03/05/14 17:11:07 31Z0A600_001 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.
03/05/14 17:11:14 31Z0A600_002 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 symbol.
03/05/14 17:11:26 31Z0A600_003 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.
03/05/14 17:11:30 31Z0A600_004 CONTENTS ENGINE SAFETY ........................................................................................ 5 IMPORTANT SAFETY INFORMATION ................................................. 5 CONTROLS & FEATURES ......................................................................... 7 COMPONENT & CONTROL LOCATIONS ............................................. 7 CONTROLS .............................................................................................
03/05/14 17:11:34 31Z0A600_005 CONTENTS HELPFUL TIPS & SUGGESTIONS .......................................................... 35 STORING YOUR ENGINE .................................................................... 35 Storage Preparation ......................................................................... 35 Storage Precautions ......................................................................... 38 Removal From Storage ....................................................................
03/05/14 17:11:45 31Z0A600_006 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.
03/05/14 17:11:50 31Z0A600_007 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 should be observed in conjunction with engine startup, shutdown, operation, or protective apparel that may be needed to operate the equipment.
03/05/14 17:11:54 31Z0A600_008 CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS RECOIL STARTER (applicable engine types) AIR CLEANER ELECTRIC STARTER SPARK PLUGS 7
03/05/14 17:11:59 31Z0A600_009 CONTROLS & FEATURES OIL FILLER CAP/ DIPSTICK SCREEN GRID FUEL PUMP OIL PRESSURE SWITCH (applicable engine types) FUEL FILTER OIL FILTER OIL DRAIN BOLT 8
03/05/14 17:12:09 31Z0A600_010 CONTROLS & 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.
03/05/14 17:12:19 31Z0A600_011 CONTROLS & 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 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.
03/05/14 17:12:28 31Z0A600_012 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.
03/05/14 17:12:34 31Z0A600_013 BEFORE OPERATION Check the Engine Check the engine oil level (see page 22 ). Running the engine with a 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.
03/05/14 17:12:42 31Z0A600_014 OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time, please review the IMPORTANT SAFETY INFORMATION on page 5 and the chapter titled BEFORE OPERATION. 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.
03/05/14 17:12:49 31Z0A600_015 OPERATION 2. To start a cold engine, move the 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 CHOKE SLOW 3. Turn the engine switch to the ON position. 4.
03/05/14 17:12:56 31Z0A600_016 OPERATION 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. Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it. When the engine starts, release the key, allowing it to return to the ON position. 5.
03/05/14 17:13:03 31Z0A600_017 OPERATION STOPPING THE ENGINE To stop the 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. SLOW THROTTLE LEVER 2.
03/05/14 17:13:10 31Z0A600_018 OPERATION 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 FAST SLOW Do not disconnect the battery from the engine while the engine is running.
03/05/14 17:13:16 31Z0A600_019 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. 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.
03/05/14 17:13:28 31Z0A600_020 SERVICING YOUR ENGINE MAINTENANCE 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. 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.
03/05/14 17:13:41 31Z0A600_021 SERVICING YOUR ENGINE MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD (3) ITEM Perform at every indicated month or operating hour interval, whichever comes first.
03/05/14 17:13:48 31Z0A600_022 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 engine 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.
03/05/14 17:13:55 31Z0A600_023 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.
03/05/14 17:14:03 31Z0A600_024 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.
03/05/14 17:14:12 31Z0A600_025 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 oil into a suitable container. Discard the used oil filter. Use an oil filter wrench, rather than a strap wrench, to avoid striking and damaging the oil filter. FILTER MOUNTING BASE OIL FILTER OIL FILTER WRENCH SEAL 3.
03/05/14 17:14:17 31Z0A600_026 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 lbf·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.
03/05/14 17:14:25 31Z0A600_027 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 recommended range. SAE Viscosity Grades SAE TEMP The SAE oil viscosity and service classification are in the API label on the oil container.
03/05/14 17:14:31 31Z0A600_028 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 to page 28 for instructions that apply to the air cleaner and filter service.
03/05/14 17:14:39 31Z0A600_029 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). Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear.
03/05/14 17:14:49 31Z0A600_030 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.
03/05/14 17:14:54 31Z0A600_031 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.
03/05/14 17:15:03 31Z0A600_032 SERVICING YOUR ENGINE SPARK PLUG SERVICE Recommended spark plugs:BPR5ES (NGK) W16EPR-U (DENSO) 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. SPARK PLUG WRENCH 3. Inspect the spark plugs. Replace them if the electrodes are worn, or if the insulator is cracked or chipped.
