Honda GCV530 User's Manual
Contents
1. 4018 3NION3 19 61 3n18 1H5n se 3oNvuo mo1134 A 19 9 T ALINNILNOO HOLIMS 3NION3 54 TECHNICAL amp 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 Parts Catalog This manual provides complete illustrated parts lists 55 TECHNICAL amp 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 Almost all problems are solved in this way If you are dissatisfied with the decision made by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write to American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia 30005 8847 Or telephone 770 497 6400 When you2. 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 When your engine needs scheduled maintenance keep in mind that your Honda servicing dealer is specially trained in servicing Honda engines Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns Best Wishes Honda Motor Co Ltd 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 This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all the hazards associated with operating or maintaining an engine You must use your own good judgment You will find important safety information in a variety of forms including Safety Messages preceded by a safety alert symbol N and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if DANGER you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if WARNING you don t follow instructions You CAN be
3. 41 ENGINE LACKS POWER 2 ntasnn sa papa saca d 2h13 cateaeneaccaveeacdeansecnassttncs 41 Serial Number Location Us Oso suus C Doce 42 Battery Connections for Electric Starter 43 Remote Control Linkage 2 44 Carburetor Modification for High Altitude Operation 45 Oxy ena ted Fuels eR M 46 Emission Control System Information 47 Me ET aA 49 2 0 srir mesnr 50 Winnog Diagrams isosti a a aaea aa aaa iA 52 CONSUMER INFORMATION 55 Honda 55 Customer Service Information 56 bcc inside baciceovar 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 Read and understand this owner s manual before operating the engine Failure to
4. AH311V8 VE NOILINDI x uvdS 1109 NOLLINOI VON MHVdS 31411938 30019 4015 3NION3 52 olyg TECHNICAL amp CONSUMER INFORMATION iagrams D iring 12A Charge Coil 318VOliddv 8 1109 HOLIMS 3HnSSdHd 1 9 1303 H3lHVIS 2 AH3llVv8 vel NOILINDI uvds FT j 3NION3 M E AZL ig M ie TA LON MNHVdS 6351 0 E B z PUT 4018 331311934 i 15 19 AVHD 15 N33H9 LHDIT 330 anqa 1 9 ania 35NVHO 185 01 1 9i 19 ALINNILNOO HOLIMS 53 TECHNICAL amp CONSUMER INFORMATION iagrams D iring HOLIMS 3NISN3 3NION3 il 18A Charge Co GION310S ino 13 aunou5 3NION3 Alia dWV1 NOILIN I V8 YOLOW 18 NOILIN9I 331314934
5. Running the engine with low oil level can cause engine damage which is not by the Distributor s Limited Warranty 22 SERVICING YOUR ENGINE ENGINE OIL CHANGE Drain the used oil while the engine is warm Warm oil drains quickly and completely 1 Place a suitable container below the engine to catch the used oil then remove the oil filler cap dipstick and the drain bolt 2 Allow the used oil to drain completely then reinstall the drain bolt and tighten it securely 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 down a drain 3 With the engine in a level position fill to the upper limit mark on the dipstick with the recommended oil see page 26 ENGINE OIL REFILL CAPACITIES Without oil filter replacement 0 95 US qt 0 90 0 With oil filter replacement 1 11 US qt 1 05 0 NOTICE Running the engine with a low oil level can cause engine damage 4 Reinstall the oil filler cap dipstick securely UPPER LIMIT LOWER LIMIT OIL DRAIN BOLT OIL FILLER CAP DIPSTICK 23 SERVICING YOUR ENGINE OIL FILTER CHANGE 1 Drain the engine oil and retighten the drain bolt securely see page 23 2 Remove the oil filter with oil filter wrench and drain the remaining o
6. 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 5 000 feet 1 500 meters 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 45 TECHNICAL amp 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 Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE methyl tertiary butyl ether 15 by volume You may use gasoline containing up to 1596 MTBE by volume METHANOL methyl or wood alcohol 596 by volume You may use gasoline containing up to 596 metha
