Honda Engines GCV520, GCV530, GXV530 Instructions Manual

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Engine oil change
ENGINE OIL CAPACITY: 1.
OIL DRAIN BOLT UPPER LIMIT
LOWER LIMIT
OIL FILLER CAP/DIPSTICK
Drain the oil while the engine is still warm to assure rapid and
complete draining. Remove the oil filler cap/dipstick and drain bolt, and drain the oil
into a suitable container.
Retighten the drain bolt securely.
Refill to the upper limit mark on the dipstick with the recom-
mended oil (see page 8). Tighten the oil filler cap/dipstick
securely.
Please dispose of used motor oil in a manner that is compatible
with the environment. We suggest you take it in a sealed container
to your local service station for reclamation. Do not throw it in the
trash, pour it on the ground, or down a drain. Wash your hands with soap and water after handling used oil. 1.
2.
3.
0.90(0.95 US qt , 0.79 Imp qt)
1.05(1.11 US qt , 0.92 Imp qt)
Without oil filter replacement:
With oil filter replacement: 
						

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Oil filter change
2.
O-RING FILTER BASE
OIL FILTER WRENCH OIL FILTER
TORQUE:
Drain the engine oil (see page ).
Remove the oil filter with a filter wrench and let the remaining
oil drain out. Discard the oil filter.
Clean the filter base.
Tighten the oil filter to the specified torque. Coat the new O-ring on the new filter with clean engine oil.
Ask your authorized Honda dealer for advice on the filter wrench
(special tool). Use only a Honda genuine oil filter or a filter of equivalent quality
specified for your model. Using the wrong Honda filter or a non-
Honda filter which is not of equivalent quality may cause engine
damage. Pour the specified amount of recommended oil into the engine
(see page ). Start the engine and check the filter for leaks.
Stop the engine and recheck the oil level. If necessary, add oil to
bring it up to the proper level. Install the new oil filter on the filter base and tighten it by hand
until the O-ring seats against the filter base.
1.
2.
3.
4.
5.
6. 21
7.
8. 21
12 N·m (1.20 kgf·m , 9 lbf·ft) 
						

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Air cleaner service
Never use gasoline or low flash point solvents for cleaning the air
cleaner element. A fire or explosion could result.
Never run the engine wit hout the air cleaner. Rapid engine wear
will result from contaminants, such as dust and dirt being drawn
into the engine. 3.
A dirty air cleaner will restrict air flow to the carburetor. To prevent
carburetor malfunction, service the air cleaner regularly. Service
more frequently when operating the engine in extremely dusty
areas.
Remove the two air cleaner cover bolts from the air cleaner
cover, and remove the cover.
Remove the paper element from the air cleaner case. Remove
the foam element from the air cleaner cover.
Clean the air filter elements if they are to be reused.
Foam element: Clean in warm soapy water, rinse and dry thor-
oughly. Or clean in non-flammable solvent and dry.
Paper element: Tap the element lightly several times on a hard
surface to remove excess dirt, or blow compressed air (not ex-
ceeding 2.1 kg/cm
(30 psi)) through the filter from the air
cleaner case side. Never try to brush the dirt off; brushing will
force dirt into the fibers. Replace the paper element if it is
excessively dirty.
Wipe dirt from the inside of the air cleaner case and cover, using
a moist rag. Be careful to prevent dirt from entering the clean
chamber that leads to the carburetor.
1.
2.
3.
4. 
						

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25
Spark plug service
If the engine has been running, the muffler will be very hot. Be
careful not to touch the muffler. Recommended spark plugs:
Never use a spark plugs of incorrect heat range. 4.
SPARK PLUG WRENCH
0.70 0.80 mm
(0.028 0.031 in)
Measure the plug gap with a feeler gauge. Correct as necessary
by bending the side electrode.
The gap should be:
To ensure proper engine operation, the spark plugs must be
properly gapped and free of deposits.
Remove the spark plug caps and use a spark plug wrench to
remove each spark plug.
Visually inspect the spark plugs. Discard the spark plug if there
is apparent wear, or if the insulator is cracked or chipped. Clean
thesparkplugswithawirebrushiftheyaretobereused.
1.
2.
3.
BPR5ES (NGK)
W16EPR-U (DENSO)
0.70 0.80 mm (0.028 0.031 in) 
						

