Honda Engines GCV520, GCV530, GXV520, GXV530 Owners Manual
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µ INTRODUCTION CONTENTS SAFETY MESSAGES ENGLISH FRANÇAIS ESPAÑOL ENGLISH OWNER’S MANUAL MANUEL DE L’UTILISATEUR MANUAL DEL PROPIETARIO DAMAGE PREVENTION MESSAGES GCV520 · GCV530 · GXV520 · GXV530 1 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. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. This manual should be considered a permanent part of the engine and should remain with the engine if resold. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. ....................... INTRODUCTION .1 ................ SAFETY MESSAGES .1 .......... SAFETY INFORMATION .2 ..... SAFETY LABEL LOCATION .2 COMPONENT & CONTROL ................................ LOCATION .2 ................................ FEATURES .3 BEFORE OPERATION .................................... CHECKS .3 .............................. OPERATION .4 SAFE OPERATING ..................... PRECAUTIONS .4 ...... STARTING THE ENGINE .4 ...... STOPPING THE ENGINE .5 ..... SETTING ENGINE SPEED .5 ..... SERVICING YOUR ENGINE .6 THE IMPORTANCE OF .................... MAINTENANCE .6 ...... MAINTENANCE SAFETY .6 ....... SAFETY PRECAUTIONS .6 MAINTENANCE ............................ SCHEDULE .6 ........................... REFUELING .7 ........................... ENGINE OIL .7 ............ Recommended Oil .7 .................. Oil Level Check .7 ......................... Oil Change .8 ............................. OIL FILTER .8 ........................ AIR CLEANER .9 .......................... Inspection .9 ............................ Cleaning .9 We suggest you read the warranty policy to fully understand its coverage and your responsibilities of ownership. The warranty policy is a separate document that should have been given to you by your dealer. Your safety and the safety of others are 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. You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. These signal words mean: Each message tells you what the hazard is, what can happen, and what you can do to avoid or reduce injury. You will also see other important messages that are preceded by the word NOTICE. Your engine or other property can be damaged if you don’t follow instructions. This word means: 2005 Honda Motor Co., Ltd. All Rights Reserved The purpose of these messages is to help prevent damage to your engine, other property, or the environment. United States, Puerto Rico, and U.S. Virgin Islands: Review the instructions provided with the equipment powered by this engine for any additional information regarding engine startup, shutdown, operation, adjustments or any special maintenance instructions. ....................... FUEL FILTER .10 ............. COOLING SYSTEM .10 ...................... SPARK PLUG .10 ............. SPARK ARRESTER .11 HELPFUL TIPS & ...................... SUGGESTIONS .11 ... STORING YOUR ENGINE .11 ................ TRANSPORTING .12 TAKING CARE OF .... UNEXPECTED PROBLEMS .13 TECHNICAL & CONSUMER ....................... INFORMATION .13 ..... Serial Number Location .13 Battery Connections for .................... Electric Starter .14 ..... Remote Control Linkage .14 Carburetor Modifications for ..... High Altitude Operation .15 Emission Control System ......................... Information .15 .............................. Air Index .16 ..................... Specifications .16 ........ Tuneup Specifications .17 Quick Reference ......................... Information .17 ................ Wiring Diagrams .17 . CONSUMER INFORMATION .19 DISTRIBUTOR/DEALER . LOCATOR INFORMATION .19 CUSTOMER SERVICE ................... INFORMATION .19 37Z5Z602 00X37-Z5Z-6020 GCV520U·GCV530U·GXV520U·GXV530U 07/10/26 09:28:24 32Z5Z600_001
COMPONENT & CONTROL LOCATION SAFETY INFORMATION SAFETY LABEL LOCATION ENGLISH AIR CLEANER OIL DRAIN BOLTOIL PRESSURE SWITCH (applicable types) FUEL PUMP FUEL FILTERSCREEN GRID OIL FILLER CAP/ DIPSTICK Single Lever Type: Dual Lever Type: SPARK PLUGS CONTROL LEVER CHOKE LEVERTHROTTLE LEVER RECOIL STARTER (applicable types) ELECTRIC STARTEROIL FILTER (applicable types) STARTER GRIP (applicable types) 2Understand 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 1 meter (3 feet) away from buildings and other equipment during operation. Keep flammable materials away, and do not place anything on the engine while it is running. Do not allow children to operate the engine. Keep children and pets away from the area of operation. This label warns you of potential hazards that can cause serious injury. Read it carefully. If the label comes off or becomes hard to read, contact your Honda dealer for replacement. The engine emits toxic poisonous carbon monoxide gas. Do not run in an enclosed area. Gasoline is highly flammable and explosive. Turn engine off and let cool before refueling. Read Owner’s Manual before operation.For Canadian types only: French label comes with the engine. 07/10/26 09:28:46 32Z5Z600_002
