- Vehicles & accessories
- Motor vehicle accessories & components
- Engine
- Honda
- GCV160
- Owner's manual
- 48 Pages
TAKING CARE OF UNEXPECTED PROBLEMS. Honda GCV160, GCV190 48 Pages
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.
TAKING CARE OF UNEXPECTED PROBLEMS. Honda GCV160, GCV190
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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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
** 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
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?
How often should I change the engine oil?
What should I do if my engine won't start?
Related manuals
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Table of contents
- 1 INTRODUCTION
- 1 SAFETY MESSAGES
- 1 CONTENTS
- 2 COMPONENT & CONTROL LOCATION
- 2 BEFORE OPERATION CHECKS
- 2 IS YOUR ENGINE READY TO GO?
- 2 OPERATION
- 2 SAFE OPERATING PRECAUTIONS
- 2 TYPE 1: FLYWHEEL BRAKE/REMOTE THROTTLE
- 3 TYPE 2: MANUAL CHOKE/MANUAL THROTTLE
- 3 TYPE 3: FLYWHEEL BRAKE/REMOTE CHOKE/FIXED THROTTLE
- 4 TYPE 4: AUTOMATIC CHOKE RETURN/FIXED THROTTLE
- 4 TYPE 5: MANUAL CHOKE/FIXED THROTTLE
- 4 TYPE 6: REMOTE THROTTLE/BLADE BRAKE CLUTCH
- 5 TYPE 7: ELECTRIC START W/ENGINE-MOUNTED STARTER SWITCH/MANUAL CHOKE CONTROL/PRESET THROTTLE
- 5 TYPE 8: AUTOMATIC CHOKE/FIXED THROTTLE
- 5 SERVICING YOUR ENGINE
- 5 THE IMPORTANCE OF MAINTENANCE
- 6 MAINTENANCE SAFETY
- 6 SAFETY PRECAUTIONS
- 6 MAINTENANCE SCHEDULE
- 6 REFUELING
- 7 ENGINE OIL
- 7 AIR CLEANER
- 8 SPARK PLUG
- 8 FLYWHEEL BRAKE INSPECTION
- 8 SPARK ARRESTER (OPTIONAL EQUIPMENT)
- 9 STORING YOUR ENGINE
- 9 CLEANING
- 9 FUEL
- 9 ENGINE OIL
- 9 STORAGE PRECAUTIONS
- 9 REMOVAL FROM STORAGE
- 9 TRANSPORTING
- 10 TAKING CARE OF UNEXPECTED PROBLEMS
- 10 ENGINE WILL NOT START
- 10 ENGINE LACKS POWER
- 10 TECHNICAL INFORMATION
- 10 SERIAL NUMBER AND TYPE LOCATION
- 10 RADIO FREQUENCY INTERFERENCE LABEL (CANADA)
- 10 CARBURETOR MODIFICATIONS FOR HIGH ALTITUDE OPERATION
- 11 EMISSION CONTROL SYSTEM INFORMATION
- 11 AIR INDEX
- 12 SPECIFICATIONS
- 12 TUNEUP
- 12 QUICK REFERENCE INFORMATION
- 13 BATTERY CONNECTIONS
- 13 WIRING DIAGRAMS
- 14 CONSUMER INFORMATION
- 14 DISTRIBUTOR/DEALER LOCATOR INFORMATION
- 14 Honda PUBLICATIONS
- 14 CUSTOMER SERVICE INFORMATION
- 14 DISTRIBUTOR'S LIMITED WARRANTY
- 15 EMISSION CONTROL SYSTEM WARRANTY
- 17 FRANÇAIS
- 31 ESPAÑOL
- 45 INTERNATIONAL WARRANTY