Honda Automobiles GXV520 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. Honda Motor Co., Ltd.
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.

United States, Puerto Rico, and U.S. Virgin Islands:
We suggest you read the warranty policy to fully understand its
coverage and your responsibilities of ownership. The warranty
policy is a separate document that should have been given to you
by your dealer.

SAFETY MESSAGES

OWNER’S MANUAL

MANUEL DE L’UTILISATEUR

MANUAL DEL PROPIETARIO

GCV520 · GCV530 · GXV520 · GXV530

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects

or other reproductive harm.

ENGLISHFRANÇAISESPAÑOL

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:

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.

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:

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.

2005 Honda Motor Co., Ltd. All Rights Reserved

37Z5Z601
00X37-Z5Z-6010

−

GCV520U·GCV530U·GXV520U·GXV530U

CONTENTS

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

COMPONENT & CONTROL

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

................................FEATURES .3

BEFORE OPERATION

....................................CHECKS .3

..............................OPERATION .4

SAFE OPERATING

THE IMPORTANCE OF

MAINTENANCE

............................SCHEDULE .6

...........................REFUELING .7

...........................ENGINE OIL .7

.........................Oil Change .8

.............................OIL FILTER .8

........................AIR CLEANER .9

..........................Inspection .9

............................Cleaning .9

ENGLISH

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

..........SAFETY INFORMATION .2

.....SAFETY LABEL LOCATION .2

.....................PRECAUTIONS .4

......STARTING THE ENGINE .4

......STOPPING THE ENGINE .5

.....SETTING ENGINE SPEED .5

.....SERVICING YOUR ENGINE .6

....................MAINTENANCE .6

......MAINTENANCE SAFETY .6

.......SAFETY PRECAUTIONS .6

............Recommended Oil .7

..................Oil Level Check .7

.......................FUEL FILTER .10

.............COOLING SYSTEM .10

......................SPARK PLUG .10

.............SPARK ARRESTER .11

HELPFUL TIPS &

......................SUGGESTIONS .11

...STORING YOUR ENGINE .11

................TRANSPORTING .12

TAKING CARE OF

....UNEXPECTED PROBLEMS .13

TECHNICAL & CONSUMER

.......................INFORMATION .13

.....Serial Number Location .13

Battery Connections for

....................Electric Starter .14

.....Remote Control Linkage .14

Carburetor Modifications for

.....High Altitude Operation .15

Emission Control System

.........................Information .15

..............................Air Index .16

.....................Specifications .16

........Tuneup Specifications .17

Quick Reference

.........................Information .17

................Wiring Diagrams .17

.CONSUMER INFORMATION .19

Distributor/Dealer Locator

.........................Information .19

Customer Service

.........................Information .19

1

Understand the operation of all controls and learn how to stop
the engine quickly in case of emergency. Make sure the operator
receives adequate instruction before operating the equipment.
Do not allow children to operate the engine. Keep children and
pets away from the area of operation.
Your engine’s exhaust contains poisonous carbon monoxide.
Do not run the engine without adequate ventilation, and never
run the engine indoors.
The engine and exhaust become very hot during operation.
Keep the engine at least 1 meter (3 feet) away from buildings
and other equipment during operation. Keep flammable
materials away, and do not place anything on the engine while it
is running.

SAFETY LABEL LOCATION

COMPONENT & CONTROL LOCATIONSAFETY INFORMATION

FUEL PUMP

OIL FILLER CAP/
DIPSTICK

SCREEN GRID

This label warns you of potential hazards that can cause serious
injury. Read it carefully.
If the label comes off or becomes hard to read, contact your Honda
dealer for replacement.

For Canadian types only:
French label comes with
the engine.

FUEL FILTER

(applicable types)

OIL FILTER

OIL DRAIN BOLT

RECOIL STARTER
(applicable types)

OIL PRESSURE SWITCH
(applicable types)

AIR CLEANER

Single Lever Type:

Gasoline is highly flammable and explosive.
Turn engine off and let cool before refueling.

ELECTRIC STARTER

SPARK PLUGS

The engine emits toxic poisonous carbon
monoxide gas. Do not run in an enclosed area.

Dual Lever Type:

CONTROL
LEVER

Read Owner’s Manual before operation.

CHOKE
LEVER

2

ENGLISH

THROTTLE
LEVER

BEFORE OPERATION CHECKSFEATURES

Fuel-cut Solenoid

The engine is equipped with a fuel-cut solenoid that allows fuel to
flow to the carburetor main jet when the engine switch is in the ON
or START position and stops the flow of fuel to the main jet when
the engine switch is in the OFF position.

The engine must be connected to the battery to energize the fuel­cut solenoid, allowing the engine to run. If the battery is
disconnected, fuel flow to the carburetor main jet will stop.

