Honda Automobiles GXV160 User Manual

OWNER’S MANUAL

GXV160

 WARNING: 

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

31ZE7614
00X31-ZE7-6140

EM3

IPC

PRINTED IN U.S.A.

POM51741G

25,000.2003.03

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.

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.

You CAN be HURT if you don't follow

CAUTION

instructions.



CONTENTS

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

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

Damage Prevention

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

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

COMPONENT & CONTROL

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

THROTTLE CABLE

CONNECTION. . . . . . . . . . . . . . . . 2

BEFORE OPERATION

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

Is Your Engine Ready To Go . . 2

OPERATION . . . . . . . . . . . . . . . . . 2

Safe Operating Precautions . . . 2

Starting the Engine . . . . . . . . . 3

Setting Engine Speed . . . . . . . . 3

Stopping the Engine . . . . . . . . 3

SERVICING YOUR ENGINE . . . . 3

The Importance of

Maintenance. . . . . . . . . . . . . . . . 3

Maintenance Safety . . . . . . . . . 3

Safety Precautions . . . . . . . . . . 3

Maintenance Schedule . . . . . . . 4

Refueling . . . . . . . . . . . . . . . . . . 4

Fuel Recommendations . . . . . . 4

Engine Oil . . . . . . . . . . . . . . . . . 5

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

Spark Plug . . . . . . . . . . . . . . . . . 6

Idle Speed Adjustment . . . . . . . 6

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

HELPFUL TIPS &

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

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

Draining The Fuel Tank And

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

Adding A Gasoline Stabilizer
To Extend Fuel Storage Life. . . 8

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

TAKING CARE OF UNEXPECTED

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

TECHNICAL & CONSUMER

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

TECHNICAL INFORMATION . . . . 9

Serial Number Location . . . . . . 9

High Altitude Operation . . . . . . 9

Oxygenated Fuels . . . . . . . . . . 9

Emission Control System

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

Air Index . . . . . . . . . . . . . . . . . . 10

Specifications . . . . . . . . . . . . . 10

CONSUMER INFORMATION . . . 11

Honda Publications. . . . . . . . . 11

Distributor’s Limited Warranty11

Emission Control System

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

Distributor/Dealer Locator

Information. . . . . . . . . . . . . . . . 12

Warranty Service

Information. . . . . . . . . . . . . . . . 12

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

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.

© 2000 - 2003 American Honda Motor Co., Inc.—All Rights Reserved

1

COMPONENT & CONTROL LOCATION

BEFORE OPERATION CHECKS

FUEL FILLER CAP

STARTER GRIP

AIR
CLEANER

FUEL
VALVE
LEVER

FLYWHEEL
BRAKE
LEVER

CHOKE/
THROTTLE
LEVER

FUEL
TANK

OIL FILLER CAP/
DIPSTICK

SPARK
PLUG

MUFFLER

THROTTLE CABLE CONNECTION

The throttle lever is provided with holes for attaching the throttle cable.

1. Remove the screw and the cable holder.

2. Hook the solid wire cable end into the throttle lever as shown.

3. Move the throttle cable control into the fast (or high) throttle
position.

4. Move the throttle lever by pulling the throttle cable until the throttle
lever just contacts the choke lever. Install the cable holder securing
the throttle cable and tighten it securely.

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 (A type: throttle lever) is in the STOP
position.

Always check the following items before you start the engine:

1. Fuel level (see page 4).

2. Oil level (see page 5).

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

CABLE
HOLDER

CHOKE
LEVER

SCREW A

SCREW B

CHOKE TRAVEL STOP

THROTTLE
CABLE

THROTTLE LEVER

5. Move the throttle control to the choke position and verify that the
engine choke rod moves the carburetor choke arm fully closed. If
necessary, adjust screw B so it just contacts the choke travel stop.

CHOKE ARM

SAFE OPERATING PRECAUTIONS

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

SAFETY INFORMATION section on page 1 and the BEFORE
OPERTION CHECKS section above.

 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.

6. Start the engine and move the throttle lever to the fast (or high)
position. Using a tachometer, check the engine speed. Turn screw
A to obtain the top no load engine speed specified by the
equipment manufacturer.

7. N types: Move the throttle cable control lever to the stop position
and confirm that the engine shuts off.

2

STARTING THE ENGINE

FUEL VALVE

1. Turn the fuel valve to the ON
position.

OFF

ON

2. FOR STARTING A COLD
ENGINE: Move the throttle
control to the choke position.

IDLE

FAST

CHOKE

3. FOR RESTARTING A WARM
ENGINE: Do not use the choke
when the engine is warm.

Move the throttle control slightly
past the idle position.

4. FLYWHEEL BRAKE MODELS:
Move the flywheel brake lever
(located on equipment) to release the flywheel brake.

5. 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 gently to prevent damage to the starter.

6. If the choke was used to start the engine, move the throttle to the
fast (or high) position as soon as the engine warms up enough to
run smoothly without use of the choke.

7. FLYWHEEL BRAKE MODELS: Continue to hold the flywheel brake
lever (located on equipment). The engine will stop if you release the
flywheel brake lever.

SETTING ENGINE SPEED

Position the throttle control for the desired engine speed. For best
engine performance, it is recommended the engine be operated with
the throttle in the FAST (or high) position.

STOPPING THE ENGINE

1. Move the throttle control to the
slow (IDLE) position.

2. Move the throttle control to the
stop position.

3. FLYWHEEL BRAKE MODELS:
Release the flywheel brake lever
(located on equipment) to stop
the engine.

4. Turn the fuel valve to the OFF
position if you do not intend to
restart the engine soon.

STOP

FUEL VALVE

OFF

IDLE

ON

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.

MAINTENANCE SAFETY

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

 WARNING

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

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

SAFETY PRECAUTIONS

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

– Carbon monoxide poisoning from engine exhaust.

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

– Burns from hot parts.

Let the engine and exhaust system cool before touching.

– Injury from moving parts.

Do not run the engine unless instructed to do so.

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

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

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

3

MAINTENANCE SCHEDULE

Every

Every

Every 6

Every 3

REGULAR SERVICE

PERIOD (4)

ITEM

Perform at every indicated month or
operating hour interval, whichever comes
first.

Engine oil Check

Replace

Air cleaner Check

Clean

Replace

Spark plug Check-adjust

Replace O

Flywheel brake pad Check O7

Spark arrester Clean O7

Idle speed Check-adjust O(3) 6

Fuel tank and filter Clean

Fuel tube Check Every 2 years

Valve clearance Check-adjust

Combustion chamber Clean After every 300 hours (3) —

First

Before

Each

Use

O

O

Months

Month

or

or

25 Hrs

5 Hrs

OO (2)

O (1)

(Replace if necessary) (3)

Months

or

50 Hrs

Yea r

or
100
Hrs

O

O(3)

O(3)

Two

Years

or 250

Hrs

O

Page

5

6

6

Shop

manual

Shop

manual

Shop

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.

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.

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

(2) Change engine oil every 25 hours when used under heavy load or

in high ambient temperatures.

(3) 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.

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

maintenance intervals.

 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.

FUEL TANK CAP

FUEL
LEVEL
LIMIT

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.

Fuel tank capacity: 0.53 US gal (2.0 l)

4