Honda Automobiles GSV190, GSV160 User Manual

OWNER’S MANUAL

GSV160 • GSV190

 WARNING: 

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

31Z2B000
00X31-Z2B-0000

CONTENTS

EM3

IPC POM53615

40,000.2003.07

PRINTED IN U.S.A.

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 is 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:

You WILL be KILLED or SERIOUSLY

DANGER

HURT if you don't follow instructions.

You CAN be KILLED or SERIOUSLY

WARNING

HURT if you don't follow instructions.



INTRODUCTION. . . . . . . . . . . . . . 1

SAFETY MESSAGES . . . . . . . . . 1

Damage Prevention

Messages . . . . . . . . . . . . . . . . . 1

Safety Information . . . . . . . . . . 1

COMPONENT & CONTROL

LOCATION . . . . . . . . . . . . . . . . . . 2

BEFORE OPERATION

CHECKS . . . . . . . . . . . . . . . . . . . . 2

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

SERVICING YOUR ENGINE . . . . 5

The Importance of

Maintenance . . . . . . . . . . . . . . . 5

Maintenance Safety . . . . . . . . . 5

Safety Precautions . . . . . . . . . 5

Maintenance Schedule . . . . . . 5

Refueling . . . . . . . . . . . . . . . . . 5

Fuel Recommendations . . . . . . 5

Engine Oil . . . . . . . . . . . . . . . . . 6

Air Cleaner . . . . . . . . . . . . . . . . 6

Spark Plug . . . . . . . . . . . . . . . . 7

Flywheel Brake

Inspection . . . . . . . . . . . . . . . . . 7

Spark Arrester . . . . . . . . . . . . . 7

HELPFUL TIPS &

SUGGESTIONS . . . . . . . . . . . . . . 8

Storing Your Engine . . . . . . . . 8

Adding A Gasoline
Stabilizer To Extend Fuel

Storage Life. . . . . . . . . . . . . . . . 8

Draining The Fuel Tank And

Carburetor . . . . . . . . . . . . . . . . . 8

Transporting . . . . . . . . . . . . . . 9

TAKING CARE OF UNEXPECTED

PROBLEMS . . . . . . . . . . . . . . . . . 9

TECHNICAL & CONSUMER

INFORMATION . . . . . . . . . . . . . . . 9

Engine Serial Number

And Type Location . . . . . . . . . . 9

High Altitude

Operation . . . . . . . . . . . . . . . . . 9

Oxygenated Fuels . . . . . . . . . 10

Emission Control System

Information . . . . . . . . . . . . . . . 10

Air Index . . . . . . . . . . . . . . . . . 11

Specifications . . . . . . . . . . . . . 11

Wiring Diagram . . . . . . . . . . . . 11

CONSUMER INFORMATION . . . 11

Honda Publications . . . . . . . . 11

U.S.A. Distributor’s Limited

Warranty . . . . . . . . . . . . . . . . . 11

International Warranty . . . . . . 11

Emission Control System

Warranty . . . . . . . . . . . . . . . . . 12

Distributor/Dealer Locator

Information . . . . . . . . . . . . . . . 13

Customer Service

Information . . . . . . . . . . . . . . . 13

CAUTION

instructions.

Each message tells you what the hazard is, what can happen, and
what you can do to avoid or reduce injury.

DAMAGE PREVENTION MESSAGES

You CAN be HURT if you don't follow

You will also see other important messages that are preceded by the
word NOTICE.

This word means:

NOTICE

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.

• 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 American Honda Motor Co., Inc.
All Rights Reserved

1

COMPONENT & CONTROL LOCATION

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 the manual.

STARTER GRIP

OIL FILLER CAP/
DIPSTICK

ENGINE CONTROL TYPES

TYPE 1: FLYWHEEL BRAKE/
REMOTE THROTTLE

THROTTLE
LEVER

TYPE 2: MANUAL CHOKE/
MANUAL THROT TLE

CHOKE LEVER

FLYWHEEL BRAKE
CONTROL LEVER

MUFFLER

FUEL FILLER CAP

AIR CLEANER

SPARK
PLUG

ENGINE CONTROL
AREA

TYPE 5: MANUAL CHOKE/FIXED

CHOKE
ROD

ENGINE
STOP
SWITCH

FUEL VALVE
LEVER

TYPE 6: REMOTE THROTTLE/BLADE
BRAKE CLUTCH (equipment control)

THROTTLE
LEVER

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 preoperation inspection before each
operation, and correct any problem.