Oil Pressure Switch (applicable types):

The engine is equipped with an oil pressure switch to prevent
damage from lack of lubrication or overheating.

If the oil pressure alarm lamp comes on, check the engine oil level
and add the correct engine oil if necessary (see page ).
To restart the engine, turn the engine switch to the OFF position.
Next, start according to the starting procedure.

If the oil pressure alarm lamp continues to light even through the
engine oil level is correct, stop operating the engine and see an
authorized Honda servicing dealers.

7

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.

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 engine switch is in the OFF position.

Always check the following items before you start the engine:

Check the General Condition of the Engine

1.

Look around and underneath the engine for signs of oil or
gasoline leaks.

2.

Remove any excessive dirt or debris, especially around the
muffler and recoil starter.

3.

Look for signs of damage.

4.

Check that all shields and covers are in place, and all nuts, bolts,
and screws are tightened.

Check the Engine

1.

Check the fuel level. Starting with a full tank will help to
eliminate or reduce operating interruptions for refueling.

2.

Check the engine oil level (see page ). Running the engine
with a low oil level can cause engine damage.

3.

Check the air filter element (see page ). A dirty air filter
element will restrict air flow to the carburetor, reducing engine
performance.

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.

7

9

ENGLISH

3

OPERATION

Operate the starter.

4.

SAFE OPERATING PRECAUTIONS

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

SAFETY INFORMATION
OPERATION CHECKS

section on page and the

on page .

3

2

BEFORE

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.

STARTING THE ENGINE

If the fuel tank is equipped with a valve, be sure the fuel valve is

1.
in the OPEN or ON position before attempting to start the engine.

SINGLE LEVER TYPE:

2.
To start a cold engine, move the control lever to the CHOKE
position.

ELECTRIC STARTER:

Turn the key to the START position, and hold it there until the
engine starts.

If the engine fails to start within 5 seconds, release the key, and
wait at least 10 seconds before operating the starter again.

Using the electric starter for more than 5 seconds at a time will
overheat the starter motor and can damage it.

When the engine starts, release the key, allowing it to return to
the ON position.

RECOIL STARTER (applicable types):

Pull the starter grip lightly until you feel resistance, then pull
briskly in the direction of the arrow as shown below. Return the
starter grip gently.

Directiontopull

To restart a warm engine, leave the control lever in the MIN.
position.

CONTROL LEVER

CHOKE

MMAAXX..

MMIINN..

DUAL LEVER TYPE:
To start a cold engine, move the choke lever to the CLOSED
position and move the throttle lever away from the MIN.
position, about 1/3 of the way toward the MAX. position.

CHOKE LEVER

MMAAXX..

CCLLOOSSEEDD

MMIINN..

THROTTLE LEVER

OOPPEENN

STARTER GRIP

Do not allow the starter grip to snap back against the engine.
Return it gently to prevent damage to the starter.

SINGLE LEVER TYPE:

5.
If the control lever has been moved to the CHOKE position to
start the engine, gradually move it to the MIN. position as the
engine warms up.

CHOKE

CONTROL LEVER

MMIINN..

DUAL LEVER TYPE:
If the choke lever was moved to the CLOSED position to start the
engine, gradually move it to the OPEN position as the engine
warms up.

Some engine applications use a remote-mounted control rather
than the engine-mounted lever shown here. Refer to the
instructions provided by the equipment manufacturer.

Turn the engine switch to the ON position.

3.

4

CCLLOOSSEEDD

CHOKE LEVER

OOPPEENN

ENGLISH

STOPPING THE ENGINE SETTING ENGINE SPEED

To stop the engine in an emergency, simply turn the engine switch
to the OFF position. Under normal conditions, use the following
procedure. Refer to the instructions provided by the equipment
manufacturer.

1.

Move the control lever (single lever type) or throttle lever (dual
lever type) to the MIN. position.

Some engine applications use a remote-mounted throttle
control rather than the engine-mounted throttle lever shown
here.

SINGLE LEVER TYPE DUAL LEVER TYPE

MMIINN..

CONTROL LEVER

2.

Turn the engine switch to the OFF position.

3.

If the fuel tank is equipped with a valve, turn the fuel valve to the

THROTTLE LEVER

MMIINN..

CLOSED or OFF position.

Position the control lever (single lever type) or throttle lever (dual
lever type) for the desired engine speed.

Some engine applications use a remote-mounted control rather
than the engine-mounted lever shown here. Refer to the
instructions provided by the equipment manufacturer.

For engine speed recommendations, refer to the instructions
provided with the equipment powered by this engine.

