Diesel and Gasoline Engines Specifications and Service Data

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Honda GCV-200 Engine

General Technical Data

Honda GCV200 Engine Specifications

Engine Model ................. Honda GCV200
Engine Type ................. 4-cycle overhead valve 1-cylinder air-cooled small gasoline engine
Number of Cylinders ................. Single
Displacement, cu.in (cc) ................. 12.3 (201)
Engine Bore, in (mm) ................. 2.60 (66.0)
Engine Stroke, in (mm) ................. 2.32 (59.0)
Rated Engine Power, hp (kW) ................. 5.6 (4.2)
Rated Engine Speed, rpm ................. 3600
Maximum Torque, Nm (ft-lbs) ................. 12.7 (9.4)
Torque Speed, rpm ................. 2500
Compression ................. 8.0:1
Valve Arrangement ................. OHV
Lubrication System ................. Forced spray type
Air Cleaner ................. Dry type
Cooling System ................. Forced air
Ignition System ................. Transistor type magneto
Breather System ................. Reed valve type
Electrical System Rating, Volts ................. 10.8
Starting System ................. Starter motor
Charging System ................. Generator
Generator Rating, Amps ................. 0.5
Battery Type ................. Rechargeable

Fuel System

Fuel System Type ................. Carburetor
Carburetor Type ................. Butterfly valve
Governor Type ................. Centrifugal weight system
Fuel Tank Capacity, qts (L) ................. 0.96 (0.91)
Fuel Type ................. Gasoline E10

Dimensions and Weight

Length, in (mm) ................. 16.3 (415)
Width, in (mm) ................. 13.0 (330)
Height, in (mm) ................. 14.2 (360)
Net Weight, lbs (kg) ................. 24.5 (11.1)

Honda GCV200 Maintenance Data

Cylinder Block and Valves

Cylinder Bore Inside Diameter (Maximum), in (mm) ................. 2.6049 (66.165)
Cylinder Head (Max. Out of Flatness), in (mm) ................. 0.002 (0.05)
Intake Valve Clearance, in (mm) ................. 0.003-0.005 (0.08-0.12)
Exhaust Valve Clearance, in (mm) ................. 0.003-0.005 (0.08-0.12)

Engine Oil and Filter

Engine Oil Type (Summer) ................. SAE 10W-30
Engine Oil Type (Winter) ................. SAE 5W-30
API Service Classifications ................. SE or higher
Oil Capacity, qts (L) ................. 0.42 (0.40)
Air Filter Element Part Number ................. 17211-Z8B-901

Carburetor Adjustment

Main Fuel ................. Not adjustable (Factory setting)
Idle Fuel ................. Not adjustable (Factory setting)
Low Idle Speed, rpm ................. 1700±150
High Idle Speed, rpm ................. 2850±100

Ignition System

Spark Plug Type ................. NGK BPR5ES
Spark Plug Gap, in (mm) ................. 0.028-0.032 (0.70-0.80)
Module Air Gap, in (mm) ................. 0.012-0.020 (0.30-0.50)
Ignition Timing, deg ................. 20 BTDC
Spark Plug Torque, Nm (ft-lbs) ................. 20 (14)

Service Intervals

Clean Air Cleaner Element ................. Every 25 hours
Change Engine Oil ................. Every 50 hours
Check and Adjust Spark Plug ................. Every 100 hours
Check Carburetor Adjustment ................. Every 100 hours
Check and Adjust Valve Clearance ................. Every 150 hours
Replace Air Cleaner Element ................. Every 250 hours
Replace Spark Plug ................. Every 250 hours

Honda GCV200 Service Data

Cylinder Block

Cylinder Bore Inside Diameter (Std), in (mm) ................. 2.5984-2.5990 (66.000-66.015)
Cylinder Bore Inside Diameter (Wear Limit), in (mm) ................. 2.6049 (66.165)
Connecting Rod Small End Inside Diameter (Std), in (mm) ................. 0.5120-0.5126 (13.005-13.020)
Connecting Rod Small End Inside Diameter (Wear Limit), in (mm) ................. 0.515 (13.07)
Connecting Rod Big End Inside Diameter (Std), in (mm) ................. 1.1031-1.1036 (28.020-28.033)
Connecting Rod Big End Inside Diameter (Wear Limit), in (mm) ................. 1.1050 (28.066)
Connecting Rod Big End Oil Clearance, in (mm) ................. 0.0016-0.0025 (0.040-0.063)
Crankshaft Main Journal Outside Diameter (PTO Side), in (mm) ................. 1.1016-1.1021 (27.980-27.993)
Crankshaft Main Journal Outside Diameter (Flywheel Side), in (mm) ............ 0.9992-0.9997 (25.380-25.393)
Crank Pin Outside Diameter, in (mm) ................. 1.1012-1.1016 (27.970-27.980)
Rocker Arm Inside Diameter (Std), in (mm) ................. 0.2362-0.2374 (6.000-6.030)
Rocker Arm Inside Diameter (Wear Limit), in (mm) ................. 0.2379 (6.043)
Rocker Arm Shaft Outside Diameter (Std), in (mm) ................. 0.2346-0.2358 (5.960-5.990)
Rocker Arm Shaft Outside Diameter (Wear Limit), in (mm) ................. 0.2344 (5.953)
Rocker Arm Shaft Bearing Inside Diameter (Std), in (mm) ................. 0.2362-0.2369 (6.000-6.018)
Rocker Arm Shaft Bearing Inside Diameter (Wear Limit), in (mm) ................. 0.2379 (6.043)

