Honda Engines GCV520, GCV530, GXV520, GXV530 Owners Manual
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HELPFUL TIPS & SUGGESTIONS STORING YOUR ENGINE Storage Preparation Cleaning Fuel SPARK ARRESTER (applicable types) Spark Arrester Cleaning Adding a Gasoline Stabilizer to Extend Fuel Storage Life ENGLISH SPARK ARRESTER SCREEN SPECIAL SCREWSMUFFLER MUFFLER PROTECTOR 6mm FLANGE BOLT SPARK ARRESTER 6mm FLANGE BOLTS 11 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. 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. 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 filter, and water that passes through the air filter or muffler can enter the cylinder, causing damage. The spark arrester must be serviced every 100hours to keep it functioning as designed. If the engine has been running, the muffler will be hot. Allow it to cool before servicing the spark arrester. Your engine is not factory-equipped with a spark arrester. The spark arrester is optional part. 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. 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. Install the spark arrester and muffler protector in the reverse order of disassembly. Remove the three 6 mm flange bolts from the muffler protector, and remove the muffler protector. Remove the four special screws from the spark arrester and remove the spark arrester from the muffler. Stop the engine, and if the fuel tank is equipped with a fuel valve, move the fuel valve to the CLOSED or OFF position. 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. Add gasoline stabilizer following the manufacturer’s instructions. 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. 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. Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under the Distributor’s Limited Warranty. 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 deterioration problems may occur within a few months, or even less if the gasoline was not fresh when you filled the fuel tank. Depending on the region where you operate your equipment, fuel formulations may deteriorate and oxidize rapidly. Fuel deteriorate oxidation can occur in as little as 30 days and may cause damage to the carburetor and/or fuel system. Please check with your servicing dealer for local storage recommendations. 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. 1. 2. 3. 1. 2. 3. 4. 07/10/26 09:31:30 32Z5Z600_011

µµStorage Precautions TRANSPORTING Removal from Storage Draining the Fuel Tank and Carburetor Engine Oil ENGLISH CARBURETOR DRAIN SCREW 12If 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. If possible, avoid storage areas with high humidity, because that promotes rust and corrosion. Keep the engine level in storage. 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. Do not use sheet plastic as a dust cover. A nonporous cover will trap moisture around the engine, promoting rust and corrosion. Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel. 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. Check your engine as described in the BEFORE OPERATION CHECKS section of this manual (see page ). Remove the battery and store it in a cool, dry place. Recharge the battery once a month while the engine is in storage. This will help to extend the service life of the battery. If the cylinders were coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal. 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. Keep the engine level when transporting to reduce the possibility of fuel leakage. If the fuel tank is equipped with a fuel valve, move the fuel valve to the CLOSED or OFF position. Wipe up spills immediately. Handle fuel only outdoors. Stop engine and keep heat, sparks, and flame away. 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. Loosen the carburetor drain screw, and drain the carburetor into an approved gasoline container. After all the fuel has drained into the container, tighten the drain screw securely. Change the engine oil (see page ). Remove the spark plugs (see page ). Pour a tablespoon 5 10 cm (5 10 cc) of clean engine oil into each cylinder. Turn the engine for a few seconds by turning the engine switch to the START position to distribute the oil in the cylinders. Reinstall the spark plugs. 2. 1. 3. 1. 2. 3. 4. 5.3 8 10 07/10/26 09:31:48 32Z5Z600_012

µ TAKING CARE OF UNEXPECTED PROBLEMS TECHNICAL & CONSUMER INFORMATION ENGINE WILL NOT STARTPossible Cause Correction TECHNICAL INFORMATION Serial Number Location ENGINE LACKS POWERPossible Cause Correction ENGLISH SERIAL NUMBER & ENGINE TYPE LOCATION 13 Engine serial number: __ __ __ __ __ __ __ __ __ __ __ Engine type: ___ ___ ___ ___ Date Purchased: ______ / ______ / ______ Recharge battery. Replace fuse Move lever to ON or OPEN position. Move lever to CHOKE (CLOSED) position unless the engine is warm. Turn engine switch to ON position. Refuel (p. 7). Drain fuel tank and carburetor (p. 12). Refuel with fresh gasoline (p. 7). Gap or replace spark plug(s) (p. 10). Dry and reinstall spark plugs. Start engine with throttle lever in MAX. position. Replace or repair faulty components as necessary. Check battery and fuse. Check control positions. Check fuel. Remove and inspect spark plugs. Take engine to an authorized Honda servicing dealer, or refer to shop manual. Check air filter. Check fuel. Take engine to an authorized Honda servicing dealer, or refer to shop manual.Filter element(s) restricted. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline. Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc.Clean or replace filter element(s) (p. 9). Drain fuel tank and carburetor (p. 12). Refuel with fresh gasoline (p. 7). Replace or repair faulty components as necessary.Record the engine serial number, type and purchase date in the space below. You will need this information when ordering parts and when making technical or warranty inquiries. Battery discharged. Fuse burnt out. Fuel valve OFF. (If equipped) Choke OPEN. Engine switch OFF. Out of fuel. Bad fuel; engine stored without treating or draining gasoline, or refueled with bad gasoline. Spark plug(s) faulty, fouled, or improperly gapped. Spark plug(s) wet with fuel (flooded engine). Fuel filter restricted, carburetor malfunction, ignition malfunction, valves stuck, etc. 1. 2. 3. 4. 5. 1. 2. 3. 07/06/08 11:43:30 32Z5Z600_013