SINGLE LEVER TYPE DUAL LEVER TYPE

CONTROL LEVER

MMAAXX..

THROTTLE LEVER

MMAAXX..

MMIINN..MMIINN..

Do not disconnect the battery from the engine while the engine is
running. Disconnecting the battery causes the fuel-cut solenoid to
shut off the flow of fuel to the carburetor main jet, and the engine
will stop.

ENGLISH

5

SERVICING YOUR ENGINE

THE IMPORTANCE OF MAINTENANCE

Good maintenance is essential for safe, economical and trouble­free operation. It will also help reduce pollution.

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.

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.

To reduce the possibility of fire or explosion, be careful when
working around gasoline. Use only a non-flammable 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

Every

Every 6

REGULAR SERVICE PERIOD (3)

Perform at every

indicated month or

operating hour interval,

whichever comes first.

ITEM

Engine oil

Oil filter

()

applicable types

Air filter

Spark plugs

Spark arrester

()

applicable types

Cooling system

Idle speed

Valve clearance

Timing belt

Combustion

chamber

Fuel filter

Fuel tube

Replace paper element type only.

＊

(1)

Service more frequently when used in dusty areas.

(2)

These items should be serviced by your Honda servicing

Check level

Change

Replace

Check

Clean

Replace

Check-adjust

Replace

Clean

Clean

Check-adjust

Check-adjust

Check

Clean

Check-replace

Check

Each

Use

Every 3

First

Months

Months

Month

or

or

or

100 Hrs

50 Hrs

20 Hrs

(1)

After every 300 Hrs (2)(4)

After every 300 Hrs (2)

Every 2 years

(Replace if necessary) (2)

Year

or

200 Hrs

＊

(2)

(2)

(2)

Refer

to

Page

7

8

8

9

9

10

11

10

Shop

manual

Shop

manual

Shop

manual

Shop

manual

Shop

manual

Shop

manual

dealer, unless you have the proper tools and are mechanically
proficient. Refer to the Honda shop manual for service
procedures.

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.

6

(3)

For commercial use, log hours of operation to determine
proper maintenance intervals.

(4)

Check that there is no crack and abnormal wear-out in the belt,
and replace if it is abnormal.

Failure to follow this maintenance schedule could result in non­warrantable failures.

ENGLISH

REFUELING

ENGINE OIL

Recommended Fuel

Unleaded gasoline

U.S.
Except U.S.

Pump octane rating 86 or higher
Research octane rating 91 or higher
Pump octane rating 86 or higher

This engine is certified to operate on unleaded gasoline with a
pump octane rating of 86 or higher (a research octane rating of 91
or higher).
Refuel in a well-ventilated area with the engine stopped. If the
engine has been running, allow it to cool first. Never refuel the
engine inside a building where gasoline fumes may reach flames
or sparks.
You may use regular unleaded gasoline containing no more than
10% Ethanol (E10) or 5% Methanol by volume. In addition,
Methanol must contain cosolvents and corrosion inhibitors. Use of
fuels with content of Ethanol or Methanol greater than shown
above may cause starting and/or performance problems. It may
also damage metal, rubber, and plastic parts of the fuel system.
Engine damage or performance problems that result from using a
fuel with percentages of Ethanol or Methanol greater than shown
above are not covered under warranty.

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.

Oil is a major factor affecting performance and service life. Use
4-stroke automotive detergent oil.

Recommended Oil

Use 4-stroke motor oil that
meets or exceeds the
requirements for API service
classification SJ or later (or
equivalent). Always check the
API service label on the oil
container to be sure it includes
the letters SJ or later (or

AMBIENT TEMPERATURE

equivalent).

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

Check the engine oil level with the engine stopped and in a level
position.

Remove the oil filler cap/dipstick and wipe it clean.

1.

Insert the oil filler cap/dipstick into the oil filler neck, but do not

2.
screw it in, then remove it to check the oil level.

If the oil level is near or below the lower limit mark on the

3.
dipstick, fill with the recommended oil to the upper limit mark.
Do not overfill.

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.

Refuel carefully to avoid spilling fuel. After refueling, tighten the
fuel tank cap securely.

Keep gasoline away from appliance pilot lights, barbecues,
electric appliances, power tools, etc.

Spilled fuel is not only a fire hazard, it causes environmental
damage. Wipe up spills immediately.

Reinstall the oil filler cap/dipstick.

4.

OIL FILLER CAP/DIPSTICK

OIL FILLER CAP/
DIPSTICK

UPPER LIMIT

LOWER LIMIT

Running the engine with a low oil level can cause engine damage.
This type of damage is not covered by the

Distributor’s Limited

Warranty.

ENGLISH

7

Oil Change OIL FILTER (applicable types)

Drain the used oil when the engine is warm. Warm oil drains
quickly and completely.

