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A FEW WORDS ABOUT SAFETY
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It
could also damage the engine or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some
procedures require the use of special tools. Any person who intends to use a replacement part, service procedure, or a
tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the
engine.
If you need to replace a part, use genuine Honda parts with the correct part number, or an equivalent part. We strongly
recommend that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s
safety and the reliability of the engine. Any error or oversight
while servicing an engine can result in faulty operation, damage
to the engine, or injury to others.
For Your Safety
Because this manual is intended for the professional service
technician, we do not provide warnings about many basic shop
safety practices (eg, Hot parts – wear gloves). If you have not
received shop safety training or do not feel confident about your
knowledge of safe servicing practices, we recommend that you
do not attempt to perform the procedures described in this
manual.
Some of the most important general service safety precautions
are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and
repair procedures. Only you can decide whether or not you
should perform a given task.
Important Safety Precautions
• Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following:
! Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely.
! Protect your eyes by using proper safety glasses, goggles, or face shields any time you hammer, drill, grind, or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
! Use other protective wear when necessary, for example, gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Make sure the engine is off before you begin any servicing procedures, unless the instructions tell you to do otherwise. This will help eliminate several potential hazards:
! Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
! Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
! Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the way.
• Gasoline vapors are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline.
! Use only a nonflammable solvent, not gasoline, to clean parts.
! Never drain or store gasoline in an open container.
! Keep all cigarettes, sparks, and flames away from all fuel-related parts.
!WARNING
Improper service or repairs can create an unsafe
condition that can cause your customer or others
to be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
!WARNING
Failure to properly follow instructions and
precautions can cause you to be seriously hurt
or killed.
Follow the procedures and precautions in this
manual carefully.
gc160_gcaha_3721673_forward
OUTLINE OF CHANGESGC160 • GC190 • GS190
Model GC160 • GC190 • GS190(After modification)
GC160 • GC190 • GS190(Before modification)Item
IGNITION COIL
• GX style transistorized ignition coil
• Stud bolt (dark gray) dimensions changed to meet coil height change
• Flange bolt height increased to meet coil height change
FLYWHEEL
• Cast iron flywheel
• Separate starter pulley, cooling fan, and screen grid (applicable types)
OIL ALERT® UNIT
Added to increase durability of oil level switch.
STUD BOLT (DARK GRAY)
6 x 23 mm FLANGE BOLT
STUD BOLT (SILVER)
6 x 20 mm FLANGE BOLT
CAST IRON FLYWHEEL
COOLING FAN
SCREEN GRID
STARTER PULLEYINTEGRATED FLYWHEEL, STARTER PULLEY, COOLING FAN, AND SCREEN GRID
OIL ALERT® UNIT
gc160_gcaha_3721673_forward
GC160
GC190 • GS190 1. SPECIFICATIONS
1. SPECIFICATIONS
* The power rating of the engine indicated in this document is the net power output tested on a production engine for
the engine model and measured in accordance with SAE J1349 at 3,600 rpm (net power) and at 2,500 rpm (max. net
torque). Mass production engines may vary from this value. Actual power output for the engine installed in the final
machine will vary depending on numerous factors, including the operating speed of the engine in application,
environmental conditions, maintenance, and other variables.
1. SPECIFICATIONS.................................. 1-1 2. PERFORMANCE CURVES......................1-2
Model GC160LA GC190LA GS190LA
Type 4-stroke, overhead camshaft single cylinder
Displacement 160 cc (9.8 cu-in) 187 cc (11.4 cu-in)
Bore x stroke 64 x 50 mm (2.5 x 2.0 in) 69 x 50 mm (2.71 x 1.97 in)
Net power * (in accordance with SAE J1349)
3.4 kW (4.6 hp) at 3,600 rpm 3.9 kW (5.2 hp) at 3,600 rpm
Max. net torque * (in accordance with SAE J1349)
9.4 N•m (6.9 lbf •ft) at 2,500 rpm 11.2 N•m (8.3 lbf•ft) at 2,500 rpm
Compression ratio 8.5 : 1
Fuel consumption 1.5 /hr at 3,600 rpm 1.6 /hr at 3,600 rpm
Cooling system Forced-air
Ignition system Transistorized magneto ignition
Ignition timing 20° B.T.D.C.