7. servicing dealer or ignition malfunction necessary refer to shop manual valves stuck etc ENGINE LACKS Possible Cause Correction 1 Check air filter Filter element s clogged Clean or replace filter element s p 28 2 Check fuel Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and ca rburetor p 37 Refuel with fresh gasoline 3 Take engine to an authorized Honda servicing dealer or refer to shop manual Fuel filter clogged carburetor malfunction ignition malfunction valves stuck etc Replace or repair faulty components as necessary TECHNICAL amp 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 warranty inquires see page 56 Engine serial number 42 TECHNICAL amp 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 negative battery cable so your tools cannot cause a short circuit if n un a grounded part while tighteni
8. HURT if you don t follow CAUTION instructions Safety Headings such as MPORTANT SAFETY INFORMATION Safety Section such as ENGINE SAFETY Instructions how to use this engine correctly and safely This entire book is filled with important safety information please read it carefully 5 IMPORTANT SAFETY INFORMATION 5 X 7 COMPONENT amp CONTROL LOCATIONS 7 CONTROLS pe c 9 Throttle Lever m E 9 Recoil Starter applicable engine types 9 FEATURES e 10 Fuel cut Solenoid C 10 11 IS YOUR ENGINE READY TO GO meiste 11 Check the General Condition of the Engine 11 Check the 12 Check the Equipment Powered by This Engine 12 P 13 AFE OPERATING PRECAUTIONS 13 STARTING THE ENGINE 2 511 55 25 up ERR DUM REIS 13 STOPPING THE ENGINE scciancxecadvacurscssks
9. Spark plug gap 0 028 0 031 in Refer to page 31 0 70 0 80 mm Valve clearance cold IN 0 10 0 04 mm See your authorized EX 0 15 0 04 mm Honda dealer Other specifications 50 No other adjustments needed TECHNICAL amp CONSUMER INFORMATION Specifications GXV530 OEA Type Length Width X Height 18 0 X 16 8 X 13 0 in 456 X 427 x 331 mm Dry weight 67 2 Ibs 30 5 kg Engine type 4 stroke overhead camshaft 2 cylinders 90 V Twin Displacement 32 3 cu in 530 cm Bore Stroke 3 03 X 2 24 in 77 X 57 mm Max output 16 bhp 9 7 kW 13 1 PS at 3 600 rpm Max torque 26 5 Ibf ft 35 9 N m 3 66 kgf m at 2 500 rpm Fuel consumption 0 51 Ib hph 313 g kWh 230 g PSh Cooling system Forced air Ignition system Transistorized magneto PTO shaft rotation Counterclockwise GXV530 Tuneup ITEM SPECIFICATION MAINTENANCE Spark plug gap 0 028 0 031 in Refer to page 31 0 70 0 80 mm Valve clearance cold IN 0 10 0 04 mm See your authorized EX 0 15 0 04 mm Honda dealer Other specifications No other adjustments needed 51 TECHNICAL amp CONSUMER INFORMATION Diagrams iring HOLIMS 3NION3 3A Charge Coil GION310S ino 15 15 ion ame ALIQNILNOO HOLIMS 3NION3 7109
10. do so could result in personal injury or equipment damage Know how to stop the engine quickly and understand the operation of all controls Never permit anyone to operate the engine without proper instructions Do not allow children to operate the engine Keep children and pets away from the area of operation Refuel With Care Gasoline is extremely flammable and gasoline vapor can explode Refuel outdoors in a well ventilated area with the engine stopped Never smoke near gasoline and keep other flames and sparks away Always store gasoline in an approved container If any fuel is spilled make sure the area is dry before starting the engine Hot Exhaust The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful not to touch the muffler while it is hot Let the engine cool before storing it indoors To prevent fire hazards and to provide adequate ventilation for stationary equipment applications keep the engine at least 3 feet 1 meter away from building walls and other equipment during operation Do not place flammable objects close to the engine 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 shou
11. jet when the engine switch is in the OFF position 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 Pressure Switch applicable engine types The engine is equipped with a oil pressure switch to prevent damage from lack of lubrication or overheating If oil pressure alarm lamp comes on check the engine oil level and add the correct engine oil if necessary see page 22 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 10 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 A WARNING Improperly maintaining this engine or failing to correct a problem before operation could cause a malfunction in which you could be seriously injured Always perform a preoperation inspection before each operation and correct any problem Before beginning your preoperation checks