1.

Place a suitable container below the engine to catch the used oil,
then remove the oil filler cap/dipstick, drain boltand washer.

Allow the used oil to drain completely, then reinstall the drain

2.
bolt and new washer, and tighten the drain bolt securely.

Please dispose of used motor oil in a manner that is compatible
with the environment. We suggest you take used oil in a sealed
containerto your local recycling center or service station for
reclamation. Do not throw it in the trash, pour it on the ground,
or down a drain.

3.

With the engine in a level position, fill to the upper limit mark on
the dipstick with the recommended oil (see page ).

7

Running the engine with a low oil level can cause engine
damage.

WASHER

UPPER LIMIT

LOWER LIMIT

Oil Filter Change

1.

Drain the engine oil, and retighten the drain bolt securely.

2.

Remove the oil filter with an oil filter wrench, and drain the
remaining oil into a suitable container. Dispose the used oil and
filter in a manner compatible with the environment.

Use an oil filter wrench, rather than a strap wrench, to avoid
striking and damaging the oil filter.

OIL FILTER

OIL FILTER WRENCH

FILTER MOUNTING BASE

OIL DRAIN BOLT

4.

Install the oil filler cap/dipstick and tighten securely.

OIL FILLER CAP/DIPSTICK

SEAL

3.

Clean the filter mounting base, and coat the seal of the new oil
filter with clean engine oil.

Use only a genuine Honda oil filter or a filter of equivalent
quality specified for your model. Using the wrong filter, or a
non-Honda filter which is not of equivalent quality, may cause
engine damage.

4.

Screw on the new oil filter by hand until the seal contacts the
filter mounting base, then use an oil filter wrench to tighten the
filter an additional 7/8 turn.

Oil filter tighteningtorque:

5.

Refill the crankcase with the specified amount of the
recommendedoil (see page ). Reinstall the oil filler cap/

12 N·m (1.2 kgf·m , 9 lbf·ft)

7

dipstick.

6.

Start the engine, and check for leaks.

7.

Stop the engine, and check the oil level as described on page .
If necessary, add oil to bring the oil level to the upper limit mark
on the dipstick.

7

8

ENGLISH

AIR CLEANER

5.

Clean the air filter elements if they are to be reused.

A dirty air cleaner will restrict air flow to the carburetor, reducing
engine performance. If you operate the engine in very dusty areas,
clean the air filter more often than specified in the MAINTENANCE
SCHEDULE.

Operating the engine without an air filter, or with a damaged air
filter, will allow dirt to enter the engine, causing rapid engine wear.
This type of damage is not covered by the

Distributor’s Limited

Warranty.

Inspection

Remove the air cleaner cover and inspect the filter elements.
Clean or replace dirty filter elements. Always replace damaged
filter elements.

Cleaning

Remove the two air cleaner cover bolts from the air cleaner

1.
cover, and remove the cover.

Remove the foam filter element.

2.

Remove the paper filter element from the grid.

3.

AIR CLEANER COVER BOLTS

AIR CLEANER COVER

Paper air filter element: Tap the filter element several times on a
hard surface to remove dirt, or blow compressed air [not
exceeding 207 kPa (2.1 kgf/cm

, 30 psi)] through the filter
element from the inside. Never try to brush off dirt; brushing will
force dirt into the fibers.

Foam air filter element: Clean in warm soapy water, rinse, and
allow to dry thoroughly. Or clean in non-flammable solvent and
allow to dry. Dip the filter element in clean engine oil, then
squeeze out all excess oil. The engine will smoke when started if
too much oil is left in the foam.

Excess oil will restrict air flow through the foam filter element
and may transfer to the paper filter element, soaking and
clogging it.

Wipe dirt from the inside of the air cleaner base and cover, using

6.
a moist rag. Be careful to prevent dirt from entering the air duct
that leads to the carburetor.

7.

Place the foam filter element into the air cleaner cover.

8.

Install the grid over the paper filter element then install the
assembly into the air cleaner base. The grid must be placed
between the foam element and the paper element to prevent oil
from transferring to the paper element.

9.

Install the cover and tighten the two air cleaner cover bolts
securely.

FOAM FILTER ELEMENT

GRID

PAPER FILTER ELEMENT

AIR CLEANER BASE

AIR DUCT

Inspect both air filter elements, and replace them if they are

4.
damaged. Always replace the paper air filter element at the
scheduled interval (see page ).

6

ENGLISH

9

FUEL FILTER

SPARK PLUG

Inspection

Check the fuel filter for water accumulation or sediment.
If the fuel filter is found with excessive water accumulation or
sediment, take the engine to your authorized Honda servicing
dealer.

