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Honda Lawn Mower, GCV 160 engine

#1

U

ukpat714

I have a Honda lawnmower with a GCV160 engine that is 3-4 years old. My son borrowed the mower and after he was finished cleaned grass from underneath of the deck. In the process, gas spilled out and when he brought it back it would not start. Previously, it started on the first pull every time. I called a local repair shop who said to let the lawnmower sit for 2-3 days to dry out. Also, remove spark plug and air filter so they can dry out plus after spark plug is removed pull start rope 5-6 times to blow out any dirt in spark plug cavity. I let the mower sit but before I tried to start it I removed the air filter and carburetor to make sure it was dry too. When I re-assembled everything the engine was sputtering and black smoke coming out of the muffler. The engine continued to run however so I mowed the grass for about 45 minutes, stopping a few times to empty the grass catcher and restart the engine. The engine continued to sputter but run. The next day I took the carburetor off again and put it back on (with the metal arm forward) thinking I didn't assemble it properly the first time. This time the gas leaked out almost immediately after I opened the gas supply line. I removed the carburetor a couple of other times with the same result. Is their a simple fix for this or should I take it to the repair shop and cut my losses?
Thanks!
Pat


#2

lawn mower fanatic

lawn mower fanatic

ukpat714 said:
I have a Honda lawnmower with a GCV160 engine that is 3-4 years old. My son borrowed the mower and after he was finished cleaned grass from underneath of the deck. In the process, gas spilled out and when he brought it back it would not start. Previously, it started on the first pull every time. I called a local repair shop who said to let the lawnmower sit for 2-3 days to dry out. Also, remove spark plug and air filter so they can dry out plus after spark plug is removed pull start rope 5-6 times to blow out any dirt in spark plug cavity. I let the mower sit but before I tried to start it I removed the air filter and carburetor to make sure it was dry too. When I re-assembled everything the engine was sputtering and black smoke coming out of the muffler. The engine continued to run however so I mowed the grass for about 45 minutes, stopping a few times to empty the grass catcher and restart the engine. The engine continued to sputter but run. The next day I took the carburetor off again and put it back on (with the metal arm forward) thinking I didn't assemble it properly the first time. This time the gas leaked out almost immediately after I opened the gas supply line. I removed the carburetor a couple of other times with the same result. Is their a simple fix for this or should I take it to the repair shop and cut my losses?
Thanks!
Pat
Click to expand...

I can't help you with the mechanical part, but which way did your son tip the mower? You should always tip it so the air filter is up and the muffler is down.


#3

Lawnboy18

Lawnboy18

Check the order of the gaskets. The Honda GCV160 has MANY gaskets for the carb and they have to be place correctly otherwise the mower won't run right! I can give you the order if you want!


#4

U

ukpat714

lawn mower fanatic said:
I can't help you with the mechanical part, but which way did your son tip the mower? You should always tip it so the air filter is up and the muffler is down.
Click to expand...


Thanks, I knew that but unfortunately he didn't. He needs to read the owner's manual and buy his own mower. :):rolleyes:


#5

U

ukpat714

Lawnboy18 said:
Check the order of the gaskets. The Honda GCV160 has MANY gaskets for the carb and they have to be place correctly otherwise the mower won't run right! I can give you the order if you want!
Click to expand...

Yes, please do. I'm open to any suggestion as long as it's not too complicated. I have no experience with repairing lawn mowers other than changing oil and spark plug.

Thanks!


#6

robert@honda

robert@honda

ukpat714 said:
Yes, please do. I'm open to any suggestion as long as it's not too complicated. I have no experience with repairing lawn mowers other than changing oil and spark plug.

Thanks!
Click to expand...

On the back of the mower deck is the model and serial number; get me those, and I'll post some information that will show you how to get it all back together correctly. There are many idfferent versions of that engine, so let's get the serial numbers to know exactly what you've got:

lmserialnumber_zps63822669.jpg


#7

U

ukpat714

robert@honda said:
On the back of the mower deck is the model and serial number; get me those, and I'll post some information that will show you how to get it all back together correctly. There are many idfferent versions of that engine, so let's get the serial numbers to know exactly what you've got:

lmserialnumber_zps63822669.jpg
Click to expand...

Model No. 96144000500

Serial No. 011910M004648

thanks!


#8

S

shadeytree

If gas is running out as soon as you turn on the fuel cutoff to the on position, the float in the carburetor is not pushing the pin up into the orifice properly. Either the pin is not set properly into the top of the float, the rubber tip on the pin is damaged or has trash in it, or the float is not floating.

My guess is; when your son tilted the mower it disturbed the trash that had accumulate in the carburetor bowl over the years, and now it is clogging a port inside the carburetor.


#9

robert@honda

robert@honda

ukpat714 said:
Model No. 96144000500

Serial No. 011910M004648

thanks!
Click to expand...

Those are not Honda model or serial numbers; that 96144.... number comes up a Poulan brand mower, and probably just has a Honda engine.

So, I can still help, but need the serial number off the SIDE Of the ENGINE BLOCK. It is in the form of "GXXXX-1234567" (for or five letters, a dash, and 7 numbers). Get me that I can match up the correct carburetor/gaskets you'll need.


#10

Lawnboy18

Lawnboy18

ukpat714 said:
Yes, please do. I'm open to any suggestion as long as it's not too complicated. I have no experience with repairing lawn mowers other than changing oil and spark plug.

Thanks!
Click to expand...

