Honda Automobiles GXV160 User Manual

INTRODUCTION  
Thank you for purchasing a Honda engine. We want to help you to get  
the best results from your new engine and to operate it safely. This  
manual contains information on how to do that; please read it carefully  
before operating the engine. If a problem should arise, or if you have  
any questions about your engine, consult an authorized Honda  
servicing dealer.  
All information in this publication is based on the latest product  
information available at the time of printing. 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.  
OWNER’S MANUAL  
GXV160  
This manual should be considered a permanent part of the engine and  
should remain with the engine if resold.  
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  
and one of three words: DANGER, WARNING, or CAUTION.  
These signal words mean:  
WARNING:  
You WILL be KILLED or SERIOUSLY  
HURT if you don't follow instructions.  
DANGER  
The engine exhaust from this product  
contains chemicals known to the State  
of California to cause cancer, birth  
defects or other reproductive harm.  
You CAN be KILLED or SERIOUSLY  
HURT if you don't follow instructions.  
WARNING  
POM51741G  
25,000.2003.03  
31ZE7614  
00X31-ZE7-6140  
IPC  
You CAN be HURT if you don't follow  
instructions.  
EM3  
PRINTED IN U.S.A.  
CAUTION  
CONTENTS  
Each message tells you what the hazard is, what can happen, and  
what you can do to avoid or reduce injury.  
INTRODUCTION . . . . . . . . . . . . . . 1  
SAFETY MESSAGES . . . . . . . . . 1  
Damage Prevention  
Messages . . . . . . . . . . . . . . . . . . 1  
Safety Information. . . . . . . . . . . 1  
COMPONENT & CONTROL  
LOCATION . . . . . . . . . . . . . . . . . . 2  
THROTTLE CABLE  
CONNECTION. . . . . . . . . . . . . . . . 2  
BEFORE OPERATION  
CHECKS . . . . . . . . . . . . . . . . . . . . 2  
Is Your Engine Ready To Go . . 2  
OPERATION . . . . . . . . . . . . . . . . . 2  
Safe Operating Precautions . . . 2  
Starting the Engine . . . . . . . . . 3  
Setting Engine Speed . . . . . . . . 3  
Stopping the Engine . . . . . . . . 3  
SERVICING YOUR ENGINE. . . . 3  
The Importance of  
Maintenance. . . . . . . . . . . . . . . . 3  
Maintenance Safety . . . . . . . . . 3  
Safety Precautions . . . . . . . . . . 3  
Maintenance Schedule . . . . . . . 4  
Refueling . . . . . . . . . . . . . . . . . . 4  
Fuel Recommendations . . . . . . 4  
Engine Oil . . . . . . . . . . . . . . . . . 5  
Air Cleaner . . . . . . . . . . . . . . . . 6  
Spark Plug . . . . . . . . . . . . . . . . . 6  
Idle Speed Adjustment . . . . . . . 6  
Spark Arrester . . . . . . . . . . . . . . 7  
HELPFUL TIPS &  
SUGGESTIONS. . . . . . . . . . . . . . . 8  
Storing Your Engine . . . . . . . . . 8  
Draining The Fuel Tank And  
Carburetor . . . . . . . . . . . . . . . . . 8  
Adding A Gasoline Stabilizer  
To Extend Fuel Storage Life. . . 8  
Transporting . . . . . . . . . . . . . . . 9  
TAKING CARE OF UNEXPECTED  
PROBLEMS. . . . . . . . . . . . . . . . . . 9  
TECHNICAL & CONSUMER  
INFORMATION . . . . . . . . . . . . . . . 9  
TECHNICAL INFORMATION . . . . 9  
Serial Number Location . . . . . . 9  
High Altitude Operation . . . . . . 9  
Oxygenated Fuels . . . . . . . . . . 9  
Emission Control System  
Information. . . . . . . . . . . . . . . . 10  
Air Index. . . . . . . . . . . . . . . . . . 10  
Specifications . . . . . . . . . . . . . 10  
CONSUMER INFORMATION . . . 11  
Honda Publications. . . . . . . . . 11  
Distributor’s Limited Warranty11  
Emission Control System  
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  
NOTICE  
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.  