µ µ´´µ ´ ´ µ ´µ µ ´ µ· · ENGLISH Remote Control Linkage Battery Connections for Electric Starter Recommended Battery STARTER SOLENOID BATTERY POSITIVE ( ) CABLE BATTERY NEGATIVE ( ) CABLESingle Lever Type: Dual Lever Type:THROTTLE/CHOKE CABLE (SOLID WIRE) STOPPER RUBBER LEVER SPRING CONTROL LEVERCHOKE RETURN SPRING THROTTLE CABLE (SOLID WIRE) CHOKE CABLE (SOLID WIRE) 5 16 mm SCREW CABLE HOLDER CHOKE RETURN SPRING 5 16 mm SCREW (2) CABLE HOLDER (2) INSTALLATION: INSTALLATION: INSTALLATION: THROTTLE LEVER CHOKE LEVER 14The 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. Coat the terminals and cable ends with grease. Connect the battery negative ( ) cable to the battery negative ( ) terminal as shown. Connect the battery positive ( ) cable to the battery positive ( ) terminal as shown. Connect the battery negative ( ) cable to an engine mounting bolt, frame bolt, or other good engine ground connection. Connect the battery positive ( ) cable to the starter solenoid terminal as shown. WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds. Wash hands after handling.Keep all sparks, open flames, and smoking materials away from the battery. A battery can explode if you do not follow the correct procedure, seriously injuring anyone nearby. 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 negative ( ) battery cable, so your tools cannot cause a short circuit if they touch a grounded part while tightening the positive ( ) battery cable end.12 V 30 Ah 12 V 30 Ah 1. 2. 3. 4. 5.GCV520 GXV520 GCV530 GXV530 Install with the short end hook toward the control base side. To install the stopper rubber, first align the boss with the hole of the control lever bracket, then turn the rubber 90° and secure it to the bracket as shown. Install with the short end hook toward the control base side. 07/10/26 09:32:18 32Z5Z600_014

ENGLISH Carburetor Modifications for High Altitude Operation Emission Control System Information Source of Emissions Problems That May Affect Emissions Tampering and Altering The U.S., California Clean Air Acts and Environment Canada 15 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 1,500 meters (5,000 feet) 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. Even with carburetor modification, engine horsepower will decrease about 3.5% for each300-meter (1,000-foot) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made. 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. High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above 1,500 meters (5,000 feet), 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.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. Honda utilizes appropriate air/fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide, oxides of nitrogen and hydrocarbons. Additionally, Honda fuel systems utilize components and control technologies to reduceevaporative emissions. Black exhaust smoke or high fuel consumption. Afterburning (backfiring). Misfiring or backfiring under load. Rough idle. Hard starting or stalling after starting. If you are aware of any of the following symptoms, have your engine inspected and repaired by your servicing dealer.Altering or defeating the governor linkage or speed-adjusting mechanism to cause the engine to operate outside its design parameters. Removal or alteration of any part of the intake, fuel, or exhaust systems. Tampering with or altering the emission control system may increase emissions beyond the legal limit. Among those acts that constitute tampering are: The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards. EPA, California and Canadian regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems. 07/10/26 09:32:33 32Z5Z600_015

