Honda GCV520, Owner'S Manual

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Page 2: ...for printing Illustrations are based on the GCV530 QEA3 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 The engine exhaust from this product contains chemicals known to the State of California to cause...

Page 3: ...tion is intended to help you avoid damage to your engine other property or the environment 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 ...

Page 4: ...l 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 preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if y...

Page 5: ...ment Powered by This Engine 12 OPERATION 13 SAFE OPERATING PRECAUTIONS 13 STARTING THE ENGINE 13 STOPPING THE ENGINE 16 SETTING ENGINE SPEED 17 SERVICING YOUR ENGINE 18 THE IMPORTANCE OF MAINTENANCE 18 MAINTENANCE SAFETY 19 MAINTENANCE SCHEDULE 20 FUEL RECOMMENDATIONS 21 ENGINE OIL LEVEL CHECK 22 ENGINE OIL CHANGE 23 OIL FILTER CHANGE 24 ENGINE OIL RECOMMENDATIONS 26 AIR FILTER INSPECTION 27 AIR C...

Page 6: ...INFORMATION 42 TECHNICAL INFORMATION 42 Serial Number Location 42 Battery Connections for Electric Starter 43 Remote Control Linkage 44 Carburetor Modification for High Altitude Operation 45 Oxygenated Fuels 46 Emission Control System Information 47 Air Index 49 Specifications 50 Wiring Diagrams 52 CONSUMER INFORMATION 55 Honda Publications 55 Customer Service Information 56 QUICK REFERENCE INFORM...

Page 7: ...ions Do not allow children to operate the engine Keep children and pets away from the area of operation 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 ...

Page 8: ...r run the engine in a closed garage or confined area Review the instructions provided with the equipment powered by this engine for any additional safety precautions that should be observed in conjunction with engine startup shutdown operation or protective apparel that may be needed to operate the equipment 03 05 14 17 11 50 31Z0A600_007 ...

Page 9: ...7 CONTROLS FEATURES COMPONENT CONTROL LOCATIONS SPARK PLUGS ELECTRIC STARTER AIR CLEANER RECOIL STARTER applicable engine types 03 05 14 17 11 54 31Z0A600_008 ...

Page 10: ...8 CONTROLS FEATURES OIL FILLER CAP DIPSTICK FUEL PUMP FUEL FILTER OIL FILTER OIL DRAIN BOLT SCREEN GRID OIL PRESSURE SWITCH applicable engine types 03 05 14 17 11 59 31Z0A600_009 ...

Page 11: ...ections 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 Pulling the starter grip operates the recoil starter to crank the engin...

Page 12: ...engine to run If the battery is disconnected fuel flow to the carburetor main jet will stop 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 To restart the engine turn the engine switch to the OFF position Next start accordin...

Page 13: ...ng 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 be sure the engine is level and the engine switch is in the OFF position Look around and underneath the engine for signs of oil or gasoline leaks Remove any excessi...

Page 14: ...e page 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 Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine startup 27 22 03 05 14 17 12 34 31Z0A60...

Page 15: ...n kill you Avoid any areas or actions that expose you to carbon monoxide Review the instructions provided with the equipment powered by this engine for any safety precautions that should be observed in conjunction with engine startup shutdown or operation 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 Always keep...

Page 16: ... 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 Turn the engine switch to the ON position 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 2 3...

Page 17: ...and wait at least 10 seconds before operating the starter again Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it If 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 When the engine starts release the key allowing it to return to the ON position 5 03...

Page 18: ... 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 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 1 2 3 03 05 1...

Page 19: ...ith 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 Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here 03 05 14 17 13 10 31Z0A600_...

Page 20: ...ecommendations 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 qualifi...

Page 21: ...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 ensure the best quality and reliability use only new genuine H...

Page 22: ...ilter optional part Air filter Spark plug Spark arrester optional part Cooling system Combustion chamber Idle speed Valve clearance Fuel filter Fuel line Perform at every indicated month or operating hour interval whichever comes first REGULAR SERVICE PERIOD 3 ITEM Change Replace Replace Replace Check Check Clean Clean 1 2 2 2 Clean Check level 22 23 24 27 28 31 33 Each use First month or 20 Hrs E...

Page 23: ...ionally 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 Running the engine with persistent spark knock or pinging can cause engine damage Ru...

Page 24: ... and wipe it clean Insert and remove the dipstick without screwing it into the oil filler neck Check the oil level shown on the dipstick 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 Reinstall the oil filler cap dipstick Running the engine with a low oil level can cause engine damage which is not by the Dist...

Page 25: ...rely 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 With the engine in a level position fill to the upper limit mark on the dipstick with the recommended oil see page 26 Running ...

Page 26: ...lent quality may cause engine damage 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 Drain the engine oil and retighten the drain bolt securely see page 23 Remove the oil filter with oil filter wrench and drain the remaining oil into a suitable container Di...

Page 27: ...ft 12 N m 1 2 kgf m Refill the crankcase with the specified amount of the recommended oil see page 26 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 22 If necessary add oil to bring the oil level to the upper limit mark on the dipstick 4 5 6 7 Oil filter tightening torque 03 05 14 17 14 17 31Z0A600_026 ...

Page 28: ...tive detergent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range The SAE oil viscosity and service classification are in the API label on the oil container Honda recommends that you use API SERVICE category SJ oil 03 05 14 17 14 25 31Z0A600_027 ...

Page 29: ...NT AIR CLEANER BASE PAPER FILTER ELEMENT GRID AIR DUCT Remove the air cleaner cover and inspect the filter elements Clean or replace dirty filter elements Always replace damaged filter elements Refer to page for instructions that apply to the air cleaner and filter service 28 03 05 14 17 14 31 31Z0A600_028 ...

Page 30: ...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 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 eleme...

Page 31: ... 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 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 Place the foam filter element into the air cleaner cover Install the grid over the paper filter elem...

Page 32: ...SPECTION FUEL FILTER 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 03 05 14 17 14 54 31Z0A600_031 ...

Page 33: ...ch 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 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 Install the spark plug carefully by hand to av...

Page 34: ...n the cylinder head Attach the spark plug caps After the spark plug seats tighten with a 13 16 inch spark plug wrench to compress the washer If reinstalling the used spark plugs tighten 1 8 1 4 turn after the spark plug seats If installing a new spark plugs tighten 1 2 turn after the spark plug seats 6 7 03 05 14 17 15 08 31Z0A600_033 ...

Page 35: ... 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 Remove the 6 mm flange bolts from the muffler protector and remove the muffler protector Remove the special ...

Page 36: ...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 3 4 03 05 14 17 15 20 31Z0A600_035 ...

Page 37: ... 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 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 ...

Page 38: ...rage If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline Add fuel stabilizer following the manufacturer s instructions 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 Stop the engine and if the fuel tank is equipped with a fuel valve move the fuel ...

Page 39: ...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 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 outdoo...

Page 40: ...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 Change the engine oil see page 23 Remove the spark plugs see page 31 Pour a tablespoon 5 10 cc o...

Page 41: ...ore 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 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 ga...

Page 42: ...ing 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 03 05 14 17 16 03 31Z0A600_041 ...

Page 43: ...n malfunction valves stuck etc Clean or replace filter element s p 28 Drain fuel tank and carburetor p 37 Refuel with fresh gasoline Replace or repair faulty components as necessary Check battery and fuse Check control positions Check fuel Remove and inspect spark plug Take engine to an authorized Honda servicing dealer or refer to shop manual Battery discharged Fuse burnt out if equipped Fuel val...

Page 44: ...Serial Number Location ENGINE SERIAL NUMBER Engine serial number Record the engine serial number in the space below You will need this serial number when ordering parts and when making technical or warranty inquires see page 56 03 05 14 17 16 24 31Z0A600_043 ...