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.  
Warranty. . . . . . . . . . . . . . . . . . 11  
Distributor/Dealer Locator  
Information. . . . . . . . . . . . . . . . 12  
Warranty Service  
Information. . . . . . . . . . . . . . . . 12  
© 2000 - 2003 American Honda Motor Co., Inc.—All Rights Reserved  
1
STARTING THE ENGINE  
SERVICING YOUR ENGINE  
FUEL VALVE  
1. Turn the fuel valve to the ON  
position.  
THE IMPORTANCE OF MAINTENANCE  
Good maintenance is essential for safe, economical and trouble-free  
operation. It will also help reduce pollution.  
ON  
OFF  
WARNING  
Improper maintenance, or failure to correct a problem  
before operation, can cause a malfunction in which you  
can be seriously hurt or killed.  
2. FOR STARTING A COLD  
ENGINE: Move the throttle  
control to the choke position.  
IDLE  
FAST  
CHOKE  
Always follow the inspection and maintenance  
recommendations and schedules in this owner’s manual.  
3. FOR RESTARTING A WARM  
ENGINE: Do not use the choke  
when the engine is warm.  
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.  
Move the throttle control slightly  
past the idle position.  
4. FLYWHEEL BRAKE MODELS:  
Move the flywheel brake lever  
(located on equipment) to release the flywheel brake.  
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.  
5. Pull the starter grip lightly until resistance is felt, then pull briskly.  
NOTICE  
Do not allow the starter grip to snap back against the engine.  
Return it gently to prevent damage to the starter.  
Maintenance, replacement, or repair of the emission control  
devices and systems may be performed by any engine repair  
establishment or individual, using parts that are “certified” to  
EPA standards.  
6. If the choke was used to start the engine, move the throttle to the  
fast (or high) position as soon as the engine warms up enough to  
run smoothly without use of the choke.  
MAINTENANCE SAFETY  
7. FLYWHEEL BRAKE MODELS: Continue to hold the flywheel brake  
lever (located on equipment). The engine will stop if you release the  
flywheel brake lever.  
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.  
SETTING ENGINE SPEED  
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.  
WARNING  
Failure to properly follow maintenance instructions and  
precautions can cause you to be seriously hurt or killed.  
STOPPING THE ENGINE  
IDLE  
STOP  
Always follow the procedures and precautions in this  
owner’s manual.  
1. Move the throttle control to the  
slow (IDLE) position.  
SAFETY PRECAUTIONS  
• Make sure the engine is off before you begin any maintenance or  
repairs. This will eliminate several potential hazards:  
2. Move the throttle control to the  
stop position.  
3. FLYWHEEL BRAKE MODELS:  
Release the flywheel brake lever  
(located on equipment) to stop  
the engine.  
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.  
4. Turn the fuel valve to the OFF  
position if you do not intend to  
restart the engine soon.  
FUEL VALVE  
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.  
ON  
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.  
OFF  
Remember that an authorized Honda servicing dealer knows your  
engine best and is fully equipped to maintain and repair it.  
To ensure the best quality and reliability, use only new genuine Honda  
parts or their equivalents for repair and replacement  
3
MAINTENANCE SCHEDULE  
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.  
REGULAR SERVICE  
PERIOD (4)  
Before First Every 3 Every 6 Every Every  
Each Month Months Months Year Two  
Use  
or  
or  
or  
or  
Years  
ITEM  
5 Hrs 25 Hrs 50 Hrs 100 or 250  
Page  
Perform at every indicated month or  
operating hour interval, whichever comes  
first.  
Hrs  
Hrs  
WARNING  
Gasoline is highly flammable and explosive, and you can  
be burned or seriously injured when refueling.  
Engine oil  
Check  
O
O
5
6
6
Replace  
Check  
O
O (2)  
Air cleaner  
• Stop engine and keep heat, sparks, and flame away.  
• Refuel only outdoors.  
Clean  
O (1)  
Replace  
Check-adjust  
Replace  
Check  
O
O
• Wipe up spills immediately.  
Spark plug  
O
Flywheel brake pad  
Spark arrester  
Idle speed  
O
7
7
6
NOTICE  
Clean  
O
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).  
Check-adjust  
Clean  
O(3)  
Fuel tank and filter  
Shop  
manual  
O(3)  
Fuel tube  
Check  
Every 2 years  
(Replace if necessary) (3)  
Shop  
manual  
Never use stale or contaminated gasoline or oil/gasoline mixture.  
Avoid getting dirt or water in the fuel tank  
Valve clearance  
Combustion chamber  
Check-adjust  
Clean  
Shop  
manual  
O(3)  
Adding Fuel  
After every 300 hours (3)  
1. Remove the fuel tank cap.  
(1) Service more frequently when used in dusty areas.  
FUEL TANK CAP  
(2) Change engine oil every 25 hours when used under heavy load or  
in high ambient temperatures.  
FUEL  
LEVEL  
LIMIT  
(3) 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.  
(4) For commercial use, log hours of operation to determine proper  
maintenance intervals.  
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: 0.53 US gal (2.0 l)  
4
ENGINE OIL  
Oil Change  
Recommended Oil  
Drain the engine oil when the engine is warm. Warm oil drains quickly  
and completely.  
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 container to be sure it includes the letters SH,  
SJ, or equivalent.  
OIL FILLER  
CAP/  
DIPSTICK  
OIL FILLER  
CAP/  
DIPSTICK  
UPPER  
LIMIT  
LOWER  
LIMIT  
100oF  
SEALING WASHER  
DRAIN BOLT  
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.  
1. Turn the fuel valve to the OFF position to reduce the possibility of  
fuel leakage (see page 3).  
Oil Level Check  
2. Place a suitable container next to the engine to catch the used oil.  
1. Check the oil with the engine stopped and level.  
2. Remove the oil filler cap/dipstick and wipe it clean.  
3. Remove the drain bolt and drain the oil into the container by slightly  
tipping the engine toward the oil filler cap/dipstick.  
3. Insert the oil filler cap/dipstick into the oil filler neck as shown, but  
do not screw it in, then remove it to check the oil level.  
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. If the oil level is near or below the lower limit mark on the dipstick,  
fill with the recommended oil to the upper limit mark. Do not overfill.  
5. Reinstall the oil filler cap/dipstick.  
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: 0.69 US qt (0.65 l)  
NOTICE  
Running the engine with a low oil level can cause engine damage.  
5. Reinstall the oil filler cap/dipstick securely.  
OIL FILLER CAP/DIPSTICK  
UPPER LIMIT  
LOWER LIMIT  
5
AIR CLEANER  
SPARK PLUG  
A dirty air cleaner will restrict air flow to the carburetor and cause poor  
engine performance. Inspect the elements each time the engine is  
operated. You will need to clean the elements more frequently if you  
operate the engine in very dusty areas.  
Recommended spark plugs: BPR5ES (NGK)  
W16EPR-U (DENSO)  
The recommended spark plugs are the correct heat range for normal  
engine operating temperatures.  
NOTICE  
NOTICE  
Operating the engine without an air cleaner or with a damaged air  
cleaner, 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).  
Incorrect spark plugs can cause engine damage.  
For good performance, the  
SPARK PLUG  
SPARK PLUG CAP  
spark plug must be properly  
WRENCH  
gapped and free of deposits.  
Inspection  
WING BOLT  
1. Disconnect the cap from  
the spark plug, and  
1. Remove the two wing bolts,  
then remove the air cleaner  
remove any dirt from the  
spark plug area.  
AIR CLEANER  
cover. Be careful to prevent  
COVER  
dirt and debris from falling  
into the air cleaner base.  
2. Use the proper size spark  
plug wrench to remove the  
spark plug.  
2. Remove the paper element  
PAPER  
ELEMENT  
and the foam element from  
the air cleaner base.  
3. Inspect the spark plug. Replace it if  
damaged, badly fouled, if the  
sealing washer is in poor condition,  
or if the electrode is worn. If the  
spark plug is to be reused, clean it  
with a wire brush.  
0.028 ~ 0.031 in  
(0.70 ~ 0.80 mm)  
FOAM  
ELEMENT  
3. Remove the foam element  
from the paper element.  
4. Inspect the filter elements.  
Replace damaged  
AIR CLEANER  
BASE  
SEALING  
WASHER  
elements. Clean or replace  
dirty elements.  
4. Measure the electrode gap with a  
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  
electrode.  
Cleaning  
1. Remove the air cleaner  
cover and foam element,  
as described in the  
INSPECTION procedure  
above.  
5. Install the spark plug carefully, by  
hand, to avoid cross-threading.  
2. Remove the paper element from the air cleaner base.  
6. After the spark plug is seated, tighten with the proper size spark  
plug wrench to compress the washer.  
3. Paper element: Tap the element several times on a hard surface to  
remove excess dirt, or blow compressed air [not exceeding 30 psi  
(207 kPa)] through the element from the wire screen side. Never try  
to brush off dirt; brushing will force dirt into the fibers. Replace the  
paper element if it is excessively dirty.  
7. When installing a new spark plug, tighten 1/2 turn after the spark  
plug seats to compress the washer.  
8. When reinstalling the original spark plug, tighten 1/8 - 1/4 turn after  
the spark plug seats to compress the washer.  
4. Foam element: Clean in warm, soapy water or nonflammable  
solvent, rinse and dry thoroughly. Do not use gasoline as a cleaning  
solvent, because that would create a risk of fire or explosion. Dip  
the element in clean engine oil, then squeeze out all excess oil.  
NOTICE  
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.  
Excess oil will restrict air flow through the foam element and may  
transfer to the paper element, soaking and clogging it.  
9. Attach the spark plug cap to the spark plug.  
5. Wipe dirt from the air cleaner base and cover using a moist rag. Be  
careful to prevent dirt from entering the air duct that leads to the  
carburetor.  
IDLE SPEED ADJUSTMENT  
1. Start the engine outdoors,  
and let it warm up to normal  
operating temperature.  
6. Reinstall the air cleaner elements, and make sure both elements  
are properly positioned. Install the air cleaner cover and tighten the  
two wing bolts securely.  
2. Move the throttle control to  
the slow (IDLE) position.  
3. Using a screwdriver, turn the  
throttle stop screw to obtain  
the standard idle speed or  
the idle speed specified by  
the equipment  
manufacturer.  
THROTTLE STOP SCREW  
Standard Idle Speed:  
N type: 1,700 ± 150 rpm  
A type: 2,100 ± 150 rpm  
6
FLYWHEEL BRAKE INSPECTION (A types only)  
SPARK ARRESTER (optional equipment)  
1. Check to see if the inspection  
screw is contacting the brake  
bracket.  
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.  
2. If the inspection screw is  
contacting the brake bracket,  
take the engine to an  
The spark arrester must be serviced every 100 hours to keep it  
functioning as designed.  
authorized Honda engine  
servicing dealer for flywheel  
brake pad inspection.  
If the engine has been running, the muffler will be hot. Allow it to cool  
before servicing the spark arrester.  
INSPECTION  
SCREW  
BRAKE  
BRACKET  
Spark Arrester Removal  
3. Release the flywheel brake  
lever (located on equipment),  
and verify that there is a strong  
resistance when pulling on the  
recoil starter. Also verify that  
the governor arm is moved to  
the idle (slow), position and  
there is freeplay in the cable.  
The cable freeplay should be  
10 - 15 mm from the centerline  
as shown when the cable is  
new.  
1. Remove the two nuts from the muffler shield, using a 10 mm  
wrench.  
2. Remove the muffler shield, identification plate and muffler.  
3. Remove the spark arrester from the muffler.  
BRAKE  
CABLE  
CABLE  
FREE  
PLAY  
MUFFLER  
MUFFLER  
SHIELD  
4. Move the flywheel brake  
lever to release the flywheel  
brake, and verify that there  
is clearance between the  
governor arm and the  
STOPPER  
GASKET  
SPARK  
ARRESTER  
throttle return rod when the  
throttle is in the fast (or high)  
position.  
IDENTIFICATION  
PLATE  
6 mm NUTS  
THROTTLE  
RETURN  
ROD  
Also verify that there is at  
least 2 mm clearance  
between the stopper and the  
brake cable bracket.  
BRAKE  
CABLE  
BRACKET  
Spark Arrester Cleaning & Inspection  
GOVERNOR  
ARM  
CLEARANCE  
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.  
7
HELPFUL TIPS & SUGGESTIONS  
DRAINING THE FUEL TANK AND CARBURETOR  
STORING YOUR ENGINE  
Storage Preparation  
WARNING  
Gasoline is highly flammable and explosive, and you can  
be burned or seriously injured when handling fuel.  
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.  
• Stop engine and keep heat, sparks, and flame away.  
• Refuel only outdoors.  
• Wipe up spills immediately.  
Cleaning  
1. Place an approved gasoline container below the carburetor, and  
use a funnel to avoid spilling fuel.  
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.  
2. Remove the drain bolt, then move the fuel valve lever to the ON  
position (see page 2).  
3. After all the fuel has drained into the container, reinstall the drain  
bolt and washer. Tighten the drain bolt securely.  
NOTICE  
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 cleaner elements, and water that passes through the air  
cleaner 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.  
FLOAT BOWL  
WASHER  
DRAIN BOLT  
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.  
Engine Oil  
1. Change the engine oil (see page 5).  
2. Remove the spark plug (see page 6).  
SPARK PLUG  
HOLE  
OIL  
3. Pour a tablespoon (5 - 10 cc) of clean  
engine oil into the cylinder.  
4. Pull the recoil starter several times to  
distribute the oil.  
Fuel system damage or engine performance problems resulting from  
neglected storage preparation are not covered under the Distributor’s  
Limited Warranty (see page 11).  
5. Reinstall the spark plug.  
Storage Precautions  
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.  
If your engine will be stored with gasoline in the fuel tank and  
carburetor, it is important to reduce the hazard of gasoline vapor  
ignition. Select a well-ventilated storage area away from any appliance  
that operates with a flame, such as a furnace, water heater, or clothes  
dryer. Also avoid any area with a spark-producing electric motor, or  
where power tools are operated.  
ADDING A GASOLINE STABILIZER TO EXTEND FUEL  
STORAGE LIFE  
When adding a gasoline stabilizer, fill the fuel tank with fresh gasoline.  
If only partially filled, air in the tank will promote fuel deterioration  
during storage. If you keep a container of gasoline for refueling, be  
sure that it contains only fresh gasoline.  
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 3).  
1. Add gasoline stabilizer following the manufacturer’s instructions.  
Keep the engine level in storage. Tilting can cause fuel or oil leakage.  
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.  
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.  
3. Stop the engine, and turn the fuel valve to the OFF position (see  
page 3).  
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.  
8
TRANSPORTING  
Carburetor Modification For High Altitude Operation  
Keep the engine level when transporting to reduce the possibility of  
fuel leakage. Turn the fuel valve to the OFF position (see page 3).  
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.  
TAKING CARE OF UNEXPECTED PROBLEMS  
ENGINE WILL NOT  
START  
Possible Cause  
Correction  
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.  
1. Check control positions. Fuel valve OFF.  
Choke OFF.  
Move lever to ON.  
Move the choke/throttle  
lever to CHOKE ON  
position unless engine is  
warm.  
Ignition switch OFF.  
Move the throttle lever to  
FAST position.  
(A type: flywheel brake  
lever to RUN position.)  
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.  
2. Check fuel.  
Out of fuel.  
Refuel.  
Bad fuel; engine stored  
without treating or draining  
Drain the fuel tank and  
carburetor (p. 8). Refuel  
gasoline, of refueled with bad with fresh gasoline.  
gasoline.  
NOTICE  
3. Remove and inspect  
spark plug.  
Spark plug faulty, fouled, or  
improperly gapped.  
Clean or replace the spark  
plug (p. 6).  
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.  
Spark plug wet with fuel  
(flooded engine).  
Dry and reinstall spark  
plug. Start engine with  
choke/throttle lever in  
FAST position.  
4. Take engine to an  
authorized Honda  
Fuel filter clogged, carburetor Replace or repair faulty  
malfunction, ignition  
malfunction, valves stuck,  
etc.  
components as necessary.  
servicing dealer, or  
refer to shop manual.  