·· ·· ·· ·· · µµµµ µµÎ Î Î Î ENGLISH Specifications Replacement Parts Descriptive Term Applicable to Emissions Durability Period Air IndexMaintenanceGCV520/GXV520 (QEA-1 type) 16458 427 331 mm (18.016.813.0in) 30.5 kg (67.2 lbs) 530 cm (32.3 cu-in) [77.0 57.0 mm (3.03 2.24 in)] 9.8 kW (13.3 PS, 13.1 bhp) at 3,600 rpm Counterclockwise Transistor magnetoForced air 33.2 N·m (3.39 kgf·m, 24.5 lbf·ft) at 2,500 rpm 1.00 (1.06 US qt , 0.88 Imp qt) 0.90 (0.95 US qt , 0.79 Imp qt) The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine model and measured in accordance with SAE J1349 at 3,600 rpm (Net Power) and at 2,500 rpm (Max. Net Torque). Mass production engines may vary from this value. Actual power output for the engine installed in the final machine will vary depending on numerous factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables.32.9 N·m (3.35 kgf·m, 24.3 lbf·ft) at 2,500 rpm Length Width Height Dry mass [weight] Engine type Displacement [Bore Stroke] Net power Max. Net torque (GCV520U) Max. Net torque (GXV520U) Engine oil capacity Cooling system Ignition system PTO shaft rotation The emission control systems on your Honda engine were designed, built, and certified to conform with EPA, California (models certified for sale in California), and Canadian emission regulations. We recommend the use of genuine Honda parts whenever you have maintenancedone. 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. Extended Intermediate Moderate 125 hours [0 80 cm (0 80 cc) inclusive] 250 hours [greater than 80 cm (80 cc)] 50 hours [0 80 cm (0 80 cc) inclusive] 125 hours [greater than 80 cm (80 cc)] The durability description is intended to provide you with information relating to 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 for additional information. 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. Follow the maintenance schedule on page . 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. 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. 300 hours [0 80 cm (0 80 cc) inclusive] 500 hours [greater than 80 cm (80 cc)] 1,000 hours [225 cm (225 cc) and greater] An Air Index Information label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board.Without oil filter replacement: With oil filter replacement: 6 (Models certified for sale in California) 4-stroke, overhead camshaft, 2 cylinders (90° V-Twin) (in accordance with SAE J1349 ) (in accordance with SAE J1349 ) (in accordance with SAE J1349 ) 07/10/26 09:32:52 32Z5Z600_016

·· ·· ·· ·· · µ µ ¶ ¶ Î Î Î Î ´ µ ENGLISH Wiring Diagrams Tuneup Specifications ITEM Quick Reference InformationMAINTENANCE SPECIFICATION With 12A Charge coil With 3A Charge coil GCV530/GXV530 GCV520/530, GXV520/530 (QEA-1 type) 17 458 427 331 mm (18.0 16.8 13.0 in) 30.5 kg (67.2 lbs) 530 cm (32.3 cu-in) [77.0 57.0 mm (3.03 2.24 in)] 11.3 kW (15.4 PS, 15.2 bhp) at 3,600 rpm 34.3 N·m (3.50 kgf·m, 25.3 lbf·ft) at 2,500 rpm 0.90 (0.95 US qt , 0.79 Imp qt) 1.00 (1.06 US qt , 0.88 Imp qt) Forced air Transistor magneto Counterclockwise The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine model and measured in accordance with SAE J1349 at 3,600 rpm (Net Power) and at 2,500 rpm (Max. Net Torque). Mass production engines may vary from this value. Actual power output for the engine installed in the final machine will vary depending on numerous factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables. No other adjustments needed. Spark plug gap Idle speed Valve clearance (cold) Other specifications Unleaded gasoline (Refer to page 7) Fuel Engine oil Spark plug MaintenanceU.S. Except U.S.Pump octane rating 86 or higher Research octane rating 91 or higher Pump octane rating 86 or higher SAE 10W-30, API SJ or later, for general use. Refer to page 7. Before each use: Check engine oil level. Refer to page 7. Check air filter. Refer to page 9. First 20 hours: Change engine oil. Refer to page 8. Subsequent: Refer to the maintenance schedule on page 6. BPR5ES (NGK) W16EPR-U (DENSO)Refer to page 10. See your authorized Honda dealer 34.2 N·m (3.49 kgf·m, 25.2 lbf·ft) at 2,500 rpm Length Width Height Dry mass [weight] Engine type Displacement [Bore Stroke] Net power Max. Net torque (GCV530) Max. Net torque (GXV530) Engine oil capacity Cooling system Ignition system PTO shaft rotation 0.7 0.8 mm (0.028 0.031 in) 1,400 rpm IN: 0.10 0.04 mm EX: 0.15 0.04 mmWithout oil filter replacement: With oil filter replacement: 4-stroke, overhead camshaft, 2 cylinders (90° V-Twin) (in accordance with SAE J1349 ) (in accordance with SAE J1349 ) (in accordance with SAE J1349 ) START ON OFF OFF ON START Black Yellow Blue Green WhiteBr O Lb Lg P GrBrown Orange Pink Gray Light blue Light green Bl Y Bu G R W (A) (B) (C) (D) (E) (F) (G) (H) (I) (J) (K) (L) (M)ENGINE SWITCH STARTER MOTOR SPARK PLUG RECTIFIER MAIN FUSE (25 A) ENGINE GROUND FUEL CUT SOLENOID BATTERY 3A CHARGE COIL No.2 IGNITION COIL No.1 IGNITION COIL ENGINE STOP DIODE Black Yellow Blue Green Red WhiteBr O Lb Lg P GrBrown Orange Pink Gray Light blue Light green Bl Y Bu G R W ENGINE SWITCH MAIN FUSE (25 A) CHARGE LAMP OIL PRESSURE ALARM LAMP OIL PRESSURE SWITCH FUEL CUT SOLENOID STARTER MOTOR BATTERY 12A CHARGE COIL No.2 IGNITION COIL No.1 IGNITION COIL SPARK PLUG ENGINE GROUND ENGINE STOP DIODE REGULATOR/RECTIFIER (A) (B) (C) (D) (E) (F) (G) (H) (I) (J) (K) (L) (M) (N) (O) (P)SPARK PLUG SPARK PLUGRed 200 150 07/10/26 09:33:16 32Z5Z600_017