Spark plug (NGK) BPR6ES (NGK brand)
Carburetor Horizontal type, butterfly valve
Governor Centrifugal mechanical governor
Lubrication system Splash
Oil capacity 0.58 (0.61 US qt) 0.55 (0.58 US qt)
Recommended operating ambient temperature
-15 ~ 40°C (5 ~ 104°F) -5 ~ 40°C (23 ~ 104°F)
Starting system Recoil starter
Stopping system Ignition primary circuit ground
Fuel used Unleaded gasoline with a pump octane rating of 86 or higher
Fuel tank capacity 1.8 (1.9 US qt)
PTO shaft rotation Counterclockwise (from PTO shaft side)
gc160_gcaha_3721673_forward
GC
160
GC
190 •
GS
190
2.
PE
RF
OR
MA
NC
E C
UR
VE
S
GC
160L
AG
C190L
AG
S190L
A
gc160_
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3721673_
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1. S
PE
CIF
ICA
TIO
NS
GC
160
• G
C190 •
GS
190
1.
WIR
ING
DIA
GR
AM
1.
WIR
ING
DIA
GR
AM
....
....
....
....
....
....
....
1-1
2. W
IRE
RO
UT
ING
....
....
....
....
....
....
....
....
1-2
SP
AR
KP
LU
GIG
NIT
ION
CO
IL
IGN
ITIO
N
SW
ITC
H
OIL
LE
VE
L
SW
ITC
H
OIL
AL
ER
TU
NIT
WIT
H O
IL A
LE
RT
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GC160 • GC190 • GS190
2. WIRE ROUTING
CAST IRON FLYWHEEL TYPES
• With Fixed Throttle
Verify that the engine stop switch wire is not pinched by the fan cover.
FAN COVER
ENGINE STOP SWITCH LEAD
The engine stop switch wire must be secured by the cable clip.
gc160_gcaha_3721673_forward
GC160 • GC190 • GS190
• With Variable Throttle and Oil Alert®
Verify that the engine stop switch cable is not pinched by the fan cover.
FAN COVER
ENGINE STOP SWITCH LEAD
The engine stop switch wire must be secured by the cable clip.
The engine stop switch wire must pass between the engine boss and and rib before passing under the wire clamp.
WIRE CLAMP
STOP SWITCHWIRECLAMP
SWITCH PROTECTOR
Verify that the rubber tube protector is through the casting hole.
Route the engine stop switch wire through the air cleaner guide.
gc160_gcaha_3721673_forward
GC160 • GC190 • GS190
• Snowblower Type
Verify that the engine stop switch cable is not pinched by the fan cover.
FAN COVER
ENGINE STOP SWITCH LEAD
The engine stop switch wire must be secured by the cable clip.
Secure the ground terminal in the position shown with the5 x 8 mm washer-screw.
gc160_gcaha_3721673_forward
GC160 • GC190 • GS190
• Tiller Type
Verify that the engine stop switch cable is not pinched by the fan cover.
FAN COVER
ENGINE STOP SWITCH LEAD
The engine stop switch wire must be secured by the cable clip.
Secure the ground terminal in the position shown with the5 x 8 mm washer-screw.
Verify that the engine stop switch cable is not pinched by the fan cover.
CABLE D CLIP
gc160_gcaha_3721673_forward
1.
INS
PE
CT
ION
•P
IST
ON
RIN
G W
IDT
H
•P
IST
ON
RIN
G S
IDE
CL
EA
RA
NC
E
•P
IST
ON
RIN
G E
ND
GA
P S
tandard
Serv
ice lim
it
To
p r
ing
(GC
160LA
)0.9
3 ~
0.9
5 m
m(0
.036 ~
0.0
37 in)
0.9
1 m
m(0
.035 in)
To
p r
ing
(GC
/GS
190LA
)0.9
5 ~
0.9
7 m
m(0
.037 ~
0.0
38 in)
0.9
3 m
m(0
.036 in)
Second r
ing
0.9
7 ~
0.9
9 m
m0.0
38 ~
0.0
39 in)
0.9
5 m
m(0
.037 in)
Sta
ndard
Serv
ice lim
it
To
p r
ing
(GC
160LA
)0.0
55 ~
0.0
89 m
m(0
.002 ~
0.0
04 in)
0.1
50 m
m(0
.006 in)
To
p r
ing
(GC
/GS
190LA
)0.0
35 ~
0.0
69 m
m(0
.001 ~
0.0
03 in)
0.1
50 m
m(0
.006 in)
Second r
ing
0.0
15 ~
0.0
49 m
m(0
.0006 ~
0.0
019 in)
0.1
50
mm
(0.0
06 in)
Sta
ndard
Serv
ice lim
it
To
p r
ing
0.2
0 ~
0.3
5 m
m(0
.008 ~
0.0
14 in)
1.0
0 m
m(0
.040 in)
Second r
ing
0.3
5 ~
0.5
0 m
m(0
.014 ~
0.0
20 in)
1.0
0 m
m(0
.040 in)
Oil
ring
0.2
0 ~
0.7
0 m
m(0
.008 ~
0.0
30 in)
1.0
0 m
m(0
.040 in)
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GC160 • GC190 • GS190 2. SERVICE INFORMATION
1. TROUBLESHOOTINGOIL ALERT® SYSTEM
NOTICE
Never start the engine when the oil has been drained.
