Honda Power Equipment GCV190 User Manual 2
OWNER’S MANUAL
GCV160 • GCV190
(Appearance may differ in final application)
[1]
[2]
[3]
[5]
[9]
[8]
[6]
[7]
[4]
WARNING
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
COMPONENT LOCATION
1 Fuel filler cap 6 Spark plug
2 Starter grip 7 Muffler
3 Fuel tank 8 Starter motor (if equipped)
4 Control location * 9 Oil filler cap/ dipstick
5 Air cleaner 10 Engine serial number
* The engine control area differs based on the engine type. Refer to the individual figures on page 2 to
determine your engine control type when reading the Operation section and other sections in this manual.
[10]
ENGLISHFRANÇAISESPAÑOL
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00X31-Z8B-0420
EM5
434780-Rev 9
© 2003–2013 American Honda Motor Co., Inc.—All Rights Reserved
POM31Z8B0420
WPG.300000.2013.04
PRINTED IN U.S.A.
1
[3]
[2]
[1]
[3]
[2]
[1]
[3]
[1]
[2]
[1]
X
[2]
[3]
[1]
OFF
ON
[3]
[2]
[1]
X
X
ON
OUVERT
ABIERTA
OFF
FERMÉ
CERRADA
Type/Tipo 1, 2 Type/Tipo 3 Type/Tipo 4
EN [1] Fuel Valve
[2] Remote Choke/Throttle
[3] Flywheel Brake
FR [1] Robinet d’essence
[2] Levier de Starter/Papillon
[3] Frein de Volant
ES [1] Valvula de combustible
[2] Cebador/Aceleración Remota
[3] Freno del Volante
EN [1] Fuel Valve
[2] Automatic Return Choke
[3] Flywheel Brake, Fixed Throttle
FR [1] Robinet d’essence
[2] Starter À Retour Automatique
[3] Frein de Volant, Carburateur Préréglé
ES [1] Valvula de combustible
[2] Retorno Automático Del Cebador
[3] Freno del Volante, Aceleración Fija
EN [1] Fuel Valve
[3] Flywheel Brake
Fixed Throttle
FR [1] Robinet d’essence
[3] Starter Automatique
Carburateur Préréglé
ES [1] Valvula de combustible
[3] Automático Cebador
Aceleración Fija
Type/Tipo 5, 6 Type/Tipo 7 Type/Tipo 8, 9
EN [1] Fuel Valve
[2] Remote Choke/Throttle
Blade Brake Clutch
FR [1] Robinet d’essence
ES [1] Valvula de combustible
[1]
Fuel valve
Robinet d’essence
Valvula de combustible
[2] Levier de Starter/Papillon
Frein-embrayage À Aubes
[2] Cebador/Aceleración Remota
Cebador/Aceleración
2
EN [1] Fuel Valve
[2] Manual Choke
[3] Stop Switch
FIxed Throttle
FR [1] Robinet d’essence
[2] Starter Manuel
[3] Bouton d’Arret du Moteur
Carburateur Préréglé
ES [1] Valvula de combustible
[2] Manual Choke
[3] Interruptor de Para del Motor
Aceleración Fija
EN [1] Fuel Valve
[2] Manual Choke
[3] Manual Throttle
FR [1] Robinet d’essence
ES [1] Valvula de combustible
[2] Starter Manuel
[3] Papillon Manuel
[2] Control Manual
[3] Aceleración Manual
Figure/Figura 1
[1]
[1]
-20 20 30 40°C-10 0 10
40 60 100°F80020
30
5W-30 • 10W-30
[3]
[2]
[1]
[4]
[3]
[2]
[4]
[3]
[4]
[5]
[1]
[2]
[1]
0.028 ~ 0.030 in
(0.70 ~ 0.80 mm)
[2]
[4]
[1]
[2]
[3]
[5]
1/8 in
(3 mm)
minimum
[1]
[5]
[3]
[4]
[2]
Figure/Figura 2
Figure/Figura 3
Figure/Figura 4 Figure/Figura 5 Figure/Figura 6
Figure/Figura 7 Figure/Figura 8
3
INTRODUCTION
NOTICE
Thank you for purchasing a Honda engine! We want to help you get
the best results from your new engine and operate it safely. This
manual contains information on how to do that; please read it carefully
before operating the engine. If a problem should arise, or if you have
any questions about your engine, consult an authorized Honda
servicing dealer.
All information in this publication is based on the latest product
information available at the time of printing. American Honda Motor
Co., Inc. reserves the right to make changes at any time without
notice and without incurring any obligation. No part of this publication
may be reproduced without written permission.
This manual should be considered a permanent part of the engine
and should remain with the engine if resold.
Review the instructions provided with the equipment powered by this
engine for any additional information regarding engine startup,
shutdown, operation, adjustments, or any special maintenance
instructions.