Here is a link to the gasket order : Honda GCV160 Parts List and Diagram - (Type A2R)(VIN# GJAE-1000001-9999999) : eReplacementParts.com

To make sure they are in the right order, remove your air filter by unclipping the two clips on top. Then remove the cover, pull out the filter. After that, take a 10 mm wrench and unscrew the two bolts. They are very long and they hold the carb and all the gaskets. So, simply unscrew them, but DON'T pull them out. Once they are unscrewed, pull on the airbox while pushing in the bolts to make sure they hold the carb and gaskets. Once that is out, check the gasket order.

I hope my crappy explanations will help you out. I am not too good explaining with a key board...

If you manage to do all of this and you want to open up the carb, let me know and I will further assist you!


#11

U

ukpat714

robert@honda said:
Those are not Honda model or serial numbers; that 96144.... number comes up a Poulan brand mower, and probably just has a Honda engine.

So, I can still help, but need the serial number off the SIDE Of the ENGINE BLOCK. It is in the form of "GXXXX-1234567" (for or five letters, a dash, and 7 numbers). Get me that I can match up the correct carburetor/gaskets you'll need.
Click to expand...

The mower is a "Black Max" model I purchased at Sam's with the Honda engine. Below are the numbers off the engine block:

GJARA 1185153

GCV160LA0 S3A T89

Thanks again!


#12

U

ukpat714

shadeytree said:
If gas is running out as soon as you turn on the fuel cutoff to the on position, the float in the carburetor is not pushing the pin up into the orifice properly. Either the pin is not set properly into the top of the float, the rubber tip on the pin is damaged or has trash in it, or the float is not floating.

My guess is; when your son tilted the mower it disturbed the trash that had accumulate in the carburetor bowl over the years, and now it is clogging a port inside the carburetor.
Click to expand...

I took the carb off originally because the engine was sputtering constantly. It ran (somewhat) so I was able to mow most of the yard, but it had the same sputtering pattern (run full, sputter and act like it was going to die and then repeat the cycle). The yard normally takes less than 1 tank full of gas to mow and this time it took almost 2.5 tank fulls to mow the yard. That is why I took the carb off to see if there was some other problem. I tried to reinstall the gaskets in the same order, but I may have missed something. As I stated earlier, I'm a novice at repairing a lawn mower engine.

thanks!


#13

U

ukpat714

Lawnboy18 said:
Here is a link to the gasket order : Honda GCV160 Parts List and Diagram - (Type A2R)(VIN# GJAE-1000001-9999999) : eReplacementParts.com

To make sure they are in the right order, remove your air filter by unclipping the two clips on top. Then remove the cover, pull out the filter. After that, take a 10 mm wrench and unscrew the two bolts. They are very long and they hold the carb and all the gaskets. So, simply unscrew them, but DON'T pull them out. Once they are unscrewed, pull on the airbox while pushing in the bolts to make sure they hold the carb and gaskets. Once that is out, check the gasket order.

I hope my crappy explanations will help you out. I am not too good explaining with a key board...

If you manage to do all of this and you want to open up the carb, let me know and I will further assist you!
Click to expand...

I'm hesitant about opening the carb and trying to repair it since I don't want to create a worse problem than I already have. :laughing: I'll let you know if I decide to do so!

Thanks!


#14

robert@honda

robert@honda

ukpat714 said:
The mower is a "Black Max" model I purchased at Sam's with the Honda engine.
Click to expand...

Okay, a whole new carburetor is only $13.34, Honda Part Number 16100-Z0L-852.

I'd replace the two gaskets at the same time, number 11 and 13:

GCV160CARBforblackmax_zps825e9d35.jpg


#15

Lawnboy18

Lawnboy18

#26 also!!! It is a paper one! It has been replaced with a better one!


#16

U

ukpat714

robert@honda said:
Okay, a whole new carburetor is only $13.34, Honda Part Number 16100-Z0L-852.

I'd replace the two gaskets at the same time, number 11 and 13:

GCV160CARBforblackmax_zps825e9d35.jpg
Click to expand...

Thanks for the info. I'll check the existing gaskets and see if they're installed correctly. If they are installed per the diagram then I'll order another carb.


#17

U

ukpat714

Lawnboy18 said:
#26 also!!! It is a paper one! It has been replaced with a better one!
Click to expand...

Right, it makes sense to replace all gaskets since they are cheap. Thanks!


#18

U

ukpat714

ukpat714 said:
I took the carb off originally because the engine was sputtering constantly. It ran (somewhat) so I was able to mow most of the yard, but it had the same sputtering pattern (run full, sputter and act like it was going to die and then repeat the cycle). The yard normally takes less than 1 tank full of gas to mow and this time it took almost 2.5 tank fulls to mow the yard. That is why I took the carb off to see if there was some other problem. I tried to reinstall the gaskets in the same order, but I may have missed something. As I stated earlier, I'm a novice at repairing a lawn mower engine.

thanks!
Click to expand...

I tried cleaning the carburetor & float with carburetor cleaner, but it still leaked gas. So, I bought a new carburetor and a couple of gaskets that appeared more warn and it did the trick! The mower is running like it did before my son put it on life support! Thanks for your help!


#19

U

ukpat714

ukpat714 said:
Thanks for the info. I'll check the existing gaskets and see if they're installed correctly. If they are installed per the diagram then I'll order another carb.
Click to expand...

I tried cleaning the carburetor & float with carburetor cleaner, but it still leaked gas. So, I bought a new carburetor and a couple of gaskets that appeared more warn and it did the trick! The mower is running like it did before my son put it on life support! Thanks for your help!


#20

lawn mower fanatic

lawn mower fanatic

ukpat714 said:
I tried cleaning the carburetor & float with carburetor cleaner, but it still leaked gas. So, I bought a new carburetor and a couple of gaskets that appeared more warn and it did the trick! The mower is running like it did before my son put it on life support! Thanks for your help!
Click to expand...

Glad you got it fixed! :thumbsup:


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