The most common spark plug for a Honda GCV160 is the NGK BPR5ES, typically with a standard gap around 0.030 inches (0.76 mm). Always verify the exact specification in your engine’s manual or on the unit’s labeling, as variations can exist by model year or market.
The Honda GCV160 is a 160cc overhead-valve engine used in a range of lawn-care and light-duty equipment. Spark plug choice affects starting reliability, throttle response, and emissions, so using the correct part is important. Because the GCV160 has evolved through different generations and regional versions, the exact part number and gap can differ. The guide below covers the plug most often recommended and how to confirm the right one for your specific unit.
Common spark plug options for the GCV160
The following plug is most frequently recommended as a replacement for GCV160 engines. If your manual specifies a different plug, follow that instruction.
- NGK BPR5ES — standard replacement for most GCV160 engines; heat range 5; typical gap around 0.030 inches (0.76 mm).
Note: Some GCV160 variants or regional models may call for an alternate heat range or a different part number. Always verify with the OEM documentation or Honda Parts Catalog for your specific model and serial number.
How to verify the correct plug for your unit
To confirm you have the right spark plug, check the engine’s label under the shroud or consult the owner’s manual for the exact part number and gap specification. If you’re dealing with an older or region-specific model, there may be a different recommended plug. When replacing, ensure the thread length and reach match the existing plug and that the gap is set to the specified value before installation.
Replacement steps
Before starting the replacement, gather a spark plug wrench, a feeler gauge (to verify the gap), and a clean rag. Make sure the engine is cool before you begin.
- Disconnect the spark plug cap from the spark plug to avoid any accidental arcing.
- Clean around the spark plug to prevent debris from entering the combustion chamber when you loosen it.
- Using the spark plug wrench, carefully loosen and remove the old plug.
- Check the gap on the new NGK BPR5ES plug with a feeler gauge and adjust to about 0.030 inches (0.76 mm) if needed.
- Thread the new plug in by hand to avoid cross-threading, then snug it with the wrench and tighten to the manufacturer’s torque specification or until it is securely seated.
- Reconnect the spark plug cap and test the engine by starting it to ensure proper operation.
If in doubt, defer to the OEM specification for your exact model year and region, and avoid over-tightening the plug to prevent damage to the cylinder head.
Summary
For most Honda GCV160 engines, NGK BPR5ES with a 0.030-inch gap is the standard replacement. Always verify the exact part number and gap from your manual or engine label, especially if you have a regional or older variant. Proper plug selection supports reliable starting, smooth running, and efficient operation of the GCV160.