Honda GSV160 User's Manual
Contents
1. High Altitude Operation Oxygenated Fuels Emission Control System Information AIF IndeX iios RE XXX Specifications Wiring Diagram CONSUMER INFORMATION Honda Publications U S A Distributor s Limited Warranty 2 2 International Warranty Emission Control System Warranty Distributor Dealer Locator Information Customer Service Information 9 INTRODUCTION Thank you for purchasing a Honda engine We want to help you to get the best results from your new engine and to operate it safely This manual contains information on how to do that please read it carefully before operating the engine If a problem should arise or if you have any questions about your engine consult an authorized Honda servicing dealer All information in this publication is based on the latest product information available at the time of printing American Honda Motor Co Inc reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission This manual should be considered a permanent part of the engine and should remain with the engine if resold Review the instructions provided with the equipment powered by this engine for any additional information regarding engine startup shutdown operation adjustments or2. THIZUEAED UI ASAJU QXaU30 aod oan padoig bunt AUJURA urgesu ajuaseXd a won tnb aau ruciwu ara Guide re uou arzutags GI a aaas 0 SUDOIZRhD pp up appari reptstenb sp ryjesnua BIOPOUI Tap rureqqead ep ewearddu re erue ed rp ruorzipuno aj e uprzeu Tao red HpuoH Ep appr vanana om Jed nojour D tad e penb e uLIDIUO2 onos wlzUuEIUI iD LUMEN Hj a ajaa rjuanzas HE v3edgiadBosss pe Ltorn ivo3 TE Bp aiampoid sun pjjgur ouerssedinba ayo oamauad oan aod BPUOP Mopot Ins aiqeaiydide oa gpuog FIVA vT OOTHHNAD OS Wad gpuopg THOLON I ddd WIVNOIZVNHALNI VIZNVHYD V TIOS INOIZVIIHONI HS HES MEARS ee BUTTE Gi cee ae Cyl GE URS SY fT Y ex IE OO EG a ee SET EIS Geo snot ae fag 36 E BE SRL et CE Tr p P d s Ser ar SOUS Bk LILIIia mgri iSo E Dios Eie E E te EM s e 2 H SEM us ol See RS at eb ET E B Co SPD denen T Sie B REIR GE EH E P5 Bl S ETH Sie ADE SG EE M ER I8 pe Ee ae T Lh ie Se H EET EE GAEE ETGEN Us at SpE SL T Uf S HS Rueaa4edaraD Uepionh SUBRE op Jepuo ezap jez uap4o A JUL Duaaledejae5 icjmu ap Jap si jeeploO0 UBA Joipap ap ue amp ipu SI 2nugi eB ap Jepun Bou jinpoad yey yep Uaz ue JEEP ap Jepoz dooxueg UEA slime jay jeu uanBzae 20388 yasay 12npojd joy n UBA Beas Jajgap ep egu jo 1dOooxJ8 Usjonpod eugasuxya e EDUOH Sip ze Eep uas Jggu 1onpoad FAO n Duaug mnub4p6 ap Japuo 32npo4d joy UEA uadaaedau SLUNSING SIP epuor uaaB Jeem uepug ul ou jpjeB auup pb aq ugjnojenearimeds jo abeau Qe woop ul
3. Move the choke throttle stop lever to the SLOW position and allow the engine to idle for a few seconds 3 Move the choke throttle stop lever to the STOP position 4 Turn the fuel valve OFF see page 2 For best engine performance it is recommended the engine be operated with the throttle lever in the FAST or high 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 AA WARNING Improper maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual To help you properly care for your engine the following pages include a maintenance schedule routine inspection procedures and simple maintenance procedures using basic hand tools Other service tasks that are more difficult or require special tools are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your engine under severe conditions such as sustained high load or high temperature operation or use in unusually wet or dusty conditions consult your servicing dealer for recommendations applicable to your individual needs and use Maintenance rep
4. na 15 Emission Control System Warranty Your new Honda Power Equipment engine complies with both the U S EPA and State of California emission regulations American Honda provides the same emission warranty coverage for engines sold in all 50 states Your Warranty Rights And Obligations California The California Air Resources Board and American Honda Motor Co Inc are pleased to explain the emission control system warranty on your Honda Power Equipment engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the State s stringent anti smog standards Other States In other areas of the United States your engine must be designed built and equipped to meet the U S EPA emission standards for spark ignited engines at or below 19 kilowatts All States American Honda Motor Co Inc must warrant the emission control system on your power equipment engine for the period of time listed below provided there has been no abuse neglect or improper maintenance of your power equipment engine Where a warrantable condition exists American Honda Motor Co Inc will repair your power equipment engine at no cost to you including diagnosis parts and labor Your emission control system may include such parts as the carburetor or fuel injection system the ignition system and catalytic converter Also included may be hoses connectors and other emission related assemblies Manuf