CONTENTS
SAFETY MESSAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BEFORE OPERATION CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STARTING/STOPPING THE ENGINE (ALL TYPES) . . . . . . . . . . . 5
SERVICING YOUR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REFUELING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AIR CLEANER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FLYWHEEL BRAKE INSPECTION (if equipped). . . . . . . . . . . . . . . 8
SPARK ARRESTER (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STORING YOUR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TAKING CARE OF UNEXPECTED PROBLEMS . . . . . . . . . . . . . . . . 10
TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CONSUMER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DAMAGE PREVENTION MESSAGES
You will also see other important messages that are preceded by the
word NOTICE.
This word means:
Your engine or other property can be damaged
if you don’t follow instructions.
The purpose of these messages is to help prevent damage to your
engine, other property, or the environment.
SAFETY INFORMATION
• Understand the operation of all controls and learn how to stop the
engine quickly in case of emergency. Make sure the operator
receives adequate instruction before operating the equipment.
• Do not allow children to operate the engine. Keep children and pets
away from the area of operation.
• Your engine’s exhaust contains poisonous carbon monoxide. Do
not run the engine without adequate ventilation, and never run the
engine indoors.
• The engine and exhaust become very hot during operation. Keep
the engine at least 3 feet (1 meter) away from buildings and other
equipment during operation. Keep flammable materials away, and
do not place anything on the engine while it is running.
SAFETY LABEL LOCATION
The label shown on page 1 contains important safety information.
Please read it carefully. See page 1.
This label is considered a permanent part of your engine. So if the
label comes off or becomes hard to read, contact your dealer for a
replacement.
BEFORE OPERATION CHECKS
IS YOUR ENGINE READY TO GO?
For your safety , to ensure compliance with environmental regulations,
and to maximize the service life of your equipment, it is very important
to take a few moments before you operate the engine to check its
condition. Be sure to take care of any problem you find, or have your
servicing dealer correct it, before you operate the engine.
SAFETY MESSAGES
Your safety and the safety of others are very important. We have
provided important safety messages in this manual and on the
engine. Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you
or others. Each safety message is preceded by a safety alert
symbol
CAUTION.
These signal words mean:
Each message tells you what the hazard is, what can happen, and
what you can do to avoid or reduce injury.
4
and one of three words, DANGER, WARNING, or
DANGER
WARNING
CAUTION
You WILL be KILLED or SERIOUSLY
HURT if you don't follow instructions.
You CAN be KILLED or SERIOUSLY
HURT if you don't follow instructions.
You CAN be HURT if you don't follow
instructions.
WARNING
Improperly maintaining this engine, or failing to correct a problem
before operation, could cause a malfunction in which you could be
seriously injured.
Always perform a pre-operation inspection before each operation,
and correct any problem.
Before beginning your preoperation checks, be sure the engine is
level and the flywheel brake lever, throttle lever, or engine stop switch
is in the STOP or OFF position.
Always check the following items before you start the engine:
1. Fuel level (page 7).
2. Oil level (page 8).
3. Air cleaner (page 8).
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
NOTICE
Type 1: Flywheel Brake, Remote Choke/Throttle
SAFE OPERATING PRECAUTIONS
Before operating the engine for the first time, please review the
SAFETY MESSAGES and the BEFORE OPERATION CHECKS
page 4.
For your safety, do not operate the engine in an enclosed area such
as a garage. Your engine's exhaust contains poisonous carbon
monoxide gas that can collect rapidly in an enclosed area and cause
illness or death.
WARNING
Exhaust contains poisonous carbon monoxide gas that can build
up to dangerous levels in closed areas. Breathing carbon
monoxide can cause unconsciousness or death.
Never run the engine in a closed or even partially closed area
where people may be present.
Review the instructions provided with the equipment powered by this
engine for any safety precautions that should be observed with
engine startup, shutdown, or operation.
Do not operate the engine on slopes greater than 20°.
STARTING/STOPPING THE ENGINE (ALL TYPES)
ST ARTING THE ENGINE
1. Move the choke/throttle lever* [2] to the CHOKE position.
2. Move the flywheel brake lever* [3] to the RUN position.
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
4. Move the choke/throttle lever* [2] to the FAST position.
STOPPING THE ENGINE
1. Move the choke/throttle lever* [2] to the SLOW position.
2. Release the flywheel brake lever* [3] to stop the engine.
Type 2: Flywheel Brake, Automatic Choke,
Remote Throttle
ST ARTING THE ENGINE
1. Move the remote throttle lever* [2] to the FAST position.
2. Move the flywheel brake lever* [3] to the RUN position.
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
STOPPING THE ENGINE
1. Move the remote throttle lever* [2] to the SLOW position.
2. Release the flywheel brake lever* [3] to stop the engine.
Type 3: Flywheel Brake, Automatic Return Choke,
Fixed Throttle
See the figures on page 2 to identify the type of control used on your
equipment. Type specific starting and stopping information can be
found after the general information shown below.
• Fuel valve ON: Turn the fuel valve [1] to the ON position before
starting the engine.
• Manual choke (if equipped): Place the choke lever/rod [2] in the
CHOKE position when starting a cold engine.