BEFORE OPERATION CHECKS FEATURES IS YOUR ENGINE READY TO GO? Check the General Condition of the Engine Check the Engine Fuel-cut Solenoid Oil Pressure Switch (applicable types): Check the Equipment Powered by This Engine ENGLISH3 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. Improperly maintaining this engine, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always perform a pre-operation inspection before each operation, and correct any problem. Before beginning your pre-operation checks, be sure the engine is level and the engine switch is in the OFF position. Always check the following items before you start the engine: Look around and underneath the engine for signs of oil or gasoline leaks. Remove any excessive dirt or debris, especially around the muffler and recoil starter. Look for signs of damage. Check that all shields and covers are in place, and all nuts, bolts, and screws are tightened. Check the engine oil level (see page ). Running the engine with a low oil level can cause engine damage. Check the air filter element (see page ). A dirty air filter element will restrict air flow to the carburetor, reducing engine performance. Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine startup. Check the fuel level. Starting with a full tank will help to eliminate or reduce operating interruptions for refueling. The engine must be connected to the battery to energize the fuel- cut solenoid, allowing the engine to run. If the battery is disconnected, fuel flow to the carburetor main jet will stop. 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. The engine is equipped with an oil pressure switch to prevent damage from lack of lubrication or overheating. If the oil pressure alarm lamp comes on, check the engine oil level and add the correct engine oil if necessary (see page ). To restart the engine, turn the engine switch to the OFF position. Next, start according to the starting procedure. If the oil pressure alarm lamp continues to light even through the engine oil level is correct, stop operating the engine and see an authorized Honda servicing dealers. 1. 2. 1. 2. 3. 4. 7 3. 7 9 07/06/08 11:39:40 32Z5Z600_003
OPERATION SAFE OPERATING PRECAUTIONS STARTING THE ENGINE ENGLISH MMIINN.. MMAAXX.. THROTTLE LEVER STARTER GRIP CCLLOOSSEEDD OOPPEENNCHOKE LEVER MMIINN.. MMAAXX.. CHOKE CONTROL LEVER Directiontopull 4 Before operating the engine for the first time, please review the SAFETY INFORMATIONsection on page and theBEFORE OPERATION CHECKS on page . Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter. Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown below. Return the starter grip gently. RECOIL STARTER (applicable types): When the engine starts, release the key, allowing it to return to the ON position. Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it. If the engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again. Turn the key to the START position, and hold it there until the engine starts. ELECTRIC STARTER: Operate the starter. Turn the engine switch to the ON position. Some engine applications use a remote-mounted control rather than the engine-mounted lever shown here. Refer to the instructions provided by the equipment manufacturer. To start a cold engine, move the choke lever to the CLOSED position and move the throttle lever away from the MIN. position, about 1/3 of the way toward the MAX. position. DUAL LEVER TYPE: For your safety, do not operate the engine in an enclosed area such as a garage. Your engine’s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death. Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas. Breathing carbon monoxide can cause unconsciousness or death. Never run the engine in a closed, or even partly closed area where people may be present. To restart a warm engine, leave the control lever in the MIN. position. To start a cold engine, move the control lever to the CHOKE position. SINGLE LEVER TYPE: If the fuel tank is equipped with a valve, be sure the fuel valve is in the OPEN or ON position before attempting to start the engine. Review the instructions provided with the equipment powered by this engine for any safety precautions that should be observed with engine startup, shutdown or operation.3. 1. 2.2 3 4. 07/10/26 09:29:21 32Z5Z600_004
ENGLISH SETTING ENGINE SPEED STOPPING THE ENGINE MMIINN..MMIINN.. CONTROL LEVER THROTTLE LEVER CONTROL LEVER THROTTLE LEVER MMIINN..MMIINN.. MMAAXX..MMAAXX.. SINGLE LEVER TYPE DUAL LEVER TYPE SINGLE LEVER TYPE DUAL LEVER TYPE CONTROL LEVER MMIINN.. CCHHOOKKEE CHOKE LEVER OOPPEENN CCLLOOSSEEDD 5 Position the control lever (single lever type) or throttle lever (dual lever type) for the desired engine speed. Some engine applications use a remote-mounted control rather than the engine-mounted lever shown here. Refer to the instructions provided by the equipment manufacturer. 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. Disconnecting the battery causes the fuel-cut solenoid to shut off the flow of fuel to the carburetor main jet, and the engine will stop. To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. Refer to the instructions provided by the equipment manufacturer. Move the control lever (single lever type) or throttle lever (dual lever type) to the MIN. position. Some engine applications use a remote-mounted throttle control rather than the engine-mounted throttle lever shown here. Turn the engine switch to the OFF position. If the fuel tank is equipped with a valve, turn the fuel valve to the CLOSED or OFF position. If the control lever has been moved to the CHOKE position to start the engine, gradually move it to the MIN. position as the engine warms up. If the choke lever was moved to the CLOSED position to start the engine, gradually move it to the OPEN position as the engine warms up. SINGLE LEVER TYPE: DUAL LEVER TYPE:1. 2. 3. 5. 07/10/26 09:29:37 32Z5Z600_005