Engine does not start with the engine switch ON.
Check the oil level before proceeding. Add the recommended engine oil if necessary.
1. TROUBLESHOOTING .......................... 2-1
Perform the spark test (P. 2-11 of the baseshop manual).
Sparks Refer to HARD STARTING (P. 2-8 of the base shop manual).
Disconnect the oil level switch yellow lead from the Oil Alert unit yellow/red lead. Perform the spark test (P. 2-11 of the base shop manual).
Sparks Faulty oil level switch. Replace the oil level switch (P. 8-12 of the base shop manual).
Proceed to next page.
No spark
OILALERT®UNIT
YELLOWLEAD
YELLOW/REDLEAD
No spark
gc160_gcaha_3721673_forward
GC
160
• G
C190 •
GS
190
Dis
co
nn
ect
the
Oil
Ale
rt u
nit b
lack/r
ed
le
ad
fro
m
the e
ngin
e s
witch b
lack lead.
Perf
orm
the s
park
te
st
(P.
2-1
1 o
f th
e b
ase s
hop m
anual).
Spa
rks
Oil
Ale
rt u
nit f
au
lty.
Re
pla
ce
th
e O
il A
lert
un
it(P
. 8
-1).
Dis
co
nn
ect th
e e
ng
ine
sto
p s
witch
bla
ck le
ad
fro
m
the ignitio
n c
oil.
Perf
orm
th
e s
park
te
st
(P.
2-1
1 o
f th
e b
ase s
hop m
anual).
Spark
sF
au
lty e
ngin
e s
top s
witch o
r sto
p s
witch lead.
Re
pla
ce
th
e e
ng
ine
sto
p s
witch
(P.
6-8
of
the
b
ase
sh
op
ma
nu
al) o
r sto
p s
witch
le
ad
(P. 7
-1).
Se
e I
GN
ITIO
N S
YS
TE
M t
rou
ble
sh
oo
tin
g (
P.
2-1
1
of
the b
ase s
hop m
anual).
OIL
AL
ER
T
UN
IT
OIL
AL
ER
T
UN
ITB
LA
CK
/R
ED
LE
AD
OIL
AL
ER
T
UN
ITB
LA
CK
LE
AD
No s
park
EN
GIN
ES
TO
P
SW
ITC
HB
LA
CK
LE
AD
IGN
ITIO
N C
OIL
No
spa
rk
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7. FLYWHEEL/IGNITION COILGC160 • GC190 • GS190
1. FLYWHEEL/IGNITION COILCAST IRON FLYWHEEL TYPE
1. Remove the recoil starter (P. 5-1 of base shop manual) and fan cover (P. 6-7 of base shop manual).
2. Remove the fan cover stud (dark gray), the 6 x 23 mm flange bolt, and the ignition coil.
3. Remove the 14 mm special nut, starter pulley, screen grid, and the cooling fan.
4. Remove the flywheel.
1. FLYWHEEL/IGNITION COIL.................7-1
CAST IRON FLYWHEEL
REMOVAL: P. 7-2 of the base shop manual.
• Do not hit the flywheel with a hammer.
• Remove using a six inch two jaw puller (commercially available).
• Avoid the magnet section when attaching the puller.
INSTALLATION: P. 7-3 of the base shop manual.
• Make sure there are no metal objects stuck to the magnets.
• Adjust the ignition coil air gap after reassembly (P. 7-2).
14 mm SPECIAL NUT
REMOVAL: P. 7-2 of the base shop manual.