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26
The spark plugs must be securely tightened. Improperly tightened
spark plugs can become very hot and may damage the engine.Check that the spark plug washer is in good condition and
thread the spark plug in by hand to prevent cross-threading.
After the spark plug is seated, tighten with a spark plug wrench
to compress the washer.
When installing a new spark plug, tighten 1/2 turn after the spark
plug seats to compress the washer. When reinstalling a used spark
plug, tighten 1/8 1/4 turn after the spark plug seats to compress
the washer. 4.
5. 
						

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Spark arrester maintenance (optional part)
If the engine has been running, the muffler will be very hot. Allow
it to cool before proceeding.
Be careful not to damage the spark arrester screen. The spark arrester must be serviced every 100 hours to maintain
its efficiency. 5.
SPARK ARRESTER SCREEN
The spark arrester must be free of breaks and holes. Replace, if
necessary. Use a brush to remove carbon deposits from the spark arrester
screen.
Install the spark arrester and the muffler protector in the reverse
order of disassembly. Removethethree6mmflangebolts fromthemuffler
protector , and remove the muffler protector.
Remove the four special screws from the spark arrester ,
and remove the spark arrester from the muffler .
1.
2.
3.
4. 
						

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Fuel filter
Gasoline is extremely flammable and is explosive under certain
conditions. Do not smoke or allow flames or sparks in the area. 6.
FUEL FILTER
Check the fuel filter for water accumulation or sediment.
If the fuel filter contains excessive water accumulation or
sediment, take the engine to your authorized Honda engine
dealer.
1.
2. 
						

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TROUBLESHOOTING
If any fuel is spilled, make sure the area is dry before testing the
spark plug or starting the engine. Fuel vapor or spilled fuel may
ignite.
CARBURETOR
DRAIN SCREW
Engine will not start using recoil starter:
If the engine still does not start, take the engine to an authorized
Honda dealer. Are the battery cables securely connected and free of corrosion?
Is the battery fully charged?
Is the fuse good (if equipped)?
Is the engine switch in the ON position?
Is there enough oil in the engine?
Is the fuel valve ON (if fuel line is equipped with a valve)?
Is there fuel in the fuel tank?
Is gasoline reaching the carburetor?
To check, loosen the drain screw with the fuel valve ON.Remove both spark plug caps. Clean any dirt from around the
base of the spark plugs, then remove both spark plugs.
Install the spark plugs in the spark plug caps, and ground the
side electrodes to any engine ground.
Turn the engine switch to the START position (with a recoil
starter not equipped), or turn the engine switch on and pull
the recoil starter (with a recoil starter equipped), and see if
there are sparks at the electrode gaps of both spark plugs.
If there are no sparks, replace the spark plugs. If OK, reinstall
the spark plugs. Try to start the engine again according to the
instructions.
Is there a spark at the spark plugs?
9. 1.
2.
3.
4.
5.
6.
7.
8.
10. a.
b.
c.
d. 
						

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TRANSPORTING/STORAGE
To avoid severe burns or fire hazards, let the engine cool before
transporting it or storing it indoors.
When transporting the engine, turn the fuel valve OFF and keep
the engine level to prevent fuel spillage. Fuel vapor or spilled
fuel may ignite.
Gasoline is extremely flammable and is explosive under certain
conditions. Do not smoke or allow flames or sparks in the area.
DRAIN SCREW CARBURETOR
Before storing the unit for an extended period;
Be sure the storage area is free of excessive humidity and dust.
Drain the fuel.
Keep the engine level to reduce the possibility of fuel leakage,
when transporting. If the fuel tank is equipped with a valve, turn
the fuel valve to the CLOSED or OFF position.
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 draining is
completed, tighten the carburetor drain screw.
1.
2.
a.
b.