Î µ µ µÎ ENGLISH SERVICING YOUR ENGINE THE IMPORTANCE OF MAINTENANCE MAINTENANCE SAFETY 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. SAFETY PRECAUTIONS Carbon monoxide poisoning from engine exhaust. Burns from hot parts. Injury from moving parts.MAINTENANCE SCHEDULE 6Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in this owner’s manual. Some of the most important safety precautions follow. However, we cannot warn you ofevery conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. 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. 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.Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. Good maintenance is essential for safe, economical and trouble- free operation. It will also help reduce pollution. Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards: Be sure there is adequate ventilation whenever you operate the engine. Let the engine and exhaust system cool before touching. 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.To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a non-flammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and flames away from all fuel related parts. Remember that an authorized Honda servicing dealer knows your engine best and is 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. Replace paper element type only. Service more frequently when used in dusty areas. These items should be serviced by your Honda servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures. Failure to follow this maintenance schedule could result in non- warrantable failures.Check that there is no crack and abnormal wear-out in the belt, and replace if it is abnormal. For commercial use, log hours of operation to determine proper maintenance intervals. (1) (2) (3) (4) REGULAR SERVICE PERIOD (3) Perform at every indicated month or operating hour interval, whichever comes first. ITEMEach UseFirst Month or 20 HrsEvery 3 Months or 50 Hrs (1)Every 6 Months or 100 Hrs After every 300 Hrs (2)(4) After every 300 Hrs (2) Every 2 years (Replace if necessary) (2)Refer to Page 7 8 8 9 9 10 11 10 Shop manual Shop manual Shop manual Shop manual Shop manual Shop manual Check level Change Replace Check Clean Replace Check-adjust Replace Clean Clean Check-adjust Check-adjust Check Clean CheckEvery Year or 200 Hrs (2) (2) (2) Engine oil Oil filter () Air cleaner Spark plugs Spark arrester () Cooling system Idle speed Valve clearance Timing belt Combustion chamber Fuel filter Fuel tube Check-replace applicable types applicable types 07/10/26 09:29:59 32Z5Z600_006
ENGLISH REFUELING Recommended FuelENGINE OIL Recommended Oil Oil Level Check AMBIENT TEMPERATURE UPPER LIMIT LOWER LIMIT OIL FILLER CAP/DIPSTICK OIL FILLER CAP/ DIPSTICK 7 Unleaded gasoline Pump octane rating 86 or higher Research octane rating 91 or higher Pump octane rating 86 or higher U.S. Except U.S.Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil. Check the engine oil level with the engine stopped and in a level position. Remove the oil filler cap/dipstick and wipe it clean. Reinstall the oil filler cap/dipstick. Insert the oil filler cap/dipstick into the oil filler neck, but do not screw it in, then remove it to check the oil level. 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. This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher (a research octane rating of 91 or higher). Refuel in a well-ventilated area with the engine stopped. If the engine has been running, allow it to cool first. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks. You may use regular unleaded gasoline containing no more than 10% ethanol (E10) or 5% methanol by volume. In addition, methanol must contain cosolvents and corrosion inhibitors. Use of fuels with content of ethanol or methanol greater than shown above may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system. Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty.Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SJ or later (or equivalent). Always check the API service label on the oil container to be sure it includes the letters SJ or later (or equivalent). 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. Running the engine with a low oil level can cause engine damage. This type of damage is not covered by the Distributor’s Limited Warranty. Spilled fuel is not only a fire hazard, it causes environmental damage. Wipe up spills immediately. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc. Refuel carefully to avoid spilling fuel. After refueling, tighten the fuel tank cap securely. Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid getting dirt or water in the fuel tank. 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. Wipe up spills immediately. Refuel only outdoors. Stop engine and keep heat, sparks, and flame away. Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling. If your equipment will be used on an infrequent or intermittent basis, please refer to the fuel section of the HELPFUL TIPS AND SUGGESTIONS chapter (see page ) for additional information regarding fuel deterioration.1. 2. 3. 4. 11 07/10/26 09:30:20 32Z5Z600_007
