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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.
Important Safety Precautions
• 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.
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A FEW WORDS ABOUT SAFETY
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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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Summarization of Contents

SAFETY PRECAUTIONS AND GUIDELINES
Service Information for Technicians
General information for professional technicians on service and repair.
Customer Safety Importance
Importance of proper service for customer safety and engine reliability.
Technician Safety Guidelines
Advice for technicians on shop safety practices and confidence.
General Safety Precautions
General precautions like understanding practices, clothing, equipment, and hazards.
OUTLINE OF MODEL CHANGES
Fuel Tank Design Changes
Details on the redesigned fuel filler neck.
Fuel Tank Cap Features
Information on the fuel cap with charcoal filter, tether, and ratchet.
ENGINE SPECIFICATIONS OVERVIEW
GC160, GC190, GS190 Model Specs
Detailed specifications for GC160LA, GC190LA, GS190LA models.
ENGINE DIMENSIONS AND WEIGHTS
Overall Engine Dimensions and Weight
Table detailing overall dimensions and weight of the engine.
ENGINE PERFORMANCE CURVES
Torque and Power Output Graphs
Graphs illustrating engine performance characteristics across models.
ENGINE OVERALL DIMENSIONAL DRAWINGS
Detailed Engine Measurement Diagrams
Detailed diagrams showing engine measurements and key features.
PTO DIMENSIONAL DRAWINGS
PTO Shaft Type Dimensions
Drawings showing PTO shaft dimensions for Q, V, and P types.
ELECTRICAL SYSTEM SPECIFICATIONS
Wiring Diagram and Color Codes
Schematic showing electrical connections including ignition, switches, and oil alert.
Wire Routing Illustration
Information on routing electrical wires within the engine assembly.
SERVICING IMPORTANCE AND SAFETY
Significance of Proper Servicing
Emphasizes proper servicing for safety and preventing damage.
Key Safety Precautions
General safety practices, clothing, equipment, and hazard awareness.
ENGINE SERIAL NUMBER LOCATION
Location of Engine Serial Number
Indicates the engine serial number is stamped on the cylinder barrel.
GENERAL SERVICE RULES
Guidelines for Service Procedures
Rules for using genuine parts, special tools, cleaning, and fasteners.
MAINTENANCE STANDARDS: ENGINE AND CARBURETOR
Engine and Carburetor Specifications
Specifications for engine maximum/idle speed, compression, and carburetor settings.
MAINTENANCE STANDARDS: IGNITION AND SPARK PLUG
Spark Plug and Ignition Coil Specs
Specifications for spark plug gap and ignition coil resistance.
MAINTENANCE STANDARDS: VALVES
Valve Component Standards
Standards for valve clearance, stem O.D., guide I.D., seat width, spring length, and head diameter.
MAINTENANCE STANDARDS: INTERNAL COMPONENTS
Rod, Crankshaft, Cam Pulley, Rocker Arm Specs
Specifications for various internal engine parts like bearings, journals, and shafts.
MAINTENANCE STANDARDS: CYLINDER AND PISTON
Cylinder, Piston, Ring Specs
Standards for cylinder bore, piston skirt, ring width, and clearances.
CAM PULLEY, CRANKSHAFT, PISTON, CYLINDER BLOCK INSPECTION
Piston Ring Width Standards
Standards and service limits for piston ring width.
Piston Ring Side Clearance Standards
Standards and service limits for piston ring side clearance.
Piston Ring End Gap Standards
Standards and service limits for piston ring end gap.
TORQUE VALUES FOR ENGINE COMPONENTS
Standard Torque Specifications Table
Table listing torque values for various engine components and fasteners.
SPECIAL TOOLS FOR MAINTENANCE
Maintenance Tool List and Uses
List of special tools required for maintenance and their uses.
GENERAL TROUBLESHOOTING GUIDE
Common Engine Symptoms and Causes
Lists common engine problems like hard starting and lack of power with potential causes.
ADVANCED ENGINE TROUBLESHOOTING
Engine Speed and Performance Problems
Addresses problems with engine revving, high-speed, and low-speed performance.