INSTALLATION: P. 7-3 of the base shop manual.
TORQUE: 75 ~ 85 N•m (55 ~ 63 ft-lb)
FAN COVER STUD (DARK GRAY)
12 N•m (9 ft-lb)
FAN COVER STUD, SILVER (2)
12 N•m (9 ft-lb)
IGNITION COIL
INSPECTION: P. 7-2
ADJUSTMENT: P. 7-2
SCREEN GRID (applicable types)
INSTALLATION: Align the tab with the cutout in the starter pulley.
COOLING FAN
• Align the four cooling fan bottom lugs with the four flywheel holes.
• Align the three top lugs with the starter pulley holes.
ENGINE STOP LEAD
ROUTING: P. 1-2
STARTER PULLEY
REMOVAL: It is not necessary to remove the starter pulley from the cooling fan during removal.
CUTOUT
HOLE (3)
LUG (3)
HOLE (4)
6 x 23 FLANGE BOLT)
12 N•m (9 ft-lb)
6 x 12 mm FLANGE BOLT
LUG (4)
Align with the holes in the flywheel.
WIRE CLAMP(OIL ALERT TYPES)
STOP SWITCH WIRE CLAMP
6 x 12 mm FLANGE BOLT
ENGINE STOP LEAD (OIL ALERT TYPES)
ROUTING: P. 1-3
TAB
Align with the cutout in the starter pulley.
gc160_gcaha_3721673_forward
GC160 • GC190 • GS190
INSPECTION
Transistorized Ignition Coil
Cast Iron Flywheel Type
Primary Side
Measure the resistance of the primary coil by
attaching one ohmmeter lead to the ignition coil's
primary terminal while touching the other test
lead to the iron core.
Secondary Side
Measure the resistance of the secondary side of
the coil by removing the spark plug cap and
attaching one lead of the ohmmeter to the spark
plug wire (high tension lead) and the other test
lead to the iron core.
If the resistance is not within specification,
replace the ignition coil.
ADJUSTMENT
Ignition Coil Air Gap
Cast Iron Flywheel Type
Adjustment is required only when the ignition coil
or the flywheel has been removed.
1. Loosen the ignition coil bolts.
2. Insert a long feeler gauge of the proper
thickness between two legs of the coil
assembly.
• Avoid the flywheel magnet.
• Both gaps must be adjusted simultaneously.
3. Push the coil assembly firmly toward the
flywheel and tighten the bolts.
Primary Side
Resistance0.68 ~ 0.84
Secondary Side
Resistance5.6 ~ 6.9 k
Specified clearance0.2 ~ 0.5 mm
(0.008 ~ 0.020 in)
PRIMARY SIDE
SECONDARY SIDE
0.2 ~ 0.5 mm(0.008 ~ 0.020 in)
FLYWHEEL
FEELERGAUGE
gc160_gcaha_3721673_forward
8. CAM PULLEY/CRANKSHAFT/PISTON/CYLINDER BARREL GC160 • GC190 • GS190
1. CRANKCASE COVER/CRANKSHAFT/CYLINDER BARREL
a. REMOVAL/INSTALLATION
Oil Alert Unit Type
Remove the cam pulley and rocker arm (P. 8-1 of the base shop manual).
1. CRANKCASE COVER/CRANKSHAFT/CYLINDER BARREL .......................................... 8-1
CYLINDER BARREL
INSPECTION: P. 8-16of the base shop manual
INSTALLATION: P. 8-6of the base shop manual
6 x12 mm FLANGE BOLT
CONNECTING ROD CAP
INSTALLATION: P. 8-5of the base shop manual
CRANKSHAFT
INSPECTION: P. 8-16of the base shop manual
INSTALLATION: Be carefulnot to damage the oil seal.After installation, clean the crankshaft tapered surface.
