HONDA GCV520 GCV530 VERTICAL SHAFT Engine Repair Manual

NAVIGATION TIPS GXV520-530_(ALL) 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 rhe proper training, tools, and l'lquipment could cause injury to you and/or others. It could also damage the engine or create an unsafe condition. This manual describes the propar methods and procedures for perforrr.ing 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 r~:~commended by Honda, must determ!ne the risks to their personal safety and the saf~ 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 Safe·ty Because this manual is ~ntended for the professional service technician, we do not provide warnings about many basic shop safety practices (e. g., Hot parts-wear glovesl. If you have not received shop safety training or do not feel confident about your knowledge of s:ofe servicing practices, we recommend that you do not attemptto pE!rforrn the procedures described in this manual. Some of the m~st important general service safety precautions are given below. However, we cannot warn you of every conceivable haz.ard 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 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. --··· ·_) A WARNING Fa i I u re to pro petly fo II ow instructio rJS and precautions can cause you to be seriously hurt or killed. 1 Follow the procedures and precautions in this I L.:~:_~:lUal carefu~ly. • Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate cloth,ng 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 completefy. C Protect your eyes by using proper safety g!asses, goggles, or face shields any time you hammer, drill, grind, or work around pressurized air or liquids, and springs or other store-energy components. If there is any doubt, put on eye protec1ion. [J 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 oft before you begin any servic"mg procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: D Carbon monoxide poisoning frotn engine exhaust. Be sure there is adequate ventilation whenever you run the engine. 0 Burns from hot parts. Let the engine and exhaust system cool before working in those areas. 0 Injury from moving parts. H the instruction tells you to run the engine, be sure your hands, fingers, and clothing <tre out of the W<Jy. • Gasotine vapors are explosive. To reduce the possrbility of a fire or €xp,osion, be careful when working around gasoline. 0 Use only a nonfl-ammable solvent, not gasoline, to clean parts. 0 Never drain or store gasoline in an open container. 0 Keep all cigarettes, sparks, and names away from all fuel-related parts.

open more bookmarks ' -'click to condense the bookmarks RECOIL STARTER/FAN C FLYWHEEL GENERATOR GXV52D-530_(ALL) GREEN BOX UNK$ Click here to go to this page in the manual ... '\ \ &•U!IP!ll

GXV520-530_(ALL) 1. SPECIFICATIONS Model GXV520 GXV530 -- Description code GJAPM GJARM . -- . T ype 4-stroke, over head camshaft, go• V-twin Total displacement 530 em• (32.3 cu-in) -···- . .. - -- B ore and stroke 77 x 57 mm (3.0 x 2.2 in) .. Net power" 9.8 kW (13.1 HP)/3,600 min-1 (rpm) ' 11.3 kW (15.4 HP)/3, 600 min-1 (rpm) ··~---- Max. net torque" 33.2 N·m (3.39 kgf •m, 24.5 lbf•ft)/ 34.2 N•m (3.49 kgf• m, 25.2 lbfoft)/ 2,500 min-1 (rpm) 2,500 min-1 (rpm) -- - ---· --·- -· - Compression ratio 8.0 : 1 ... Fuel consumption 3.2 .t' !h/ 3,000 min-1 (rpm) 3.9 b h/3,000 min-1 (rpm) Cooling system For ced-air Ignition system T ransistorized magneto i gnition Ignition ti ming 20· B.T.D.C. Spark pl ug BPR5ES (NGK), W16EPR-U (DENSO) -- I Carburetor Horizontal type, two barrels, butterfly valve .. . -- I Air cleaner i Dual element type ..... __ . ·· ··---- Lubricating system Forced pressure and forced s plash (dual lubr i cation) or forced splash Oil capacity At disassembly: 1.3 .e (1.37 US qt, 1. 141mp qt) At replace ment of only oil: 0.90 .e (0.95 US qt. 0.79 Imp qt) With o il fi lte r rep l acement: 1.05 .e (1.37 US qt, 1.14 1 mp qt) .. -· ··· Starting sy stem El ect ric st arter and r eco il starte r or electric starte r -- -- St opping system Ign it io n pr imary ci r cuit ground ,_ _ ___ - Fuel used Automotive unleaded gasoline (m i nimum 86 pump octane) - P.T .O . shaft rotation Countercl ockwise (vi ewed f rom P.T.O. si de) --- -- Governor Centrifugal governor * The power rating of the engine indicated in this docu ment 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 tor que). Mass production engi nes may vary from this value. Actual power out put 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.

GXV520-530 _{ALL) DIMENSIONS AND WEIGHTS Mod~ GXV520, GXV530 GXV530 J ··- Type i OXA4, OXA5 _QRA4, ORA5 QEA3 EXA1 ! __.:_:____ . -- .... Overall length 469 mm (18.1 in} 459 mm (18.1 in) 456 mm 118.0 in} 456 mm (18.0 fnl .. · ·- Overall width 462 mm (17.8 in) 452 mm (17.8 in) 427 mm 116.8 in) 427 mm {16.8 fnl -- ···-· ·····- - Overa .. ll he ! gh1 355 mm (14.0 in} 396 mm (15.6 in) 331 mm 113.0 inJ 331 mm {13.0 in) -· . . . ... Dry weight 34.6 kg ( 76.3 lbs) 35.3 kg 177.8 lbs) 32 .3 kg_ 171.2 lbs) 32.1 kg (70.6 lbsl J . .. Operating weight 35.7 kg 08.7 lbs) 36.4 kg (80.2 lbs) '-- 33.4 kg 173.6 lbsJ ~.2 kg (73.0 lbsl I TYPE Of HONDA GXV520, GXV630 ENGINES If may be necessary to refer to this chart for reference purposes when reading this manual. ~ .... __ --- - Model GXV520, GXV530 GXV530 ---------- .. . Item _ --. ~~-- Type OXA4 OXA5 ORA4 QRAS I QEA3 EXA1 i -. Oi l pump and Oil filter. 0 0 0 0 0 0 I . - Fuel pump - - - - 0 0 .. Fuel cut solenoid valve 0 0 0 0 0 0 · -· . Control assembly 21ever 21ever 21evar 2 lever 1 lever 2 lever --- ... . .. Starter motor 0 0 0 0 0 0 .... Recoil starter - - 0 0 - - . -- Charge ~oil 3A 3A JA 3A 18A 12A Regulator/Rectifier - - - - tO> 0 .. .. ·- Rooti fier (0 1 (Q) (Q } (Q ) - - .. .. -··-· Exhaust pi pe With fl ange With flange · With f la nge Wi th f lange 0 - fan cover protector 0 0 - - - - .. . . .. . Dual lubrica1ion 0 0 0 0 - - (Q }: Optional parts

3. PERFORMANCE CURVES GXV520-530 _{ALL) GXV530: (N·m) 36 34 32 30 28 10 9 8 7 6 NET TORQUE (lbf·ft) 26 24 22 20 NET POWER (HP) -t 16 15 14 13 12 11 10 9 2000 2500 3000 3600 ENGINE SPEED (rpm)

GXV520-530_ (ALL) GCV520 · GCV530 -4.-D-IM_E_N-SI_O_N_A_L_D_R_A_W_IN_G_S-------...I ~ {*1]: Starter motor type fl•2.]: Recoil starter ·cype [•3]: Type equipped with fan cover pr otector • Recoil starter type ~ Cii! ...... rD; .... r-J ._... - N ,...; ~~~ ' i 1 ... [*1] 456 (18.01 [*2)459 (18.11 312 {12.31 Unit: mm (in} 144 ~5.4) j_ ___ ~ - r~ ,....., N "' ....... ~~==~~--- --r- ,0 0 ,., .... .... ('I') M .... o· w!2 f"<t ... I~ M M *

