Download Print this page

Honda GCV520 Owner's Manual

Honda automobiles automobile parts user manual.
Hide thumbs

Advertisement

Advertisement

   Also See for Honda GCV520

   Related Manuals for Honda GCV520

   Summary of Contents for Honda GCV520

  • Page 2

    The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Keep this owner’s manual handy, so you can refer to it at any time. This owner’s manual is considered a permanent part of the engine and should remain with the engine if resold.

  • Page 3

    INTRODUCTION Congratulations on your selection of a Honda engine. We are certain you will be pleased with your purchase of one of the finest engines on the market. We want to help you get the best results from your new engine and to operate it safely.

  • Page 4

    INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this engine safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.

  • Page 5: Table Of Contents

    CONTENTS ENGINE SAFETY IMPORTANT SAFETY INFORMATION CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS CONTROLS Throttle Lever Recoil Starter (applicable engine types) FEATURES Fuel-cut Solenoid BEFORE OPERATION IS YOUR ENGINE READY TO GO? Check the General Condition of the Engine Check the Engine Check the Equipment Powered by This Engine OPERATION SAFE OPERATING PRECAUTIONS...

  • Page 6

    CONTENTS HELPFUL TIPS & SUGGESTIONS STORING YOUR ENGINE Storage Preparation Storage Precautions Removal From Storage TRANSPORTING TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START ENGINE LACKS POWER TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location Battery Connections for Electric Starter Remote Control Linkage Carburetor Modification for High Altitude Operation Oxygenated Fuels...

  • Page 7: Engine Safety

    ENGINE SAFETY IMPORTANT SAFETY INFORMATION Most accidents with engines can be prevented if you follow all instructions in this manual and on the engine. Some of the most common hazards are discussed below, along with the best way to protect yourself and others. Owner Responsibilities Honda engines are designed to give safe and dependable service if operated according to instructions.

  • Page 8

    ENGINE SAFETY Carbon Monoxide Hazard Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas. Never run the engine in a closed garage or confined area. Other Equipment Review the instructions provided with the equipment powered by this engine for any additional safety precautions that should be observed in conjunction with engine startup, shutdown, operation, or protective apparel that may be needed to operate the equipment.

  • Page 9: Controls & Features

    CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS ELECTRIC STARTER RECOIL STARTER (applicable engine types) SPARK PLUGS AIR CLEANER...

  • Page 10

    CONTROLS & FEATURES FUEL PUMP FUEL FILTER OIL FILTER OIL FILLER CAP/ DIPSTICK OIL PRESSURE SWITCH (applicable engine types) OIL DRAIN BOLT SCREEN GRID...

  • Page 11: Controls

    CONTROLS Throttle Lever The throttle lever controls engine speed. Moving the throttle lever in the directions shown makes the engine run faster or slower. Set the lever to CHOKE when the engine is cold. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here.

  • Page 12: Features

    CONTROLS & FEATURES FEATURES Fuel-cut Solenoid The engine is equipped with a fuel-cut solenoid that allows fuel to flow to the carburetor main jet when the engine switch is in the ON or START position and stops the flow of fuel to the main jet when the engine switch is in the OFF position.

  • Page 13: Before Operation

    BEFORE OPERATION 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 you 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.

  • Page 14: Check The Engine

    BEFORE OPERATION Check the Engine Check the engine oil level (see page low oil level can cause engine damage. Check the air filter (see page to the carburetor, reducing engine performance. Check the fuel level. Starting with a full tank will help to eliminate or reduce operating interruptions for refueling.

  • Page 15: Operation

    OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time, please review the IMPORTANT SAFETY INFORMATION on page and the chapter titled BEFORE OPERATION . 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.

  • Page 16

    OPERATION To start a cold engine, move the throttle lever to the CHOKE position. To restart a warm engine, leave the throttle lever in the SLOW position. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here. Refer to the instructions provided with the equipment powered by this engine for remote control information.

  • Page 17

    ELECTRIC STARTER (applicable engine types): Turn the key to the START position, and hold it there until the engine starts. If the engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again. Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.

  • Page 18: Stopping The Engine

    OPERATION STOPPING THE ENGINE To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. Move the throttle lever to the SLOW position. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here.

  • Page 19: Setting Engine Speed

    SETTING ENGINE SPEED Position the throttle lever for the desired engine speed. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here. For engine speed recommendations, refer to the instructions provided with the equipment powered by this engine. Do not disconnect the battery from the engine while the engine is running.

  • Page 20: Servicing Your Engine

    SERVICING YOUR ENGINE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. 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.

  • Page 21: Maintenance Safety

    MAINTENANCE SAFETY Some of the most important safety precautions are as follows: 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. Failure to properly follow maintenance instructions and precautions can cause you to be...

