TAKING CARE OF UNEXPECTED PROBLEMS. Honda GCV160, GCV190 48 Pages

TAKING CARE OF UNEXPECTED PROBLEMS. Honda GCV160, GCV190

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Below you will find brief information for Engine GCV160, Engine GCV190. This manual instructs on how to operate the Honda GCV160 and GCV190 engines safely and efficiently. It includes sections on before operation checks, operation, servicing your engine, maintenance schedule, refueling, engine oil, air cleaner, spark plug, flywheel brake inspection, spark arrester, storing your engine, transporting, taking care of unexpected problems, technical information, and consumer information. The manual also includes a distributor’s limited warranty, emission control system warranty, and international warranty information.

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TAKING CARE OF UNEXPECTED PROBLEMS. Honda GCV160, GCV190 | Manualzz

POM52684-N.book Page 10 Friday, May 2, 2008 9:05 AM

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL NOT START

Possible Cause

Fuel valve OFF

Choke OFF

Ignition switch or engine stop switch OFF

Correction

Move lever to ON.

Move the choke/throttle lever, choke rod, or choke lever to the ON position unless the engine is warm.

Move the flywheel brake lever to the RUN position. (TYPES 2 & 6: Throttle lever to

FAST position. TYPE 5: Engine stop switch to ON.)

Refer to the equipment manufacturer’s instructions for servicing the battery and related components.

Electric Starter types only

Battery under-charged.

Battery cables are loose or corroded.

Fuse is blown.

If starter motor operates but the engine does not start, go to

Out of fuel (below).

Out of fuel

Bad fuel; engine stored without treating or draining 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.

Refuel.

Refuel with fresh gasoline.

Adjust or replace the spark plug (p. 8).

Dry and reinstall spark plug. Start engine with choke/throttle lever in FAST position.

(TYPES 4 & 5: Choke OFF position).

Replace or repair faulty components as necessary.

ENGINE LACKS POWER

TECHNICAL INFORMATION

SERIAL NUMBER AND TYPE LOCATION

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

MODEL

GCV160

GCV190

SERIAL

NUMBER

LOCATION

SERIAL NUMBER

__ __ __ __ __– __ __ __ __ __ __ __

__ __ __ __ __– __ __ __ __ __ __ __

Date purchased: ____________________

ELECTRIC STARTER TYPES

TYPE

LOCATION

ENGINE TYPE

__ __ __ __

__ __ __ __

SERIAL NUMBER AND

TYPE LOCATION

SERIAL NUMBER TYPE

RADIO FREQUENCY INTERFERENCE LABEL (CANADA)

This engine complies with Canadian radio frequency interference regulations, ICES-002.

Possible Cause

Air filter clogged

Bad fuel; engine stored without treating or draining gasoline

Fuel filter clogged, carburetor malfunction, ignition malfunction, valves stuck, etc.

Correction

Clean or replace the air filter (p. 7).

Refuel with fresh gasoline.

Replace or repair faulty components as necessary.

CARBURETOR MODIFICATIONS FOR HIGH ALTITUDE

OPERATION

At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting.

Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.

High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above

1,500 meters (5,000 feet), have your servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life.

Even with carburetor modification, engine horsepower will decrease about 3.5% for each 300-meter (1,000-foot) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.

NOTICE

When the carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use. Operation at altitudes below 1,500 meters (5,000 feet) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have your servicing dealer return the carburetor to original factory specifications.

10

ENGLISH

POM52684-N.book Page 11 Friday, May 2, 2008 9:05 AM

EMISSION CONTROL SYSTEM INFORMATION

Source of Emissions

The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

Honda utilizes appropriate air/fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons. Additionally, Honda fuel systems utilize components and control technologies to reduce evaporative emissions.

The U.S., California Clean Air Act, and Environment Canada

EPA, California, and Canadian regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems.

The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards.

Tampering and Altering

Tampering with or altering the emission control system may increase emissions beyond the legal limit. Among those acts that constitute tampering are:

• Removal or alteration of any part of the intake, fuel, or exhaust systems.

• Altering or defeating the governor linkage or speed-adjusting mechanism to cause the engine to operate outside its design parameters.

Problems That May Affect Emissions

If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer.

• Hard starting or stalling after starting.

• Rough idle.

• Misfiring or backfiring under load.

• Afterburning (backfiring).

• Black exhaust smoke or high fuel consumption.

Replacement Parts

The emission control systems on your Honda engine were designed, built, and certified to conform with EPA, California, and Canadian emission regulations. We recommend the use of genuine Honda parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system.

A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.

Maintenance

Follow the maintenance schedule on page 6. Remember that this

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

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 15) for additional information.

Descriptive Term

Moderate

Intermediate

Extended

Applicable to Emission

Durability Period

50 hours (0–80 cc inclusive)

125 hours (greater than 80 cc)

125 hours (0–80 cc inclusive)

250 hours (greater than 80 cc)

300 hours (0–80 cc inclusive)

500 hours (greater than 80 cc)

1000 hours (225 cc and greater)

ENGLISH

11

POM52684-N.book Page 12 Friday, May 2, 2008 9:05 AM

SPECIFICATIONS

GCV160

Length x Width x Height

(without electric start)

Length x Width x Height

(with electric start)

Dry weight (without electric start)

Dry weight (with electric start)

Engine type

Displacement

[Bore x Stroke]

Net power *

(in accordance with SAE J1349)

Max. net torque *

(in accordance with SAE J1349)

Fuel tank capacity

Oil capacity

Cooling system

Ignition system

PTO shaft rotation

367 x 331 x 360 mm

(14.4 x 13.0 x 14.2 in)

367 x 354 x 360 mm

(14.4 x 13.9 x 14.2 in)

9.8 kg (22 lb)

11.6 kg (26 lb)

4-stroke, overhead cam, single cylinder

161 cm

3

(9.8 cu in)

[64 x 50 mm (2.5 x 2.0 in)]

3.3 kW (4.4 hp) at 3,600 rpm

9.4 N•m (6.9 ft-lb) at 2,500 rpm

GCV190

Length x Width x Height

Dry weight

Engine type

Displacement

[Bore x Stroke]

Net power *

(in accordance with SAE J1349)

367 x 331 x 368 mm

(14.4 x 13.0 x 14.5 in)

12.3 kg (27.1 lb)

4-stroke, overhead cam, single cylinder

187 cm

3

(11.4 cu in)

[69 x 50 mm (2.7 x 2.0 in)]

3.8 kW (5.1 hp) at 3,600 rpm

Max. net torque *

(in accordance with SAE J1349)

Fuel tank capacity

Oil capacity

Cooling system

Ignition system

PTO shaft rotation

11.3 N•m (8.3 ft-lb) at 2,500 rpm

0.93 l (0.25 US gal)

0.55 l (0.58 US qt)

Forced air

Transistorized magneto

Counterclockwise

* The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine model and measured in accordance with SAE J1349 at 3600 rpm (net power) and

2500 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.

Tuneup

0.93 l (0.25 US gal)

55 l (0.58 US qt)

Forced air

Transistorized magneto

Counterclockwise

Quick Reference Information

Fuel

Engine Oil

Carburetor

Spark plug

Type

Type

Idle Speed

NGK

Unleaded gasoline with a pump octane

rating of 86 or higher (page 6).

SAE 10W-30, API SJ or later, for general use. ** Refill amount: 0.35 ~ 0.40 l

(12.0 ~ 13.5 oz)

1,400 ± 150 rpm

BPR6ES - Pressure washer applications

Maintenance Before each use

First 5 hours

Subsequent

BPR5ES - All other applications

Check engine oil level. Refer to page 7.

Check air filter. Refer to page 7.

Change engine oil. Refer to page 7.

Refer to the maintenance schedule on

page 6.

** Actual amount will vary due to residual oil remaining in the engine. Always

use the dipstick to confirm the actual level (see page 7).

Spark plug gap

Valve clearance (cold)

Other specifications

0.7 ~ 0.8 mm

(0.028 ~ 0.031 in)

IN: 0.15 ± 0.04 mm

EX: 0.20 ± 0.04 mm

Refer to page 8.

See your authorized

Honda dealer.

No other adjustments needed.

12

ENGLISH

POM52684-N.book Page 13 Friday, May 2, 2008 9:05 AM

Battery Connections

Use the following materials to connect a 12-volt battery to the starter on TYPE 7 units (electric start with engine-mounted starter switch/ manual choke control/preset throttle):

Battery – 12-volt lead acid battery with a recommended ampere-hr rating of 3 Ah or a 14.4-volt NiCd battery with a recommended ampere-hr rating of 1.7 Ah.

Wire – 12-gauge (minimum) wire with a maximum length of

3 meters (10 ft).

Fuse – 40-ampere blade type fuse.

Terminal – Delphi 56 series male connector and terminal to connect to the starter motor.

Coat the battery terminals and cable ends with dielectric grease. Be careful not to connect the battery in reverse polarity.

B WARNING

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

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

Wiring Diagrams

RECOIL STARTER

(All Types)

SPARK

PLUG

IGNITION

COIL

ELECTRIC STARTER

(TYPE 4 with Flywheel Brake)

ENGINE STOP

SWITCH

IGNITION

COIL

SPARK

PLUG

WARNING: Battery posts, terminals and related accessories contain

lead and lead compounds. Wash hands after handling.

1. Connect the battery positive (+) cable using the appropriate connector and insulator to the supplied starter connector.

2. Connect the battery negative (-) cable to an engine mounting bolt, frame bolt, or the provided ground position on the starter motor

(requires 5 x 8 mm screw).

3. Connect the battery positive (+) cable to the battery positive (+) terminal as shown.

4. Connect the battery negative (-) cable to the battery negative (-) terminal as shown.

The following diagram only shows connections for TYPE 7 units

(electric start with engine-mounted starter switch/manual choke control/preset throttle). Connections are different for the other electric starter types (TYPES 4 and 6).

ELECTRIC STARTER

(TYPE 6 with Blade Brake Clutch)

SPARK

PLUG

STARTER

MOTOR

STARTER

MOTOR

ENGINE STOP

SWITCH

Supplied by equipment manufacturer.

STARTER

SWITCH

FUSE

(40A)

BATTERY

Supplied by equipment manufacturer.

STARTER GROUND (-)

CONNECTION

STARTER

MOTOR

IGNITION

COIL

FUSE

(40A)

STARTER

SWITCH

BATTERY

NEGATIVE (-)

TERMINAL

BATTERY

NEGATIVE (-)

CABLE

BATTERY

ELECTRIC STARTER

(TYPE 7 with Starter Switch on the engine)

Supplied by equipment manufacturer.

BATTERY

STARTER

SWITCH

FUSE

(40A)

STARTER MOTOR

POSITIVE (+) CONNECTOR

(from starter switch)

40 AMP FUSE

BATTERY POSITIVE

(+) TERMINAL

BATTERY POSITIVE (+)

CABLE

This engine is not equipped with a charging system to keep the battery charged during engine operation. The battery will loose charge during starter motor operation only. There is no drain on the battery once the engine is running.

SPARK

PLUG

The battery must be charged by an external battery charging system.

Refer to the equipment manufacturer’s instructions or the battery manufacturer for specific external battery charging recommendations.

ENGLISH

IGNITION

COIL

STARTER SWITCH

STARTER

MOTOR

BATTERY

13

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Key Features

  • Safe operation instructions
  • Maintenance schedule
  • Servicing procedures
  • Troubleshooting guide
  • Warranty information

Frequently Answers and Questions

What type of fuel should I use for my Honda GCV160/GCV190 engine?
This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher. You may use regular unleaded gasoline containing no more than 10% Ethanol (E10) or 5% Methanol by volume.
How often should I change the engine oil?
Change the engine oil every 50 hours of operation or every season, whichever comes first. For commercial use, log hours of operation to determine proper maintenance intervals. Change engine oil every 25 hours when used under heavy load or in high ambient temperatures.
What should I do if my engine won't start?
Check if the fuel valve is ON, the choke is ON, the ignition switch or engine stop switch is ON. Ensure the battery is charged and the cables are secure. Additionally, check for out of fuel, bad fuel, faulty spark plug, flooded engine, clogged fuel filter, carburetor malfunction, ignition malfunction, or stuck valves.

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