12. 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 Maintenance Follow the maintenance schedule 20 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 48 TECHNICAL amp 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 The lower the Air Index the less pollution 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 Warranty for additional information Descriptive Term Applicable to Emissions Durability Period Moderate 50 hours 0 65 cc 125 hours greater than 65 cc Intermediate 125 hours 0 65 cc 250 hours greater than 65 cc Extended 300 hours 0 65 cc 500 hours greater than 65 cc The Air Index Inf
13. secure it to the bracket as shown CONTROL LEVER LEVER SPRING 1 LEVER TYPE CHOKE RETURN SPRING INSTALLATION Install with the shot end THROTTLE CABLE 5 x 16 mm SCREW 2 hook toward the control SOLID WIRE base side CABLE HOLDER 2 CHOKE CABLE SOLID WIRE CHOKE CONTROL LEVER CONTROL LEVER 2 LEVER TYPE 44 TECHNICAL amp 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 High altitude performance can be improved by specific modifications to the carburetor If you always operate your engine at altitudes above 5 000 feet 1 500 meters 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 Even with carburetor modification engine horsepower will decrease about 3 596 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made NOTICE
14. the engine starts release the key allowing it to return to the ON position the throttle lever has been moved to the CHOKE position to start the engine gradually move it to the SLOW position as the engine warms up CHOKE THROTTLE LEVER 15 stop engine in an emergency simply turn the engine switch to the OFF position Under normal conditions use the following procedure 1 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 Refer to the instructions provided with the equipment powered by this engine for remote control information NN THROTTLE LEVER 2 Turn the engine switch to the OFF position 3 If the fuel tank is equipped with a valve turn the fuel valve to the CLOSED or OFF position 16 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 THROTTLE LEVER NX X 7 Do not disconnect the battery from the engine while the engine is running Disconnecting the battery causes the fuel cut solenoid to shut off
15. the flow of fuel to the carburetor main jet and the engine will stop FAST SLOW 17 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 AWARNING 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 follow the inspection and maintenance recommendations and schedules in this owner s manual 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 The maintenance schedule applies to normal operating conditions If you operate your engine under unusual 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 Maintenance replacement or repair of emission control devices and systems may be done by any engine repair establishment or individual using parts that are certified to EPA standards 18 SERVICING YOUR ENGINE MAINT
16. within the emission standards Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters 47 TECHNICAL amp 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 Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your Honda engine were designed built and certified to conform with EPA and California emission regulations We recommend the use of genuine Honda parts whenever you have maintenance done 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 A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The
17. write or call please give us this information Model and serial number page 42 Name of dealer who sold the engine to you Name and address of dealer who services your engine Date of purchase Your name address and telephone number A detailed description of the problem 56 QUICK REFERENCE INFORMATION Fuel Type Unleaded gasoline with a pump octane rating of 86 or higher Engine Oil Type AE TOW 30 API SJ for general use page 26 Capacity Without oil filter replacement 0 95 US qt 0 90 2 With oil filter replacement 1 11 US qt 1 05 0 Spark Plug Type NGK BPR5ES DENSO W16EPR U Gap 0 028 0 031 in 0 70 0 80 mm Carburetor Idle speed 1 400 550 rpm Maintenance Before Check engine oil level each use Check air filter First 20 Change engine oil hours Subsequent Refer to the maintenance schedule on page 20 HONDA The Power of Dreams 31Z0A602 EM3 4000 2003 01 00 31 20 6020 CHi Printed in Japan