Before beginning your preoperation checks, be sure the engine is level
and the flywheel brake lever (type 2: throttle lever, type 4: 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 5).

2. Oil level (see page 6).

3. Air cleaner (see page 6).

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
CHOKE/FIXED THROTTLE

FLYWHEEL
BRAKE
CONTROL
CABLE

CHOKE
CONTROL
CABLE

FUEL VALVE
LEVER

TYPE 4: AUTOMATIC CHOKE RETURN/
FIXED THROTTLE

CHOKE
LEVER

FLYWHEEL
BRAKE
CONTROL
CABLE

FUEL VALVE
LEVER

FUEL VALVE LEVER

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 A Cold Engine

1. Turn the fuel valve to the ON

position.

ON

FUEL
VALVE

OFF

2

2. Move the throttle control
(see equipment manual) to
move the choke/throttle
lever to the CHOKE position.

SLOW

CHOKE/
THROTTLE
LEVER

FAST

CHOKE

TYPE 2 (MANUAL CHOKE CONTROL/ MANUAL THROTTLE CONTROL)

Starting A Cold Engine

1. Turn the fuel valve to the ON position (see page 2).

2. Move the choke lever to the ON position.

3. Move the throttle lever to the FAST position.

SLOW

STOP

FAST

CHOKE LEVER

3. Move the flywheel brake
control (see equipment

FLYWHEEL
BRAKE LEVER

manual) to move the
flywheel brake lever to 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.

Starting A Warm Engine:

1. Place the choke/throttle lever in the FAST position.

2. Move the flywheel brake lever to the RUN position.

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

Stopping The Engine

1. Move the choke/throttle control to the

SLOW

FAST

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
page 2).

OFF

FUEL
VALVE

THROTTLE
LEVER

ON

ON

4. Pull the starter grip lightly until resistance is felt, then pull briskly
(see 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.

Starting A Warm Engine:

1. Move the throttle lever to the FAST position.

2. Pull the starter grip lightly until resistance is felt, then pull briskly
(see page 3).

Stopping The Engine

1. Move the throttle lever to the SLOW position.

2. Move the throttle lever to the STOP position.

3. Turn the fuel valve to the OFF position (see page 2).

TYPE 3 (FLYWHEEL BRAKE/REMOTE CHOKE/PRESET THROTTLE)

Starting A Cold Engine

1. Turn the fuel valve to the
ON position (see page 2).

CHOKE
ARM

2. Move the choke control
cable (see equipment
manual) so that the choke
arm moves to the choke
ON position.

CHOKE CONTROL
CABLE

FUEL VALVE ON

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 page 3).

5. If the choke was used to start

RUN

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.

6. The engine speed is preset on this type.

OFF

ON

3

Starting A Warm Engine

1. Move the flywheel brake lever to the RUN position.

2. Pull the starter grip lightly until resistance is felt, then pull briskly
(see page 3).

Stopping The Engine

1. Release the flywheel brake lever to stop the engine.

2. Turn the fuel valve to the OFF position (see page 2).

TYPE 4 (AUTOMATIC CHOKE RETURN/PRESET THROTTLE)

Starting A Cold Engine

1. Turn the fuel valve to the ON
position (see page 2).

2. Move the choke lever to the
choke position ().

3. Move the flywheel brake
lever to the RUN position.

4. Pull the starter grip lightly
until resistance is felt, then
pull briskly (see page 3).

Begin pulling the recoil starter as soon as you 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.

5. If the engine does not start within several consecutive pulls of the
recoil starter, release the flywheel brake lever and move the choke
lever to the ON position.