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.  
ENGINE LACKS POWER  
Possible Cause  
Correction  
1. Check air cleaner.  
Filter elements clogged.  
Clean or replace filter  
elements (p. 6).  
2. Check fuel.  
Bad fuel; engine stored  
without treating or draining  
gasoline, of refueled with bad with fresh gasoline.  
gasoline.  
Drain the fuel tank and  
carburetor (p. 8). Refuel  
If you use oxygenated fuel, be sure it is unleaded and meets the  
minimum octane rating requirements.  
3. Take engine to an  
authorized Honda  
Fuel filter clogged, carburetor Replace or repair faulty  
malfunction, ignition  
malfunction, valves stuck,  
etc.  
components as necessary.  
Before using an oxygenated fuel, try to confirm the fuel’s contents.  
Some states/provinces require this information to be posted on the  
pump.  
servicing dealer, or  
refer to shop manual.  
TECHNICAL & CONSUMER INFORMATION  
The following are the EPA approved percentages of oxygenates:  
TECHNICAL INFORMATION  
Serial Number Location  
ETHANOL — (ethyl or grain alcohol) 10% by volume  
You may use gasoline containing up to 10% ethanol  
by volume. Gasoline containing ethanol may be  
marketed under the name Gasohol.  
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.  
MTBE  
(methyl tertiary butyl ether) 15% by volume  
You may use gasoline containing up to 15% MTBE  
by volume.  
SERIAL NUMBER AND  
TYPE LOCATION  
METHANOL — (methyl or wood alcohol) 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.  
SERIALNUMBER TYPE  
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).  
MODEL  
SERIAL NUMBER  
ENGINE TYPE  
GXV160  
GJ03– ___ ___ ___ ___ ___ ___ ___  
___ ___ ___ ___  
9
Emission Control System Information  
Source of Emissions  
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 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.  
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.  
Honda utilizes lean carburetor settings and other systems to reduce  
the emissions of carbon monoxide, oxides of nitrogen, and  
hydrocarbons.  
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 11) for  
The U.S. and California Clean Air Acts  
additional information.  
EPA and California regulations require all manufacturers to furnish  
written instructions describing the operation and maintenance of  
emission control systems.  
Descriptive Term  
Moderate  
Applicable to Emissions Durability Period  
50 hours (0–65 cc)  
125 hours (greater than 65 cc)  
The following instructions and procedures must be followed in order to  
keep the emissions from your Honda engine within the emission  
standards.  
Intermediate  
Extended  
125 hours (0–65 cc)  
250 hours (greater than 65 cc)  
300 hours (0–65 cc)  
Tampering and Altering  
500 hours (greater than 65 cc)  
Tampering with or altering the emission control system may increase  
emissions beyond the legal limit. Among those acts that constitute  
tampering are:  
The Air Index Information hang tag/label must remain on the engine  
until it is sold. Remove the hang tag before operating the engine.  
Specifications  
• Removal or alteration of any part of the intake, fuel, or exhaust  
systems.  
Length x Width x Height  
16.3 x 14.1 x 13.9 in  
(415 x 359 x 354 mm)  
• Altering or defeating the governor linkage or speed-adjusting  
mechanism to cause the engine to operate outside its design  
parameters.  
Dry weight  
32.6 lb (14.8 kg)  
32.1 lb (14.6 kg)  
Engine type  
4-stroke, overhead valve, single cylinder  
9.9 cu in (163 cm3)  
[2.7 x 1.8 in (68 x 45 mm)]  
Problems That May Affect Emissions  
Displacement  
[Bore x Stroke]  
If you are aware of any of the following symptoms, have your engine  
inspected and repaired by your servicing dealer.  
Maximum output  
Maximum torque  
Fuel consumption  
Cooling system  
Ignition system  
5.5 bhp at 3,600 rpm  
7.59 ft-lb (1.05 kg/m) at 2,500 rpm  
0.56 lb/hph (340 g/kWh)  
Forced air  
• Hard starting or stalling after starting.  
• Rough idle.  
• Misfiring or backfiring under load.  
• Afterburning (backfiring).  