ENGLISH Oil Change OIL FILTER (applicable types) Oil Filter Change LOWER LIMIT UPPER LIMIT WASHER OIL FILLER CAP/DIPSTICKOIL FILTER WRENCHFILTER MOUNTING BASE SEAL OIL FILTER OIL DRAIN BOLT 8 Drain the used oil when the engine is warm. Warm oil drains quickly and completely. 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. 12 N·m (1.2 kgf·m , 9 lbf·ft) With the engine in a level position, fill to theupper limit mark on the dipstick with the recommended oil (see page ).Drain the engine oil, and retighten the drain bolt securely. Remove the oil filter with an oil filter wrench, and drain the remaining oil into a suitable container. Dispose the used oil and filter in a manner compatible with the environment. Clean the filter mounting base, and coat the seal of the new oil filter with clean engine oil. Use an oil filter wrench, rather than a strap wrench, to avoid striking and damaging the oil filter. Use only a genuine Honda oil filter or a filter of equivalent quality specified for your model. Using the wrong filter, or a non-Honda filter which is not of equivalent quality, may cause engine damage. 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 ). Reinstall the oil filler cap/ dipstick. Start the engine, and check for leaks. Stop the engine, and check the oil level as described on page . If necessary, add oil to bring the oil level to the upper limit mark on the dipstick. Place a suitable container below the engine to catch the used oil, then remove the oil filler cap/dipstick, drain bolt and washer. Allow the used oil to drain completely, then reinstall the drain bolt and new washer, and tighten the drain bolt securely. Running the engine with a low oil level can cause engine damage. This type of damage is not covered by the Distributor’s Limited Warranty. Install the oil filler cap/dipstick securely.1. 2. 3. 4. 3. 4. 1. 2. 5. 6. 7. 7 7 7 07/10/26 09:30:38 32Z5Z600_008
ENGLISH AIR CLEANER Inspection Cleaning AIR CLEANER COVER FOAM FILTER ELEMENT GRID AIR CLEANER COVER BOLTS AIR DUCT PAPER FILTER ELEMENT AIR CLEANER BASE 9 A dirty air cleaner 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. Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered by the Distributor’s Limited Warranty.Clean the air filter elements if they are to be reused. Paper air filter element: Tap the filter element several times on a hard surface to remove dirt, or blow compressed air [not exceeding 207 kPa (2.1 kgf/cm , 30 psi)] through the filter element from the inside. Never try to brush off dirt; brushing will force dirt into the fibers. Foam air filter element: Clean in warm soapy water, rinse, and allow to dry thoroughly. Or clean in non-flammable solvent and allow to dry. Dip the filter element in clean engine oil, then squeeze out all excess oil. The engine will smoke when started if too much oil is left in the foam. Remove the air cleaner cover and inspect the filter elements. Clean or replace dirty filter elements. Always replace damaged filter elements. Remove the two air cleaner cover bolts from the air cleaner cover, and remove the cover. Remove the foam filter element. Remove the paper filter element from the grid. Inspect both air filter elements, and replace them if they are damaged. Always replace the paper air filter element at the scheduled interval (see page ). Excess oil will restrict air flow through the foam filter element and may transfer to the paper filter element, soaking and clogging it. Place the foam filter element into the air cleaner cover. Install the grid over the paper filter element then install the assembly into the air cleaner base. The grid must be placed between the foam element and the paper element to prevent oil from transferring to the paper element. Install the cover and tighten the two air cleaner cover bolts securely. Wipe dirt from the inside of 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. 1. 2. 4. 3.5. 6. 7. 8. 9. 6 07/06/08 11:42:00 32Z5Z600_009
µ µµ µ µ ENGLISH SPARK PLUG Recommended Spark Plugs: FUEL FILTER Inspection COOLING SYSTEM FUEL FILTER SEALING WASHER SPARK PLUG WRENCH SCREEN GRID 0.7 0.8 mm (0.028 0.031 in) 10BPR5ES (NGK) W16EPR-U (DENSO) For good performance, the spark plugs must be properly gapped and free of deposits. The recommended spark plugs have the correct heat range for normal engine operating temperatures. Incorrect spark plugs can cause engine damage. Remove the spark plugs with a 13/16-inch spark plug wrench. Inspect the spark plugs. Replace them if damaged, badly fouled, if the sealing washer is in poor condition, or if the electrode is worn. Measure the spark plug electrode gaps with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending thesideelectrode. The gap should be: Install the spark plug carefully, by hand, to avoid cross- threading. When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. When reinstalling the original spark plug, tighten 1/8 1/4 turn after the spark plug seats to compress the washer. A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head. Attach the spark plug caps to the spark plugs. 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. Check the screen grid for blockage and remove the blockage if necessary.Disconnect the spark plug caps, and remove any dirt from around the spark plug area. After the spark plug is seated, tighten with a 13/16-inch spark plug wrench to compress the sealing washer. 0.7 0.8 mm (0.028 0.031 in) 1. 2. 3. 4. 5. 6. 7. 07/10/26 09:31:10 32Z5Z600_010