  • Page 22: Maintenance Schedule

    SERVICING YOUR ENGINE MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (3) ITEM Perform at every indicated month or operating hour interval, whichever comes first. Engine oil Check level Change Oil filter Replace (optional part) Air filter Check Clean Replace Spark plug Check-adjust Replace Spark arrester Clean...

  • Page 23: Fuel Recommendations

    FUEL RECOMMENDATIONS Use unleaded gasoline with a pump octane rating of 86 or higher. These engines are certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.

  • Page 24: Engine Oil Level Check

    SERVICING YOUR ENGINE ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position. Place the engine on a level surface. Remove the oil filler cap/dipstick and wipe it clean. Insert and remove the dipstick without screwing it into the oil filler neck.

  • Page 25: Engine Oil Change

    ENGINE OIL CHANGE Drain the used oil while the engine is warm. Warm oil drains quickly and completely. Place a suitable container below the engine to catch the used oil, then remove the oil filler cap/dipstick and the drain bolt. Allow the used oil to drain completely, then reinstall the drain bolt, and tighten it securely.

  • Page 26: Oil Filter Change

    SERVICING YOUR ENGINE OIL FILTER CHANGE Drain the engine oil, and retighten the drain bolt securely (see page 23). Remove the oil filter with oil filter wrench, and drain the remaining oil into a suitable container. Discard the used oil filter. Use an oil filter wrench, rather than a strap wrench, to avoid striking and damaging the oil filter.

  • Page 27

    Screw on the new oil filter by hand until the seal contacts the filter mounting base, then use an oil filter wrench to tighten the filter an additional 7/8 turn. Oil filter tightening torque: Refill the crankcase with the specified amount of the recommended oil (see page 26).

  • Page 28: Engine Oil Recommendations

    SERVICING YOUR ENGINE ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. 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 recommended range.

  • Page 29: Air Filter Inspection

    AIR FILTER INSPECTION Remove the air cleaner cover and inspect the filter elements. Clean or replace dirty filter elements. Always replace damaged filter elements. Refer to page for instructions that apply to the air cleaner and filter service. AIR CLEANER COVER BOLTS SERVICING YOUR ENGINE AIR CLEANER COVER FOAM FILTER ELEMENT...

  • Page 30: Air Cleaner Service

    SERVICING YOUR ENGINE AIR CLEANER SERVICE A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If you operate the engine in very dusty areas, clean the air filter more often than specified in the MAINTENANCE SCHEDULE. (see page 20).

  • Page 31

    Clean the air filter elements if they are to be reused. Paper filter element: Tap the filter element several times on a hard surface to remove dirt, or blow compressed air [not exceeding 30 psi (207 kPa, 2.1 kgf/cm )] through the filter element from the clean side that faces the engine.

  • Page 32: Fuel Filter Inspection

    SERVICING YOUR ENGINE FUEL FILTER INSPECTION Check the fuel filter for water accumulation or sediment. If the fuel filter is found with excessive water accumulation or sediment, take the engine to your authorized Honda servicing dealer. FUEL FILTER...

  • Page 33: Spark Plug Service

    SPARK PLUG SERVICE Recommended spark plugs: Incorrect spark plugs can cause engine damage. Disconnect the spark plug caps, and remove any dirt from around the spark plug area. Remove the spark plugs with a 13/16-inch spark plug wrench. Inspect the spark plugs. Replace them if the electrodes are worn, or if the insulator is cracked or chipped.

  • Page 34

    SERVICING YOUR ENGINE After the spark plug seats, tighten with a 13/16-inch spark plug wrench to compress the washer. If reinstalling the used spark plugs, tighten 1/8 1/4 turn after the spark plug seats. If installing a new spark plugs, tighten 1/2 turn after the spark plug seats.

  • Page 35: Spark Arrester Service (optional Equipment)

    SPARK ARRESTER SERVICE (optional equipment) Your engine is not factory-equipped with a spark arrester. In some areas, it is illegal to operate an engine without a spark arrester. Check local laws and regulations. A spark arrester is available from authorized Honda servicing dealers. The spark arrester must be serviced every 100 hours to keep it functioning as designed.

  • Page 36

    SERVICING YOUR ENGINE Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen. The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged. SPARK ARRESTER SCREEN Install the spark arrester, and muffler protector in the reverse order of disassembly.

  • Page 37: Helpful Tips & Suggestions

    HELPFUL TIPS & SUGGESTIONS STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine troublefree 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 after storage. Cleaning If the engine has been running, allow it to cool for at least half an hour before cleaning.

  • Page 38

    HELPFUL TIPS & SUGGESTIONS The Distributor’s Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation. You can extend fuel storage life by adding a fuel stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor.