5. January 1 1995 and sold in the State of California and U S EPA certified engines manufactured on or after September 1 1996 and sold in all of the United States are covered by this warranty for a period of two years from the date of delivery to the original retail purchaser This warranty is transferable to each subsequent purchaser for the duration of the warranty period Warranty repairs will be made without charge for diagnosis parts or labor All defective parts replaced under this warranty become the property of American Honda Motor Co Inc A list of warranted parts is on the reverse side of this warranty statement Normal maintenance items such as spark plugs and filters that are on the warranted parts list are warranted up to their required replacement interval only American Honda Motor Co Inc is also liable for damages to other engine components caused by a failure of any warranted part during the warranty period Only Honda approved replacement parts may be used in the performance of any warranty repairs and must be provided without charge to the owner The use of replacement parts not equivalent to the original parts may impair the effectiveness of your engine emission control system If such a replacement part is used in the repair or maintenance of your engine and an authorized Honda dealer determines it is defective or causes a failure of a warranted part your claim for repair of your engine may be denied If the part in que
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7. 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 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 Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are collectively referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions If you use oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirements Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 1096 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE methyl tertiary butyl ether 1596 by volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood a
8. 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 e 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 e Hard starting or stalling after starting e Rough idle Misfiring or backfiring under load e 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 and California 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 e
9. CTION OF THE PRODUCT OWNER S MANUAL SUCH AS SPARK PLUGS AND FILTERS Disclaimer of Consequential Damage and Limitation of Implied Warranties AMERICAN HONDA MOTOR CO INC DISCLAIMS ANY RESPONSIBILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SUCH AS LOSS OF TIME OR THE USE OF THE POWER EQUIPMENT OR ANY COMMERCIAL LOSS DUE TO THE FAILURE OF THE EQUIPMENT AND ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY THIS WARRANTY IS APPLICABLE ONLY WHERE THE CALIFORNIA OR U S EPA EMISSION CONTROL SYSTEM WARRANTY REGULATION IS IN EFFECT Emission Control System Warranty Parts SYSTEMS COVERED PARTS BY THIS WARRANTY DESCRIPTION Fuel Metering Carburetor assembly Fuel injection pump Fuel injection nozzle Fuel regulator Air induction Air filter housing Air filter element Crankcase breather tube Flywheel magneto Ignition pulse generator Ignition coil assembly Ignition control module Spark plug cap Spark plug Ignition Miscellaneous Parts Covered up to the first required replacement only See the Maintenance Schedule on page 5 Tubing fittings seals gaskets and clamps associated with these listed systems Distributor Dealer Locator Information To find an Authorized Honda Engine Distributor Dealer anywhere in the United States Call 800 426 7701 or visit our website www honda engines com Customer Service Information Servicing dealership personnel are trained professionals They sh
10. EXTEND TO PARTS AFFECTED OR DAMAGED BY THE PRODUCT IN WHICH THE ENGINE IS INSTALLED OR BY ACCIDENT AND OR COLLISION MISUSE NEGLECT PARTS WORN BEYOND SERVICE LIMITS DUE TO NORMAL WEAR NORMAL SERVICE LIFE PARTS AFFECTED OR DAMAGED BY THE CONVERSION TO OR USE OF FUEL OTHER THAN THE FUEL S WHICH THE ENGINE IS ORIGINALLY MANUFACTURED TO USE POOR OPERATION RELATED TO FUEL CONTAMINATION OR FUEL QUALITY PARTS DAMAGED BY FUEL CONTAMINATION THE INCORPORATION OF OR USE OF UNSUITABLE ATTACHMENTS OR PARTS THE UNAUTHORIZED ALTERATION OF ANY PART OR ANY CAUSES OTHER THAN DEFECTS IN MATERIAL OR WORKMANSHIP OF THE ENGINE USE OF THE HONDA GENERAL PURPOSE ENGINE FOR RACING OR COMPETITION WILL VOID THIS WARRANT Y Disclaimer of Consequential Damage and Limitation of Implied Warranties AMERICAN HONDA DISCLAIMS ANY RESPONSIBILITY FOR LOSS OF TIME OR USE OF THE ENGINE OR THE EQUIPMENT IN WHICH THE ENGINE IS INSTALLED TRANSPORTATION COMMERCIAL LOSS OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGE ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN LIMITED WARRANTY Some states do not allow limitations on how long an implied warranty lasts and or do not allow the exclusion or limitation of incidental or consequential damages so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state International Warranty See pages 14
11. HONDA ENGINES OWNER S MANUAL GSV160 GSV190 JEE eMe AA WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 31Z2B000 CONTENTS INTRODUCTION SAFETY MESSAGES Damage Prevention Messages Is Your Engine Ready To Go NONEM Safe Operating Precautions Type 1 Operation Type 2 Operation Type 3 Operation Type 4 Operation Type 5 Operation Type 6 Operation SERVICING YOUR ENGINE e Importance o Maintenance Maintenance Safety Safety Precautions Maintenance Schedule Refueling Fuel Recommendations Engine Oil Air Cleaner Spark Plug Flywheel Brake Inspection Spark Arrester 2003 American Honda Motor Co Inc All Rights Reserved HELPFUL TIPS amp SUGGESTIONS Storing Your Engine Adding A Gasoline Stabilizer To Extend Fuel Storage Life Draining The Fuel Tank And Carburetor POM53615 40 000 2003 07 PRINTED IN U S A 8 TAKING CARE OF UNEXPECTED PROBLEMS TECHNICAL amp CONSUMER INFORMATION Engine Serial Number And Type Location
12. RESET THROTTLE Starting A Cold Engine 1 Turn the fuel valve to the ON position see page 2 2 Move the choke control cable see equipment manual so that the choke arm moves to the choke ON position CHOKE CONTROL CABLE FUEL VALVE ON 3 Move the flywheel brake lever to the RUN position 4 Pull the starter grip lightly until resistance is felt then pull briskly see page 3 STOP 5 If the choke was used to start RUN the engine move the choke control cable so that the choke arm moves to the OFF position as soon as the engine warms up enough to run smoothly without use of the choke 6 The engine speed is preset on this type Starting A Warm Engine 1 Move the flywheel brake lever to the RUN position 2 Pull the starter grip lightly until resistance is felt then pull briskly see page 3 Stopping The Engine 1 Release the flywheel brake lever to stop the engine 2 Turn the fuel valve to the OFF position see page 2 TYPE 4 AUTOMATIC CHOKE RETURN PRESET THROTTLE Starting A Cold Engine 1 Turn the fuel valve to the ON position see page 2 2 Move the choke lever to the choke position I 3 Move the flywheel brake lever to the RUN position 4 Pull the starter grip lightly until resistance is felt then pull briskly see page 3 Begin pulling the recoil starter as soon as you move the flywheel brake lever to the RUN position The choke lever automatically begins
13. acturer s Warranty Coverage The 1995 and later power equipment engines are warranted for two years If any emission related part on your engine is defective the part will be repaired or replaced by American Honda Motor Co Inc Owner s Warranty Responsibility As the power equipment engine owner you are responsible for the performance of the required maintenance listed in your owner s manual American Honda Motor Co Inc recommends that you retain all receipts covering maintenance on your power equipment engine but American Honda Motor Co Inc cannot deny warranty coverage solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the power equipment engine owner you should however be aware that American Honda Motor Co Inc may deny you warranty coverage if your power equipment engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your power equipment engine to a Honda Power Equipment dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should write or call the Honda Power Equipment Customer Relations Department Refer to page 13 for contact information 12 Warranty Coverage Honda power equipment engines manufactured after
14. akage Turn the fuel valve to the OFF E TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT Possible Cause START Check control positions Choke OFF Move the choke throttie lever choke rod or choke lever to CHOKE ON position unless engine is warm Ignition switch or engine stop Move the flywheel brake switch OFF lever to RUN position Types 2 amp 6 Throttle lever to FAST position Type 5 Engine stop switch to ON Refuel Correction Check fuel Out of fuel Bad fuel engine stored Drain the fuel tank and without treating or draining carburetor p 8 Refuel gasoline or refueled with bad with fresh gasoline gasoline Spark plug faulty fouled or Replace the spark plug p improperly gapped T Spark plug wet with fuel Dry and reinstall spark flooded engine plug Start engine with choke throttle lever in FAST position Types 4 amp 5 Choke OFF position Replace or repair faulty components as necessary Remove and inspect spark plug 4 Take engine to an Fuel filter clogged carburetor authorized Honda malfunction ignition servicing dealer or malfunction valves stuck refer to shop manual etc ENGINE LACKS Possible Cause POWER 1 Check air filter Filter clogged Clean or replace filter p 6 2 Check fuel Bad fuel engine stored Drain the fuel tank and without treating or draining carburetor p 8 Refuel gasoline of refueled with bad with fresh gasoline gasoline Fuel
15. any special maintenance instructions SAFETY MESSAGES Your safety and the safety of others is very important We have provided important safety messages in this manual and on the engine Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message is preceded by a safety alert symbol A and one of three words DANGER WARNING or CAUTION These signal words mean eee MM MO Marii i HURT if you don t follow 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 The purpose of these messages is to help prevent damage to your engine other property or the environment SAFETY INFORMATION e Understand the operation of all controls and learn how to stop the engine quickly in case of emergency Make sure the operator receives adequate instruction before operating the equipment Your engine s exhaust contains poisonous carbon monoxide Do not run the engine without adequate ventilation and never run the engine indoors The engine and exhaust become very hot during operation Keep the engine at least 3 feet 1 meter away from buildings and other equipment during operation Keep flammable materials away and do not place anything on the engine while it is running Your eng
16. ark 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 Removal ile Spark Arrester Cleaning amp Inspection 1 Remove the two special SPARK ARRESTER MUFFLER PROTECTOR Remove the three 6 mm bolts from the muffler protector and remove the muffler protector screws from the spark arrester and remove the spark arrester from the muffler ae SPECIAL F 6mm BOLT 3 SCREW 2 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 Install the spark arrester in the reverse order of removal HELPFUL TIPS amp SUGGESTIONS 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 ope
17. art of the original product and any warranty on those parts will expire coincident with the original product warranty To Obtain Warranty Service You must take your Honda general purpose engine or the equipment in which it is installed together with proof of original retail purchase date at your expense to a Honda engine dealer or distributor authorized to sell that product in the United States Puerto Rico or the U S Virgin Islands during their normal business hours Many Honda engine dealers and distributors are listed in the yellow pages of the telephone directory under gasoline engines lawn amp garden equipment amp supplies etc If you are unable to obtain warranty service or are dissatisfied with the warranty service you receive take the following steps First contact the owner of the dealership or distributor involved Normally this should resolve the problem However 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 honda engines com or by calling 1 800 426 7701 If you are still dissatisfied after speaking with the Regional Engine Distributor you may contact the Honda Power Equipment Customer Relations Department of American Honda Motor Co Inc Refer to page 13 for contact information Exclusions THIS WARRANTY DOES NOT
18. artially 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 3 m the engine and turn the fuel valve to the OFF position see Remove th 2 Remove the spark plug see 3 Pour a tablespoon 5 10 cc of 4 Pull the recoil starter several DRAINING THE FUEL TANK AND CARBURETOR WARNING Gasoline is highly flammable and explosive and you can be burned or seriously injured when handling fuel e Stop engine and keep heat sparks and flame away e Refuel only outdoors e Wipe up spills immediately Place an approved gasoline container below the carburetor and use a funnel to avoid spilling fuel then move the fuel valve lever to the ON drain bolt see page 2 position After all the fuel has drained into the container reinstall the drain bolt and washer Tighten the drain bolt securely SHER FLOAT BOWL DRAIN BOLT Engine Oil 1 Change the engine oil see page 6 page 7 clean engine oil into the cylinder times to distribute the oil 5 Reinstall the spark plug Storage Precautions If your engine will be stored with
19. ated 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 Attach the spark plug cap to the spark plug FLYWHEEL BRAKE INSPECTION 1 Remove the fuel tank from Install the fuel tank and Remove the three flange nuts from the recoil starter and remove the recoil starter from the engine RECOIL FLANGE NUTS 3 the engine without disconnecting the fuel tube If the fuel tank contains fuel keep it level as you remove it and set it beside the engine in a level position Check the brake shoe wx xcd BRAKE SHOE thickness If it is less than 0 12 in 3 mm take the engine to your authorized Honda servicing dealer e THICKNESS nb recoil starter and tighten the three nuts securely SPARK ARRESTER optional equipment In some areas it is illegal to operate an engine without a USDA United States Department of Agriculture qualified spark arrester Check local laws and regulations A USDA qualified spark arrester is available from an authorized Honda servicing dealer The sp
20. ean the filter elements more frequently if you operate the engine in very dusty areas Operating the engine without a filter or with a damaged filter will allow dirt to enter the engine causing rapid engine wear This type of damage is not covered under the Distributor s Limited Warranty see page 11 Inspection 1 Press the latch tabs on the top of the air cleaner cover and remove the cover NO Remove the foam element from the air cleaner cover LA Remove the screen grid from the paper element 4 Check both elements to be sure they are clean and in good condition 5 Reinstall the screen grid over the paper element Make sure that the screen grid completely surrounds the paper pleats 6 Reinstall the foam element in the air cleaner cover 7 Set the paper element and screen grid in the air cleaner body then install the air cleaner cover AIRDUCT PAPER FILTER cad Se SCREEN e n GRID dz 23 LATCH TABS Ka dee n pd LOWER TABS AIR CLEANER BODY AIR CLEANER COVER Cleaning 1 Paper Element Tap the paper element several times on a hard surface to remove dirt or blow compressed air not exceeding 30 psi 207 kPa 2 1 kg cm 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 Foam Element Wash the element in a solution of household detergent and warm water then rinse thorough