18. E MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD 3 ITEM First Every Every Every Refer T Each month 3 months 6 months year Perform at every indicated to month or operating hour interval mee i i ive page 20 Hrs 50 Hrs 100 Hrs 200 Hrs whichever comes first Engine oil Check level Change O O 22 Oilfilter Replace O optional part e filter Check Replace g e Spark plug Check adjust O Replace O Spark arrester Clean O optional part Cooling system Clean O Combustion chamber Clean After every 300 Hrs 2 Idle speed Check adjust 2 Valve clearance Check adjust 2 e Fuelfilter Check replace 2 e Fuelline Check Every 2 years Replace if necessary 2 e Emission related items Replace the paper element type only 1 Service more frequently when used in dusty areas 2 These items should be serviced by your servicing dealer unless you have the proper tools and are mechanically proficient Refer to Honda shop manual for service procedures 3 For commercial use log hours of operation to determine proper maintenance intervals 20 SERVICING YOUR ENGINE 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 eng
19. ENANCE 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 A WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in the owner s manual Safety Precautions Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts 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 nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuel related parts Remember that your 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 19 SERVICING YOUR ENGIN
20. HONDA ENGINES Owner s Manual GCV520 GCV530 GXV530 Click here to save this manual to your computer 2003 Honda Motor Co Ltd All Rights Reserved WARNING 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 The information and specifications included in this publication were in effect at the time of approval for printing Illustrations are based on the GCV530 OEA3 type Honda Motor Co Ltd reserves the right however to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever No part of this publication may be reproduced without written permission 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 This manual contains the information on how to do that please read it carefully As you read this manual you will find information preceded by a NOTICE symbol That information is intended to help you avoid damage to your engine other property or the environment
21. ILTER ELEMENT AIR CLEANER BASE AIR DUCT 4 Inspect both air filter elements and replace them if they are damaged Alwa eplace the paper filter element at the scheduled interval see page 20 28 SERVICING YOUR ENGINE 5 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 Never try to brush off dirt brushing will force dirt into the fibers Replace the paper filter element if it is excessively dirty Foam filter element Clean in warm soapy water rinse and allow to dry thoroughly Or clean in nonflammable 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 6 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 on the carburetor 7 Place the foam filter element into the air cleaner cover 8 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 9 Install the cover and tighten the two air cleaner cover bolts
22. be sure the engine is level and the engine switch is in the OFF position Check the General Condition of 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 11 BEFORE OPERATION Check the Engine Check the engine oil level see page 22 Running the engine with low oil level can cause engine damage Check the air filter see page 27 A dirty air filter will restrict air flow 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 Check the Equipment Powered by This Engine Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine startup 12 OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time please review the IMPORTANT SAFETY INFORMATION on and the chapter titled BEFORE OPERATION A WARNING 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 Review the instructions provided with the equipment powered by
23. csseas snaesecnsaawciecssenescencatcoiensane 16 SETTING ENGINE SPEED 17 T 18 THE IMPORTANCE OF MAINTENANCE soiscccsscissscassconinsdccenessecanenenssene 18 MAINTENANCE SAFETY 19 MAINTENANCE SCHEDULE 20 FUEL RECOMMENDATIONS 21 ENGINE OIL LEVEL CHECK MENS 22 ENGINE OIL CHANGE idecesscntaceusaasanteassansnacatacnsees 23 s NI CET T 24 ENGINE OIL RECOMMENDATIONS seen 26 AIR FILTER 2 ud uiri cud sore puc se pau bore 27 AIR CLEANER SERVICE picta uud rcc adc nat RSS RS 28 FUEL FILTER INSPECTION a 30 SPARK PLUG SERVICE dde 31 SPARK ARRESTER SERVICE optional equipment 33 CONTENTS Storage Preparation cud causas c ase RC 35 Storage PROC AUTON NS c ocaeca ated edet babel cust deis ada 38 Removal From Storage Cod sias ese 39 TRAINS POR FIBI 40 re eer 41 ENGINE WILL NOT START tux odiis hea soca Rae
