Honda GX160 Engine

⚠ Do not over-torque.

1. Turn engine stop switch to ON. With generator on level surface, pull starter grip and check Oil Alert indicator.
2. If Oil Alert flashes, add oil to upper limit; if still flashing proceed to step 6.
3. Remove the maintenance cover.
4. Drain the fuel tank and carburetor float bowl into an approved container.
5. Remove the spark plug and pull starter grip several times to remove unburned fuel.
6. Insert a new spark plug in the spark plug cap and check for spark; spark means the problem was the spark plug.
7. Remove the two 5 x 20 mm screws, four front cover screws, and the front cover.
8. Pull the control panel away and disconnect the yellow oil level switch wire; recheck for spark.
9. Spark means the problem is the oil level switch; replace it following the shop manual procedure.
10. Remove the four 5 x 16 mm washer screws and the muffler protector.
11. Remove fuel cap, lift neck seal and remove 10 mm circlip, two 6 x 100 mm screws and washers, two 6 x 20 mm screw-washers, 5 x 10 mm screw-washer.
12. Lay the unit flat on its right side cover on a protective pad and separate the left side cover.
13. Remove the fuel tube and diaphragm tube from the fuel pump.
14. Disconnect the engine stop switch 2-pin connector and check for spark.
15. Remove the two 3 x 16 mm self-tapping screws and the engine stop switch; install new switch and harness band, tighten screws securely.

⚠ Do not over-torque.

Tools: Hose pinching pliers, SUN-HCP6, Load bank test set

1. Turn engine stop switch to ON. With generator on level surface, pull starter grip and verify Oil Alert indicator is not flashing.
2. If flushing, add oil to upper limit; if still flashing, troubleshoot the Oil Alert system per shop manual.
3. Remove the maintenance cover.
4. Pinch the carburetor inlet fuel line using hose pinching pliers and drain the carburetor float bowl.
5. Remove the spark plug and pull starter grip several times to remove unburned fuel.
6. Insert a new spark plug in the spark plug cap and check for spark; spark means the problem was the spark plug.
7. Locate the engine stop switch 2-pin connector (black and green wires), disconnect it, and check for spark.
8. From the maintenance cover opening disconnect Eco-Throttle 2-pin, ignition control module 8-pin, inverter 6-pin, and engine harness 6-pin connectors.
9. Remove the four 6 x 15 mm special screws and slide the front cover away from the generator.
10. Remove the 3 x 16 mm and 3 x 12 mm self-tapping screws and the engine stop switch; discard the switch and harness band.
11. Install the new engine stop switch and harness band; tighten the 3 x 12 mm and 3 x 16 mm screws securely. Do not over-torque.
12. Reassemble the generator.
13. Add fuel and start the engine; test the generator by performing the load bank test.