Troubleshoot GCV160-A1AE

S

snapper re200

Member
2003 Craftsman push mower with Honda GCV160 -A1AE engine.
After several years of storage w/proper prep, got it out May 2025. Ran rough. Cleaned carb, then ran fine. Ran dry, did seasonal maint/stored again.
Got the mower back out this week: started first pull, ran fine, but stopped after 5sec.
Decided to install new OEM carb 16100-Z0L-023 from Partzilla.
Starts first pull, runs fine, stops after approx 23 sec every time.
Troubleshooting performed:
  • Note: manual choke engine -not auto choke issue.
  • Verified good flow from tank to carb. Steady stream that would certainly exceed consumption.
  • Tank outlet screen appeared OK
  • Verified float/needle not sticking. Also tapped bowl while running/still 23sec run.
  • Pulled main jet, verified clear then sprayed w/carb cleaner.
  • Restarts after stop (not ignition coil issue).
  • Verified not a tank vent issue -still runs only 23sec w/tank cap removed.
I'm at a loss. I assume it's running until float bowl empties/fuel supply issue.
Any help troubleshooting appreciated!
Thanks for your time.
 
Pull the kill wire off the coil and see if it keeps running. If it does, you’ve eliminated carburetor, coil, timing, and spark plug as issues. Only thing left would be finding out why it is grounding out.
 
ILENGINE said:
This is going to sound doubt in some ways but I suggest you replace the spark plug. Spark plugs on Honda engines tend to do weird things including the symptom that you are having.
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Amen about Honda plugs. Have to tell this story. Please forgive me. I had a good friend who had many talents but he was the opposite of a MacGyver. Completely ignorant of all things mechanical. I had just bought a Honda, the first one I ever worked on. Got it for $20 because it would start and stop and sometimes not start at all. I love a good mystery, so did all the normal stuff and would tell him about it as we walked to our cars after work. Each time he’d say, “Change the spark plug.” I kept telling him that it is never the plug, almost always the carburetor. When I eventually replaced the plug and that cured it, I confessed that he had been right all along. And as any good friend would do, he never ever let me forget it.
 
If it says TORCH on it, let's see, okay, put it in your neighbors mailbox. Clean it up nice so they think it's new. Tell them you had some extra good plugs laying around. LOL :p
 
Oddjob said:
Amen about Honda plugs. Have to tell this story. Please forgive me. I had a good friend who had many talents but he was the opposite of a MacGyver. Completely ignorant of all things mechanical. I had just bought a Honda, the first one I ever worked on. Got it for $20 because it would start and stop and sometimes not start at all. I love a good mystery, so did all the normal stuff and would tell him about it as we walked to our cars after work. Each time he’d say, “Change the spark plug.” I kept telling him that it is never the plug, almost always the carburetor. When I eventually replaced the plug and that cured it, I confessed that he had been right all along. And as any good friend would do, he never ever let me forget it.
Click to expand...
My first experience with this issue was a push mower that run about 5 minutes, and then would die like running out of gas. Drain the carb, and it would start and run another 5 minutes. Repeated a few times, and thought something else is going on, and decided to replace the plug and it started and run until it ran out of gas. My own pressure washer with a GX340 was running and backfired and died. You could crank it and all it would do is backrire once. Replaced the plug and went back to pressure washer. Have worked on several Honda ATV's over the years that wouldn't start, and if you remove the plug and reinstalled it in the spark plug wire, and grounded the plug the plug would fire from the center electrode to the side of the plug, and never spark to the side electrode sitting directly over the center electrode. Replace the plug and would start and run as normal.
 
ILENGINE said:
My first experience with this issue was a push mower that run about 5 minutes, and then would die like running out of gas. Drain the carb, and it would start and run another 5 minutes. Repeated a few times, and thought something else is going on, and decided to replace the plug and it started and run until it ran out of gas. My own pressure washer with a GX340 was running and backfired and died. You could crank it and all it would do is backrire once. Replaced the plug and went back to pressure washer. Have worked on several Honda ATV's over the years that wouldn't start, and if you remove the plug and reinstalled it in the spark plug wire, and grounded the plug the plug would fire from the center electrode to the side of the plug, and never spark to the side electrode sitting directly over the center electrode. Replace the plug and would start and run as normal.
Click to expand...
Honda plugs are physically bigger than most. I always suspected that their ignition systems put out bigger and fatter sparks and this was the reason they started so easily but when I experienced failed plugs I wondered if the stronger current could also be the reason the plugs went bad. Total speculation on my part, I know. Does anyone know if Honda ignitions generate more current than other brands?
 
Oddjob said:
Does anyone know if Honda ignitions generate more current than other brands?
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I have a Honda GXV160. Forgot if I spark jump tested it or not.

Had two older Briggs on Snapper pushers that would barely jump the plug gap in free air, out of the engine. Below is how they jumped with new coils. Also another cheap Chinese coil jumps the same as the Stens. Bet if I had resistor plugs they would not have started. Reason why I preach about open gap style testers. Gotta stress that coil out.

1776980449776.jpeg
 
ILENGINE said:
This is going to sound doubt in some ways but I suggest you replace the spark plug. Spark plugs on Honda engines tend to do weird things including the symptom that you are having.
Click to expand...
ILENGINE -YOU DA MAN!
Went to O'Reilly Auto Parts and got a new NGK BPR6ES P/N 4008.
Started first pull.....AND NOW KEEPS RUNNING.
With the mower dying at 23sec like clockwork, would have never considered the plug being the problem!.
Good for another 23yrs -and guess I have a spare/used carb now LOL.
THANKS.
 
snapper re200 said:
2003 Craftsman push mower with Honda GCV160 -A1AE engine.
After several years of storage w/proper prep, got it out May 2025. Ran rough. Cleaned carb, then ran fine. Ran dry, did seasonal maint/stored again.
Got the mower back out this week: started first pull, ran fine, but stopped after 5sec.
Decided to install new OEM carb 16100-Z0L-023 from Partzilla.
Starts first pull, runs fine, stops after approx 23 sec every time.
Troubleshooting performed:
  • Note: manual choke engine -not auto choke issue.
  • Verified good flow from tank to carb. Steady stream that would certainly exceed consumption.
  • Tank outlet screen appeared OK
  • Verified float/needle not sticking. Also tapped bowl while running/still 23sec run.
  • Pulled main jet, verified clear then sprayed w/carb cleaner.
  • Restarts after stop (not ignition coil issue).
  • Verified not a tank vent issue -still runs only 23sec w/tank cap removed.
I'm at a loss. I assume it's running until float bowl empties/fuel supply issue.
Any help troubleshooting appreciated!
Thanks for your time.
Click to expand...
in a case like that, I would drain the tank and carb bowl, use only new fresh fuel. If there is a drain on the bowl, I would put a pan under it then loosed in it and see if fuel keeps flowing out the bowl for about 30 seconds to be sure that the flow is sustained. If it will not start right away after 23 seconds, they I would put a spark tester on the plug and have it ready to go to see if one still has spark. On GP I would replace the spark plug with a good brand one from a local auto parts store or mower shop and not from online. Lots of counterfeits out there.
 
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