03/05/14 17:15:08 31Z0A600_033 SERVICING YOUR ENGINE 6. 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. 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.
03/05/14 17:15:16 31Z0A600_034 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.
03/05/14 17:15:20 31Z0A600_035 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 it is damaged. SPARK ARRESTER SCREEN 4. Install the spark arrester, and muffler protector in the reverse order of disassembly.
03/05/14 17:15:30 31Z0A600_036 HELPFUL TIPS & 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.
03/05/14 17:15:36 31Z0A600_037 HELPFUL TIPS & 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.
03/05/14 17:15:43 31Z0A600_038 HELPFUL TIPS & 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.
03/05/14 17:15:51 31Z0A600_039 HELPFUL TIPS & 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.
03/05/14 17:15:59 31Z0A600_040 HELPFUL TIPS & 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.
03/05/14 17:16:03 31Z0A600_041 HELPFUL TIPS & SUGGESTIONS TRANSPORTING 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 lever to OFF.
03/05/14 17:16:17 31Z0A600_042 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START 1. Check battery and fuse. 2. Check control positions. 3. Check fuel. 4. Remove and inspect spark plug. 5. Take engine to an authorized Honda servicing dealer, or refer to shop manual. ENGINE LACKS POWER 1. Check air filter. 2. Check fuel. 3. Take engine to an authorized Honda servicing dealer, or refer to shop manual. Possible Cause Correction Battery discharged. Fuse burnt out. (if equipped) Fuel valve OFF.
03/05/14 17:16:24 31Z0A600_043 TECHNICAL & 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 or warranty inquires (see page 56 ).
03/05/14 17:16:31 31Z0A600_044 TECHNICAL & 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.
03/05/14 17:16:42 31Z0A600_045 TECHNICAL & 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 INSTALLATION: Install with the shot end hook toward the control base side.
03/05/14 17:16:48 31Z0A600_046 TECHNICAL & 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.
03/05/14 17:17:01 31Z0A600_047 TECHNICAL & 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.
03/05/14 17:17:11 31Z0A600_048 TECHNICAL & 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.
03/05/14 17:17:22 31Z0A600_049 TECHNICAL & 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.
03/05/14 17:17:35 31Z0A600_050 TECHNICAL & 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.
03/05/14 17:17:53 31Z0A600_051 TECHNICAL & CONSUMER INFORMATION Specifications GCV520-QEA Type Length × Width × Height Dry weight Engine type Displacement [Bore × Stroke] Max. output Max. torque Fuel consumption Cooling system Ignition system PTO shaft rotation 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) ] 14 bhp (9.7 kW, 13.1 PS) at 3,600 rpm 26.5 lbf·ft (35.9 N·m, 3.
03/05/14 17:18:04 31Z0A600_052 TECHNICAL & CONSUMER INFORMATION Specifications GXV530-QEA Type Length × Width × Height Dry weight Engine type Displacement [Bore × Stroke] Max. output Max. torque Fuel consumption Cooling system Ignition system PTO shaft rotation 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.
03/05/14 17:18:16 31Z0A600_053 TECHNICAL & CONSUMER INFORMATION Wiring Diagrams 3A Charge Coil 52
03/05/14 17:18:28 31Z0A600_054 TECHNICAL & CONSUMER INFORMATION Wiring Diagrams 12A Charge Coil 53
03/05/14 17:18:41 31Z0A600_055 TECHNICAL & CONSUMER INFORMATION Wiring Diagrams 18A Charge Coil 54
03/05/14 17:18:48 31Z0A600_056 TECHNICAL & 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.
03/05/14 17:18:58 31Z0A600_057 TECHNICAL & 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.
03/05/14 17:19:07 31Z0A600_058 QUICK REFERENCE INFORMATION Fuel Type Engine Oil Type Capacity Spark Plug Type Gap Carburetor Maintenance Idle speed Before each use First 20 hours Subsequent Unleaded gasoline with a pump octane rating of 86 or higher (page 21) SAE 10W-30, API SJ, for general use (page 26) Without oil filter replacement: 0.95 US qt (0.90 ) With oil filter replacement: 1.11 US qt (1.05 ) NGK: BPR5ES DENSO: W16EPR-U 0.028−0.031 in (0.70−0.