Page 45: ...end Use a 12 volt battery with an ampere hour rating of at least 45 Ah 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 Connect the battery positive cable to the starter solenoid terminal as shown Connect the battery negative cable to an engine mounting bolt frame bolt or other ...

Page 46: ...ROTTLE CABLE SOLID WIRE STOPPER RUBBER INSTALLATION 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 Install with the shot end hook toward the control base side Install with the shot end hook toward the control base side To install the stopper rub...

Page 47: ... 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 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modi...

Page 48: ...ine containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol methyl tertiary butyl ether 15 by volume You may use gasoline containing up to 15 MTBE by volume methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline ...

Page 49: ...ns of carbon monoxide oxides of nitrogen and hydrocarbons 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 within the emission standards Tampering with or altering the emission c...

Page 50: ...nal 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 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 Follow the maintenance schedule on ...

Page 51: ...See your Emission Control Warranty for additional information The Air Index Information hang tag must remain on the engine until it is sold Remove the hang tag before operating the engine Descriptive Term Moderate Intermediate Extended Applicable to Emissions Durability Period 50 hours 0 65 cc 125 hours greater than 65 cc 125 hours 0 65 cc 250 hours greater than 65 cc 300 hours 0 65 cc 500 hours g...

Page 52: ...ation Length Width Height Dry weight Engine type Displacement Bore Stroke Max output Max torque Fuel consumption Cooling system Ignition system PTO shaft rotation Spark plug gap Valve clearance cold Other specifications 0 028 0 031 in 0 70 0 80 mm 0 10 0 04 mm 0 15 0 04 mm 18 0 16 8 13 0 in 456 427 331 mm 67 2 lbs 30 5 kg 32 3 cu in 530 cm 3 03 2 24 in 77 57 mm 16 bhp 11 3 kW 15 4 PS at 3 600 rpm ...

Page 53: ...e cold Other specifications Refer to page 31 See your authorized Honda dealer 18 0 16 8 13 0 in 456 427 331 mm 67 2 lbs 30 5 kg 4 stroke overhead camshaft 2 cylinders 90 V Twin 32 3 cu in 530 cm 3 03 2 24 in 77 57 mm 16 bhp 9 7 kW 13 1 PS at 3 600 rpm 26 5 lbf ft 35 9 N m 3 66 kgf m at 2 500 rpm 0 51 lb hph 313 g kWh 230 g PSh Forced air Transistorized magneto Counterclockwise 0 028 0 031 in 0 70 ...

Page 54: ...52 TECHNICAL CONSUMER INFORMATION Wiring Diagrams 3A Charge Coil 03 05 14 17 18 16 31Z0A600_053 ...

Page 55: ...53 TECHNICAL CONSUMER INFORMATION Wiring Diagrams 12A Charge Coil 03 05 14 17 18 28 31Z0A600_054 ...

Page 56: ...54 TECHNICAL CONSUMER INFORMATION Wiring Diagrams 18A Charge Coil 03 05 14 17 18 41 31Z0A600_055 ...

Page 57: ...l give you additional information for maintaining and repairing your engine You may order them from your Honda engine dealer This manual covers complete maintenance and overhaul procedures It is intended to be used by a skilled technician This manual provides complete illustrated parts lists 03 05 14 17 18 48 31Z0A600_056 ...

Page 58: ...e dissatisfied with the decision made by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write to Your name address and telephone number Date of purchase Name and address of dealer who services your engine Name of dealer who sold the engine to you A detailed description of the problem Or telephone 770 497 6400 When you write or call please give us th...

Page 59: ...uretor Maintenance Type Type Capacity Type Gap Idle speed Before each use First 20 hours Subsequent BPR5ES W16EPR U 0 028 0 031 in 0 70 0 80 mm Check engine oil level Check air filter Change engine oil Refer to the maintenance schedule on page 20 1 400 rpm NGK DENSO page 33 page 21 page 26 Without oil filter replacement With oil filter replacement 200 150 03 05 14 17 19 07 31Z0A600_058 ...

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