Move the choke lever/rod to the OFF position as soon as the
engine fully warms up and runs smoothly without use of the choke,
or for restarting a warm engine.
• Engine speed: For best engine performance, it is recommended
the engine be operated with the throttle in the FAST (or high)
position.
• Starter grip: Pull the starter grip lightly until resistance is felt, and
then pull briskly.
Do not allow the starter grip to snap back against the engine.
Return it gently to prevent damage to the starter.
To ensure easy restarting and maximum performance from the
Auto Choke System™ types, allow the engine to run for at least
three minutes after starting a cold engine before shutting down.
This minimum run time will be longer if the te mp erature is below
70°F (21°C).
• Fuel valve OFF: After stopping the engine, turn the fuel valve [1] to
the OFF position.
If your equipment will not be used for 3 to 4 weeks, we recommend
running the engine’s carburetor out of fuel. You can do this by
leaving the fuel valve OFF , rest arting the engine, and running it out
of fuel. Running time should be less than 3 mi nu te s.
Refer to the Type number for your engine, and the corresponding
graphic on page 2.
ST ARTING THE ENGINE
1. Move the automatic return choke [2] to the CHOKE position.
The choke lever automatically returns to the OFF position
3 - 4 seconds after the flywheel brake is moved to the RUN
position. Reset the choke if the engine does not start within this
time frame.
2. Move the flywheel brake lever* [3] to the RUN position.
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
The throttle is preset on this type.
STOPPING THE ENGINE
Release the flywheel brake lever* [3] to stop the engine.
Type 4: Flywheel Brake, Automatic Choke, Fixed Throttle
ST ARTING THE ENGINE
1. Move the flywheel brake lever* [3] to the RUN position.
2. Pull the starter grip lightly until resistance is felt; then pull briskly.
STOPPING THE ENGINE
Release the flywheel brake lever* [3] to stop the engine.
Type 5: Blade Brake Clutch, Remote Choke/Throttle
ST ARTING THE ENGINE
1. Move the choke/throttle lever* [2] to the CHOKE position.
2. Make sure the blade control lever* is released.
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
4. Move the choke/throttle* [2] to the FAST position as the engine
warms, and then engage the blade control lever*.
STOPPING THE ENGINE
1. Release the blade control lever*.
2. Move the choke/throttle lever* [2] to the SLOW position, and then
the STOP position.
* See the equipment manual for control location.
5
Type 6: Blade Brake Clutch, Automatic Choke,
Remote Throttle
STARTING THE ENGINE
1. Move the remote throttle lever* [2] to the FAST position.
2. Make sure the blade control lever* is released.
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
4. Allow the engine to warm to operating temperature, and then
engage the blade control lever*.
STOPPING THE ENGINE
1. Release the blade control lever*.
2. Move the remote throttle lever* [2] to the SLOW position, and then
to the STOP position.
Type 7: Manual Choke, Manual Throttle
STARTING THE ENGINE
1. Move the choke lever [2] to the CHOKE
2. Move the throttle control [3] to the FAST position.
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
4. Move the choke lever [2] to the OFF position as the engine warms.
STOPPING THE ENGINE
Move the throttle control [3] to the SLOW
the STOP position.
position.
position, and then to
Type 8: Manual Choke, Engine Stop Switch, Fixed Throttle
STARTING THE ENGINE
1. Pull the choke rod [2] to the CHOKE position.
2. Turn the engine stop switch [3] to the ON position.
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
The engine speed is preset on this type.
4. Move the choke rod to the OFF position as the engine warms.
STOPPING THE ENGINE
Turn the engine stop switch [3] to the OFF position.
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.
Remember that an authorized Honda servicing dealer knows your
engine best and is fully equipped to maintain and repair it.
To ensure the best quality and reliability, use only new Honda
Genuine parts or their equivalents for repair and replacement.
Maintenance, replacement, or repair of the emission control
devices and systems may be performed by any engine repair
establishment or individual, using parts that are “certified” to
EP A standards.
MAINTENANCE SAFETY
Some of the most important safety precautions follow. However, we
cannot warn you of every conceivable hazard that can arise in
performing maintenance. Only you can decide whether or not you
should perform a given task.
Type 9: Manual Choke, Engine Stop Switch, Auto Throttle
STARTING THE ENGINE
1. Pull the choke rod [2] to the CHOKE
2. Turn the engine stop switch [3] to the ON position.
3. Pull the starter grip lightly until resistance is felt; then pull briskly.
4. Move the choke rod [2] to the OFF position as the engine warms.
The auto throttle feature only functions when the engine is fully
warm.
STOPPING THE ENGINE
1. Remove the load from the engine so that the auto throttle returns
the engine to idle.
2. Turn the engine stop switch [3] to the OFF position.
* See the equipment manual for control location.
position.
FREQUENCY OF USE
If your equipment will be used on an infrequent or intermittent basis
(more than 4 weeks between usage), refer to the Fuel section of the
STORAGE chapter (page 9) for additional information regarding fuel
deterioration.
6
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.