24. e 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 35 HELPFUL TIPS amp 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 ADDING A FUEL STABILIZER TO EXTEND FUEL STORAGE LIFE When adding a fuel 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 1 Add fuel stabilizer following the manufacturer s instructions 2 After adding a fuel stabilizer run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor 3 Stop the engine and if the fuel tank is equipped with a fuel valve move
25. er 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 Unless all fuel has been drained from the fuel tank leave the fuel valve in the CLOSED or OFF position to reduce the possibility of fuel leakage 38 HELPFUL TIPS amp 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 Do not use sheet plastic as a dust cover A nonporous cover will trap moisture around the engine promoting rust and corrosion 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 Removal From Storage Check your engine as described in the BEFORE OPERATION chapter of this manual 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 that it contains only fresh gasoline Gasoline oxidizes and deteriorates over time causing hard starting If the cylinders were coated with oil during storage preparation the engine may smoke briefly at startup This is normal 39 HELPFUL TIPS amp SUGGESTIONS TRANSPORTING If the en
26. gine 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 lever to OFF 40 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Correction 1 Check battery and fuse Battery discharged Recharge battery Fuse burnt out if equipped Replace fuse 2 Check control Fuel valve OFF Move lever to ON positions if equipped Choke OPEN Move lever to CLOSED CHOKE unless engine is warm Engine switch OFF Turn engine switch to if equipped ON 3 Check fuel Out of fuel Refuel Bad fuel engine stored without treating or draining gasoline or refueled with bad gasoline Drain fuel tank and carburetor p 37 Refuel with fresh gasoline 4 Remove and inspect spark plug Spark plugs faulty fouled or improperly gapped Clean gap or replace spark plugs 31 Spark plugs wet with fuel flooded engine Dry and reinstall spark plugs Start engine with throttle lever in FAST position 5 Take engine to an authorized Honda Fuel filter clogged carburetor malfunction Replace or repair faulty components as POWER
27. il into a suitable container Discard the used oil filter NOTICE Use an oil filter wrench rather than a strap wrench to avoid striking and damaging the oil filter OIL FILTER OIL FILTER WRENCH SEAL 3 Clean the filter mounting base and coat the seal of the new oil filter with clean engine oil NOTICE 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 24 SERVICING YOUR ENGINE 4 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 9 Ibf ft 12 N m 1 2 kgf m 5 Refill the crankcase with the specified amount of the recommended oil see page 26 Reinstall the oil filler cap dipstick 6 Start the engine and check for leaks 7 Stop the engine and check the oil level as described on page 22 If necessary add oil to bring the oil level to the upper limit mark on the dipstick 25 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 recomme
28. ine 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 Occasionally you may hear a light spark knock or pinging metallic rapping noise while operating under heavy loads This is no cause for concern If spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline If spark knock or pinging persists see an authorized Honda servicing dealer NOTICE Running the engine with persistent spark knock or pinging can cause engine damage Running the engine with persistent spark knock or pinging is considered misuse and the Distributor s Limited Warranty does not cover parts damaged by misuse 21 SERVICING YOUR ENGINE ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position 1 Place the engine on a level surface 2 Remove the oil filler cap dipstick and wipe it clean 3 Insert and remove the dipstick without screwing it into the oil filler neck Check the oil level shown on the dipstick 4 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 see page 26 5 Reinstall the oil filler cap dipstick OIL FILLER CAP DIPSTICK OIL FILLER CAP DIPSTICK UPPER LIMIT LOWER LIMIT Y
