Honda GCV160 Craftsman Push Mower. Runs Only on Choke You What THEY Did WRONG and How to Repair It

Honda GCV160 Craftsman Push Mower. Runs Only on Choke You What They Did WRONG and How to Repair It. A large shop in town installed a screw to hold the choke on so the mower will run. I will show you the mistake they made and how to repair it. It is a simple mistake, if your not paying attention to detail. IT IS VERY EASY TO REPAIR.

[@johnk860]

Great vid. Learned more than I wanted to. Something I'd like to pass on: A mechanic told me about a home-made tool to speed up reassembly. Cut an M6 threaded rod to make two 4" long pieces. Then cut a slot on one end. When you pull the carb bolts out, thread the rods into the holes, one at a time and then slide the carb parts off one at a time. The rods act as guides for disassembly and you don't have to worry about the gaskets moving out of place as you reassemble the carb.

[@guyeakin9479]

that's how I do it. have 2 stud bolts, makes it fairly easy.

[@malcolmnason1052]

Use 2 long 6mm.studs to make carb and gaskets and spacer easier to install and replace studs with bolts,one at a time after assembly. Much easier ,I did it today. Love you videos

[@ashleyflint3501]

Fantastic, great to watch people who know exactly what the problems are without countless guesses. Loved it !

[@JohnRoth-u7e]

Thanks for showing how to it all the gaskets on for one with auto choke I have one to do and all the videos I saw didn't have the auto choke it helps alot

[@kbssmallenginerepair2615]

Excellent video T-Bone. You just can’t make this stuff up. A screw into the air box to make the engine run on choke? I’d walk into that shop and fire the dope myself! 🤦🏻‍♂️

[@RaleysSmallEngines]

Thank you so much my friend. It is ridiculous to know that a legit dealer would do this. We see some crazy things sometimes. I hope you have a wonderful day brother.

[@nobaddog1]

Out of the hundreds of Honda carb videos yours is the best. I can't go wrong. Thanks.

[@RaleysSmallEngines]

Wow... So nice of you to say that. We thank you very much my friend.

[@deaniespikes2643]

I've been working on a mower for a neighbor with the same issue. Your video hit the spot! Just perfect! I had to laugh at the number of times that your parts "threw themselves to the floor!" Thanks for the help!

[@RaleysSmallEngines]

Lol glad it helped and you got a laugh. Thanks for watching my friend

[@thuffman44]

I recently had a mower given to me that has this exact same problem. I was just about to use that screw trick to fix it too! lol. Happy I found your video. The carb is in great shape, but the dang thing wont stay running once the chock opens. Will double check the gaskets now that I watched what you did. Thanks so much for sharing your knowledge. I'm more familiar repairing computers than small engines. Your video was helpful

[@vanrijn1669]

Great explanation. One of the best for putting the carb gaskets back in the right order. Thanks for posting your repairs.

[@RaleysSmallEngines]

Really appreciate that, thank you very much for watching.

[@sajidqazi7082]

Shown the perfect Way of doing things.

[@RaleysSmallEngines]

Thank you

[@BAAcic]

Brilliant. Precisely what I needed to see. As I have one exactly the same, that I had just put back together while crossing my fingers that I hadn't put something in wrong. And then you showed me the position of the choke lever pushing the other lever which on my one I had done it wrong. So rather than me kicking the whole thing in anger and throwing it away, it now works. Wonderful, thanks

[@RaleysSmallEngines]

Wow, thank you! That was the goal, to help someone!! Thanks so much for commenting my friend

[@christophermcgrath1869]

Made the same mistake myself when replacing carb and gaskets on my Husq. 7021P with GCV 160. Had to keep turning choke back on until mower warmed up, but even then it still ran erratically. Saw symptom in your video and checked this, and sure enough, was upside down. Runs perfectly now! Thanks for the video!

[@henrydevereux9701]

Thanks for the detailed explanation. Your video helped me resolve a hard start issue with a used mower that I bought 2 years ago. It was difficult to cold start but would start relatively easily with starting fluid. I had pretty much given up on it. Turns out, the choke lever was in the wrong position. Once I corrected that issue, it now starts on the first pull!

