of California, U.S. EPA certified engines manufactured on or after September 1,
1996 and sold in all of the United States, and Canadian certified engines manufactured on
or after January 1, 2005 are covered by this warranty for a period of two years from the
date of delivery to the original retail purchaser. This warranty is transferable to each
subsequent purchaser for the duration of the warranty period.
Warranty repairs will be made without charge for diagnosis, parts or labor. All defective
parts replaced under this warranty become the property of Honda. Warranted parts are
listed under Emission Control System Warranty Parts later on this page. Normal
maintenance items, such as spark plugs and filters, that are on the warranted parts list are
warranted up to their required replacement interval only.
Honda is also liable for damages to other engine components caused by a failure of any
warranted part during the warranty period.
Only Honda approved replacement parts may be used in the performance of any warranty
repairs and must be provided without charge to the owner. The use of replacement parts
not equivalent to the original parts may impair the effectiveness of your engine emission
control system. If such a replacement part is used in the repair or maintenance of your
engine, and an authorized Honda dealer determines it is defective or causes a failure of a
warranted part, your claim for repair of your engine may be denied. If the part in question
is not related to the reason your engine requires repair, your claim will not be denied.
To Obtain Warranty Service:
You must take your Honda Power Equipment engine or the product on which it is installed,
along with your sales registration card or other proof of original purchase date, at your
expense, to any Honda Power Equipment dealer who is authorized by Honda to sell and
service that Honda product during his normal business hours. Claims for repair or
adjustment found to be caused solely by defects in material or workmanship will not be
denied because the engine was not properly maintained and used.
If you are unable to obtain warranty service, or are dissatisfied with the warranty service
you received, contact the owner of the dealership involved. Normally this should resolve
your problem. However, if you require further assistance, write or call the Honda Power
Equipment Customer Relations Department in your region.
Honda Canada Inc.
Power Equipment Customer Relations
or
715 Milner Avenue
Toronto, ON M1B 2K8
Telephone: (888) 946-6329
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ENGLISH
Exclusions:
Failures other than those resulting from defects in material or workmanship are not
covered by this warranty. This warranty does not extend to emission control systems or
parts which are affected or damaged by owner abuse, neglect, improper maintenance,
misuse, misfueling, improper storage, accident and/or collision, the incorporation of, or
any use of, any add-on or modified parts, unsuitable attachments, or the unauthorized
alteration of any part.
This warranty does not cover replacement of expendable maintenance items made in
connection with required maintenance services after the item's first scheduled
replacement as listed in the maintenance section of the product owner's manual, such as:
spark plugs and filters.
Disclaimer of Consequential Damage and Limitation of Implied
Warranties:
American Honda Motor Co., Inc. and Honda Canada Inc. disclaim any responsibility for
incidental or consequential damages such as loss of time or the use of the power
equipment, or any commercial loss due to the failure of the equipment; and any implied
warranties are limited to the duration of this written warranty. This warranty is applicable
only where the California, U.S. EPA, or Environment Canada emission control system
warranty regulation is in effect.
Emission Control System Warranty Parts:
SYSTEMS COVERED
BY THIS WARRANTY:
PAR TS
DESCRIPTION:
Fuel Metering Carburetor assembly, (includes starting
enrichment system), Engine temperature
sensor, Engine control module, Fuel
regulator, Intake manifold
Evaporative Fuel tank, Fuel cap, Fuel hoses, Vapor
hoses, Carbon canister, Canister
mounting brackets, Fuel strainer, Fuel
cock, Fuel pump, Fuel hose joint, Seal
cap, Canister purge hose joint
Exhaust Catalyst, Exhaust manifold
Air Induction Air filter housing, Air filter element*,
Crankcase breather tube
Ignition Flywheel magneto, Ignition pulse
generator, Crankshaft position sensor,
Power coil, Ignition coil assembly,
Ignition control module, Spark plug cap,
Spark plug*
Miscellaneous Parts Tubing, fittings, seals, gaskets, and
clamps associated with these listed
systems.
Note: This list applies to parts supplied by Honda and does not cover parts
supplied by the equipment manufacturer. Please see the original equipment
manufacturer’s emissions warranty for non-Honda parts.
* Covered up to the first required replacement only. See the Maintenance
Schedule (page 6).
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