21. filter clogged carburetor authorized Honda malfunction ignition servicing dealer or malfunction valves stuck refer to shop manual etc Correction Take engine to an Replace or repair faulty components as necessary TECHNICAL amp CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number and Type Location Record the engine serial SERIAL NUMBER number and type in the AMBTVBE space below You will LOCATION need this information when ordering parts and when making technical or warranty inquiries GJACA BEBEEER Fill SERIALNUMBER TYPE 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 trimmer 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 3 596 for
22. 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 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 see page 2 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 Removal From Storage Check your engine as described in the BEFORE OPERATION CHECKS section of this manual see page 2 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 Keep the engine level when transporting to reduce the possibility of fuel le
23. gine until it is sold Remove the hang tag before operating the engine Specifications GSV160 Length x Width x Height 14 6 x 13 5 x 14 2 in 370 5 x 342 5 x 360 mm Dry weight 28 2 Ib 12 8 kg Engine type 4 stroke overhead cam single cylinder Displacement 9 8 cu in 160 cm 5 5 bhp 4 1 kW 5 5 PS at 3 600 rpm 8 41 ft lb 11 4 Nem 1 16 kg m at 2 500 rpm PTO shaft rotation Counterclockwise GSV190 Length x Width x Height 14 6 x 13 5 x 14 2 in 370 5 x 342 5 x 360 mm Dry weight 28 7 Ib 13 0 kg Engine type 4 stroke overhead cam single cylinder Displacement 11 4 cu in 187 cm Bore x Stroke 2 7 x 2 0 in 69 x 50 mm Maximum output 6 5 bhp 4 8 kW 6 5 PS at 3 600 rpm Maximum torque 9 74 ft Ib 13 2 N m 1 35 kg m at 2 500 rpm Fuel consumption 0 51 Ib hph 313 g kWh 230 g PSh Cooling system Ignition system Transistorized magneto PTO shaft rotation Counterclockwise Tuneup Specifications ITEM SPECIFICATION MAINTENANCE Spark plug gap 0 028 0 031 in 0 7 0 8 mm Refer to page 7 INN Valve clearance cold IN 0 15 0 04 mm See your authorized EX 0 20 0 04 mm Honda dealer Other specifications No other adjustments needed Wiring Diagram ENGINE STOP SWITCH SPARK PLUG CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing you engine You may order them from an authorized Honda engine
24. iller cap dipstick and fill with the recommended oil to the upper limit mark Do not overfill 5 Reinstall the oil filler cap dipstick esr OIL FILLER CAP DIPSTICK ME Mu M Ej UPPER LIMIT LOWER LIMIT Oil Change Drain the engine oil when the engine is warm Warm oil drains quickly and completely OIL FILLER Es CAP CG DIPSTICK e UPPER e LIMIT 5 3 t LOWER LIMIT 1 Turn the fuel valve to the OFF position to reduce the possibility of fuel leakage see page 2 2 Place a suitable container next to the engine to catch the used oil 3 Remove the oil filler cap dipstick and drain the oil into the container by tipping the engine toward the oil filler neck 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 or pour it on the ground or down a drain 4 With the engine in a level position fill to the upper limit mark on the dipstick with the recommended oil see above Engine Oil Capacity 0 58 qt 0 55 Running the engine with a low oil level can cause engine damage 5 Reinstall the oil filler cap dipstick securely AIR CLEANER A dirty air cleaner will restrict air flow to the carburetor and cause poor engine performance Inspect the filter elements each time the engine is operated You will need to cl
25. immediately Fuel can damage paint and some types of plastic Be careful not to spill fuel when filling your fuel tank Damage caused by spilled fuel is not covered under the Distributor s Limited Warranty see page 11 Never use stale or contaminated gasoline or oil gasoline mixture Avoid getting dirt or water in the fuel tank Adding Fuel 1 Remove the fuel tank cap 2 Add fuel to the bottom of the fuel level limit in the neck of the fuel tank Do not overfill Wipe up spilled fuel before starting the engine Fuel tank capacity 0 29 gal 1 1 FUEL LEVEL MARK MAXIMUM FUEL LEVEL ENGINE OIL Recommended Oil Use 4 stroke motor oil that meets or exceeds the requirements for API service classification SH SJ or equivalent Always check the API service label on the oil 20 0 20 49 container to be sure it includes the 30 20 10 0 10 20 letters SH SJ or equivalent TO 20 66 80 UE 30 AUT 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 1 Check the oil with the engine stopped and level 2 Remove the oil filler cap dipstick and wipe it clean 3 Insert the oil filler cap dipstick into the oil filler neck as shown then remove it to check the oil level Do not screw it in 4 If the oil level is near or below the lower limit mark on the dipstick remove the oil f