6. Move the flywheel brake lever to the RUN position and immediately
begin operating the recoil starter.

7. The throttle is preset on this type.

Starting A Warm Engine

1. Move the flywheel brake lever to the brake OFF position.

2. Pull the starter grip lightly until resistance is felt, then pull briskly
(see 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 page 2).

OFF

CHOKE
LEVER

STOP

RUN

ON

FLYWHEEL
BRAKE LEVER

TYPE 5 (MANUAL CHOKE CONTROL/PRESET THROTTLE)

Starting A Cold Engine

1. Turn the fuel valve to the ON
position (see page 2).

2. Pull the choke rod to the ON
position.

3. Turn the engine stop switch to
the ON position.

4. Pull the starter grip lightly until
resistance is felt, then pull
briskly (see 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.

6. The engine speed is preset on this type.

ENGINE STOP SWITCH

OFF

ON

CHOKE
ROD

ON

Starting A Warm Engine

1. Turn the engine stop switch to the ON position.

2. Pull the starter grip lightly until resistance is felt, then pull briskly
(see page 3).

Stopping The Engine

1. Move the engine switch to the OFF position.

2. Turn the fuel valve to the OFF position (see page 2).

TYPE 6 (REMOTE THROTTLE/BLADE BRAKE CLUTCH)

Starting A Cold Engine

1. Turn the fuel valve to the ON position (see page 2).

2. Move the choke/
throttle/stop lever to

STOP

SLOW

the CHOKE position.

Make sure the blade
brake clutch control
lever is disengaged
(see equipment
manual).

CHOKE/
THROTTLE/
STOP
LEVER

3. Pull the starter grip
lightly until resistance
is felt, then pull briskly
(see page 3).

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 brake clutch control lever (see equipment manual).

Starting A Warm Engine

1. Place the choke/throttle/stop lever in the FAST position.

Make sure the blade brake clutch control lever is disengaged (see
equipment manual).

2. Pull the starter grip lightly until resistance is felt, then pull briskly
(see page 3).

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 page 2).

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

FAST

CHOKE

4

SERVICING YOUR ENGINE

MAINTENANCE SCHEDULE

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.

MAINTENANCE SAFETY

Some of the most important safety precautions follow. However, we
cannot warn you of every conceivable hazard that can arise in
performing maintenance. Only you can decide whether or not you
should perform a given task.

 WARNING

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

Always follow the procedures and precautions in this
owner’s manual.

or
50

hours

Every 6
months

hours

REGULAR SERVICE PERIOD (3)

Perform at every indicated

Item

month or operating hour
interval, which ever comes first.

Engine oil

Air cleaner

Flywheel brake
operation

Flywheel brake shoe Check O (2) O (2) 7

Spark plug

Spark arrester
(optional parts)

Idle speed Check-adjust O(2)

Valve clearance Check-Adjust O(2)

Combustion chamber Clean Every 250 hours (2) —

Fuel tank and filter Clean O(2)

Fuel tube Check Every 2 years (Replace if necessary) (2)

Check level O6

Change OO6

Check O

Replace O (*)

Check-adjust O†

Check-adjust O

Replace O

Clean O7

Before

each

use

First

month

or
20

hours

months

Every 3

or

100

Every

year

or

200

hours

Page

6Clean O (1)

7

Shop

manual

Shop

manual

Shop

manual

Shop

manual

(*) Replace paper element type only.
(1) Service more frequently when used in dusty areas.
(2) 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.

(3) For commercial use, log hours of operation to determine proper

maintenance intervals.

† See your equipment manual.

REFUELING

Use unleaded gasoline with a pump octane rating of 86 or higher. This
engine is certified to operate on unleaded gasoline. Unleaded gasoline
produces fewer engine and spark plug deposits and extends exhaust
system life.

 WARNING

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.

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.

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.

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 the Distributor’s Limited Warranty (see page 11).

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

Adding Fuel

1. Remove the fuel tank cap.

2. Add fuel to the bottom of the
fuel level limit in the neck of
the fuel tank. Do not overfill.

FUEL LEVEL MARK

MAXIMUM FUEL LEVEL

Wipe up spilled fuel before
starting the engine.

Fuel tank capacity: 0.29 gal (1.1 )

5