[@RaleysSmallEngines]

Awesome!! Thanks for watching

[@badiyan]

I found what I have been looking for answer to my questions, very understandable and clear explanation videoing . This gentleman knows what he is looking for and has solutions to fix any wrong or missing parts and the sequences where they should be. I'm very lucky and pleased/ Thank you, 🙂🙂🙂🙂🙂

[@RaleysSmallEngines]

Thank you

[@jonlambshead5115]

New Subscriber To Your Channel- WOW I'm Just Shaking My Head as To What Those People Done with The Screw To Make It RUN ( Unbelievable ) I Have Worked On Small Engines For Many, Many Years & It Amazes Me What Some People Do. There Are a Ton Of Videos Like Yours Out There To Explain What To Do If You Are Unsure. Even though I Work On Mowers I Like Watching Other Mechanics Working on Small Engines . Keep Up The Good Work And Videos. WATCHING From Australia

[@johnpeters1303]

As many below have said, I too think your explanations and video of reassembly details are superior. My issue, is a Honda GVC 160 wouldn't start. I took off carburetor and cleaned, reassembled and it fired with choke on, (a manual by push-pull rod to rear) and would run some. When I took choke off it died. Thought I had gaskets in wrong places for proper breathing and repositioned 1 or 2 gaskets. Now it fires right up and runs for a few seconds on "Run" but then dies. It starts up repeatedly in "Run" position but will not stay running beyond maybe 45 seconds. This engine is on a power washer.

[@JohnBassile]

Awesome Video showing and explaining everything step by step.

[@williammoore2417]

They messed that mower up glad it made it to you …. Great work

[@johncollins8304]

Liked, subbed and bookmarked for future reference! I could have done with this last year. I have three of these. Couldn't believe Honda could make them so hard to reassemble. I found the previous person had quite understandably let the outer gasket slip from one side this preventing the choke from opening fully. I cut some threaded bar to slip each piece on separately, then holding, pressing hard the whole assembly against the manifold, I replaced one bar with the bolt, tightened it down lightly, then did the same thing the other side. Mr Honda deserves some special prize for this dumb design. I wonder if they have changed it.

[@johncollins8304]

Editing is not possible, so having re-read that I'd like to clarify: I put --lightly screwed -- the temporary threaded rods I'd cut, into the manifold then slid each item on... Hope that's clearer.

[@CSHayes]

The other shop should be ashamed with that HACK job. I can't believe a shop could screw up that many things on one mower. I really like these engines but HATE removing the carb because it is a pain in the butt to line up all of those parts with 2 hands. Wish Honda would have used studs in the block and you could slide everything on and then tighten 2 nuts to hold everything together. Another great video T-Bone!

[@RaleysSmallEngines]

Yes they should be ashamed. Yes studs would be much easier. I am very fast at these but trying to work around a camera umm yep makes it hard. I've done tons of these, yes and easy repair. Thanks for watching and commenting my friend.

[@jesusdrummer21]

Gotta find your video on making gaskets

[@RaleysSmallEngines]

Dang, I'm trying to remember also. There are a couple of them I think. You can use a tiny hammer and ping around the part and the holes, this will imprint it on to the gasket then just cut it out. Thanks for watching my friend.

[@henrymurawskibigdogrepair]

Ok good video but get you some threaded rod the same size as the screws and work backwards with all the parts

[@RaleysSmallEngines]

Yes sir, good idea, I have seen that done. Usually I'm standing in front of the mower and it's much easier but couldn't because of the camera. We probably do 3 or 4 Hondas a week and I am very fast on them.

[@schlomoshekelstein908]

@@RaleysSmallEngines i just use 2 dowels. stick the dowel in the engine block, put everything on, remove 1 dowel, add screw, repeat

[@craiggaynor3141]

Thanks! I love the plain step-by- explanation.👍👍

[@RaleysSmallEngines]

Thank you very much

[@ehickeytube]

Thanks Raley, big help.