FUEL FILTER

COOLING SYSTEM

Check the screen grid for blockage and remove the blockage if
necessary.

SCREEN GRID

Recommended Spark Plugs:

BPR5ES (NGK)
W16EPR-U (DENSO)

The recommended spark plugs have the correct heat range for
normal engine operating temperatures.

Incorrect spark plugs can cause engine damage.

For good performance, the spark plugs must be properly gapped
and free of deposits.

Disconnect the spark plug caps, and remove any dirt from

1.
around the spark plug area.

Remove the spark plugs with a 13/16-inch spark plug wrench.

2.

SPARK PLUG WRENCH

Inspect the spark plugs. Replace

3.
them if damaged, badly fouled,
if the sealing washer is in poor
condition, or if the electrode is
worn.

0.70 0.80 mm

−

(0.028 0.031 in)

−

Measure the spark plug

4.
electrode gaps with a wire-type
feeler gauge. Correct the gap, if
necessary, by carefully bending

SEALING
WASHER

thesideelectrode.
The gap should be:

0.70 0.80 mm (0.028 0.031 in)

−−

Install the spark plug carefully,

5.
by hand, to avoid cross­threading.

After the spark plug is seated, tighten with a 13/16-inch spark

6.
plug wrench to compress the sealing washer.

When installing a new spark plug, tighten 1/2 turn after the spark
plug seats to compress the washer.

When reinstalling the original spark plug, tighten 1/8 1/4 turn

−

after the spark plug seats to compress the washer.

A loose spark plug can overheat and damage the engine.
Overtightening the spark plug can damage the threads in the
cylinder head.

Attach the spark plug caps to the spark plugs.

7.

10

ENGLISH

SPARK ARRESTER (applicable types)

HELPFUL TIPS & SUGGESTIONS

Your engine is not factory-equipped with a spark arrester. The
spark arrester is optional part. In some areas, it is illegal to operate
an engine without a spark arrester. Check local laws and
regulations. A spark arrester is available from authorized Honda
servicing dealers.

The spark arrester must be serviced every 100 hours to keep it
functioning as designed.

If the engine has been running, the muffler will be hot. Allow it to
cool before servicing the spark arrester.

Spark Arrester Cleaning

1.

Remove the 6 mm flange bolts from the muffler protector, and
remove the muffler protector.

2.

Remove the special screws from the spark arrester and remove
the spark arrester from the muffler.

MUFFLER

SPARK ARRESTER

6mm
FLANGE BOLT

SPECIAL SCREWS

6mm
FLANGE BOLTS

3.

Use a brush to remove carbon deposits from the spark

MUFFLER
PROTECTOR

arrester screen. Be careful to avoid damaging the screen.

The spark arrester must be free of breaks and holes. Replace
the spark arrester if it is damaged.

STORING YOUR ENGINE

Storage Preparation

Proper storage preparation is essential for keeping your engine
trouble-free and looking good. The following steps will help to
keep rust and corrosion from impairing your engine’s function and
appearance, and will make the engine easier to start when you use
it again.

Cleaning

If the engine has been running, allow it to cool for at least half an
hour before cleaning. Clean all exterior surfaces, touch up any
damaged paint, and coat other areas that may rust with a light film
of oil.

Using a garden hose or pressure washing equipment can force
water into the air cleaner or muffler opening. Water in the air
cleaner will soak the air filter, and water that passes through the
air filter or muffler can enter the cylinder, causing damage.

Fuel

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
deterioration 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 the

Distributor’s Limited Warranty

.

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.

SPARK ARRESTER SCREEN

4.

Install the spark arrester and muffler protector in the reverse
order of disassembly.

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.

Stop the engine, and if the fuel tank is equipped with a fuel

3.
valve, move the fuel valve to the CLOSED or OFF position.

ENGLISH

11

Draining the Fuel Tank and Carburetor

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.
Handle fuel only outdoors.
Wipe up spills immediately.

Disconnect the fuel line to the engine, and drain the fuel tank

1.
into an approved gasoline container. If the fuel tank is
equipped with a valve, turn the fuel valve to the OPEN or ON
position to enable draining. After draining is completed,
reconnect the fuel line.

Loosen the carburetor drain screw, and drain the carburetor

2.
into an approved gasoline container.

CARBURETOR

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 spark­producing electric motor, or where power tools are operated.

If possible, avoid storage areas with high humidity, because that
promotes rust and corrosion.

Keep the engine level in storage. Tilting can cause fuel or oil
leakage.

With the engine and exhaust system cool, cover the engine to
keep out dust. A hot engine and exhaust system can ignite or melt
some materials. Do not use sheet plastic as a dust cover.
A nonporous cover will trap moisture around the engine,
promoting rust and corrosion.