HARD STARTING DIAGNOSIS
Hard Starting Troubleshooting Steps
Step-by-step guide to diagnose and resolve hard starting issues.
SERVICE INFORMATION AND DIAGNOSTICS
Oil Alert System Starting Issues
Guide for diagnosing issues related to the oil alert system when the engine won't start.
ELECTRICAL SYSTEM DIAGNOSTICS
Oil Alert and Stop Switch Troubleshooting
Diagnosing issues related to the oil alert unit and engine stop switch.
IGNITION SYSTEM DIAGNOSTIC PROCEDURES
Starting Issues: Ignition System Checks
Steps for diagnosing ignition system problems when the engine won't start.
Spark Plug Test Method
Detailed instructions for performing a spark plug test.
ENGINE STALLING TROUBLESHOOTING
Diagnosing Engine Stalling Causes
Flowchart for diagnosing why the engine starts but then stalls.
ENGINE POWER LOSS DIAGNOSTIC GUIDE
Diagnosing Engine Power Loss
Flowchart for diagnosing and resolving engine power loss.
ENGINE SPEED INCREASE ISSUES
Diagnosing Failed Speed Increase
Flowchart for diagnosing why engine speed does not increase.
ELECTRICAL HARNESS ROUTING DIAGRAMS
Harness Routing Illustrations
Diagrams illustrating how to route the wiring harnesses.
REGULAR ENGINE MAINTENANCE SCHEDULE
Scheduled Maintenance Intervals
Schedule for checking and changing engine oil, air cleaner, spark plug, etc.
ENGINE OIL SYSTEM CHECKS
Oil Alert System Functionality Test
Procedure to test the oil alert system's functionality.
Engine Oil Level Check Steps
Steps to check and maintain the engine oil level.
ENGINE OIL CHANGE PROCEDURE
Steps for Oil Replacement
Detailed steps for draining, refilling, and disposing of used engine oil.
AIR CLEANER MAINTENANCE AND CLEANING
Air Filter Cleaning Instructions
Instructions for cleaning the air filter, including cautions and replacement advice.
SPARK PLUG INSPECTION AND MAINTENANCE
Spark Plug Service and Cleaning
Steps for cleaning, inspecting, gapping, and installing spark plugs.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
Initial Valve Clearance Check
Procedure to inspect valve clearance with the engine cold.
VALVE CLEARANCE ADJUSTMENT DETAILS
Step-by-Step Valve Clearance Adjustment
Detailed steps for adjusting valve clearance using special tools.
CARBURETOR ADJUSTMENT PROCEDURES
Pilot Screw and Idle Speed Adjustment
Information on pilot screw limiter cap and adjusting the throttle stop screw for idle speed.
GOVERNOR SYSTEM ADJUSTMENT AND TESTING
Governor Adjustment Steps
Steps to adjust the governor for maximum engine speed.
FUEL TANK AND STRAINER MAINTENANCE
Fuel Tank and Strainer Cleaning Steps
Procedure for draining fuel and cleaning the fuel tank and strainer.
FUEL LINE AND PUMP CHECKS
Fuel Line and Pump Inspection
Instructions for checking fuel lines and pump for damage or leaks.
OPTIONAL SPARK ARRESTER CLEANING
Cleaning the Spark Arrester
Steps for cleaning the optional spark arrester.
MUFFLER REMOVAL AND INSTALLATION
Muffler Component Service
Procedures for removing and installing the muffler, including cautions.
RECOIL STARTER AND FAN COVER SERVICE
Fan Cover Installation Steps
Instructions for installing the fan cover, checking high tension cord.
Starter Rope Replacement Procedure
Procedure for replacing the starter rope.
STARTER ROPE REPLACEMENT DETAILS
Steps for Starter Rope Installation
Detailed steps for replacing and winding the starter rope.
STARTER ROPE WINDING AND OPERATION CHECK
Winding and Testing Starter Rope
Instructions for winding the starter rope and checking ratchet operation.
FUEL TANK REMOVAL AND INSTALLATION
Fuel Tank Service Steps
Steps for removing and installing the fuel tank, including draining fuel.
