Honda GCV160 - Gasket Sequence 

My Honda mower with GCV 160 engine was surging like crazy. I thought carburetor. Cleaned it twice but the engine kept on surging. I bought a new carb, installed it, and still didn’t solve the surging problem. I got lucky and found your video . As I was watching it, I realized that the last 2 gaskets that connect to the intake were placed wrong. I followed the gasket sequence that you showed and problem solved. You are the master of the trade. Thank you for an outstanding video. God Bless.

I’ve had my Troy Bilt with a GV160 engine for 14 years. As many times as I’ve rebuilt the carburetor, I still come back to your video for the gasket sequence. You explained it SO well in a clear and concise manner!

I have watched about half a dozen videos about the gasket locations on the GCV160, all of them others don’t hold a candle to this one, so concise, no Flim-Flam, just a video showing which is located in which location and how to identify each different one. FABULOUS

Adding to everyone else here. Popped the air cleaner housing off and found gaskets everywhere. After trying to puzzle together the order by looking at dirt signatures and turned to RU-vid and found this gem. Thanks for putting this together!

fucked around with carb for about 2 hours couldn't get it to run properly then I come across this video and followed your instructions and now running sweetas.thanks

Thanks a million ! I searched everywhere and finally found your video. You explain it very well. Thank you again!

Dude..... the Honda gasket struggle is REAL!!!!! I had to watch your video to double check my work, thank you thank you.

Thanks for the info on gasket placement. I've been fighting my mower and was about to light it on fire, when I found your video. Went back and found that I had the back two gaskets and insulator in the wrong order. Rearranged them like you showed and the mower runs like a top. You saved me some serious money!

Like everyone else on here I wanted to thank you for putting this clear and well explained video out. Was able to get it back together and running in 5 minutes after seeing how gaskets get replaced. Thanks again!

This helped me tonight. I am a white belt with any engine stuff. I took the carb apart last and was not careful to remember the gasket sequence. This saved me. Thank you.

Man I've spent all day trying to figure out the order of these things after taking my carb off to replace the plastic insulator piece. After looking literally everywhere online and trying different orders and the mower not running correctly, I called a timeout for the day. Now I'm drinking a beer and after a strange Google search I saw this video. Gonna give it a whirl tomorrow! Thank you sir, you are a scholar and a gentleman

Thanks a million; this really helped me get a backup mower up and running after buying it in as-is condition for 20 bucks. The previous owner--a lawn care guy--said that it needed a new carburetor, and I assumed that it just needed to be serviced. But after cleaning the ports and jets thoroughly, it still ran rough, surging really hard, and only a little less so when choked...it was clearly running lean. It turns out that the previous owner had done two things wrong: (1) the air dam was installed backwards...blocking the hole where the ball bearing is, and (2) he was missing a gasket, probably because this particular model (GJAEA-6214884) uses a *metal* air dam, so it needs two identical gaskets (part # 16221-883-800) on each side to create a seal (as opposed to the paper air dam shown in the video, which can seal on its own without any additional gaskets). By the time I figured that I needed another gasket the parts store was closed, so I just used an Exacto knife to cut a new gasket out of thin cardboard, using the existing one as a template...runs great now.

Dude. This video has saved my sanity. I've been trying to figure out what's wrong with my mower for the longest time. Always assumed it was air in leakage but couldn't figure it out. You're video was perfect. Thanks so much for making it

The best easiest to understand casket sequence out there. I wasn't for sure where the metal spacer went though I had quessed it correct. Had to be sure though. Thank you.

Thank you so much. I could not keep my honda wood splitter running since replacing the gas line. Turns out I had turned around some of the gaskets. Runs perfectly now. Very satisfying. Thanks!!

Helped me out today for sure, very good video, I was stumped after taking the carb off and having everything fall apart, thank you!

Man perfect. This is actual help. Not another video out there like it. Completely overlooked but def necissary. If your engine is surging,or only starting with choke like mine (AKA vacuum leak) caused by something so simple as correct gasket sequence, this video is where it's at. Thanks a ton man!!!

So helpful, you should get a medal of honor!!!

10/10 amazing video! Short, clear, straight, and to the point! Very informative and you cover every small detail! I just did an autochoke version and had my doubts but this helped me out! Also helped me on the free pressure washer i just got with manual choke

Awesome video; never could really understand the proper sequence of these gaskets until now and totally different from what the exploded parts view show and never could get my mower to stop surging when I used the exploded parts view. Thanks for your help.

THANK YOU! I almost gave up hope, no, to be honest, I DID give up hope. My soul was crumpled up, crying in the corner, and defeated by the Lawnmower Gods. Then, I somehow found this video and my life is better again. Thanks so much!!! :-D

Excellent! Definitive! I watched a ton of these videos on the gasket sequence. No jibber jabber. What I call a 'Joe Friday/Dragnet explanation: Just the facts, Jack. So easy even a cave man could follow it.

That last gasket against the engine block is the one that do it your selfers normally drop out when they assemble the carb and the engine hunts and basically you will get the repair job. Nice video that should help out a lot of your viewers.

Thank you! Can’t tell you how much I labored over getting this right even from the parts diagram.

Man o man I’ve been cursing out this Japanese over engineered carburetor setup ever since I pulled the bolts to clean the the carb. So thankful I found your video as it made assembly the gaskets and carburetor a breeze!

Thank-you for this! The assembly manuals aren't clear about where that steel gasket goes. You made getting my engine back together again a whole lot easier.

OMG...thank you! I have been staring at this thing for a week trying to figure out how to reassemble. No other videos explain what the "metal gasket" part is for or where it goes! Mine is a 2010 Homelite power washer with GCV190. It does not have the large throttle control/choke control plate...just that dang metal gasket. Thanks brother.

Great video. Like others I had accidentally put the spacer on upside down, after replacing carb and gaskets. Mower needed choke on for several minutes while warming up, and would then run erratically. After watching your video I found the problem and mower runs much smoother, with the choke working as it should. Thank you.

Great video - I was going to buy a new carb! I cleaned the existing one because it had a tank of bad gas. Put it back together and it would only run with the choke on. I watched your video installed gaskets in the right direction and order; now my splitter runs like a champ. THANK YOU!

Your video came through when I needed it, just now. Very well explained, got my Husqvarna back in business! Thanks!

Thank you for making a video CLEARLY showing exactly what I needed to know. On the GCV160s with auto-choke, that square plastic piece next to the block is replaced with the automatic choke module. Fits the same in sequence, and is the same thickness, though.

This is awesome. Nobody can fix my GVC160 even after a new carby and I'm convinced they all left a gasket off or got the sequence wrong as mine will run on choke till it gets warm and I'm convinced it's taking air. $7 for a new kit and this video might put me back in mower heaven. Thank you!

One minor problem. For those of us with the autochoke assembly on their GCV160 the plates are entirely different. Other people watching this will want to take that into account.

Darn. Going back out in the morning and doing it yet again. Can't remember if I put the spacer block against the engine correctly

Such a well put together video. Made an awful conundrum easy. Thanks

Thank you very much man. I bought a used mower with GCV160 and had to replace the carb as it was badly corroded. When I re-assembled it I found that it was leaking gas. Long story short turns out I did not tighten the bolts enough. On my model the air dam is actually metal which was confusing, nonetheless your video helped out a lot.

its like ya knew i was going to have gaskets fall out when takin the carb off today. thanks!

Thank you for taking the time to do this video. It was very helpful. Just what I needed to finish what was supposed to be simple carb cleaning.

Thank you for this video! I was having a problem with my mower surging after replacing the carb. Turns out I had the rubber spacer thing on backwards and once I turned it around the mower ran great!

THANKS FOR THIS AWESOME video!!I I cleaned the carb on my honda mower and i know i must have put a gasket wrong, because it is not running right,so i m going to order new ones and now i will install them right. thanks to you.

Excellent display of the orientation of the gaskets. I, too, thank you for the video.

FINALLY SOMEONE HAS A SIMPLE VIDEO ON THIS !!!!

Thanks so much for the video! Now I can put it back together with confidence.

Exactly what I needed. Thanks. Especially for showing the alternate "metal" shim, since that's what's on my Honda HRX217 mower.

Thanks for a very clear and well done explanation. Just what I was looking for, and this will help me with mechanical anger management as I defeat the bloody carb.

I also have to add my thanks for this. Absolutely bloody brilliant! Top man.

Thanks for that helpful info, it show me heaps it did make it a bit better , then I reset the mixer screw and that made a bigger difference . thanks again.

I just wanted to say thanks for all the great vids. It's helped a lot and I appreciate them.

Good looking out bruh! Im having a surging problem on my gcv190 pressure washer. I cleaned the carb and jet(s) . Did a tune-up (oil change and spark plug replacement ) , and using non ethonal gas . Just to have it still surging. I believe this may be the solution. Thanks ,whether this fixes it or not. This video is still informative and valuable. 😅😂 - 2024

Thanks, helped me to fix my mower.

I REUSED OLD SWOLLEN GASKETS IT CAME WITH AND IT IS RUNNING RICH SO I CAN SEE THAT TECHNICALLY NEW GASKETS INTO THE RIGHT ORDER MIGHT BE THE ANSWER TO THE PROBLEM . THANKS AGAIN

Thank you! This is showing me everything I need to know

You're right when you take the carb bolts out all the gaskets fall and the sequence is gone. Just the vid I needed to put everything back in the proper order. thanks

Your video is great. I wish you would have kept the assembly process the same like when you started. Placing the two long bolts and holding them up with a piece of tape until you have finished the assembly would leave nothing for the imagination. I, too broke the same gasket and had to make one as well as the air dam. If you have a single hole punch like you would use in place of a 3 hole punch, it does a great job. Thanks again. . .

Thank you!! Perfect explanation with super clear visuals.

Excellent. Followed to put my carb, etc back on Excell 2425 pressure washer! Thanks!

Wow, thank you for the great video. You made it so easy to follow. Thanks.

Great Video , it does fall all out when you pull the bolts out. Thank you

Yup, line everything up vertically on the bolts off of the engine, then put it all into place as a unit when you assemble it to the engine. So much easier than trying to hold things in line horizontally while hoping that the gaskets all stay in place before the screws are put in last from the airbox.

Thanks for posting this video! It was just what I needed to sort out an issue I had putting the carb back on. Thanks again.

Been waiting on this very informative video for a long time , finally somebody has made one - a big big thank you .

Thank you so much. This was a great tutorial and I definitely needed it. You are awesome my friend.

Awesome! Just pulled mine apart today and I needed this.

Well Done Bud, saved me a lot of hassle!

A big help reminder , will save and watch for future ....👍😉

great video, but i still have a problem… it still leaks on the front of the carburrator(just behind the airfilterbox)….between the metal plate gasket ,than a paper gasket and then the carburrator.. ?? my gaskets are mounted correct but still no luck pfffff …. any suggestions?

Many thanks for the vid. Very handy as I DID reverse one of the spacers. See what happens tomorrow. Regards Pat

Thanks. Exactly what I was looking for.

This was very helpful thank you!

this was very helpful. thank you

Excellent tutorial, very helpful, thanks!

Thank you! It helped a lot!

Thanks. Clearly explained.

Super helpful. Thank you.

Excellent video, very hlepful!

exactly what I was missing . Thanks !

Mine has the long metal plate (often called control bracket). It also has another metal plate (heat deflector) with a gasket before and after it. In the install sequence, they go on after the spacer and before the carb. In the video, the plate & it's 2 gaskets have been combined into 1 piece. I believe it comes that way on models newer than my 2004.

perfect video, thank you.

Awesome Man, Thanks So Much!!

Thank you. My troy bilt is exactly like this. Do have a question where can you get the metal gasket if needed?.

Great video! Can you give me a clarification? at minute 3:07 cover the carburetor hole at the top right, why? shouldn't it be aligned like all the other gasket holes? Thank you

Thank you got a free honda poster washer carb was just silaconed on

Thank you for sharing your knowledge.

Thanks almost got rid of my mower but I just had the gaskets in the wrong order.

I have a GCV160LA1 S3B and it has an auto choke system. I wasnt smart enough to take a picture and didnt realize the 2 bolts held everything on but I essentially have a cover, carb, choke assembly, and 2 gaskets that get bolted in all together and the diagram drawing that I found isn't exactly like my mower b/c its showing all these other gaskets that aren't on mine so I'm trying to make sense of it. I just ordered a new OEM carb b/c it was only $15 and just bought some gasket paper and glue. My first time making new gaskets. Question - I have the 2 gaskets that fell off when I took the bolts out. One of them is a heat shield gasket like on your video. Is it better to make new gaskets tracing/cutting from the old gaskets or should i trace/cut from the part that the gasket sticks to?

Great job on cutting that gasket out Mon Ami............... Some model Honda's are a pain to get everything back on because you have to hook up the linkages to the carb first or I should say hook the carb to the linkages first......... If Honda didn't have the Zee bend on the linkage and use a turn clip or a E clip to hold the linkage it would be a lot easier to install everything first then just put the linkage on the carb.... I think you and me could teach them a trick or 2 ......... What you think ???? When I worked at PHI helicopters they would pay techs good money or anyone that was an employee money for a better idea that would help the company out......... I have a good trick to installing all that stuff and need to make a video on it soon....... Plus Tard Mon Ami ~!~!

Great video...............saved my bacon.....Thanks.

What is a torque on flange bolts to tight carburetor assembly to the engine?

I’m having difficulty putting things back together, my hands are clumsy and big. I wish you would show us how rot reassembled one with the big metal plate, that’s what I’m working on. I’ve had my pressure washer for many years, and I became disabled in 2011 which has really effected my ability to get things done.

I just ordered a brand new set and the people sent me two of the smaller gaskets instead of the larger one that goes near the front half of the carb. Looks like I will be making one today also. I've got the longer bracket. Also ordered some kind of heat wax or something of that nature I suppose...I've got no idea how that works...Do I heat it or what...lol...awesome explanation and sequence.

You're a lifesaver. Thank you so much. :)

Well done video.

Thanks, what a life saver!

Thank you very much😊

Dude thanks! I needed this! 👍🏿

First. Thank you. Many people can sleep tonight cause of your ability to include every detail which most do not do. This carb set up was probably designed by a super intelligent engineer with zero common sense or real-world experience. You are correct. Pull the 2 bolts that holds the set up on the engine and to my horror everything falls. You can't even put it back correctly by memory or take photos, It doesn't give you that chance. So thank you again. But here is the next problem. Even if you know the proper sequence and configuration, it is a feat that can drive you mad. In your video you use the metal gasket because your mower doesn't have the metal bar and you just skewr the bolts with all the parts on a table then attach everything to the engine. But if you have the metal bar instead of the gasket you can't shish kabob it all to the bolts on a table. You are forced to put the bolts through the filter housing and 2 gaskets then through the metal bar that is attached to the engine. Then with a balancing act you have to keep the 2 bolts in place while sliding the rest of the parts in perfect order onto the bolts from behind with your vision of the the process obstructed by the filter box. This is a 2 person Job. I used my 2 hands 1 knee and my mouth the first time before your video. Now, if you prefer, you can remove the bar or bracket from the engine and just slide it onto the bolts in it's proper order on the table. But. You will need to properly reinstall the choke linkage and throttle linkage that must be disconnected to remove the bracket. It's really a toss up which procedure is worst. This gasket sequence is IMPERATIVE. If you get it wrong your engine will hunt and surge and you won't know why. When you exhausted all cleaning and adjusting and buy a new carb you will have no relief. It will still surge with the new carb until all the gaskets are installed correctly. Many of which are NOT part of the carb gasket kit. Thank you. You are the god of lawnmower repair

Excellent. Great Video. Thanks.

Exelent explain thank you

Great help. Thanks.

thanks very detailed.