26. ine or other property can be damaged if you don t follow instructions Click here to save this manual to your computer COMPONENT amp CONTROL LOCATION The engine control area differs based on the engine type Refer to the individual diagrams below to determine your engine control type when reading the Operation section and other sections in the manual STARTER GRIP FUEL FILLER CAP AIR CLEANER FUEL TANK OIL FILLER CAP DIPSTICK ENGINE CONTROL MUFFLER AREA ENGINE CONTROL TYPES TYPE 1 FLYWHEEL BRAKE REMOTE THROTTLE TYPE 5 MANUAL CHOKE FIXED ENGINE STOP SWITCH FUEL VALVE LEVER THROTTLE LEVER FLYWHEEL BRAKE CONTROL LEVER TYPE 2 MANUAL CHOKE MANUAL THROTTLE CHOKE LEVER TYPE 6 REMOTE THROTTLE BLADE BRAKE CLUTCH equipment control FUEL VALVE LEVER IM ap um 2 E Re mal de h d E SS b THROTTLE Ea UR iu Eugen LEVER oN fe ee j 5 aw W E ape kee ee Ge THROTTLE LEVER FUEL VALVE LEVER TYPE 3 FLYWHEEL BRAKE REMOTE CHOKE FIXED THROTTLE FLYWHEEL BRAKE CONTROL CABLE CHOKE CONTROL CABLE FUEL VALVE LEVER TYPE 4 AUTOMATIC CHOKE RETURN FIXED THROTTLE CHOKE LEVER FLYWHEEL BRAKE CONTROL CABLE FUEL VALVE LEVER BEFORE OPERATION CHECKS 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 yo
27. ip lightly until resistance is felt then pull briskly see page 3 Stopping The Engine 1 Move the engine switch to the OFF position 2 Turn the fuel valve to the OFF position see page 2 TYPE 6 REMOTE THROTTLE BLADE BRAKE CLUTCH Starting A Cold Engine 1 Turn the fuel valve to the ON position see page 2 2 Move the choke throttle stop lever to the CHOKE position Make sure the blade brake clutch control FAST SLOW STOP CHOKE lever is disengaged CHOKE see equipment THROTTLE STOP manual EUER 3 Pull the starter grip lightly until resistance is felt then pull briskly see page 3 4 As soon as the engine starts slowly move the choke throttle stop lever to the FAST position 5 Allow the engine to warm to operating temperature then engage the blade brake clutch control lever see equipment manual Starting A Warm Engine 1 Place the choke throttle stop lever in the FAST position Make sure the blade brake clutch control lever is disengaged see equipment manual 2 Pull the starter grip lightly until resistance is felt then pull briskly see page 3 Throttle Setting Position the choke throttle stop lever for the desired engine speed For best engine performance it is recommended the engine be operated with the choke throttle stop lever in the FAST or high position Stopping The Engine 1 Disengage the blade brake clutch control lever see equipment manual 2
28. lacement 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 AA 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 njury from moving parts Do not run the engine unless instructed to do so e Read the instructions before you begin and make sure you have the tools and skills required To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Remember that an authorized Honda servicing dealer knows your engine best and is full
29. lcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under the Distributor s Limited Warranty see page 11 10 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 lean carburetor settings and other systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons The U S and California Clean Air Acts EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems The following instructions and procedures
30. ly or wash in nonflammable or high flash point solvent Allow the element to dry thoroughly Soak the element in clean engine oil and squeeze out the excess oil The engine will smoke during initial start up if too much oil is left in the foam or the oil could saturate the paper element making the engine inoperable 3 Wipe dirt from the air cleaner body and cover using a moist rag Be careful to prevent dirt from entering the air duct that leads to the carburetor SPARK PLUG Recommended Spark Plug NGK BPR6ES 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 Use the proper size spark Measure the electrode gap with a Disconnect the cap from the spark plug and remove any dirt from the spark plug area iini SPARK PLUG WRENCH plug wrench to remove the spark plug Inspect the spark plug Replace it if damaged badly fouled if the sealing washer is in poor condition or if the electrode is worn 0 028 0 031 in 0 70 0 80 mm SEALING Y WASHER suitable gauge The correct gap is 0 028 0 031 in 0 70 0 80 mm If adjustment is needed correct the gap by carefully bending the side j electrode Install the spark plug carefully by hand to avoid cross threading After the spark plug is se
31. mission 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 5 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 12 for additional information Descriptive Term Applicable to Emissions Durability Period 50 hours 0 65 cc 125 hours greater than 65 cc Moderate Intermediate 125 hours 0 65 cc 250 hours greater than 65 cc Extended 300 hours 0 65 cc 500 hours greater than 65 cc The Air Index Information hang tag label must remain on the en