FUEL TANK TUBE INSTALLATION
Connecting Fuel Tank Tube to Pump
Instructions for connecting the fuel tank tube to the fuel pump.
AIR CLEANER AND CARBURETOR SERVICE PROCEDURES
Air Cleaner and Carburetor Component Service
Procedures for removing and installing the air cleaner and carburetor assembly.
Control Linkage Component Service
Procedures for removing and installing control linkage components.
CARBURETOR OVERHAUL AND REASSEMBLY
Detailed Carburetor Overhaul Steps
Detailed steps for taking apart and putting back together the carburetor.
CARBURETOR INSPECTION AND REPAIRS
Float Level Height Measurement
Procedure to measure and check the float level height.
Pilot Screw and Limiter Cap Replacement
Steps for replacing the pilot screw and limiter cap.
AIR CLEANER ASSEMBLY AND CONTROL LINKAGE SERVICE
Air Cleaner Assembly Service
Steps for taking apart and reassembling the air cleaner.
Control Linkage Component Service
Procedures for removing and installing control linkage components.
FUEL AND AIR SYSTEMS COMPONENT INSTALLATION
Fuel Pump and Tube Installation
Instructions for installing fuel pump, tubes, and diaphragm tube.
Air Cleaner Unit Installation
Procedure for installing the air cleaner, ensuring wire routing.
THROTTLE CONTROL TYPE SPECIFICS
Remote Throttle Type Details
Details for the remote throttle type control system.
Manual Throttle Type Details
Details for the manual throttle type control system.
GOVERNOR SPRING AND ENGINE STOP SWITCH SERVICE
Governor Spring Reassembly Steps
Instructions for reassembling the governor spring.
Engine Stop Switch Continuity Test
Procedure to inspect the engine stop switch continuity.
FLYWHEEL AND IGNITION COIL SERVICE PROCEDURES
Flywheel and Ignition Coil Service
Steps for removing and installing the flywheel and ignition coil.
FLYWHEEL AND STOP SWITCH WIRE INSTALLATION
Stop Switch Wire Installation Steps
Procedure for installing the stop switch wire with oil level switch.
Flywheel Removal Steps
Steps for removing the flywheel using special nuts and tools.
FLYWHEEL INSTALLATION PROCEDURE
Steps for Flywheel Installation
Instructions for installing the flywheel, including cleaning and torque specs.
IGNITION COIL INSPECTION AND ADJUSTMENT
Ignition Coil Resistance Testing
Procedures to measure primary and secondary coil resistance.
Ignition Coil Air Gap Adjustment
Steps for adjusting the air gap between the ignition coil and flywheel.
BREATHER VALVE REMOVAL AND INSTALLATION
Breather Valve Service Steps
Instructions for removing and installing the breather valve.
CAM PULLEY AND ROCKER ARM SERVICE PROCEDURES
Cam Pulley and Rocker Arm Service
Steps for servicing the cam pulley and rocker arm assembly.
CAM PULLEY INSTALLATION AND INSPECTION PROCEDURES
Decompressor Weight Inspection
Checking decompressor weight for wear and smooth movement.
Cam Pulley Installation Steps
Steps for installing the cam pulley onto the timing belt and crankshaft.
CYLINDER HEAD COMPONENTS SERVICE PROCEDURES
Rocker Arm Shaft Installation Steps
Procedure for installing the rocker arm shaft.
Cylinder Head Cover Installation Steps
Steps for cleaning and installing the cylinder head cover with liquid packing.
CRANKCASE, CRANKSHAFT, CYLINDER BARREL SERVICE PROCEDURES
Crankcase Cover Service
Steps for removing and installing the crankcase cover.
Crankshaft and Timing Belt Installation
Procedures for installing the crankshaft and timing belt.
CRANKCASE AND PISTON ASSEMBLY PROCEDURES
Crankcase Cover Removal Steps
Procedure for removing the crankcase cover.
Piston and Connecting Rod Assembly
Steps for installing the piston assembly and connecting rod.