MAINTENANCE SCHEDULE
NOTICE
Perform at every indicated month/year or operating hour interval,
whichever comes first.
Regular
Service Period
(1)
Item Page
If your equipment will be used on an infrequent or intermittent basis
(more than 4 weeks between usage), refer to the Fuel section of the
STORAGE chapter (page 9) for additional information regarding fuel
deterioration.
Never use stale or contaminated gasoline or oil/gasoline mixture.
Avoid getting dirt or water in the fuel tank.
Before each
use
First month
Check: Engine oil level
Check: Air filter
page 8
page 8
Change: Engine oil page 7
or 5 hours
Every 3 months
Clean: Air filter
(2)
page 8
or 25 hours
Every 6 months
or 50 hours
Change: Engine oil
Clean: Air filter
Check: Flywheel brake pad
(2)
(3)
page 7
page 8
page 8
(if equipped)
Every year
or 100 hours
6 month items plus:
Check-adjust: Spark plug
Clean: Spark arrester (if equipped)
Check: Blade brake clutch
page 8
page 9
(5)
(if equipped)
Every 2 years
or 200 hours
Check-adjust: Idle speed
Clean: Fuel tank and filter
Check-adjust: Valve clearance
Yearly items plus:
Replace: Air filter
Replace: Spark plug
(4)
(4)
(4)
page 8
page 8
Every 2 years Check: Fuel lines (replace if necessary) (4)
(1) For commercial use, log hours of operation to determine proper
maintenance intervals.
(2) Service more frequently when used in dusty areas.
(3) Change engine oil every 25 hours when used under heavy load or in high
ambient temperatures.
(4) These items should be serviced by an authorized Honda servicing dealer ,
unless you have the proper tools and are mechanically proficient. Refer
to the Honda shop manual for service procedures.
(5) See your equipment manual or Honda engine shop manual.
Failure to follow this maintenance schedule could result in
non-warrantable failures.
REFUELING
This engine is certified to operate on unleaded gasoline with a pump
octane rating of 86 or higher.
We recommend refueling after each use to minimize the air present in
the fuel tank.
Refuel in a well-ventilated area with the engine stopped. If the engine
has been running, allow it to cool first. Never refuel the engine inside
a building where gasoline fumes may reach flames or sparks.
Y ou may use regular unleaded gasoline containing no more than 10%
ethanol (E10) or 5% methanol by volume. In addition, methanol must
contain cosolvents and corrosion inhibitors. Use of fuels with content
of ethanol or methanol greater than shown above may cause starting
and/or performance problems. It may also damage metal, rubber, and
plastic parts of the fuel system. In addition, ethanol is hygroscopic,
which means it attracts and retains water in the fuel system. Engine
damage or performance problems that result from using a fuel with
percentages of ethanol or methanol greater than shown above are not
covered by warranty.
WARNING
Gasoline is highly flammable and explosive, and you can be
burned or seriously injured when refueling.
• Stop engine and keep heat, sparks, and flame away.
• Refuel only outdoors.
• Wipe up spills immediately.
Adding Fuel
See Figure 1, page 3.
1. Remove the fuel tank cap.
2. Add fuel to the bottom of the fuel level gauge [1] in the neck of the
fuel tank. Do not overfill. Wipe up spilled fuel before starting the
engine.
3. Install the fuel tank cap and tighten it until it clicks.
Move at least 10 feet (3 meters) away from the fueling source and
site before starting the engine.
Fuel can damage paint and some types of plastic. Be careful not to
spill fuel when filling your fuel tank. Damage caused by spilled fuel is
not covered under your Distributor’s Limited Warranty.
Fuel Storage Container
Store your gasoline in a clean, plastic, sealed container designed for
fuel storage. Close the vent (if equipped) when not in use, and store
the container away from direct sunlight. If it takes more than 3 months
to use the fuel in the container, we suggest adding a fuel stabilizer to
the fuel when you fill the container. If you have some fuel left in the
storage container at the end of the season, the Environmental
Protection Agency (EPA) suggests adding the gasoline to your
vehicle’s gas tank (http://epa.gov/reg5oair/mobile/winter.html).
ENGINE OIL
Oil is a major factor affecting performance and service life. Use
4-stroke automotive detergent oil. Always change the oil in
accordance with the maintenance schedule (page 7).
Recommended Oil
See Figure 2, page 3.
Use 4-stroke motor oil that meets or exceeds the requirements for API
service category SJ or later. Always check the API service label on
the oil container to be sure it includes the letters SJ or later.
SAE 10W-30 is recommended for general use. Other viscosities
shown in the chart may be used when the average temperature in
your area is within the indicated range.
7
Oil Level Check
NOTICE
NOTICE
NOTICE
NOTICE
See Figures 2, 3, page 3.
1. Check the oil with the engine stopped and level.
2. Remove the oil filler cap/dipstick [1] and wipe it clean.
3. Insert the oil filler cap/dipstick into the oil filler neck as shown, but
do not screw it in, and then remove it to check the oil level.
