Honda GCV160 & GCV190 Problems | HRX217 Repair

Honda’s GCV160 and GCV190 engines power millions of lawn mowers including the popular HRX217 series. These engines are known for reliability but still develop problems over time. This guide covers common Honda HRX217 engine issues including carburetor cleaning, spark plug replacement, oil changes and thermowax choke repair.

Table of Contents

• Engine Overview
• Starting Problems
• Carburetor Issues
• Oil Problems
• Performance Issues
• Maintenance Schedule

Honda GCV Engine Overview

Honda’s GCV series are overhead cam (OHC) engines designed for residential lawn equipment. The GCV190 powers most Honda HRX217 mowers while the GCV160 is found in HRR and budget models.

Specification	GCV160	GCV190
Displacement	160cc	187cc
Horsepower	5.1 HP	6.0 HP
Oil Capacity	18.5 oz	18.5 oz
Fuel Tank	Varies by mower	Varies by mower
Spark Plug	BPR5ES	BPR6ES

Found on:

• Honda HRX217 mowers (GCV190)
• Honda HRR and HRN mowers (GCV160)
• Craftsman mowers (select models)
• Pressure washers
• Generators

[NEED REAL IMAGE: Honda GCV engine identification label]

Starting Problems

Won’t Start at All

Check these first:

1. Fuel - Is there fresh gas in the tank? Gas older than 30 days causes problems.

2. Fuel valve - Honda mowers have a fuel shutoff. Make sure it’s ON.

3. Choke - Auto-choke models have a thermowax actuator that can fail.

4. Spark - Pull the plug and check for spark. No spark = ignition issue.

5. Oil level - Honda engines have a low-oil shutoff. Too little oil and it won’t start.

Honda HRX217 Thermowax Choke Problems

Honda GCV engines use an automatic choke system with a thermowax actuator. The Honda HRX217 thermowax is a common failure point. When this fails, starting becomes difficult.

Symptoms of bad auto-choke:

• Hard starting when cold
• Starts only with starting fluid
• Runs fine once warm
• Choke plate doesn’t move

Testing the thermowax:

1. Remove air filter to see choke plate
2. With cold engine, plate should be closed
3. Run engine until warm
4. Plate should open as engine heats up
5. No movement = thermowax failure

Honda HRX217 thermowax replacement: Part number 16620-Z8D-305 (approximately $25-35). The Honda HRX217 thermowax choke actuator is a common repair.

[NEED REAL IMAGE: Honda GCV thermowax choke actuator]

Starts Then Dies

Engine fires but immediately stalls.

Common causes:

• Choke opening too fast (thermowax)
• Carburetor gummed up
• Fuel not reaching cylinder
• Air leak at intake

Diagnostic steps:

1. Try starting with full manual choke (if equipped)
2. Check for fuel in carburetor bowl
3. Spray carb cleaner at intake gasket while running - RPM change indicates leak
4. Clean carburetor if fuel delivery suspect

Honda HRX217 Carburetor Problems

The Honda HRX217 carburetor (and all GCV carburetors) are reliable but still clog from bad fuel.

Honda GCV Carburetor Symptoms

Symptom	Likely Cause
Won’t start	Gummed jets
Surges at idle	Partial blockage or air leak
Dies under load	High-speed jet clogged
Black smoke	Stuck float or choke
Fuel leaking	Float needle worn

Honda HRX217 Carburetor Cleaning

The Honda HRX217 carburetor is straightforward to clean. This process works for all GCV160 and GCV190 carburetors.

Tools needed:

• 10mm socket
• Flathead screwdriver
• Carburetor cleaner
• Compressed air

Steps:

1. Turn off fuel valve
2. Disconnect throttle linkage
3. Remove two mounting bolts
4. Pull carburetor off intake
5. Remove float bowl (single bolt)
6. Remove float and needle
7. Spray cleaner through all passages
8. Clear main jet with thin wire
9. Reassemble with new gaskets
10. Reinstall and test

[NEED REAL IMAGE: Honda GCV carburetor disassembled]

Honda HRX217 Carburetor Replacement

If cleaning doesn’t work, replacement Honda HRX217 carburetors are available.

Part	Number	Price
GCV160 OEM carb	16100-Z0L-023	$45-60
GCV190 OEM carb	16100-Z0Y-013	$50-70
Aftermarket	Various	$15-25

Note: Aftermarket carbs may require jetting adjustment. OEM parts work right out of the box.