29. it is damaged SPARK ARRESTER SCREEN 4 Install the spark arrester muffler protector in reverse order of disassembly 34 HELPFUL TIPS amp 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 Clean all exterior surfaces touch up any damaged paint and coat other areas that may rust with a light film of oil NOTICE 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 Water contacting a hot engine can cause damage the engine has been running allow it to cool for at least half an hour before washing Fuel Gasoline will oxidize and deteriorate in storage Old 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 The length of time that gasoline can b
30. ld be observed in conjunction with engine startup shutdown operation or protective apparel that may be needed to operate the equipment CONTROLS 8 FEATURES COMPONENT amp CONTROL LOCATIONS RECOIL STARTER applicable engine types AIR CLEANER ELECTRIC STARTER SPARK PLUGS CONTROLS amp FEATURES OIL FILLER CAP DIPSTICK SCREEN GRID Seb FUEL PUMP OIL PRESSURE SWITCH FUEL FILTER applicable engine types OIL FILTER OIL DRAIN BOLT CONTROLS amp FEATURES 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 Refer to the instructions provided with the equipment powered by this engine for remote control information GSS E XN E 0 CHOKE SLOW THROTTLE LEVER Recoil Starter applicable engine types Pulling the starter grip operates the recoil starter to crank the engine CONTROLS amp 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
31. nded range SAE Viscosity Grades SAE _ 10 0 20 40 60 80 100 The SAE oil viscosity and service classification are in the label the oil container Honda recommends that you use API SERVICE category SJ oil 26 SERVICING YOUR ENGINE 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 28 for instructions that apply to the air cleaner and filter service AIR CLEANER COVER BOLTS AIR CLEANER COVER FOAM FILTER ELEMENT GRID PAPER FILTER ELEMENT AIR CLEANER BASE AIR DUCT 27 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 NOTICE 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 1 Remove the two air cleaner cover bolts from the air cleaner cover and remove the cover 2 Remove the foam filter element 3 Remove the paper filter element from the grid AIR CLEANER COVER BOLTS AIR CLEANER COVER FOAM FILTER ELEMENT PAPER F
32. ng the positive battery cable end A WARNING A battery can explode if you do not follow the correct procedure seriously injuring anyone nearby Keep all sparks open flames and smoking materials away from the battery 1 Connect the battery positive cable to the starter solenoid terminal as shown 2 Connect the battery negative cable to an engine mounting bolt frame bolt or other good engine ground connection 3 Connect the battery positive cable to the battery positive terminal as shown 4 Connect the battery negative cable to the battery negative terminal as shown 5 Coat the terminals and cable ends with dielectric grease POSITIVE SE BATTERY CABLE N STARTER SOLENOID NEGATIVE BATTERY CABLE 43 TECHNICAL amp 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 THROTTLE CHOKE INSTALLATION CABLE SOLID WIRE Install with the shot end hook toward the control 5 X 16 mm SCREW CABLE HOLDER base side X on CX STOPPER RUBBER INSTALLATION To install the stopper rubber first align the boss with the hole of the control lever bracket then turn the rubber 90 and
33. nol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 596 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of your fuel system If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty 46 TECHNICAL amp 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 Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons The U S and California Clean Air Acts EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems The following instructions and procedures must be followed in order to keep the emissions from your Honda engine