32. moving to the OFF position when the flywheel brake lever is moved to the RUN position FLYWHEEL P STOP RUN BRAKE LEVER 5 If the engine does not start within several consecutive pulls of the recoil starter release the flywheel brake lever and move the choke lever to the ON position 6 Move the flywheel brake lever to the RUN position and immediately begin operating the recoil starter 7 The throttle is preset on this type Starting A Warm Engine 1 Move the flywheel brake lever to the brake OFF position 2 Pull the starter grip lightly until resistance is felt then pull briskly see page 3 Stopping The Engine 1 Release the flywheel brake lever to activate the flywheel brake and stop the engine 2 Turn the fuel valve to the OFF position see page 2 TYPE 5 MANUAL CHOKE CONTROL PRESET THROTTLE Starting A Cold Engine 1 Turn the fuel valve to the ON ENGINE STOP SWITCH x CHOKE position see page 2 ROD 2 Pull the choke rod to the ON position 3 Turn the engine stop switch to ON the ON position 4 Pull the starter grip lightly until resistance is felt then pull briskly see page 3 5 If the choke was used to start the engine move the choke rod to the OFF position as soon as the engine warms up enough to run smoothly without use of the choke 6 The engine speed is preset on this type Starting A Warm Engine 1 Turn the engine stop switch to the ON position 2 Pull the starter gr
33. ning 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 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 see page 11 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 ADDING A GASOLINE STABILIZER TO EXTEND FUEL STORAGE LIFE When adding a gasoline stabilizer fill the fuel tank with fresh gasoline If only p
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35. ottle control to the SLOW position FAST 2 Release the flywheel brake lever to stop the engine FLYWHEEL ne BRAKE LEVER Je Med mr cS eh 3 Turn the fuel valve to the OFF position see page 2 TYPE 2 MANUAL CHOKE CONTROL MANUAL THROTTLE CONTROL Starting A Cold Engine 1 Turn the fuel valve to the ON position see page 2 2 Move the choke lever to the ON position 3 Move the throttle lever to the FAST position stop SLOW FAST CHOKE LEVER rd sm e OFF RT liese Fw pee xd Se Ca LU D Mi FUEL JUAN Eres VALVE THROTTLE s jl c a LEVER EN VX Sis ys m GES SH ON ON 4 Pull the starter grip lightly until resistance is felt then pull briskly see page 3 5 If the choke was used to start the engine move the choke lever to the OFF position as soon as the engine warms up enough to run smoothly without use of the choke 6 Position the throttle lever for the desired engine speed For best engine performance it is recommended the engine be operated with the throttle in the FAST or high position Starting A Warm Engine 1 Move the throttle lever to the FAST position 2 Pull the starter grip lightly until resistance is felt then pull briskly see page 3 Stopping The Engine 1 Move the throttle lever to the SLOW position 2 Move the throttle lever to the STOP position 3 Turn the fuel valve to the OFF position see page 2 TYPE 3 FLYNHEEL BRAKE REMOTE CHOKE P
36. ould be able to answer any questions 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 honda engines com or by calling 1 800 426 7701 If you are still dissatisfied after speaking with the Regional Engine Distributor you may contact the Honda Power Equipment Customer Relations Office You can write to American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta GA 30005 8847 Or telephone 770 497 6400 8 30 am 6 00 pm EST When you write or call please give us this information Equipment manufacturer s name and model number that the engine is mounted on e Engine model serial number and type see page 9 e Name of dealer who sold the engine to you e Name address and contact person of dealer who services your engine e Name of Distributor you contacted and the contact person Date of purchase Your name address and telephone number e A detailed description of the problem 13 ugdern ui pe1uligd LO Loo O0000z AN
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39. red by this engine for any safety precautions that should be observed with engine startup shutdown or operation TYPE 1 FLYWHEEL BRAKE REMOTE THROTTLE Starting A Cold Engine 1 Turn the fuel valve to the ON position 2 Move the throttle control see equipment manual to move the choke throttle lever to the CHOKE position CHOKE THROTTLE LEVER FAST NO CHOKE 3 Move the flywheel brake control see equipment manual to move the flywheel brake lever to the RUN position _ FLYWHEEL e BRAKE LEVER zu 4 Pull the starter grip lightly until resistance is felt then pull briskly Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the Starter 5 If the choke was used to start the engine move the choke throttle E GRIP e HOKE JE lever to the FAST or high position tyro tie 8 as soon as the engine warms up LEVER BE enough to run smoothly without use of the choke Throttle Setting Position the throttle control for the desired engine speed For best engine performance it is recommended the engine be operated with the throttle in the FAST or high position Starting A Warm Engine 1 Place the choke throttle lever in the FAST position 2 Move the flywheel brake lever to the RUN position 3 Pull the starter grip lightly until resistance is felt then pull briskly Stopping The Engine SLOW 1 Move the choke thr