  • Page 39

    DRAINING THE FUEL TANK AND CARBURETOR Disconnect the fuel line to the engine, and drain the fuel tank into an approved gasoline container. If the fuel tank is equipped with a valve, turn the fuel valve to the OPEN or ON position to enable draining. After draining is completed, reconnect the fuel line.

  • Page 40: Storage Precautions

    HELPFUL TIPS & SUGGESTIONS Engine Oil Change the engine oil (see page 23). Engine Cylinder Remove the spark plugs (see page 31). Pour a tablespoon (5 10 cc) of clean engine oil into the cylinders. Pull the starter rope several times to distribute the oil in the cylinders.

  • Page 41: Removal From Storage

    HELPFUL TIPS & SUGGESTIONS Position the equipment so the engine is level. 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.

  • Page 42: Transporting

    HELPFUL TIPS & SUGGESTIONS TRANSPORTING If the engine has been running, allow it to cool for at least 15 minutes before loading the engine-powered equipment on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials.

  • Page 43: Taking Care Of Unexpected Problems

    TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Check battery and fuse. Check control positions. Check fuel. Remove and inspect spark plug. Take engine to an authorized Honda servicing dealer, or refer to shop manual. ENGINE LACKS POWER Check air filter. Check fuel.

  • Page 44: Technical & Consumer Information

    TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location ENGINE SERIAL NUMBER Record the engine serial number in the space below. You will need this serial number when ordering parts, and when making technical or warranty inquires (see page Engine serial number:...

  • Page 45: Battery Connections For Electric Starter

    TECHNICAL & CONSUMER INFORMATION Battery Connections for Electric Starter Use a 12-volt battery with an ampere-hour rating of at least 45 Ah. Be careful not to connect the battery in reverse polarity, as this will short circuit the battery charging system. Always connect the positive ( ) battery cable to the battery terminal before connecting the +...

  • Page 46: Remote Control Linkage

    TECHNICAL & CONSUMER INFORMATION Remote Control Linkage The throttle and choke control levers are provided with holes for optional cable attachment. The following illustrations show installation examples for a solid wire cable. Do not use a braided wire cable. REMOTE THROTTLE AND REMOTE CHOKE CHOKE RETURN SPRING INSTALLATION: Install with the shot end...

  • Page 47: Carburetor Modification For High Altitude Operation

    TECHNICAL & CONSUMER INFORMATION Carburetor Modification 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 plugs 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.

  • Page 48: Oxygenated Fuels

    TECHNICAL & CONSUMER INFORMATION 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 an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.

  • Page 49: Emission Control System Information

    TECHNICAL & CONSUMER INFORMATION 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.

  • Page 50

    TECHNICAL & CONSUMER INFORMATION Problems That May Affect Emissions If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer. Hard starting or stalling after starting. Rough idle. Misfiring or backfiring under load. Afterburning (backfiring).

  • Page 51: Air Index

    TECHNICAL & CONSUMER INFORMATION 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.

  • Page 52: Specifications

    TECHNICAL & CONSUMER INFORMATION Specifications GCV520-QEA Type Length × Width × Height Dry weight Engine type Displacement [Bore × Stroke] Max. output Max. torque Fuel consumption Cooling system Ignition system PTO shaft rotation GCV530-QEA Type Length × Width × Height...

  • Page 53

    TECHNICAL & CONSUMER INFORMATION Specifications GXV530-QEA Type Length × Width × Height Dry weight Engine type Displacement [Bore × Stroke] Max. output Max. torque Fuel consumption Cooling system Ignition system PTO shaft rotation GXV530 Tuneup ITEM Spark plug gap Valve clearance (cold) Other specifications 18.0 ×...

  • Page 54: Wiring Diagrams

    TECHNICAL & CONSUMER INFORMATION Wiring Diagrams 3A Charge Coil...

  • Page 55

    TECHNICAL & CONSUMER INFORMATION Wiring Diagrams 12A Charge Coil...

  • Page 56: 18a Charge Coil Wiring

    TECHNICAL & CONSUMER INFORMATION Wiring Diagrams 18A Charge Coil...

  • Page 57: Consumer Information

    TECHNICAL & CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing your engine. You may order them from your Honda engine dealer. Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician.

  • Page 58: Customer Service Information

    TECHNICAL & CONSUMER INFORMATION Customer Service Information 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 or General Manager can help.

  • Page 59: Quick Reference Information

    QUICK REFERENCE INFORMATION Fuel Engine Oil Spark Plug Carburetor Maintenance Type Unleaded gasoline with a pump octane rating of 86 or higher (page 21) Type SAE 10W-30, API SJ, for general use Capacity Without oil filter replacement: 0.95 US qt (0.90 ) With oil filter replacement: 1.11 US qt (1.05 ) Type...

This manual also for:

Gcv530, Gxv530

Comments to this Manuals

Symbols: 0
Latest comments: