6
ASSEMBLY / PRE-OPERATION
Read these instructions and this manual in its entirety before you attempt to assemble
or operate your new lawn mower.
IMPORTANT:
This lawn mower is shipped WITHOUT OIL OR GASOLINE in the engine.
Your new lawn mower has been as sem bled at the factory with the exception of those parts
left unassembled for shipping pur pos es. To ensure safe and proper op er a tion of your lawn
mower, all parts and hard ware you assemble must be tight ened securely. Use the correct
tools as nec es sary to ensure proper tightness. All parts such as nuts, wash ers, bolts, etc.,
nec es sary to complete the as sem bly have been placed in the parts bag.
TO ASSEMBLE GRASS CATCH ER
1. Put grass catcher frame into grass bag
with rigid part of bag on the bottom.
Make sure the frame handle is outside
of the bag top.
2. Slip vinyl bindings over frame.
NOTE
: If vinyl bindings are too stiff, hold
them in warm water for a few minutes. If
bag gets wet, let it dry before using.
TO INSTALL ATTACHMENTS
Your lawn mower was shipped ready to be
used as a mulcher. To convert mower to
bagging or discharging, see “TO CON-
VERT MOWER” in the Operation section
of this manual.
Frame
opening
Vinyl
bindings
Frame
handle
TO REMOVE MOWER FROM CARTON
1. Remove loose parts included with
mower.
2. Cut down two end corners of carton
and lay end panel down fl at.
3. Remove all packing materials except
padding be tween upper and lower
handle and padding holding operator
presence control bar to upper handle.
4. Roll lawn mower out of carton and
check carton thor ough ly for additional
loose parts.
HOW TO SET UP YOUR MOW ER
TO UNFOLD HANDLE
IMPORTANT
: Unfold handle carefully so
as not to pinch or damage control cables.
1. Raise lower handle section to operating
position and align hole in handle with one
of three height positioning holes.
2. Insert handle bolt through handle and
bracket and secure with knob.
3. Repeat for opposite side of handle.
4. Remove protective padding, raise up-
per handle section into place on lower
handle and tighten both handle knobs.
5. Remove any packing material from
around control bar.
Your lawn mower handle can be adjusted
for your mowing comfort. Refer to “AD-
JUST HANDLE” in the Service and Adjust-
ments section of this manual.
Handle
bracket
Knob
Bolt
MOWING
POSITION
Lower handle
LIFT
UP
Operator
presence
control bar
Upper
handle
LIFT
UP
Handle
knob
27
MODEL NUMBER GCV160-LABHH
HONDA 4-CYCLE ENGINE
CYLINDER BARREL
KEY PART
NO. NO.
DESCRIPTION
1 12000-Z0L-406 Cylinder Assembly
12000-Z0L-840 Cylinder
Assembly
3 12310-Z0J-000 Cover, Cylinder Head
12311-ZL8-D00 Cover,
Head
12311-ZL8-000 Cover,
Head
4 12355-ZL8-000 Cover, Breather
(Breather
Valve
Assembly)
5 90013-883-000 Bolt, Flange (#6 x 12)
(CT200)
6 90014-952-000 Bolt, Flange (#6 x 14)
(CT200)
7 91201-ZL8-003 Oil Seal (25.4 x 62 x 6)
8 98079-55846
Spark Plug (BPR5ES)
(NGK)
10 12209-ZM0-003 Seal, Valve Stem
11 14711-ZL8-000 Valve, Intake
(Technostar)
14711-Z0J-000 Valve, Intake (Rocknel)
14711-Z0J-800 Valve,
Intake
12 14721-ZL8-000 Valve, Exhaust
13 14751-ZL8-000 Spring, Valve
14 14771-Z0J-000 Retainer, Valve Spring
CARBURETOR
KEY PART
NO. NO.
DESCRIPTION
1 16010-883-015 Gasket Set
2 16013-ZL1-003 Float Set
3 16015-Z0L-881 Chamber Set, Float
5 16028-ZE0-005 Screw Set
16028-ZK7-S91 Screw
Set
7 16100-Z0L-852 Carburetor Assembly
(BB62Z
B)
8 16155-ZM0-013 Valve, Float
9 16166-ZM0-003 Nozzle, Main
10 16211-ZL8-000 Insulator, Carburetor
11 16212-ZL8-000 Gasket, Insulator
13 16228-ZL8-000 Gasket, Carburetor
15 93500-05006-0H Screw, Pan (#5 x 6)
16 99101-124-0600 Jet, Main (#60)
99101-124-0620 Jet, Main (#62)
99101-124-0650 Jet, Main (#65)
26 16951-Z0L-000 Guide, Air
CONTROL
KEY PART
NO. NO.
DESCRIPTION
1 16551-ZM0-010 Arm, Governor
2 16555-Z0L-801 Rod, Governor
3 16561-Z0L-000 Spring, Governor
4 16562-ZM0-000 Spring, Throttle Return
10 90015-ZE5-010 Bolt, Governor Arm
13 94050-06000
Nut, Flange (6 mm)
15 93892-04012-00 Screw, Washer Head
(#4 x 12)
16 94103-04000
Washer, Plain (4 mm)
CRANKSHAFT
KEY PART
NO. NO.
DESCRIPTION
3 13310-ZM0-610 Crankshaft
5 90402-ZL8-000 Washer, Thrust
RECOIL STARTER
KEY PART
NO. NO.
DESCRIPTION
1 28400-Z0L-V20ZA Starter Assembly,
Recoil, “NH1” (Long Rope)
(Black)
8 28461-ZL8-003 Grip, Recoil Starter
9 28462-Z0L-V20 Rope, Recoil Starter,
“Long
Type”
(Black)
11 90201-ZM0-000 Nut, Flange (6 mm)