Transistorized magneto  
Counterclockwise  
PTO shaft rotation  
• Black exhaust smoke or high fuel consumption.  
Replacement Parts  
Tuneup Specifications  
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.  
ITEM  
SPECIFICATION  
MAINTENANCE  
Spark plug gap  
0.028 – 0.031 in (0.7 – 0.8 mm) Refer to page 6.  
Valve clearance  
(cold)  
IN: 0.15 ± 0.04 mm  
EX: 0.20 ± 0.04 mm  
See your authorized  
Honda dealer  
Other specifications  
No other adjustments needed.  
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 4. 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.  
10  
Emission Control System Warranty  
CONSUMER INFORMATION  
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.  
Honda Publications  
These publications will give you additional information for maintaining  
and repairing you engine.You may order them from an authorized  
Honda engine servicing dealer.  
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.  
Shop Manual  
This manual covers complete maintenance and overhaul  
procedures. It is intended to be used by a skilled  
technician.  
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.  
Parts Catalog  
This manual provides complete, illustrated parts lists.  
All States  
Distributor’s Limited Warranty  
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.  
PRODUCTS COVERED BY THIS  
WARRANTY:  
LENGTH OF WARRANTY:  
(FROM DATE OF ORIGINAL  
PURCHASE)  
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.  
PRODUCT  
APPLICATIONS  
NONCOMMERCIAL/ COMMERCIAL/  
NONRENTAL  
RENTAL  
GXV Series  
Engines  
ALL (1)  
24 months  
24 months  
Manufacturer'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.  
(1) Honda GXV series general purpose engines have a 3 months warranty period when  
installed on concession type vehicles.  
Owner's Warranty Responsibility:  
To Qualify for this Warranty:  
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.  
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:  
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.  
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 part of the original product and any  
warranty on those parts will expire coincident with the original product warranty.  
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.  
To Obtain Warranty Service:  
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 12 for contact information.  
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 & garden equipment & supplies, etc.  
Warranty Coverage:  
Honda power equipment engines manufactured after 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.  
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  
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 12 for contact information.  
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.  
Exclusions:  
THIS WARRANTY DOES NOT 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 WARRANTY.  
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 question 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.  
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.  
If you are unable to obtain warranty service, or are dissatisfied with the warranty service  
you receive, see To Obtain Warranty Service on page 12.  
This warranty gives you specific legal rights, and you may also have other rights which vary  
from state to state.  
11  
Exclusions:  
Distributor/Dealer Locator Information  
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.  
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  
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 SECTION OF THE PRODUCT OWNER'S MANUAL, SUCH AS:  
SPARK PLUGS AND FILTERS.  
Servicing dealership personnel are trained professionals. They should  
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.  
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.  
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.  
Emission Control System Warranty Parts:  
SYSTEMS COVERED  
BY THIS WARRANTY:  
PARTS  
DESCRIPTION:  
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:  
Carburetor assembly, Fuel injection pump,  
Fuel injection nozzle, Fuel regulator  
Fuel Metering  
Exhaust  
Catalyst  
American Honda Motor Co., Inc.  
Power Equipment Division  
Customer Relations Office  
4900 Marconi Drive  
Air filter housing, Air filter element*,  
Crankcase breather tube  
Air Induction  
Flywheel magneto, Ignition pulse generator,  
Ignition coil assembly, Ignition control  
module, Spark plug cap, Spark plug*  
Alpharetta, GA 30005-8847  
Ignition  
Or telephone: (770) 497-6400, 8:30 am - 6:00 pm EST  
When you write or call, please give us this information:  
Tubing, fittings, seals, gaskets, and clamps  
associated with these listed systems.  
Miscellaneous Parts  
* Covered up to the first required replacement only.  
See the Maintenance Schedule on page 4.  
• Equipment manufacturer’s name and model number that the  
engine is mounted on  
• Engine model, serial number, and type (see page 9)  
• Name of dealer who sold the engine to you  
• Name, address, and contact person of dealer who services your  
engine  
• Name of Distributor you contacted and the contact person  
• Date of purchase  
Your name, address and telephone number  
• A detailed description of the problem  
12  

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