4. If the oil level is near or below the lower limit mark [2] on the
dipstick, remove the oil filler cap/dipstick, and fill with the
recommended oil to the upper limit mark [3]. Do not overfill.
5. Reinstall the oil filler cap/dipstick [1].
Oil Change
See Figure 3, page 3.
Drain the engine oil when the engine is warm. Warm oil drains quickly
and completely.
1. Turn the fuel valve to the OFF position to reduce the possibility of
fuel leakage.
2. Place a suitable container next to the engine to catch the used oil.
3. Remove the oil filler cap/dipstick [1] and drain the oil into the
container by tipping the engine toward the oil filler neck [4].
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 [3] on
the dipstick with the recommended oil.
Refill amount: 12.0 ~ 13.5 oz (0.35 ~ 0.40 )
Always check the oil level with the dipstick after filling.
Running the engine with a low oil level can cause engine damage.
5. Reinstall the oil filler cap/dipstick [1] securely.
AIR CLEANER
A properly maintained air filter will help prevent dirt from entering your
engine. Dirt entering the carburetor can be drawn into small passages
in the carburetor and cause premature engine wear. These small
passages can become blocked, causing starting or running problems.
You will need to clean the filter more frequently if you operate the
engine in very dusty areas.
Cleaning
See Figure 4, page 3.
1. Tap the filter several times on a hard surface to remove dirt, or
blow compressed air not exceeding 30 psi (207 kPa) through the
filter from the clean side that faces the engine. Never try to brush
off dirt. Brushing will force dirt into the fibers.
2. Wipe dirt from the air cleaner body [4] and cover using a moist rag.
Be careful to prevent dirt from entering the air duct [5] that leads to
the carburetor.
SPARK PLUG
See Figure 5, page 3.
Recommended Spark Plug:
NGK - BPR6ES Pressure washer applications
NGK - BPR5ES All other applications
The recommended spark plug is the correct heat range for normal
engine operating temperatures.
Incorrect spark plugs can cause engine damage.
For good performance, the spark plug must be properly gapped and
free of deposits.
1. Disconnect the cap from the spark plug, and remove any dirt from
the spark plug area.
2. Use the proper size spark plug wrench [1] to remove the spark
plug.
3. Inspect the spark plug. Replace it if damaged, badly fouled, if the
sealing washer [2] is in poor condition, or if the electrode is worn.
4. Measure the electrode gap with a suitable gauge. The correct gap
is 0.028 ~ 0.030 in (0.70 ~ 0.80 mm). If adjustment is needed,
correct the gap by carefully bending the side electrode.
5. Install the spark plug carefully, by hand, to avoid cross-threading.
6. After the spark plug is seated, tighten with the proper size spark
plug wrench to compress the washer.
When installing a new spark plug, tighten 1/2 turn after the spark
plug seats to compress the washer.
When reinstalling the original spark plug, tighten 1/8 ~ 1/4 turn
after the spark plug seats to compress the washer.
Properly tighten the spark plug. A loose spark plug can become
very hot and can damage the engine. Overtightening the spark
plug can damage the threads in the cylinder head.
Operating the engine without a filter, or with 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.
We recommend the use of a Honda Genuine air filter to ensure it
seals and performs as designed. Using a non-Honda air filter can
result in dirt bypassing the filter, causing damage to the engine or fuel
system.
Inspection
See Figure 4, page 3.
1. Press the latch tabs [1] on the top of the air cleaner cover [2], and
remove the cover. Check the filter [3] to be sure it is clean and in
good condition.
2. Reinstall the filter and air cleaner cover.
8
7. Attach the spark plug cap to the spark plug.
FLYWHEEL BRAKE INSPECTION (if equipped)
See Figures 6, 7, page 3.
Start the engine outdoors. Move the throttle lever to the FAST position
and release the flywheel brake lever; the engine should stop quickly.
1. Remove the three flange nuts [1] from the recoil starter [2], and
remove the recoil starter from the engine.
2. Remove the fuel tank [3] from the engine without disconnecting the
fuel tube [4]. If the fuel tank contains fuel, keep it level as you
remove it and set it beside the engine in a level position.
3. Check the brake shoe [5] thickness. If it is less than 3 mm, take the
engine to your authorized Honda servicing dealer.
4. Install the fuel tank and recoil starter, and tighten the three nuts
securely.
SPARK ARRESTER (if equipped)
NOTICE
NOTICE
See Figure 8, page 3.
The spark arrester may be standard or an optional part, depending on
the engine type. In some areas, it is illegal to operate an engine
without a spark arrester. Check local laws and regulations. A spark
arrester is available from authorized Honda servicing dealers.
The spark arrester must be serviced every 100 hours to keep it
functioning as designed.
If the engine has been running, the muffler will be hot. Allow it to cool
before servicing the spark arrester.
Removal
1. Remove the three 6 mm bolts [1] from the muffler protector [2], and
remove the muffler protector.
2. Remove the special screw [3] from the spark arrester [4], and
remove the spark arrester from the muffler [5].