CYLINDER BARREL AND CRANKSHAFT ASSEMBLY PROCEDURES
Thrust Washer Installation Steps
Instructions for installing the thrust washer and timing belt.
Cylinder Barrel and Bolt Installation
Steps for aligning cylinder barrel marks and installing flange bolts.
PISTON SERVICE PROCEDURES
Piston Ring Inspection and Reassembly
Procedures for inspecting and reassembling piston rings, including gap staggering.
Piston Pin Clip Installation Steps
Steps for installing the piston pin clips.
PISTON AND CONNECTING ROD REASSEMBLY PROCEDURES
Piston and Connecting Rod Assembly Steps
Detailed steps for assembling the piston and connecting rod with oil and clips.
VALVE MECHANISM SERVICE PROCEDURES
Valve Component Disassembly and Reassembly
Steps for removing and installing valve components like springs, retainers, and valves.
CYLINDER BARREL CLEANING PROCEDURE
Combustion Chamber Cleaning Steps
Steps for cleaning the combustion chamber using a special tool and paper.
GOVERNOR ASSEMBLY SERVICE PROCEDURES
Governor Component Service Steps
Steps for servicing the governor components like the governor arm, weights, and slider.
CRANKCASE COVER COMPONENT INSTALLATION
Oil Level Switch and Bearing Installation
Installation details for oil level switch, filler extension, and radial ball bearing.
RADIAL BALL BEARING SERVICE PROCEDURES
Radial Ball Bearing Removal Steps
Procedure for removing the radial ball bearing using special tools.
Radial Ball Bearing Installation Steps
Procedure for installing a new radial ball bearing.
OIL LEVEL SWITCH INSPECTION PROCEDURE
Continuity Check for Oil Level Switch
Steps to check oil level switch continuity with an ohmmeter.
CAM PULLEY AND ROCKER ARM INSPECTION PROCEDURES
Cam Pulley Height and Bearing Inspection
Measuring cam pulley height and bearing I.D.
Cam Pulley Shaft and Rocker Arm Inspection
Measuring cam pulley shaft O.D. and rocker arm I.D.
ENGINE COMPONENT MEASUREMENT STANDARDS
Rocker Arm, Cylinder, Piston Measurements
Specs for rocker arm shaft O.D., clearances, cylinder I.D., and piston skirt O.D.
Piston Clearance and Ring Width Specs
Standards for piston-to-cylinder clearance and piston ring width.
PISTON RING SPECIFICATION DETAILS
Piston Ring Width and Side Clearance Specs
Standards and service limits for piston ring width and side clearance.
Piston Ring End Gap Specs
Standards and service limits for piston ring end gap.
PISTON AND PIN MEASUREMENT PROCEDURES
Piston Pin O.D. and Bore I.D. Measurement
Procedures for measuring piston pin outer diameter and bore inner diameter.
CONNECTING ROD AND JOURNAL CLEARANCE MEASUREMENTS
Connecting Rod Big End Clearance Measurement
Procedures for measuring axial and oil clearance of the connecting rod big end.
CRANKSHAFT AND VALVE SPRING MEASUREMENT STANDARDS
Crankshaft Axial Clearance Measurement
Procedure to measure crankshaft axial runout and clearance.
Valve Spring and Face/Stem O.D. Specs
Standards for valve spring free length and valve face/stem O.D.
VALVE SEAT AND GUIDE MEASUREMENT PROCEDURES
Valve Guide I.D. Measurement
Procedure to measure valve guide inner diameter.
Valve Seat Width Measurement and Check
Steps to measure valve seat width and check seating.
VALVE SEAT RECONDITIONING PROCEDURE
Steps for Valve Seat Reconditioning
Detailed steps for reconditioning valve seats using cutters and lapping compound.
TIMING BELT OPERATION AND FUNCTION
Timing Belt Functionality Explained
Explains how the timing belt reduces noise and lubricates components.
FUEL SYSTEM COMPONENTS AND EMISSIONS
Fuel Tank Cap Emission Control System
Explains the evaporative emission control system integrated into the fuel tank cap.