[@majorpayne5289]

👍qualified feller vs a NON qualified feller. Can’t believe they drilled a screw in it & said “DONE-SHIP IT” (SUBd) 👍🇺🇸

[@zanenelson8564]

I'm working on a yardman mower that had pretty much the same Honda engine. Took carb off to clean all those little holes that were clogged up in that inside tube under the main jet the choke mechanism was working as it should. Now I put it back together and the metal arm on the choke does not come close to pushing the choke butterfly closed. It makes no contact with that black plastic piece on top of carb. Yours has a plastic extension sticking up that makes contact with the metal choke arm. Mine does not.....and I swear it never did. It's not broken off. Makes me think I have gone over the edge. Choke was working fine......now, the parts that should make contact are an inch apart. What am I missing. I do things very meticulously. . Didn't loose anything. ......but, it's as if my black plastic piece that moves the choke butterfly magically changed shape. And, as I said.... no sign of any breakage.

[@ronpurdon4342]

Great information T Bone and right to the point,thank you for your videos 😂

[@oskara1991]

Well made, easy to follow!

[@RaleysSmallEngines]

Glad you liked it!

[@mattwaters6987]

Well done! 👍

[@fixitorstripitGardenmachines]

I've seen that upsidedown on a couple that have come into me but never a screw lol. Nice job

[@RaleysSmallEngines]

Lol thanks for watching my friend

[@ronz101]

Yeah. If it's dumb it's gunna' happen. Going to look at your gasket making video too. I will need that knowledge as parts availability becomes a bigger problem over the next year. Too....the action of the choke lever was WELL covered. That's a well done in itself. 👍

[@RaleysSmallEngines]

Awesome thanks for watching my friend

[@fretman6]

That big deflector should be sheet metal with a slight bend at the bottom in towards the crankcase, with smaller separate gaskets on it.

[@jdmandan]

I have this engine on a Lawn Boy and my choke does not return as fast as yours does. Any idea why it is not returning? Thank you! Great video!

[@prostreetgsxr]

Great video but unfortunately it didn’t fix my mower. I have the same symptoms now, but I have clean the carburetor and even pushed a wire through the pilot jet. Not sure what else to look for. Everything is assembled correctly though.

[@4tarsus]

Very helpful. Thanks!!

[@RaleysSmallEngines]

Glad it helped. Thanks for watching

[@robcole8218]

Can’t beat experience

[@RaleysSmallEngines]

We see some crazy things. Thanks for commenting my friend

[@charlesoverton]

Good job . Thanks

[@daniellbrinneman]

I fixed one of these. It’s not perfect and the owner didn’t want to put a lot of money into it as they got it on the cheap. [Found the paper gasket and put it in.] I’m still learning.

[@SivaaKobalasingam]

Thank you so much

[@RaleysSmallEngines]

You're welcome

[@TheRustyRooster]

Woo-hoo look a-here ol Raley showing up the competition. Good video fella👍

[@RaleysSmallEngines]

😆 LOL thanks Rooster

[@sidguernsey1393]

great video buddy

[@philliphall5198]

Did you say a repair shop did this ??? Just shocked 😳 😂

[@KensSmallEngineRepair]

Great finds! Some people should Not be working on small engines!!!

[@RaleysSmallEngines]

Agreed. The customer liked the video and showed some of his friends.

[@philliphall5198]

Dang can’t believe anyone let alone a mechanic would do that It’s crazy, plus it’s going to foul plug and damage oil

[@farkinarkin5099]

That "repair shop" needs to be charged with crimes against a small engine. Sheeeesh. Talk about incompetent.

[@JM-mx8dr]

It is much easier if you lay the mower on it's side.

[@jamesrg68]

First thank you for the excellent video, I subscribed/ liked. Got a question . None of the parts are in wrong but still has the identical issue. Any advice?

[@bettykrocker9088]

Thanks…I learned a lot.

[@RaleysSmallEngines]

Thank you glad you enjoyed it

[@cherokeefiddler]

Good catch on the insulator. You have to have patience with these Honda carb assemblies. Some guys I know just refuse to work on Honda mowers. They give them to me and I love them! What is your remedy for these choke levers that start moving toward the front of the engine as soon as you engage the bail? Some of them want to open the choke too soon. Thanks.