34. ormation hang tag must remain on the engine until it is sold Remove the hang tag before operating the engine 49 TECHNICAL amp CONSUMER INFORMATION Specifications GCV520 OEA Type Length Width X Height 18 0 X 16 8 X 13 0 in 456 X 427 X 331 Dry weight 67 2 Ibs 30 5 kg Engine type 4 stroke overhead camshaft 2 cylinders 90 V Twin Displacement Bore Stroke 32 3 cu in 530 cm 3 03 X 2 24 77 57 mm Max output 14 bhp 9 7 kW 13 1 PS at 3 600 rpm Max torque 26 5 Ibf ft 35 9 N m 3 66 kgf m at 2 500 rpm Fuel consumption 0 51 Ib hph 313 g kWh 230 g PSh Cooling system Forced air Ignition system Transistorized magneto PTO shaft rotation Counterclockwise GCV530 OEA Type Length Width Height 18 0 X 16 8 X 13 0 in 456 X 427 X 331 Dry weight 67 2 Ibs 30 5 kg Engine type 4 stroke overhead camshaft 2 cylinders 90 V Twin Displacement Bore X Stroke 32 3 cu in 530 cm 3 03 X 2 24 in 77 X 57 mm Max output 16 bhp 11 3 kW 15 4 PS at 3 600 rpm Max torque 26 9 Ibf ft 36 5 N m 3 72 kgf m at 2 500 rpm Fuel consumption 0 51 Ib hph 313 g kWh 230 g PSh Cooling system Forced air Ignition system Transistorized magneto PTO shaft rotation Counterclockwise GCV520 GCV530 Tuneup ITEM SPECIFICATION MAINTENANCE
35. securely NOTICE Excess oil will restrict air flow through the foam filter element and may transfer to the paper filter element soaking and clogging it SQUEEZE THOROUGHLY PAPER ELEMENT SOLVENT ENGINE OIL 29 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 30 SERVICING YOUR ENGINE SPARK PLUG SERVICE Recommended spark plugs BPR5ES W16EPR U DENSO NOTICE Incorrect spark plugs can cause engine damage 1 Disconnect the spark plug caps and remove any dirt from around the spark plug area 2 Remove the spark plugs with a 13 16 inch spark plug wrench ae SPARK PLUG WRENCH 3 Inspect the spark plugs Replace them if the electrodes are worn or if the insulator is cracked or chipped Clean the spark plugs with a wire brush if you are going to reuse them 0 028 0 031 in 0 70 0 80 mm 4 Measure the spark plug electrode gap with a suitable gauge The gap should be 0 028 0 031 in 0 70 0 80 mm Correct the gap if necessary by carefully bending the side electrode 5 Install the spark plug carefully by hand to avoid cross threading 31 SERVICING YOUR ENGINE 6 After the spark plug seats tighten with a 13 16 inch spark plug
36. the fuel valve to the CLOSED or OFF position 36 HELPFUL TIPS amp SUGGESTIONS DRAINING THE FUEL TANK AND CARBURETOR 1 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 2 Loosen the carburetor drain screw and drain the carburetor into an approved gasoline container After draining is completed tighten the carburetor drain screw A WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately CARBURETOR DRAIN SCREW 37 HELPFUL TIPS amp SUGGESTIONS Engine Oil 1 Change the engine oil see page 23 Engine Cylinder 1 Remove the spark plugs see page 31 2 Pour a tablespoon 5 10 cc of clean engine oil into the cylinders 3 Pull the starter rope several times to distribute the oil in the cylinders 4 Reinstall the spark plugs Storage Precautions If 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 dry
37. this engine for any safety precautions that should be observed in conjunction with engine startup shutdown or operation Always keep hands and feet clear of rotating machinery STARTING THE ENGINE 1 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 13 2 To start a cold engine move 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 THROTTLE LEVER C SLOW 3 Turn the engine switch to the ON position 4 Operate the starter RECOIL STARTER applicable engine types Pull the starter grip lightly until you feel resistance then pull briskly Return the starter grip gently 14 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 NOTICE Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it When
38. 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 NOTICE A loose spark plug can overheat and damage the engine Overtightening the spark plug can damage the threads in the cylinder head 7 Attach the spark plug caps 32 SERVICING YOUR ENGINE 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 If the engine has been running the muffler will be very hot Allow the muffler to cool before servicing the spark arrester 1 Remove the 6 mm flange bolts from the muffler protector and remove the muffler protector 2 Remove the special screws from the spark arrester and remove the spark arrester from the muffler MUFFLER SPARK ARRESTER 6 mm FLANGE BOLT SPECIAL SCREWS 6 mm FLANGE BOLTS MUFFLER PROTECTOR 33 SERVICING YOUR ENGINE 3 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
Download Pdf Manuals
Related Search