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Honda GC160 Service Manual

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Table of Contents
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It
could also damage the engine or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some
procedures require the use of special tools. Any person who intends to use a replacement part, service procedure, or a
tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the
engine.
If you need to replace a part, use genuine Honda parts with the correct part number, or an equivalent part. We strongly
recommend that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's
safety and the reliability of the engine. Any error or oversight
while servicing an engine can result in faulty operation, damage
to the engine, or injury to others.
For Your Safety
Because this manual is intended for the professional service
technician, we do not provide warnings about many basic shop
safety practices (eg, Hot parts – wear gloves). If you have not
received shop safety training or do not feel confident about your
knowledge of safe servicing practices, we recommend that you
do not attempt to perform the procedures described in this
manual.
Some of the most important general service safety precautions
are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and
repair procedures. Only you can decide whether or not you
should perform a given task.
• Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate
clothing and using safety equipment. When performing any service task, be especially careful of the following:
! Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts,
and the skills required to perform the tasks safely and completely.
! Protect your eyes by using proper safety glasses, goggles, or face shields any time you hammer, drill, grind, or
work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put
on eye protection.
! Use other protective wear when necessary, for example, gloves or safety shoes. Handling hot or sharp parts can
cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Make sure the engine is off before you begin any servicing procedures, unless the instructions tell you to do
otherwise. This will help eliminate several potential hazards:
! Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the
engine.
! Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
! Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are
out of the way.
• Gasoline vapors are explosive. To reduce the possibility of a fire or explosion, be careful when working around
gasoline.
! Use only a nonflammable solvent, not gasoline, to clean parts.
! Never drain or store gasoline in an open container.
! Keep all cigarettes, sparks, and flames away from all fuel-related parts.
gc160_gcaha_3599750_3721672
A FEW WORDS ABOUT SAFETY
WARNING
Improper service or repairs can create an unsafe
condition that can cause your customer or others
to be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
WARNING
Failure to properly follow instructions and
precautions can cause you to be seriously hurt
or killed.
Follow the procedures and precautions in this
manual carefully.

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  Summary of Contents for Honda GC160

  • Page 1 Honda, must determine the risks to their personal safety and the safe operation of the engine. If you need to replace a part, use genuine Honda parts with the correct part number, or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 2: Outline Of Changes

    GC160 OUTLINE OF CHANGES GC190 • GS190 Model GC160LA • GC190LA • GS190LA GC160 • GC190 • GS190 2007 emission components Item NEW ANGLE 10° FUEL TANK • Redesigned fuel filler neck TETHER FUEL TANK CAP • Fuel cap has a charcoal...
  • Page 3 GC160 GC190 • GS190 Model GC160LA • GC190LA • GS190LA GC160 • GC190 • GS190 2007 emission components Item GC160 GC160LA GC/GS190LA PISTON GC/GS190 • Changed identification markings • Ring landings changed to accept thinner top and second rings 1.0 mm (0.04 in)
  • Page 4: Specifications

    GC160 1. SPECIFICATIONS GC190 • GS190 1. SPECIFICATIONS........1-1 2. PERFORMANCE CURVES......1-2 1. SPECIFICATIONS Model GC160LA GC190LA GS190LA Type 4-stroke, overhead camshaft single cylinder Displacement 160 cc (9.8 cu-in) 187 cc (11.4 cu-in) Bore x stroke 64 x 50 mm (2.5 x 2.0 in) 69 x 50 mm (2.71 x 1.97 in)
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  • Page 6: Performance Curves

    GC160 GC190 • GS190 2. PERFORMANCE CURVES GC160LA GC190LA GS190LA...
  • Page 7: Dimensional Drawnings

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  • Page 8: Pto Dimensional Drawnings

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  • Page 9: Wiring Diagram

    1. SPECIFICATIONS GC160 • GC190 • GS190 1. WIRING DIAGRAM ......1-1 2. WIRE ROUTING ........ 1-2 1. WIRING DIAGRAM WITH OIL ALERT OIL LEVEL IGNITION SPARK IGNITION ALERT SWITCH SWITCH PLUG COIL UNIT...
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  • Page 13: Maintenance Standards

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  • Page 15 gc160_gcaha_3599750_3721672 30.5 mm (1.20 in) 29.0 mm (1.14 in)
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  • Page 18 gc160_gcaha_3599750_3721672 • PISTON RING WIDTH Standard Service limit Top ring 0.93 ~ 0.95 mm 0.91 mm (GC160LA) (0.036 ~ 0.037 in) (0.035 in) Top ring 0.95 ~ 0.97 mm 0.93 mm (GC/GS190LA) (0.037 ~ 0.038 in) (0.036 in) Second ring 0.97 ~ 0.99 mm 0.95 mm 0.038 ~ 0.039 in)
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  • Page 24: Troubleshooting

    2. SERVICE INFORMATION GC160 • GC190 • GS190 1. TROUBLESHOOTING ......2-1 1. TROUBLESHOOTING OIL ALERT® SYSTEM NOTICE Never start the engine when the oil has been drained. Engine does not start with the engine switch ON. Check the oil level before proceeding. Add the recommended engine oil if necessary.
  • Page 25 GC160 • GC190 • GS190 Disconnect the Oil Alert unit black/red lead from Sparks Oil Alert unit faulty. Replace the Oil Alert unit the engine switch black lead. Perform the spark (P. 8-1). test (P. 2-11 of the base shop manual).
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  • Page 33 SJ or later oil.
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  • Page 39: Governor

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  • Page 42 gc160_gcaha_3599750_3721672 GENERAL INFO #6 =>...
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  • Page 49: Air Cleaner/Carburetor

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  • Page 64 gc160_gcaha_3599750_3721672 (ThreeBond 1216, Hondabond HT, or...
  • Page 65 8. CAM PULLEY/CRANKSHAFT/ GC160 • GC190 • GS190 PISTON/CYLINDER BARREL 1. CRANKCASE COVER/CRANKSHAFT/CYLINDER BARREL .......... 8-1 1. CRANKCASE COVER/CRANKSHAFT/CYLINDER BARREL a. REMOVAL/INSTALLATION Oil Alert Unit Type Remove the cam pulley and rocker arm (P. 8-1 of the base shop manual).
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  • Page 77 gc160_gcaha_3599750_3721672 If the cylinder I.D. is worn beyond the service limit, the cylinder barrel must be replaced. Do not hone the cylinder...
  • Page 78 gc160_gcaha_3599750_3721672 • PISTON RING WIDTH Standard Service limit Top ring 0.93 ~ 0.95 mm 0.91 mm (GC160LA) (0.036 ~ 0.037 in) (0.035 in) Top ring 0.95 ~ 0.97 mm 0.93 mm (GC/GS190LA) (0.037 ~ 0.038 in) (0.036 in) Second ring 0.97 ~ 0.99 mm 0.95 mm 0.038 ~ 0.039 in)
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  • Page 86: Fuel Tank Cap

    GC160 6. FUEL SYSTEM GC190 • GS190 1. FUEL TANK CAP........6-1 1. FUEL TANK CAP EVAPORATIVE EMISSION CONTROL SYSTEM These engines have an EVAPORATIVE EMISSION CONTROL CANISTER built into the fuel tank cap to prevent the escape of gasoline vapors into the atmosphere.

This manual is also suitable for:

Gc190Gs190