40. servicing dealer Shop Manual This manual covers complete maintenance and overhaul procedures It is intended to be used by a skilled technician Parts Catalog This manual provides complete illustrated parts lists U S A Distributor s Limited Warranty PRODUCTS COVERED BY THIS WARRANTY PRODUCT APPLICATIONS GS amp GSV Series Engines LENGTH OF WARRANT Y FROM DATE OF ORIGINAL PURCHASE NONCOMMERCIAL COMMERCIAL NONRENTAL 24 months RENTAL 12 months 3 months 1 1 Honda GS and GSV general purpose engines are not covered by this warranty when installed on concession type vehicles To Qualify for this Warranty The Honda general purpose engine must be purchased from a Honda general purpose engine dealer or distributor authorized to sell that product in the United States Puerto Rico or the U S Virgin Islands This limited warranty applies to first retail purchaser and each subsequent owner during the applicable warranty time period What American Honda Will Repair or Replace Under Warranty American Honda will repair or replace at its option any part that is proven to be defective in material or workmanship under normal use during the applicable warranty time period Warranty repairs and replacements will be made without charge for parts or labor Anything replaced under warranty becomes the property of American Honda Motor Company Inc All parts replaced under warranty will be considered as p
41. stion is not related to the reason your engine requires repair your claim will not be denied To Obtain Warranty Service You must take your Honda Power Equipment engine or the product on which it is installed along with your warranty registration card or other proof of original purchase date at your expense to any Honda Power Equipment dealer who is authorized by American Honda Motor Co Inc to sell and service that Honda product during his normal business hours Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine was not properly maintained and used If you are unable to obtain warranty service or are dissatisfied with the warranty service you receive see Jo Obtain Warranty Service on page 11 Exclusions FAILURES OTHER THAN THOSE RESULTING FROM DEFECTS IN MATERIAL OR WORKMANSHIP ARE NOT COVERED BY THIS WARRANTY THIS WARRANTY DOES NOT EXTEND TO EMISSION CONTROL SYSTEMS OR PARTS WHICH ARE AFFECTED OR DAMAGED BY OWNER ABUSE NEGLECT IMPROPER MAINTENANCE MISUSE MISFUELING IMPROPER STORAGE ACCIDENT AND OR COLLISION THE INCORPORATION OF OR ANY USE OF ANY ADD ON OR MODIFIED PARTS UNSUITABLE ATTACHMENTS OR THE UNAUTHORIZED ALTERATION OF ANY PART THIS WARRANTY DOES NOT COVER REPLACEMENT OF EXPENDABLE MAINTENANCE ITEMS MADE IN CONNECTION WITH REQUIRED MAINTENANCE SERVICES AFTER THE ITEM S FIRST SCHEDULED REPLACEMENT AS LISTED IN THE MAINTENANCE SE
42. u operate the engine to check its condition Be sure to take care of any problem you find or have your servicing dealer correct it before you operate the engine WARNING Improperly maintaining this engine or failure to correct a problem before operation can cause a malfunction in which you can be seriously hurt or killed Always perform a preoperation inspection before each operation and correct any problem Before beginning your preoperation checks be sure the engine is level and the flywheel brake lever type 2 throttle lever type 4 engine stop switch is in the STOP or OFF position Always check the following items before you start the engine 1 Fuel level see page 5 2 Oil level see page 6 3 Air cleaner see page 6 4 General inspection Check for fluid leaks and loose or damaged parts 5 Check the equipment powered by this engine Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine startup OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time please review the SAFETY INFORMATION section on page 1 and the BEFORE OPERATION CHECKS above WARNING Carbon monoxide gas is toxic Breathing it can cause unconsciousness and even kill you Avoid any areas or actions that expose you to carbon monoxide Review the instructions provided with the equipment powe
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44. y 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 REGULAR SERVICE PERIOD 3 Perform at every indicated Item month or operating hour interval which ever comes first LM Check level Engine oil Air cleaner Replace Flywheel brake Check adjust I operation Spark arrester Combustion chamber Clean chamber Clean Every 250 hours 2 E manual Spark plug Clean Fuel tank and filter Clean Every 2 years Replace if necessary 2 Replace paper element type only 1 Service more frequently when used in dusty areas 2 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 3 For commercial use log hours of operation to determine proper maintenance intervals T See your equipment manual REFUELING Use unleaded gasoline with a pump octane rating of 86 or higher This engine is certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life WARNING Gasoline is highly flammable and explosive and you can be burned or seriously injured when refueling e Stop engine and keep heat sparks and flame away e Refuel only outdoors e Wipe up spills
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