Remove the battery and store it in a cool, dry place. Recharge the
battery once a month while the engine is in storage. This will help
to extend the service life of the battery.

Removal from Storage

Check your engine as described in the

CHECKS

section of this manual (see page ).

BEFORE OPERATION

3

DRAIN SCREW

After all the fuel has drained into the container, tighten the

3.
drain screw securely.

Engine Oil

Change the engine oil (see page ).

1.

Remove the spark plugs (see page ).

2.

Pour a tablespoon 5 10 cm

3.

−−

8

10

(5 10 cc) of clean engine oil into

each cylinder.

Turn the engine for a few seconds by turning the engine switch

4.
to the START position to distribute the oil in the cylinders.

Reinstall the spark plugs.

5.

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 cylinders were coated with oil during storage preparation,
the engine may smoke briefly at startup. This is normal.

TRANSPORTING

Keep the engine level when transporting to reduce the possibility
of fuel leakage. If the fuel tank is equipped with a fuel valve, move
the fuel valve to the CLOSED or OFF position.

12

ENGLISH

TAKING CARE OF UNEXPECTED PROBLEMS TECHNICAL & CONSUMER INFORMATION

ENGINE WILL NOT START

1.

Check battery
and fuse.

2.

Check control
positions.

3.

Check fuel.

4.

Remove and
inspect spark
plugs.

5.

Take engine to
an authorized
Honda
servicing
dealer, or refer
to shop
manual.

Possible Cause Correction TECHNICAL INFORMATION

Battery
discharged.
Fuse burnt out.
Fuel valve OFF.
(If equipped)
Choke OPEN.

Recharge battery.

Replace fuse
Move lever to ON
or OPEN position.
Move lever to

Serial Number Location

Record the engine serial number, type and purchase date in the
space below. You will need this information when ordering parts
and when making technical or warranty inquiries.

CHOKE (CLOSED)
position unless the

engine is warm.
Engine switch
OFF.
Out of fuel.
Bad fuel; engine
stored without
treating or
draining

Turn engine switch

to ON position.

Refuel (p. 7).

Drain fuel tank and

carburetor (p. 12).

Refuel with fresh

gasoline (p. 7).
gasoline, or
refueled with
bad gasoline.
Spark plug(s)
faulty, fouled, or
improperly
gapped.
Spark plug(s)
wet with fuel
(flooded engine).

Gap or replace

spark plug(s)

(p. 10).

Dry and reinstall

spark plugs. Start

engine with

throttle lever in

SERIAL NUMBER &
ENGINE TYPE LOCATION

Engine serial number: __ __ __ __ __ __ __ __ __ __ __

Engine type: ___ ___ ___ ___

Date Purchased: ______ / ______ / ______

MAX. position.
Fuel filter
restricted,
carburetor

Replace or repair

faulty components

as necessary.
malfunction,
ignition
malfunction,
valves stuck, etc.

−

ENGINE LACKS POWER

1.

Check air filter.

2.

Check fuel.

3.

Take engine to
an authorized
Honda
servicing
dealer, or refer
to shop
manual.

Possible Cause Correction

Filter element(s)
restricted.

Clean or replace

filter element(s)

(p. 9).
Bad fuel; engine
stored without
treating or
draining

Drain fuel tank and

carburetor (p. 12).

Refuel with fresh

gasoline (p. 7).
gasoline, or
refueled with
bad gasoline.
Fuel filter
restricted,
carburetor

Replace or repair

faulty components

as necessary.
malfunction,
ignition
malfunction,
valves stuck, etc.

ENGLISH

13

Remote Control LinkageBattery Connections for Electric Starter

Use a 12-volt battery with an ampere-hour rating of at least 45 Ah. The throttle and choke control levers are provided with holes for

optional cable attachment.
Be careful not to connect the battery in reverse polarity, as this will
short circuit the battery charging system. Always connect the
positive ( ) battery cable to the battery terminal before
connecting the negative ( ) battery cable, so your tools cannot

＋

−

cause a short circuit if they touch a grounded part while tightening
the positive ( ) battery cable end.

＋

A battery can explode if you do not follow the correct
procedure, seriously injuring anyone nearby.

The following illustrations show installation examples for a solid

wire cable. Do not use a braided wire cable.

Single Lever Type:

CHOKE RETURN SPRING

INSTALLATION:

Install with the short
end hook toward the
control base side.

THROTTLE/CHOKE
CABLE (SOLID WIRE)

×

5 16 mm SCREW

CABLE HOLDER

Keep all sparks, open flames, and smoking materials
away from the battery.

1.

Connect the battery positive ( ) cable to the starter solenoid

＋

terminal as shown.