[@RaleysSmallEngines]

Thanks for watching. I can't remember having one with that problem. Wish I had a good answer for you.

[@mopesrus7266]

I have the same issue with the choke on my mower. It moves to the off position in a second or two. I have to hold it closed for a few min until the engine warms up. I've often thought about putting a manual choke cable/lever on it but something else always comes up to divert my attention.

[@carlthornton3076]

Very Good!... 45 🐄🦉🏴‍☠✝

[@gbpf57]

nice job!

[@lesterjones5805]

I have a troy with the same engine on the table now that only runs on choke. It doesn't have the screw but I've had a few that did and had to fix it. As far as the troy i don't know what they did wrong yet as i have gotten into it yet. Lol

[@mikehrdlicka8635]

My neighbor took his apart in lawn. I help him put together. Spacer gone. Find it superglue it together. Don't take it apart on grass

[@adriancadorin476]

Well explained

[@RaleysSmallEngines]

Thank you

[@fleadoggreen9062]

Nice job it’s a loud mower ?

[@menudo666]

Hahah.. I actually did the same screw technique and it worked for a lil while

[@rayburnett3066]

Those kinds are the hardest for me to get back on

[@robcploft5398]

Great job 👏

[@RaleysSmallEngines]

Thank you!

[@robcploft5398]

@@RaleysSmallEngines you welcome....

[@wuiliamorellana8660]

Good job

[@RaleysSmallEngines]

Thank you my friend

[@tomnekuda3818]

I worked on nearly every car/carb made.....tuned 'em.....made 'em work. This Honda set up is a damn mess. The carb is good but the the Mickey Mouse linkage/gasket set up is for the birds.

[@richardcole6566]

First of all, thank you for the3 stickers. I have a question about flywheel keys for B&S motors. Are all flywheel keys the same according to engine makes. Another words do all flywheel keys are the same for each engine make. Please advise.

[@RaleysSmallEngines]

You are welcome. I recommend looking up the correct one on Parts Tree, they have good diagrams.

[@jessm1638]

Was performing well needed maintenance on my dad’s 10+yr mower because it would start and just run for a couple of mins before shutting off. So I took apart the carb and cleaned, changed filter, spark plug, and oil and it now stays on, but my concern is when I pull that lever to choke and pull the rope to start…it doesn’t start, even after several tries. The lever moves back into the ‘run’ position, but if I pull it to ‘choke’ again… it’ll start after 1-2 pulls of the rope. Before, it would start right away after choking. Did I screw something up when I took the carb off to clean?

[@RaleysSmallEngines]

Thanks for commenting. Double check that metal choke lever is in the proper position. Those gaskets are tricky, they may look right, but maybe not. Not installed correctly they will suck air and it will not run.

[@jessm1638]

@@RaleysSmallEngines will do…thanks!

[@amend5269]

I used a helicoil to fix the coil stud

[@philliphall5198]

Just because you can buy tools it don’t make you a mechanic I’ve never seen so much stuff put together wrong and destroy, pull cover and wash it and then really look it over He was not a mechanic and never will be. Mechanic does not let it go until it runs right and does not give up and stick a screw in it

[@JohnBassile]

I have same machine with trouble with carburetor choke valve not closing when automatic lever is pushed to choke position so that I need to put some gas in carb to start so what is happening

[@davidoliver6597]

Almost like they brought it to a car dealer for repair. My experiences are just like that! Brought in for 1 problem, get it back with 4 more problems. Paper and Emer's glue will fix it! LOL

[@kendexter]

People.. that place he went to in the town to have it fixed was it Mc Donald's ?

[@johnanderson3746]

Why was it smoking at end ? * This might help you * When you are taking the two long bolts out that holds on air filter take one out then replace with long bolt with no head on it . Then same with other one . This will keep you from having to have air filter in your way when putting on gaskets and carburetor .

[@mgomez5606]

BBB should shut that shop down.

[@psbc1]

Just what the doctor ordered

[@RaleysSmallEngines]

Awesome, thanks

[@jerryabell]

I find it easier to losses the that plate,than every thing goes on and lines up for re assembly

[@jerryabell]

You did it the hard way

[@Mr_Resale419]

Go Job

[@CageyLeigh]

I have a 12 year old Honda HRX217 that runs great when the blade is engaged, but surges at idle with no blade attachment. I can’t find any information on how to increase the idle RPM. Is this possible with the Honda engines?