Honda HRX217 Oil Change & Oil Problems

Oil Leaks

Honda GCV engines can develop oil leaks at several points.

Common leak locations:

• Valve cover gasket
• Crankcase breather
• Oil fill cap
• Crankshaft seals

Valve cover leak fix:

1. Remove valve cover (10mm bolts)
2. Clean mating surfaces
3. Install new gasket
4. Torque bolts to spec (7 ft-lbs)

Breather leak: The crankcase breather can allow oil into the air filter. Check breather valve operation and replace if stuck.

Oil Consumption

Some oil consumption is normal. Excessive consumption indicates:

• Worn piston rings
• Valve seal wear
• Operating mower on slope too long
• Overfilling oil

Acceptable: Less than 1 oz per hour of operation Concerning: More than 2 oz per hour

Low Oil Shutoff

Honda engines shut down when oil gets too low. This protects the engine but can be confusing.

If engine stops and won’t restart:

1. Check oil level immediately
2. Add oil if low
3. Wait a few minutes
4. Try starting again

The sensor needs time to reset after adding oil.

[NEED REAL IMAGE: Honda GCV oil fill dipstick]

Performance Issues

Engine Surging

RPM rises and falls repeatedly.

Causes:

• Dirty air filter (most common)
• Partial carburetor blockage
• Governor adjustment
• Intake air leak

Fix sequence:

1. Replace air filter
2. Clean carburetor
3. Check intake gasket
4. Adjust governor only if above steps fail

Loss of Power

Engine runs but lacks power.

Causes:

• Dirty air filter
• Spark plug fouled or wrong gap
• Carburetor needs cleaning
• Compression loss
• Exhaust restriction

Compression test: Normal: 60-90 PSI Low compression indicates internal wear.

Overheating

Honda engines run hot but should recover quickly at idle.

Causes of overheating:

• Cooling fins clogged with debris
• Low oil level
• Engine overloaded (cutting too much at once)
• Running too lean

Prevention:

• Clean cooling fins regularly
• Check oil before each use
• Don’t overwork the engine in tall grass

Excessive Vibration

Causes:

• Bent blade (most common)
• Loose blade bolt
• Crankshaft damage
• Engine mounting loose

Check blade first: Remove and lay on flat surface. Any wobble indicates bend. Replace blade - don’t try to straighten it.

Maintenance Schedule

Keep your Honda GCV engine running with regular maintenance.

Every Use

• Check oil level
• Check air filter condition
• Inspect for loose parts

Every 25 Hours or Monthly

• Honda HRX217 oil change (SAE 30 or 10W-30)
• Clean or replace Honda HRX217 air filter
• Check Honda HRX217 spark plug

Every 50 Hours or Yearly

• Replace spark plug
• Clean fuel system
• Check valve clearance (GCV engines have no adjustment)
• Inspect muffler and exhaust

Specifications

Item	Specification
Oil type	SAE 30 or 10W-30
Oil capacity	18.5 oz (0.55L)
Spark plug	NGK BPR5ES (GCV160)
Spark plug	NGK BPR6ES (GCV190)
Plug gap	0.028-0.031”
Air filter	Foam or dual element

[NEED REAL IMAGE: Honda GCV spark plug location]

Parts Cross-Reference

Common Honda GCV160/190 parts:

Part	Honda Number	Aftermarket
Air filter	17211-ZL8-023	Various
Honda HRX217 spark plug	98079-55846	NGK BPR6ES
Carburetor (160)	16100-Z0L-023	Various
Carburetor (190)	16100-Z0Y-013	Various
Fuel filter	16910-ZE1-024	Various
Thermowax	16620-Z8D-305	Limited
Recoil starter	28400-Z8B-003	Limited

Related Guides

• Honda HRX217 Repair Guide
• Honda GX160/GX200 Carburetor
• How to Clean a Carburetor
• Lawn Mower Won’t Start
• Lawn Mower Oil Change Guide

Summary

Honda GCV engines are among the most reliable small engines made. Most problems come from old fuel and neglected maintenance. Keep the fuel fresh, change oil regularly and clean the air filter. Do these things and your Honda will run for years. When carburetor problems do occur, cleaning usually fixes them. The auto-choke thermowax is the one Honda-specific part that fails - if cold starting becomes difficult, that’s the first suspect.