THRUST WASHER
INSTALLATION: P. 8-6of the base shop manual
CRANKCASE COVER
DISASSEMBLY/REASSEMBLY: P. 8-11of the base shop manual
INSPECTION: P. 8-20of the base shop manualREMOVAL: P. 8-20of the base shop manual
6 x 25 mm FLANGE BOLT (8)
INSTALLATION: P. 8-5of the base shop manual
TORQUE: 12 N•m (9 ft-lb)
PISTON ASSEMBLY
DISASSEMBLY/REASSEMBLY: P. 8-7of the base shop manual
INSPECTION: P. 8-16 and 17of the base shop manualINSTALLATION: P. 8-5of the base shop manual
OIL ALERT UNIT
TROUBLESHOOTING:P. 2-1
OIL DRAIN BOLT
24 N•m (17 ft-lb)
CONNECTING ROD BOLT (2)
12 N•m (9 ft-lb)
gc160_gcaha_3721673_forward
gc160_
gcaha_
3721673_
forw
ard
If t
he c
ylin
der
I.D
. is
worn
beyond t
he s
erv
ice lim
it,
the
cylin
der
barr
el m
ust
be r
epla
ced.
Do n
ot
hone t
he c
ylin
der
•P
IST
ON
RIN
G W
IDT
H
•P
IST
ON
RIN
G S
IDE
CL
EA
RA
NC
E
•P
IST
ON
RIN
G E
ND
GA
P S
tandard
Serv
ice lim
it
To
p r
ing
(GC
160LA
)0.9
3 ~
0.9
5 m
m(0
.036 ~
0.0
37 in)
0.9
1 m
m(0
.035 in)
To
p r
ing
(GC
/GS
190LA
)0.9
5 ~
0.9
7 m
m(0
.037 ~
0.0
38 in)
0.9
3 m
m(0
.036 in)
Second r
ing
0.9
7 ~
0.9
9 m
m0.0
38 ~
0.0
39 in)
0.9
5 m
m(0
.037 in)
Sta
ndard
Serv
ice lim
it
To
p r
ing
(GC
160LA
)0.0
55 ~
0.0
89 m
m(0
.002 ~
0.0
04 in)
0.1
50 m
m(0
.006 in)
To
p r
ing
(GC
/GS
190LA
)0.0
35 ~
0.0
69 m
m(0
.001 ~
0.0
03 in)
0.1
50 m
m(0
.006 in)
Second r
ing
0.0
15 ~
0.0
49 m
m(0
.0006 ~
0.0
019 in)
0.1
50
mm
(0.0
06 in)
Sta
ndard
Serv
ice lim
it
To
p r
ing
0.2
0 ~
0.3
5 m
m(0
.008 ~
0.0
14 in)
1.0
0 m
m(0
.040 in)
Second r
ing
0.3
5 ~
0.5
0 m
m(0
.014 ~
0.0
20 in)
1.0
0 m
m(0
.040 in)
Oil
ring
0.2
0 ~
0.7
0 m
m(0
.008 ~
0.0
30 in)
1.0
0 m
m(0
.040 in)
gc160_
gcaha_
3721673_
forw
ard
Do n
ot
hone t
he c
ylin
der
when insta
lling n
ew
pis
ton r
ings.
GC
160
GC
190 •
GS
190
6.
FU
EL
SY
ST
EM
1.
FU
EL
TA
NK
CA
P
EV
AP
OR
AT
IVE
EM
ISS
ION
CO
NT
RO
L S
YS
TE
M
Th
ese
en
gin
es h
ave
an
EV
AP
OR
AT
IVE
EM
ISS
ION
CO
NT
RO
L C
AN
IST
ER
built
into
th
e f
uel ta
nk c
ap t
o p
revent
the
esca
pe
of
ga
so
line
va
po
rs in
to t
he
atm
osp
he
re.
PR
INC
IPL
E
CH
AR
GIN
G:
Gasolin
e v
apor
pro
duced in t
he f
ue
l ta
nk a
t h
igh
am
bie
nt
tem
pera
ture
is a
bsorb
ed
and
sto
red b
y the
cha
rcoal in
the
ca
nis
ter,
wh
ich
is b
uilt
in
to t
he
fu
el ta
nk c
ap
.
PU
RG
ING
:
When t
he p
ressure
in t
he f
uel ta
nk d
ecre
ase
s b
eca
use
of
low
am
bie
nt
tem
pe
ratu
re o
r co
nsu
mp
tio
n o
f g
aso
line
, th
e a
ir d
raw
n
thro
ugh t
he c
anis
ter
rele
ase
s t
he
sto
red g
asolin
e v
ap
or
from
the
charc
oal. T
he r
ele
ased g
asolin
e v
ap
or
retu
rns t
o t
he
fu
el ta
nk.
1.
FU
EL
TA
NK
CA
P..
....
....
....
....
....
....
....
....
.. 6
-1
gc160_
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