2.

Connect the battery negative ( ) cable to an engine mounting

−

bolt, frame bolt, or other good engine ground connection.

Connect the battery positive ( ) cable to the battery positive ( )

3.

＋＋

terminal as shown.

Connect the battery negative ( ) cable to the battery negative

4.

( ) terminal as shown.

−

Coat the terminals and cable ends with grease.

5.

BATTERY
POSITIVE ( ) CABLE

BATTERY
NEGATIVE ( ) CABLE

−

＋

−

STARTER
SOLENOID

CONTROL LEVER

Dual Lever Type:

CHOKE RETURN SPRING

INSTALLATION:

Install with the short
end hook toward the
control base side.

LEVER SPRING

THROTTLE CABLE
(SOLID WIRE)

STOPPER RUBBER

INSTALLATION:

To install the stopper
rubber, first align the boss
with the hole of the
control lever bracket, then
turn the rubber 90° and
secure it to the bracket as
shown.

×

5 16 mm SCREW (2)

CABLE HOLDER (2)

14

ENGLISH

CHOKE LEVER

CHOKE CABLE
(SOLID WIRE)

THROTTLE LEVER

Carburetor Modifications for High Altitude Operation Emission Control System Information

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.

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.

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 lean carburetor settings and other systems to

reduce the emissions of carbon monoxide, oxides of nitrogen, and

hydrocarbons.

The U.S., California Clean Air Acts 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.

ENGLISH

15

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 . Remember that this

6
schedule is based on the assumption that your machine will be
used for its designed purpose. Sustained high-load or high­temperature operation, or use in unusually wet or dusty conditions,
will require more frequent service.

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 to the engine’s emission durability period.
The descriptive term indicates the useful life period for the engine’s
emission control system. See your

Warranty

for additional information.

Emission Control System

Specifications

GCV520/GXV520 (QEA-1 type)

Length Width

××

Height
Dry mass [weight]
Engine type
Displacement
[Bore Stroke]

×

Net power

(in accordance with SAE J1349 )

Max. Net torque
(GCV520U)

(in accordance with SAE J1349 )

Max. Net torque
(GXV520U)

(in accordance with SAE J1349 )

Engine oil capacity

4-stroke, overhead camshaft, 2 cylinders (90° V-Twin)

[77.0 57.0 mm (3.03 2.24 in)]

9.8 kW (13.3 PS, 13.1 bhp) at 3,600 rpm

＊

33.2 N·m (3.39 kgf·m, 24.5 lbf·ft)

＊

32.9 N·m (3.35 kgf·m, 24.3 lbf·ft)

＊

Without oil filter replacement:

0.90

××

458 427 331 mm

××

(18.016.813.0in)

30.5 kg (67.2 lbs)

530 cm

(32.3 cu-in)

××

at 2,500 rpm

at 2,500 rpm

(0.95 US qt , 0.79 Imp qt)

With oil filter replacement:

(1.06 US qt , 0.88 Imp qt)

1.00
Cooling system
Ignition system
PTO shaft rotation

＊

The power rating of the engine indicated in this document is the

Forced air

Transistor magneto

Counterclockwise

net power output tested on a production engine for the engine
model and measured in accordance with SAE J1349 at 3,600
rpm (Net Power) and at 2,500 rpm (Max. Net Torque). Mass
production engines may vary from this value.
Actual power output for the engine installed in the final machine
will vary depending on numerous factors, including the
operating speed of the engine in application, environmental
conditions, maintenance, and other variables.

Descriptive Term Applicable to Emissions Durability Period

Moderate

Intermediate

Extended

50 hours [0 80 cm

−−

(0 80 cc) inclusive]
125 hours [greater than 80 cm
125 hours [0 80 cm

−−

(0 80 cc) inclusive]
250 hours [greater than 80 cm
300 hours [0 80 cm

−−

(0 80 cc) inclusive]
500 hours [greater than 80 cm

(80 cc)]

(80 cc)]

(80 cc)]

The Air Index Information hang tag/label must remain on the
engine until it is sold. Remove the hang tag before operating the
engine.

