BULLETIN DE SERVICE YEAR/MODEL ANNÉE/MODÈLE DATE OF ISSUE DATE EN VIGUEUR BULLETIN NUMBER NUMÉRO DU BULLETIN GCV160LA0S3T GCV160LA0S3TE FEB. 8, 2013 ENGINE #12 SERVICE BULLETIN "File Under Engine" GCV160LA0S3T GCV160LA0S3TE ENGINE WON T RESTART SYMPTOM The engine may not restart after being shut off before the engine has been properly warmed up. The engine may sputter at low RPM for a few seconds and stall, and cannot be restarted until it has rested for a few minutes. The engine may not restart if the engine has not been properly warmed up. The symptom is most likely to occur if the engine is started and only allowed to run for a brief time (usually less than one minute) before being shut off. However, this also can occur after the engine partially cools from normal operating temperatures. The symptom can occur when the engine is slightly warm, but the choke plate is still in the fully closed position because the auto-choke thermo-wax motor senses the engine is still cold. AFFECTED UNITS GCV160LA0S3T GJARA - 3180269 ~ 3540037 GCV160LA0S3TE GJAPA 1687182 ~ 1887895 CORRECTIVE ACTION There are a variety of factors that may result in an improper heat transfer to the Auto Choke System thermo-wax which may reduce choke system performance. In some cases, a sticking auto-choke control may also contribute to the symptom. In-Service Units Repair affected units with the described symptom by following the Repair Procedure on page 2. 2013 Honda Canada Inc. All Rights Reserved Page 1 of 7
REPAIR PROCEDURE The main steps in the procedure are: Replace the thermo-wax with an improved slightly longer version. Apply Hondabond HT sealant to the thermo-wax assembly to improve heat transfer. Inspect the Auto Choke System control assembly for binding and replace if necessary. Install a temperature regulator bracket on the cylinder barrel to help the thermo-wax heat up faster. Important: Allow the engine to cool for at least an hour before beginning the repair. Installing the choke components on a hot engine may result in choke binding or improper choke function. Replace thermo-wax and apply Hondabond HT 1. Turn the fuel valve OFF and drain the fuel from the carburetor float chamber into an approved container. 2. Remove the air cleaner cover and air cleaner element. 3. Completely loosen the two 6 x 85 mm bolts holding the air cleaner case, but don t remove. 4. Disconnect the crankcase breather tube while holding the bolts in place and then pull the air cleaner case, carburetor, air guide gasket, and auto choke control assembly as a unit away from the engine. 5. Remove the existing thermo-wax from the cylinder barrel. Page 2 of 7
6. Prepare the new thermo-wax for installation. Apply a small amount of Hondabond HT to the lower one-third and bottom of the new thermowax as shown. Do not apply too much. Hondabond HT: PN 08718-0004 Hondabond HT application area; sides and end 7. Insert the new thermo-wax into the cylinder barrel. Push it into the cavity until fully seated. The Hondabond HT should fill the gap between the cylinder barrel and thermo-wax. Remove any excess Hondabond HT that builds up around the thermo-wax. 8. Remove the auto-choke assembly and insulator gasket from the two 6 x 85 mm bolts. 9. Check the auto-choke control assembly for binding. Thread a flange nut onto an 8 x 20 mm or longer flange bolt until 12 mm of threads are exposed beyond the nut. Page 3 of 7
Position the end of the bolt against the autochoke plunger and slowly push it until the flange nut seats and slowly release. Do this slowly several times and make sure the choke control operates smoothly and springs back when released. If any binding exists, the auto choke assembly must be replaced. 10. Inspect the air guide and insulator gaskets. Replace any gasket that appears damaged. 11. Install the auto-choke control assembly onto the 6 x 85 mm flange bolts. 12. Install the insulator gasket in the direction shown. Be sure the gasket opening aligns with the intake port. 13. Pick up the assembled air cleaner case, carburetor, and auto choke assembly as a unit. Install it to the cylinder barrel by aligning the two 6 x 85 mm flange bolts with their mounting holes. Loosely install the bolts. Page 4 of 7
14. Install the crankcase breather tube with the paint mark even with the breather chamber cover. 15. Tighten the two 6 x 85 mm flange bolts evenly in multiple steps to the proper torque. TORQUE: 89 in lb (10 N m) 16. After tightening the bolts, push on the choke control tab to open the choke and release it to confirm the choke opens smoothly and springs closed when released. 17. Push the governor arm to the left and release to confirm the governor operates smoothly. If either component binds, remove and recheck the installation. 18. Install the air filter and air cleaner cover. Page 5 of 7
Install a temperature regulator bracket 1. Remove the three 6 mm flange nuts and the recoil starter. 2. If there is gasoline in the fuel tank, drain into an approved container. Do not tilt the fan cover with fuel in the tank. Saturating the charcoal cap will prevent the cap from venting properly. 3. Position the fan cover to the rear of the engine. 4. Place the temperature regulator bracket on the cylinder barrel as shown, making sure the bracket is positioned over the aluminum fin. 5. Install the 6 x 14 mm self-taping flange bolt making sure it is straight during installation. Tighten the bolt to the proper torque. TORQUE: 106 ~ 133 in lb (12 ~15 N m) 6. Reinstall the fan cover and recoil starter and tighten the 6 mm flange nuts to the proper torque. TORQUE: 75 in lb (8.5 N m) Check operation 1. Turn the fuel valve ON and check for leaks. 2. Start the engine and allow it to run for several minutes until it reaches normal operating temperature. The choke should fully open within 2 minutes. 3. Adjust the maximum engine speed if necessary. Engine speed: 2950 ~ 3100 RPM If adjustment is necessary, bend the governor spring tab on the throttle control plate very slightly. Bending left - increases spring tension and raises engine speed Bending right - decrease spring tension and lowers engine speed. 4. Allow the engine to cool completely. 5. Start the engine and let it run for exactly 45 seconds. 6. Stop the engine and allow it to cool for exactly 15 seconds. 7. Restart the engine to make sure the symptom does not recur. Page 6 of 7
PARTS INFORMATION Part Number Description Qty 06166-Z8D-305 Thermo-wax Kit 1. 08718-0004 Hondabond HT 1* 16600-Z8D-840 Choke control assembly 1** * One tube of Hondabond HT provides enough silicone to repair a large number of engines. ** Order only if choke control assembly is sticking. Most units will not require the choke control assembly. Thermo-wax kit contents Description Qty Thermo-wax assembly 1 Regulator bracket 1 6 x 14 mm Bolt 1 WARRANTY INFORMATION The normal warranty applies. Open a Quick Claim for Canadian engines, and a Long Claim for non-canadian engines. Be sure your claim contains the following information. Failed Part Number: 16620-Z8D-841 Labour Operation Number 311150 Description Install thermo-wax assembly and regulator bracket Flat Rate Time 0.5 Defect Code 04900 Symptom Code 09303 Note: Claims can only be submitted for units that exhibit the symptom and require repair. Do not submit a warranty claim if you only performed the new unit restarting procedure and did not repair the unit. The 1- minute restarting test is considered part of normal pre-delivery inspection. Page 7 of 7