Cleaning & Inspection
1. Use a brush to remove carbon deposits from the spark arrester
screen. Be careful not to damage the screen. Replace the spark
arrester if it has breaks or holes.
2. Install the spark arrester in the reverse order of removal.
STORING YOUR ENGINE
STORAGE PREPARATION
Proper storage preparation is essential for keeping your engine
trouble-free and looking good. The following steps will help to keep
rust and corrosion from impairing your engine’s function and
appearance, and will make the engine easier to start when you use it
again.
Cleaning
If the engine has been running, allow it to cool for at least half an hour
before cleaning. Clean all exterior surfaces, touch up any damaged
paint, and coat other areas that may rust with a light film of oil.
Using a garden hose or pressure washing equipment can force water
into the air cleaner or muffler opening. Water in the air cleaner will
soak the air filter, and water that passes through the air filter or muffler
can enter the cylinder, causing damage.
Fuel
Depending on the region where you operate your equipment, fuel
formulations may deteriorate and oxidize rapidly. Fuel deterioration
and oxidation can occur in as little as 30 days and may cause damage
to the carburetor and/or fuel system. Please check with your servicing
dealer for local storage recommendations.
The length of time that gasoline can be left in your fuel tank and
carburetor without causing functional problems will vary with such
factors as gasoline blend, your storage temperatures, and whether
the fuel tank is partially or completely filled. The air in a partially filled
fuel tank promotes fuel deterioration. Very warm storage
temperatures accelerate fuel deterioration. Fuel problems may occur
within a month of inactivity, or even less if the ga s ol i n e w as no t fre s h
when you filled the fuel tank.
Gasoline will oxidize and deteriorate in storage. Deteriorated gasoline
will cause hard starting, and it leaves gum deposits that can clog the
small passages in the fuel system. If the gasoline in your engine
deteriorates during storage, you may need to have the carburetor and
other fuel system components serviced or replaced.
If you keep a container of gasoline for refueling, be sure that it
contains only fresh gasoline. If it takes more than 3 months to use the
fuel in your storage container, we suggest adding a fuel stabilizer to
the fuel when you fill the container.
Fuel system damage or engine performance problems resulting from
neglected storage preparation are not covered under your engine
warranty.
Short Term Storage (30 - 90 days)
If your equipment will not be used between 30 and 90 days, we
recommend the following to prevent fuel-related problems:
1. Add fuel stabilizer following the manufacturer’s instructions.
When adding a fuel stabilizer, fill the fuel tank with fresh gasoline. If
only partially filled, air in the tank will promote fuel deterioration
during storage.
Note:
– All stabilizers have a shelf life and their performance will
deteriorate over time.
– Fuel stabilizers will not reconstitute stale fuel.
2. After adding a fuel stabilizer, run the engine outdoors for
10 minutes to be sure that treated gasoline has replaced the
untreated gasoline in the carburetor.
3. Turn the fuel valve to the OFF position.
4. Continue to run the engine until it stops from the lack of fuel in the
carburetor fuel bowl. Running time should be less than 3 minutes.
Long Term or Seasonal Storage (greater than 90 days)
Turn the fuel valve on, start the engine, and allow it to run long
enough to empty all the gasoline from the entire fuel system (including
the fuel tank). Do not allow gasoline to remain in your engine for more
than 90 days of inactivity.
Engine Oil
1. Change the engine oil (see page 8).
2. Remove the spark plug (see page 8).
3. Pour 1 - 2 teaspoons (5 ~ 10 cc) of clean engine oil into the
cylinder.
4. Pull the recoil starter several times to distribute the oil.
5. Reinstall the spark plug.
Storage Precautions
If your engine will be stored with gasoline in the fuel tank, it is
important to reduce the hazard of gasoline vapor ignition. Select a
well-ventilated storage area away from any appliance that operates
with a flame, such as a furnace, water heater, or clothes dryer. Also
avoid any area with a spark-producing electric motor, or where power
tools are operated.
If possible, avoid storage areas with high humidity, because that
promotes rust and corrosion.
If there is gasoline in the fuel tank, leave the fuel valve in the OFF
position.
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.
9
Removal From Storage
NOTICE
Check your engine as described in the BEFORE OPERATION
CHECKS section of this manual (see page 4).
If the fuel was drained during storage preparation, fill the tank with
fresh gasoline. If you keep a container of gasoline for refueling, be
sure it contains only fresh gasoline. Gasoline oxidizes and
deteriorates over time, causing hard starting.
If the cylinder was coated with oil during storage preparation, the
engine will smoke briefly at startup. This is normal.
TRANSPORTING
TECHNICAL INFORMATION
Serial Number and Type Location
See Figure on page 1.
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 TYPE
GCV160 or 190
Date of purchase
__ __ __ __ __– __ __ _ __ __ __ __ _ __
Keep the engine level when transporting to reduce the possibility of
fuel leakage. Turn the fuel valve to the OFF position.
Review the instructions provided with the equipment powered by this
engine for any procedures that should be followed for transporting.