171 (6.7) 5. P.T.O. DIMENSIONAL DRAWINGS 6.31 ~I.OG (0.248 :o"' 004 ) 1- lXI Ln N 1.1.. ~ 2 .. ci ::J 1:1 -a- ; - Q ~ N tb ... ... ... - -a- ~ -- - . .... , ~ - - 5 10. 2) 2 8 ~.~ (1.1 ~~D4J 60 ~ 1 (2.4 :o•·U4) - t--·--- ~- -- -- -- I ' _ .. ,.. 79 (3.1} I 4- ~ 9 [ENGINE MOUNT HOlE] ---- i'----- ·- 1--- ~ b) __ l Unit: mm (i n) Unit: mm (i n)

ENGINE SWJYCH CONTI NU ITY Bl EILAc;;K y Y ELLOW Bu BLUE <._;; r.lRI=EN R RED w WHI TE F lll GINE S TO r• DI ODe SPMIK PLUG .'J~_ l IG NI TION CO iL ,-------1 ' 1111111 ' ' rn l3 SPARK PL UG l-.fo.2 IGN II I DN CO IL B liR Gr Gr 15A C HARGE COIL l.'lr 0 Lb Lg p Gr BROWN ORANGE LIGHT BL UE I !GHT GRI=FN PI NK GRAY -- --- - -t~~: ~ ~ = ~E;~xn ~~ ~=~i~ = = = = = = = = ~ · : !liLY _ - - - -1- ;_ - _= ; -: .. L Y/_ ? .Q~q, 'W/8 • •• ·wrs :-- _u _--- i!..J -i.-.~~-: 1-'- ~r • : : _ VoJ. ______ :.-.= ,-:- _ _,.v _,J' _o~~ _______ ]-~'---- -~ ;:_-_=~U _Bl ~- .. ~ 9sq: I REGULATO R[ RE CTIFI I'.R w 2. 0~"--- -~- · ------ vf 1 o ,;; , I - ' Nl I ~.l AI N ~· I F~USE 1 2~,C. I I I ' ::;I l I ~~ I ~~ -~-- t~~>~ R~- ~--- ~-- ~-- -- ~~ - ;- - -~ : 3l1R c:::::J" -·; - 8 Y -I- i-- ·- "'' I ----------:=;~~~ ~~=Ggrr= :;_q_,_, 1 r 1 1 Gr ··~\!.r __ J , ' c ...•• · . -_-_-_-_-_ -_-_ -_- .. -+-~ - -,t,- .. - :: ........ -- -_- - .. -~- :~ .. ::; ~ ~ ~ 3~ ~ +: I ' c-· ' ' , . , ,., .. ,y ____ 0rl ' '' ' "' ' ' ' ·~·· ' ' c .:A E'" " " '><o \_:.J · ' ' '' >[ • rr• "•<' ' , , , ~·• •g•e,., ' ' ' CHARGC ~V.e ' ' , , ' ·• .<'do ci• ' ' ' ' ' - o , ' ' I ' ' ' "IV , •.• ,B , /J_ - ' ' : ' ' : ' I >: 0 I r···'o, 75 Sq I 1 I t I(} ! I ' "' ' ' '' '· ' ,,, 'I ,,~ <, •' ' _, ::, , ' '' '"••• " - ' .. ., "' ' ' USER I LOAD I <- I I \I ~ 1J I 1 l 1 -=-1 ' I. j _:i ! I' ~j BAT TE RY STAR T ER MOT DR r-- -- -{0 ENGI NE G.ROUND ,. F UEL ClJT :;OL EN OlD ENGINE GRO UND ENGI NE SWITC H • en ~ :e "'CC CD - I'D ::ll .c r:::: - -· 2 "1:'1 "1:'1 G) I'D Q.. :E c ;:::;: - :r )> ~ co C) > ("') :c ::r )> ~ ... s ca I'D n CJ) I ~ 0 -· ;:;; 1\) ~ (,.) 10 ~ r- -!::