Cylinder Head and Valves

Number of Valves ................. 2
Cylinder Head (Max. Out of Flatness), in (mm) ................. 0.002 (0.05)
Intake Valve Clearance, in (mm) ................. 0.003-0.005 (0.08-0.12)
Exhaust Valve Clearance, in (mm) ................. 0.003-0.005 (0.08-0.12)
Intake Valve Stem Outside Diameter (Std), in (mm) ................. 0.2152-0.2157 (5.465-5.480)
Intake Valve Stem Outside Diameter (Wear Limit), in (mm) ................. 0.2094 (5.318)
Exhaust Valve Stem Outside Diameter (Std), in (mm) ................. 0.2152-0.2157 (5.465-5.480)
Exhaust Valve Stem Outside Diameter (Wear Limit), in (mm) ................. 0.2094 (5.318)
Intake Valve Guide Inside Diameter, in (mm) ................. 0.2165-0.2170 (5.500-5.512)
Exhaust Valve Guide Inside Diameter, in (mm) ................. 0.2181-0.2186 (5.540-5.552)
Valve Seat Width (Intake/Exhaust), in (mm) ................. 0.03-0.04 (0.70-0.90)
Valve Spring Free Length, in (mm) ................. 1.20 (30.50)
Cam Height (Intake), in (mm) ................. 1.3485-1.3643 (34.253-34.653)
Cam Height (Exhaust), in (mm) ................. 1.3487-1.3645 (34.258-34.658)

Piston and Piston Rings

Piston Pin Bore Inside Diameter (Std), in (mm) ................. 0.5119-0.5124 (13.002-13.016)
Piston Pin Bore Inside Diameter (Wear Limit), in (mm) ................. 0.5137 (13.048)
Piston Skirt Outside Diameter, in (mm) ................. 2.5972-2.5980 (65.970-65.990)
Piston to Cylinder Bore Clearance, in (mm) ................. 0.0004-0.0018 (0.010-0.045)
Piston Pin Outside Diameter (Std), in (mm) ................. 0.5116-0.5118 (12.994-13.000)
Piston Pin Outside Diameter (Wear Limit), in (mm) ................. 0.5100 (12.954)
Top Compression Ring Width, in (mm) ................. 0.0368-0.0374 (0.935-0.950)
Second Compression Ring Width, in (mm) ................. 0.0384-0.0390 (0.975-0.990)
Oil Ring Width, in (mm) ................. 0.0937-0.0968 (2.380-2.460)
Top Compression Ring to Groove Side Clearance, in (mm) ................. 0.0022-0.0035 (0.055-0.089)
Second Compression Ring to Groove Side Clearance, in (mm) ................. 0.0006-0.0019 (0.015-0.049)
Oil Ring to Groove Side Clearance, in (mm) ................. 0.0018-0.0057 (0.045-0.144)
Top Compression Ring End Gap, in (mm) ................. 0.008-0.012 (0.20-0.30)
Second Compression Ring End Gap, in (mm) ................. 0.012-0.016 (0.30-0.40)
Oil Ring End Gap, in (mm) ................. 0.008-0.018 (0.20-0.45)
Ring End Gap (Wear Limit), in (mm) ................. 0.04 (1.00)

Honda GCV200 Tightening Torque Specs

Crankcase Cover (M8x1.25) ................. 24 Nm (18 ft-lb)
Connecting Rod Bolt (M7x1.0) ................. 12 Nm (9 ft-lb)
Valve Adjusting Lock Nut (M5x1.0) ................. 8 Nm (5.9 ft-lb)
Cylinder Head Cover Bolt (M8x1.25) ................. 24 Nm (18 ft-lb)
Flywheel Nut (M14x1.5) ................. 55 Nm (41 ft-lb)
Air Cleaner Case Bolt (M6x1.0) ................. 8.5 Nm (6.3 ft-lb)
Oil Extension Bolt (M6x1.0) ................. 10 Nm (7 ft-lb)
Recoil Starter Nut (M6x1.0) ................. 8.5 Nm (6.1 ft-lb)
Governor Holder Bolt (M6x1.0) ................. 12 Nm (9 ft-lb)
Valve Lifter Bolt (M6 x1.0) ................. 10 Nm (7 ft-lb)
Engine Stop Switch Screw (M4x0.7) ................. 1.8 Nm (1.3 ft-lb)
Spark Plug (M14x1.25) ................. 20 Nm (14 ft-lb)

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