ENGLISH With 18A Charge coil 18 ON START OFF Black Yellow Blue Green Red WhiteBr O Lb Lg P GrBrown Orange Pink Gray Light blue Light green Bl Y Bu G R W ENGINE SWITCH SPARK PLUG RECTIFIER MAIN FUSE (25 A) ENGINE GROUND ENGINE STOP DIODE CHARGE LAMP FUEL CUT SOLENOID SATARTER MOTOR BATTERY 18A CHARGE COIL No.2 IGNITION COIL No.1 IGNITION COIL (A) (B) (C) (D) (E) (F) (G) (H) (I) (J) (K) (L) (M) (N)SPARK PLUG 07/06/08 11:45:00 32Z5Z600_018

¬µ Canada: United States, Puerto Rico, and U.S. Virgin Islands: For European Area: United States, Puerto Rico, and U.S. Virgin Islands: All Other Areas: Honda’s Office United States, Puerto Rico, and U.S. Virgin Islands: American Honda Motor Co., Inc.Canada: Honda Canada, Inc. Australia: Honda Australia Motorcycle and Power Equipment Pty. Ltd. For European Area: Honda Europe NV. All Other Areas: DISTRIBUTOR/DEALER LOCATOR INFORMATION CUSTOMER SERVICE INFORMATION ENGLISH CONSUMER INFORMATION 19 or visit our website: www.honda.ca Call (888) 9HONDA9 or visit our website: www.honda-engines.com Call (800) 426-7701 visit our website: http://www.honda-engines-eu.com Servicing dealership personnel are trained professionals. They should be able to answer any question 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. If you are dissatisfied with the decision made by the dealership’s management, contact the Honda Regional Engine Distributor for your area. If you are still dissatisfied after speaking with the Regional Engine Distributor, you may contact the Honda Office as shown. If you are dissatisfied with the decision made by the dealership’s management, contact the Honda Office as shown. When you write or call, please provide this information: Equipment manufacturer’s name and model number that the engine is mounted on Engine model, serial number, and type (see page ) Name of dealer who sold the engine to you Name, address, and contact person of the dealer who services your engine Date of purchase Your name, address and telephone number A detailed description of the problem Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta, GA 30005-8847715 Milner Avenue Toronto, ON M1B 2K8 Telephone: (888) 9HONDA9 (888) 946-6329 (416) 299-3400 (416) 287-4776 (877) 939-0909 (416) 287-4776Toll free Local Toronto dialing area Local Toronto dialing area Toll free Local Toronto dialing area Facsimile:English: French: 1954 1956 Hume Highway Campbellfield Victoria 3061 Telephone: Facsimile:(03) 9270 1111 (03) 9270 1133 European Engine Center http://www.honda-engines-eu.com Please contact the Honda distributor in your area for assistance. Or telephone: (770) 497-6400, 8:30 am - 8:00 pm EST13 07/10/26 09:33:52 32Z5Z600_019