CNGINE s - ~-=--f ~~~~'0" ~ ~llcl:J l ~- ~ ' ~" '"' T- L.f : 1 1 __ , SPAR I< Pl UG No .1 IG~JI TI O~I COIL No .2 IGNITION CO IL USER LOA [) 3A CHARGE COI L r- ·- : 1- -~~--~~ --- I (I~ · ,- - '!. "- _2:_0~ CJ. ~: ,- -+ ' I : : t -- 9!. - - - -, j I I ' I •• -t- I ' I ~I -~· -· • 0 __ j ~I I I ~ ~ I I <:> 1 I 1 "='" I - ..,.- 1 a, I c; l I N. I ~AIN -I I ;= ~USE :>:: ?.5A 1 J- 5 _;_; q__ ' <- - '. I \: f I r- -- . --- 1 s: : I I ;::, '\., I ml j_ I I @, : ._.:r_ : I j-=-i : . ' .I j_: i: ~ I i l (M L.{_Q)--1 L )" - I EATTe:RV ST AR-r ER MOT OR ! L Gr -- -- --- _V:f_- - FUEL CUT SOLENO ID BI IV ;:::.~ ~ii:i _ -_ -_ -_ -_-_ -_ --:--_ -_ I ~ I I 2 ENGINE GR OUN D I ?-• I I I ENG INE S WIT CH • ~ , CD CD .c s:: -o· , cv a.. ~- r+ ~ w > 0 :r ~ .. CQ CD 2. G) 0 < Ul N 0 . G) 0 < (J'I (,.) 0 ~ ~ to.) '? 0, <..> ,o h r- ..t:

ENGINE SWITCH CONTINUITY 1!11 BLACK Br BROWN I< I _ ~ I _ I I . I y YELLOW 0 ORANGE _. SPARK PLUG I!IIJ BLUE Lb G GR~EN Lg R RED p ~ WHITE Cii r UGH1 illUE UQHT GREEN PINK ORAY Gr Gr w I'l l w 2.;. ~'1- - -~1 •---- 171 I ;- ~I : Nl I UAI N ;t 1 1 2fiA 1 ENGI~_!!~_!_-~100~ I ~~~~1- "ff_ r w · 8 1/ R c:::J.;;-Pi!B,_ --'-t'lllr.r----1 1 • Gr I 14 1 r 1!11/R F'IEGULATOAI RECT IFIER --- -· ,.~ USE I I I I .,1 I .;1 I ~· . -- +-1-- -. ----- I I --- - -- ---- 31:1 I ll r ;::::::::__: Gr Iii :; ~ }!i.fCJ._ USEF'I , ' LOAD I ' • :--- r-_----- ----------- -~ ---_-_-- ------_-;lN..-_-_-_=_ - ---------- --_ -_ -_---: ___ ._--------- ---~_: l : I -- - BI/Y r---~--~- 1 I I ... ..a '\.. - - - - - - - - - - - - - - - - .1 - - - ,. -. . I I I I I I I I I I 0'1 C' I g/ I I ~I > 1 • l .tlc:rl 1111 2" 1 ~· I '., I ~I t.': 1 et;I)!! .J el I I a I ~~ o:eJI 01-dl I 4 I J I I : : 1 I I NCI -1 IOHJTIOIII COIL -t- I 'to ' I ~ I ;!!: I )-I I I"" .,~ 'i'-~ :!t:m~'' : iii1 iD1 1 : iij: --- SPARK Pll.lGI H l) .2 IGNITION GOIL ._ .., Gr 12A CHARGE COll I ' --=--1 I -r : • I I L; BATTERY -;r STAR'rEA. lw!OTOR - -. FUE'L CUT SOlENOID 'Q) I !:HGI NI': GROIJH.IJ I {g; ENGINE GIROUI'ID I • I I . I I ENGIIHE SW fTCH • :E i - :a CJ - tD 2 .Q e C) "D i c CL - ' l> ~ C) - :D N )llo )> ("'J s: ~ • ... (I) Cl tD 1::11 S!. - G) ><: ~ to.) 9 u. c.. { ~ ~ r- ..t:

HONDA GCV520 GCV530 VERTICAL SHAFT Engine Repair Manual

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