TAKING CARE OF UNEXPECTED PROBLEMS
Engine will not start
POSSIBLE CAUSE CORRECTION
Fuel valve is OFF. Move the fuel valve lever to ON.
Choke is OFF. Unless the engine is warm, move
the choke/throttle lever, choke rod,
or choke lever to the CHOKE
position. (if equipped)
Ignition switch or engine stop
switch is OFF.
Out of fuel. Refuel.
Bad fuel; engine stored
without treating gasoline, or
refueled with bad gasoline.
Spark plug faulty, fouled, or
improperly gapped.
Spark plug wet with fuel
(flooded engine).
Fuel filter clogged, carburetor
malfunction, ignition
malfunction, valves stuck, etc.
Move the flywheel brake lever to
RUN position.
Throttle lever to FAST position.
Engine stop switch to ON.
Refuel with fresh gasoline.
Adjust or replace the spark plug
(page 8).
Dry and reinstall the spark plug.
Start the engine with the
choke/throttle lever in the FAST
position.
Choke in the OFF position.
Take the engine to an auth o r i z ed
Honda servicing dealer or refer to
the shop manual to replace or
repair faulty components as
necessary.
Radio Frequency Interference Label (Canada)
This engine complies with Canadian radio frequency interference
regulations, ICES-002.
Carburetor Modifications for High Altitude Operation
At high altitude, the standard carburetor air-fuel mixture will be too
rich. Performance will decrease, and fuel consumption will increase. A
very rich mixture will also foul the spark plug and cause hard starting.
Operation at an altitude that differs from that at which this engine was
certified, for extended periods of time, may increase emissions.
High altitude performance can be improved by specific modifications
to the carburetor. If you always operate your engine at altitudes above
5,000 feet (1,500 meters), have your servicing dealer perform this
carburetor modification. This engine, when 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 1,000-foot (300-meter) increase in altitude. The
effect of altitude on horsepower will be greater than this if no
carburetor modification is made.
When auto throttle type engines are used in high altitude applications,
the ability to idle down to 2500 rpm could be diminished. See your
servicing dealer for information on adjustments if your auto throttle
unit does not idle down with the load released or has trouble returning
to full rpm with the load applied.
Engine lacks power
POSSIBLE CAUSE CORRECTION
Air filter clogged. Clean or replace the air filter
(page 8).
Bad fuel; engine stored
without treating the gasoline,
of refueled with bad gasoline.
Fuel filter clogged, carburetor
malfunction, ignition
malfunction, valves stuck, etc.
10
Refuel with fresh gasoline.
Take the engine to an authorized
Honda servicing dealer or refer to
the shop manual to replace or
repair faulty components as
necessary.
When the carburetor has been modified for high altitude operation,
the air-fuel mixture will be too lean for low altitude use. Operation at
altitudes below 5,000 feet (1,500 meters) with a modified carburetor
may cause the engine to overheat and result in serious engine
damage. For use at low altitudes, have your servicing dealer return
the carburetor to original factory specifications.
EMISSION CONTROL SYSTEM INFORMATION
NOTICE
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. EPA, CARB, and Environment Canada
EPA, California, and Canadian emissions 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 is a violation of Federal and California law.
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 Honda Genuine
parts whenever you have maintenance done. These original-design
replacement parts are manufactured to the same standards as the
original parts, so you can be confident of their performance. The use
of replacement parts that are not of the original design and quality
may impair the effectiveness of your 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 7. 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.
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 addition al information.
DESCRIPTIVE
TERM
Moderate 50 hours (0–80 cc inclusive)
125 hours (greater than 80 cc)
Intermediate 125 hours (0–80 cc inclusive)
250 hours (greater than 80 cc)
Extended 300 hours (0–80 cc inclusive)
500 hours (greater than 80 cc)
1000 hours (225 cc and greater)
APPLICABLE TO EMISSION
DURABILITY PERIOD
SPECIFICATIONS
GCV160
TYPE RECOIL START ELECTRIC START
Length x Width x Height 14.4 x 13.0 x 14.2 in
Dry weight 22 lb (9.8 kg) 26 lb (11.6 kg)
Engine type 4-stroke, overhead cam, single cylinder
Displacement
[Bore x Stroke]
Oil capacity Dry engine: 18.6 oz (0.55 )
Fuel tank capacity 0.25 US gal (0.93 )
Fuel consumption ** 1.1 /h at 3,000 rpm
Cooling system Forced air
Ignition system Transistorized magneto
PTO shaft rotation Counterclockwise
14.4 x 13.9 x 14.2 in
(367 x 331 x 360 mm)
9.8 cu in (160 cm
[2.5 x 2.0 in (64 x 50 mm)]
Refill amount: 12.0 ~ 13.5 oz (0.35 ~ 0.41 )*
(367 x 354 x 360 mm)
3
)
GCV190
TYPE RECOIL START ELECTRIC START
Length x Width x Height 14.4 x 13.0 x 14.5 in
Dry weight 27.1 lb (12.3 kg) 29.3 lb (13.3 kg)
Engine type 4-stroke, overhead cam, single cylinder
Displacement
[Bore x Stroke]
Oil capacity Dry engine: 18.6 oz (0.55 )
Fuel tank capacity 0.25 US gal (0.93 )
Fuel consumption ** 1.3 /h at 3,000 rpm
Cooling system Forced air
Ignition system Transistorized magneto
PTO shaft rotation Counterclockwise
* Actual amount will vary due to residual oil remaining in the engine. Always
use the dipstick to confirm the actual level (see
**Actual consumption will vary, depending on the load applied to the engine.
(367 x 331 x 368 mm)
11.4 cu in (187 cm
[2.7 x 2.0 in (69 x 50 mm)]
*Refill amount: 12.0 ~ 13.5 oz (0.35 ~ 0.41 )
14.4 x 13.9 x 14.5 in
(367 x 354 x 368 mm)
page 8)
3
)
Tuneup Specifications
Spark plug gap 0.028 ~ 0.030 in
Idle speed 1,400 ± 150 rpm
Valve clearance
(cold)
(0.70 ~ 0.80 mm)
1,700 ± 150 rpm (fixed
2,500 ± 150 rpm (auto
IN: 0.006 +
EX: 0.008 +
throttle types)
throttle types)
(0.15 +
(0.20 +
0.001 in
0.02 mm)
0.001 in
0.02 mm)
Refer to
See your authorized Honda
dealer.
page 8
11
Quick Reference Information
M
OFF
ON
E
[2][1] [3]
M
[2][1]
[4]
[5]
ELECTRIC STARTER
(with blade brake clutch)
[3]
[1] [2]
[5]
[3]
BLACK
Supplied by equipment
manufacturer.
ENGINE SWITCH
CONTACT
RUN OPEN
STOP CLOSE
OFF E ON
STOP
ON
BLACK
ELECTRIC STARTER
(with flywheel brake)
BLACK
RECOIL STARTER (all types)
[4]
WHITE
WHITE
Supplied by equipment
manufacturer.
Fuel Type Unleaded gasoline with a pump octane
rating of 86 or higher (
Engine Oil Type SAE 10W-30, API SJ or later, for general
use. Refer to page 7.
* Refill amount: 12.0 ~ 13.5 oz.
Spark plug Type BPR6ES (NGK) (pressure washer types)
BPR5ES (NGK) (all other applications)
Maintenance Before each
use
First 5 hours
Subsequent Refer to the maintenance schedule on
Check engine oil level. Refer to
Check air filter. Refer to
Change engine oil. Refer to
page 7).
(0.35 ~ 0.41 )
page 8.
page 8.
page 8.
page 7.
* Actual amount will vary due to residual oil remaining in the engine. Always
use the dipstick to confirm the actual level (see
page 8)
Wiring Diagrams
CONSUMER INFORMATION
Distributor/Dealer Locator Information
United States, Puerto Rico, and U.S. Virgin Islands:
Visit our website: www.engines.honda.com
Canada:
Call (888) 9honda9 [888 946-6329]
or visit our website: www.honda.ca
Honda Publications
These publications will give you additional information for maintaining
and repairing your engine.
Shop
Manual
Parts
Catalog
Customer Service Information
Servicing dealership personnel are trained professionals. They should
be able to answer any question you may have. If you encounter a
problem that your dealer does not solve to your satisfaction, please
discuss it with the dealership's management. The Service Manager,
General Manager, or Owner can help. Almost all problems are solved
in this way.
If you are dissatisfied with the decision made by the dealership's
management, contact the Honda Regional Engine Distributor for your
area. You can find their name, address, and phone number using the
dealer/distributor locator on our website at www.hond-engines.com
If you are still dissatisfied after speaking with the Regional Engine
Distributor, you may contact the Honda Office as shown below.
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 and click on
Product Manuals.
This manual provides complete, illustrated parts lists. Available
through your Honda dealer.
[1] SPARK PLUG [4] STARTER MOTOR
[2] IGNITION COIL [5] STARTER SWITCH
[3] ENGINE STOP SWITCH
12
<Honda’s Office>
When you write or call, please provide this information:
• Equipment manufacturer’s name and model number that the
engine is mounted on
• Engine model, serial number, and type (see page 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
United States, Puerto Rico, and U.S. Virgin Islands:
American Honda Motor Co., Inc.
Power Equipment Division
Customer Relations Dept.
4900 Marconi Drive
Alpharetta, GA 30005-8847
Or telephone: (770) 497-6400, 8:30 a.m. - 7:00 p.m. ET
Canada:
Honda Canada, Inc.
180 Honda Blvd.
Markham, ON L6C OH9 or visit: www.honda.ca
Telephone: (888) 9honda9 Toll free
(888) 946-6329
Facsimile: (877) 939-0909 Toll free
DISTRIBUTOR’S WARRANTIES
The applicable warranty is the warranty policy in effect in the country where
the warranty service is provided.
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