[@RaleysSmallEngines]

Surging is generally caused by a partially blocked idle jet

[@CageyLeigh]

@@RaleysSmallEngines yes, but where is the idle jet? None of my diagrams show this part. I took the filter off, and the carb assembly, and couldn’t find anything that looked liked it needed cleaning or adjusting. Is this a problem that needs to be fixed or just live with it? Thanks for your reply.

[@PopeyeSailor-wz7ew]

Did u find the answer? ​@@CageyLeigh

[@CageyLeigh]

@@PopeyeSailor-wz7ew I poured a cleaner into my gas tank and ran that through a couple of times, and for the most part, it runs pretty good at idle. I guess the jets got cleaned enough to pass enough gas for the idle to run smoothly. Thanks.

[@capicolaspicy]

Just wonder hum much the rental place charged them to "fix the p[roblem" - that was BS. So many p[eople should NOT work on mechanical things because they don't even know enough to pay attention or even take pics during disassembly and make sure they can get it back together properly.

[@paulhogsten2613]

Rocket science isn't rocket science!

[@fishstick341]

i wanted to see how to get the top cover off.Mine wont stop unless i turn off the gas. ?

[@RaleysSmallEngines]

Just remove 3 10mm nuts and it slides right off. Sometimes the studs spin off with the nuts, still comes right off.

[@marxfish]

I'm about to stick a screw in my choke lever. Taken carb off and cleaned it and put back in correct gasket order and once the choke releases the engine starts to surge. Put the lever about halfway to choke and it levels out. Lather rinse repeat with same results. Same Husky Honda combo. Anybody?

[@roseymalino9855]

Same problem as in video: vacuum leak. Spray carb cleaner in the general area of the carb. If the engine smooths out, confirms leak.

[@brich2929]

My choke doesn't move as fast as that, maybe half as fast.

[@slikballa]

What did you do for the coil bolt

[@RaleysSmallEngines]

I haven't repaired it yet. Probably drill and tap and put a set screw to hold it in place. The other screw should hold the coil I hope. I will also inform the customer of what I did.

[@matersworkshop6123]

Some people should just stay away from tools

[@RaleysSmallEngines]

😂You are correct sir. Thanks for watching my friend.

[@alanarmstrong2323]

Governor spring needs to be in small hole on Governor arm.

[@philliphall5198]

I get pissed when I see a used head gasket put back on and the other side was blown out. Those flippers can really screw people over, plus they even video it….

[@woodstover]

Heli-coil that stripped stud.

[@philliphall5198]

Hope they didn’t touch carb. Lololo

[@sonnyc3826]

ffs i just gave this mower back to a guy and i did the same thing i put that plastic part on backwards its probably why it shaving a hard time starting..ffs of course i come across this soon as i give it to the guy

[@RaleysSmallEngines]

Dang it. Hey we all make mistakes. Call him and make it right, he will be glad you did. You will have a customer for life.

[@sonnyc3826]

@@RaleysSmallEngines yeha i just did thanks for this video i dont like letting things go until im fully satisified wiht them myself..this one was bothering me but my own inexperience and ignorance made it the way it is most i fix easy but soemtimes due to soemthing idk like this one ehre it happens

[@RaleysSmallEngines]

@@sonnyc3826 AWESOME my friend. Glad the video helped you. I know you are a good man and will make it right. The customer will love you for it.

[@mudell.hunter0426]

Not a big fan of the way Honda put that arrangement together, a bit annoying honestly.

[@JM-mx8dr]

If it is for a customer and you do not have the part then order NEW parts. Make parts if it is your own mower not a customer. And what @malcolmnason1052 said. Those 6mm studs makes the job hell of a lot easier.

[@edgenet1]

Can you imagine the pain the assembly people doing this crap 12 hours a day. This Torture.

[@edgenet1]

Shame on Honda for creating a repair death trap. I am sure they could have created a better assembly.