16

ENGLISH

GCV530/GXV530

Length Width

××

Height
Dry mass [weight]
Engine type
Displacement
[Bore Stroke]

×

Net power

(in accordance with SAE J1349 )

Max. Net torque
(GCV530)

(in accordance with SAE J1349 )

Max. Net torque
(GXV530)

(in accordance with SAE J1349 )

Engine oil capacity

(QEA-1 type)

458 427 331 mm

××

(18.0 16.8 13.0 in)

××

30.5 kg (67.2 lbs)

4-stroke, overhead camshaft, 2 cylinders (90° V-Twin)

530 cm

××

[77.0 57.0 mm (3.03 2.24 in)]

(32.3 cu-in)

11.3 kW (15.4 PS, 15.2 bhp) at 3,600 rpm

＊

34.3 N·m (3.50 kgf·m, 25.3 lbf·ft)
at 2,500 rpm

＊

34.2 N·m (3.49 kgf·m, 25.2 lbf·ft)
at 2,500 rpm

＊

Without oil filter replacement:

0.90

(0.95 US qt , 0.79 Imp qt)

With oil filter replacement:

1.00

(1.06 US qt , 0.88 Imp qt)
Cooling system
Ignition system
PTO shaft rotation

＊

The power rating of the engine indicated in this document is the

Forced air

Transistor magneto

Counterclockwise

net power output tested on a production engine for the engine
model and measured in accordance with SAE J1349 at 3,600
rpm (Net Power) and at 2,500 rpm (Max. Net Torque). Mass
production engines may vary from this value.
Actual power output for the engine installed in the final machine
will vary depending on numerous factors, including the
operating speed of the engine in application, environmental
conditions, maintenance, and other variables.

Wiring Diagrams

With 3A Charge coil

ON
OFF

START

Black

Bl

Yellow

Y

Blue

Bu

Green

G

Red

R

White

W

(A)

MAIN FUSE (25 A)

(B)

ENGINE SWITCH

(C)

ENGINE GROUND

(D)

FUEL CUT SOLENOID
STARTER MOTOR

(E)
(F)

BATTERY
3A CHARGE COIL

(G)
(H)

No.2 IGNITION COIL
SPARK PLUG

(I)
(J)

No.1 IGNITION COIL

(K)

SPARK PLUG

(L)

ENGINE STOP DIODE
RECTIFIER

(M)

Br

Brown

O

Orange
Light blue

Lb

Light green

Lg
P

Pink
Gray

Gr

Tuneup Specifications

GCV520/530, GXV520/530

SPECIFICATIONITEM

Spark plug gap

0.70 0.80 mm

−

(0.028 0.031 in)
Idle speed
Valve clearance
(cold)

1,400 rpm

IN: 0.10 0.04 mm

EX: 0.15 0.04 mm
Other
specifications

Quick Reference Information

Unleaded gasoline (Refer to page 7)Fuel

U.S.
Except
U.S.

Engine oil

SAE 10W-30, API SJ or later, for general use.

Refer to page 7.

Spark plug

BPR5ES (NGK)
W16EPR-U (DENSO)

Maintenance

Before each use:

Check engine oil level. Refer to page 7.
Check air filter. Refer to page 9.

First 20 hours:

Change engine oil. Refer to page 8.

Subsequent:

Refer to the maintenance schedule on page 6.

MAINTENANCE

Refer to page 10.

−

＋

200

−

150

±

±

See your
authorized
Honda dealer

No other adjustments needed.

Pump octane rating 86 or higher
Research octane rating 91 or higher
Pump octane rating 86 or higher

With 12A Charge coil

OFF
ON

START

Black

Bl

Yellow

Y

Blue

Bu
G

Green

R

Red
White

W

MAIN FUSE (25 A)

(A)

ENGINE SWITCH

(B)

ENGINE GROUND

(C)

CHARGE LAMP

(D)

OIL PRESSURE ALARM

(E)

LAMP
OIL PRESSURE SWITCH

(F)

FUEL CUT SOLENOID

(G)

STARTER MOTOR

(H)

BATTERY

(I)

12A CHARGE COIL

(J)

No.2 IGNITION COIL

(K)

SPARK PLUG

(L)
(M)

No.1 IGNITION COIL
SPARK PLUG

(N)

ENGINE STOP DIODE

(O)

REGULATOR/RECTIFIER

(P)

Br

Brown

O

Orange
Light blue

Lb
Lg

Light green

P

Pink
Gray

Gr

ENGLISH

17

With 18A Charge coil

OFF

ON

START

Black

Bl

Yellow

Y

Blue

Bu
G

Green

R

Red
White

W

MAIN FUSE (25 A)

(A)

ENGINE SWITCH

(B)

ENGINE GROUND

(C)

CHARGE LAMP

(D)

FUEL CUT SOLENOID

(E)

SATARTER MOTOR

(F)

BATTERY

(G)

18A CHARGE COIL

(H)

No.2 IGNITION COIL

(I)

SPARK PLUG

(J)

No.1 IGNITION COIL

(K)

SPARK PLUG

(L)

ENGINE STOP DIODE

(M)

RECTIFIER

(N)

Br

Brown
Orange

O

Light blue

Lb
Lg

Light green

P

Pink
Gray

Gr

18

ENGLISH