The engine will not start when the engine is cold.

Sticking in the auto-

choke control assembly causes the choke plate to remain partially or
fully open when the engine is cooled down
GCV140/160/190

PARTS STOCK EXCHANGE IDENTIFICATION

The improved auto-choke control assembly part numbers did not change. Conduct a parts
stock exchange and identify the “stage 1” countermeasure parts by the black nylon spring cup.

Affected Auto-Choke Control Part Numbers:

16600-Z8D-840 (GCV140/160/190 Square Intake Port)
16600-Z8B-900 (GCV160 Round Intake Port)

No part number
change
 DIAGNOSIS AND REPAIR PROCEDURE

Choke Operation Check:

1) With the engine off and cooled to room temperature, remove the air cleaner cover and
element and inspect the choke plate position. If the choke plate is partially or completely
open, the choke is sticking so proceed to the repair procedure to replace the auto choke
control assembly and thermo-wax.

The choke plate must be fully

closed when the engine is cooled
to room temperature.

2) If the choke is fully closed, start the lawn mower, allow it to run for about 3 minutes and
confirm the choke plate fully opens. Then shut the engine off and allow it to cool for a
minimum of 30 minutes and recheck the choke position. The choke should be fully closed.
Repeat the test several times if necessary. The choke must fully open within 3 minutes of
starting, and fully close within 30 minutes after shutting down. If the choke functions
correctly, the source of the problem is likely something else – follow normal troubleshooting
procedures. Only proceed to the repair procedure after confirming the choke sticks open
when the engine cools down.

Repair Procedure
Important: Allow the engine to cool for at least 45 minutes before beginning the repair.
Installing the choke components on a warm engine may result in choke binding or improper
choke function.

1. Turn the fuel valve off and drain the fuel

from the carburetor flow chamber into
an approved container.

2. Remove the air cleaner cover and paper

element.
3. Loosen, but don’t remove, the two 6 mm
air cleaner case bolts.

AIR CLEANER
CASE BOLTS
4. Disconnect the crankcase breather tube
while holding the bolts in place, and
then pull the air cleaner case, control
assembly (if equipped), 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. If the thermo-wax
bonded in place with black RTV sealant
and cannot be easily removed:
a) Using small pliers or wire cutters,
remove the thermo-wax center pin.
b) Insert a no. 6 sheet metal or drywall
screw into the thermo-wax body and
carefully pry it out. Use the side of the
valve cover as a prying surface. Do not
pry against the intake port gasket
sealing surface.
c) Use a small scraper, brake cleaner and
compressed air to remove the remaining
sealant from the cavity. Remove as
much sealant as possible, especially
from the bottom of the cavity.

6. Prepare the new thermo-wax for

installation. Measure the overall length
of the new thermo-wax before installing.
The length must be 21.5-23.0 mm. Do
not install if the length is outside this
range.
7. Apply a small amount of Hondabond HT
(TB1216, or Loctite 5900) to the lower
one-third and bottom of the new thermo-
21.5 – 23.0 mm
wax as shown. Do not apply too much.
8. Insert the new thermo-wax into the
cylinder barrel. Push it into the cavity
until fully seated. The Hondabond HT
(TB1216 or Loctite 5900) will fill any
gaps between the cylinder barrel and
thermo-wax. Remove any excess
sealant that builds up around the
thermo-wax after installation.

9. Remove the auto-choke assembly and

insulator gasket from the two air cleaner
case bolts.
10. Inspect the air guide and insulator
gaskets. Replace any gasket that
appears damaged.

11. Inspect the original auto-choke control cylinder side port shape to confirm the
correct part is being used. Do not install the wrong part.
Square Intake Port Round Intake Port
HRR216K8 (all types) HRR216K9VK/PK
HRR216K9VY/VL GCV160A0/LA0S3B/S3DB/
HRX217K3/K4 (all) GCV160A0/LA0S3HB/S3LB
HRG536C7 GCV160A0/LA0S4GB/S4HB
HRX537C2/C3
GCV140/160/190

Auto-Choke Control: 16600-Z8D-840 Auto-Choke Control: 16600-Z8B-900

12. Install the new auto-choke control assembly onto the air cleaner case bolts.
13. Install the insulator gasket in the direction shown. Be sure the gasket opening
aligns with the intake port.
ROUND INTAKE PORT SQUARE INTAKE PORT

Round intake port Square intake port

gasket. gasket.

14. Align and install the assembled air

cleaner case, carburetor, and auto-
choke assembly as a unit. Install it to
the cylinder barrel by aligning the two air
cleaner case bolts and their mounting
holes. Loosely install the bolts.

15. Install the crankcase breather tube with

the paint mark even with the breather
chamber cover.
16. Tighten the two air cleaner case bolts
even in multiple steps to the proper
torque.
Torque: 89 in▪lb (10 N▪m)
17. After tightening the bolts, push on the
choke control tab to open the choke and
release it to confirm the choke opens
smoothly and closes when released.
Also 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 cleaner element and air
cleaner cover.

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 be fully open within 2 minutes.
3. Adjust the maximum engine speed if necessary (refer to the shop manual for
the specification). If adjustment is necessary, bend the governor spring tab or
arm very slightly
Flywheel Brake Models Roto-Stop Models

4. Allow the engine to cool completely and confirm that the choke plate fully
closes.