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Honda GX630 Service Manual

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62Z6N000.book 1 ページ 2009年6月16日 火曜日 午後6時17分
How to use this manual
A Few Words About Safety
How to use this manual
SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure or a tool that is not
recommended by Honda, must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and precau-
tions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this man-
ual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have engine-power equipment up in the air. Anytime you lift this product with a hoist,
make sure that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from battery are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
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  Summary of Contents for Honda GX630

  • Page 1 Honda, must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 2 62Z6N000.book 2 ページ 2009年6月16日 火曜日 午後6時17分 CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING COVER FUEL SYSTEM GOVERNOR SYSTEM CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL MUFFLER LUBRICATION SYSTEM CYLINDER CRANKCASE TECHNICAL FEATURES WIRING DIAGRAMS INDEX...
  • Page 3: Specifications

    ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Mo- tor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 4 How to use this manual SERVICE RULES • Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product.
  • Page 5 62Z6N000.book 5 ページ 2009年6月16日 火曜日 午後6時17分 How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems Abbrev. term Full term Alternator American Petroleum institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Battery...
  • Page 6: Engine Mount Dimensional

    62Z6N000.book 1 ページ 2009年6月16日 火曜日 午後6時17分 1. SPECIFICATIONS SERIAL NUMBER LOCATION ······················ 1-2 DIMENSIONAL DRAWINGS···························1-7 DIMENSIONS AND WEIGHTS PTO DIMENSIONAL DRAWINGS ··················1-9 SPECIFICATIONS ·········································· 1-2 ENGINE MOUNT DIMENSIONAL ENGINE SPECIFICATIONS ··························· 1-3 DRAWING ·····················································1-11 PERFORMANCE CURVES ···························· 1-4...
  • Page 7: Serial Number Location

    SERIAL NUMBER LOCATION SPECIFICATIONS The engine serial number (1) is stamped on the crankcase. Refer to it when ordering parts or making technical inquiries. DIMENSIONS AND WEIGHTS SPECIFICATIONS Model GX630 GX630R GX660 GX660R GX690 GX690R Overall length Q type: 405 mm (15.9 in) V type: 426 mm (16.8 in)
  • Page 8: Maintenance

    62Z6N000.book 3 ページ 2009年6月16日 火曜日 午後6時17分 SPECIFICATIONS ENGINE SPECIFICATIONS Model GX630 GX630R GX660 GX660R GX690 GX690R Description code GCBBK GCBEK GCBCK GCBFK GCBDK GCBGK Type 4 stroke, overhead valve, 90° V–twin cylinder Displacement 688.0 cm (41.97 cu–in) Bore x stroke 78.0 x 72.0 mm (3.07 x 2.83 in) Net power (SAE J1349)* 15.5 kW (21.1 PS) /...
  • Page 9: Performance Curves

    62Z6N000.book 4 ページ 2009年6月16日 火曜日 午後6時17分 SPECIFICATIONS PERFORMANCE CURVES GX630/GX630R (N•m) (lbf•ft) (kgf•m) NET TORQUE (KW) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE (min 2000 3000 3600 ENGINE SPEED...
  • Page 10: Engine Speed

    62Z6N000.book 5 ページ 2009年6月16日 火曜日 午後6時17分 SPECIFICATIONS GX660/GX660R (N·m) (lbf·ft) (kgf·m) NET TORQUE (KW) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE (min 2000 3000 3600 ENGINE SPEED...
  • Page 11 62Z6N000.book 6 ページ 2009年6月16日 火曜日 午後6時17分 SPECIFICATIONS GX690/GX690R (N•m) (lbf•ft) (kgf•m) NET TORQUE (KW) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE (min 2000 3000 3600 ENGINE SPEED...
  • Page 12: Dimensional Drawings

    62Z6N000.book 7 ページ 2009年6月16日 火曜日 午後6時17分 SPECIFICATIONS DIMENSIONAL DRAWINGS Unit: mm (in) 67 (2.6) 287.3 (11.31) (EXHAUST M8x1.25 DEPTH 18 (EXHAUST PORT CENTER) PORT END) (2 PLACES) M8x1.25 DEPTH 18 (2 PLACES) 135 (5.3) 198.5 (7.81) 207 (8.1) 405 (15.9) 245(9.6) 205(8.1) 205(8.1) 81 (3.2) (EXHAUST...
  • Page 13 62Z6N000.book 8 ページ 2009年6月16日 火曜日 午後6時17分 SPECIFICATIONS HIGH MOUNT MUFFLER TYPE Unit: mm (in) 275.8(10.86) 380(15.0) 309.5 68(2.7) 130.5 102.5 SIDE MOUNT MUFFLER TYPE 166(6.5) 78(3.1) 209(8.2) 238.5(9.39) 280(11.0) 307(12.1)
  • Page 14: Pto Dimensional Drawings

    62Z6N000.book 9 ページ 2009年6月16日 火曜日 午後6時17分 SPECIFICATIONS PTO DIMENSIONAL DRAWINGS MOUNT PART Unit: mm (in) 5/16-24UNF-2B TAP (4 PLACES) 3/8-16UNF-2B TAP (4 PLACES) 7/16-14UNF-2B TAP (4 PLACES) 18 (0.2) 4 (0.2) 18(0.7) Q TYPE 50 (2.0) 35 (1.4) 28 (1.1) 5 (0.2) +0.05 +0.002 (0.25...
  • Page 15 62Z6N000.book 10 ページ 2009年6月16日 火曜日 午後6時17分 SPECIFICATIONS T TYPE Unit: mm (in) 70 (2.8) 49 (1.9) 43.5 (1.71) 5 (0.2) +0.05 +0.002 0.25 4.5 (0.18) 6 (0.2) 90 (3.5) B TYPE 92 (3.6) 50 (2.0) 43.5 (1.71) 5 (0.2) +0.05 9.53 (0.375 +0.002 2 (0.1) 4.5 (0.18)
  • Page 16 62Z6N000.book 11 ページ 2009年6月16日 火曜日 午後6時17分 SPECIFICATIONS S TYPE Unit: mm (in) 41 (1.6) 35 (1.4) 28 (1.1) 5 (0.2) +0.05 +0.002 (0.3 4.5 (0.18) 3 (0.1) 50 (2.0) DEN TYPE 35 (1.4) 28 (1.1) 5 (0.2) TAPER 1/10 4.5 (0.18) 30.2 (1.19) 7.8 (0.31) ENGINE MOUNT DIMENSIONAL DRAWING...
  • Page 17 62Z6N000.book 12 ページ 2009年6月16日 火曜日 午後6時17分 MEMO...
  • Page 18 62Z6N000.book 1 ページ 2009年6月16日 火曜日 午後6時17分 2. SERVICE INFORMATION MAINTENANCE STANDARDS ······················ 2-2 TOOLS·····························································2-6 TORQUE VALUES ········································· 2-4 HARNESS ROUTING······································2-8 LUBRICATION & SEAL POINT ····················· 2-5 TUBE ROUTING············································2-13...
  • Page 19: Cover

    Unit: mm (in) Part Item Standard Service limit Engine Maximum speed (at no load) GX630: 3,850 ± 150 min (rpm) GX630R: 3,850 ± 150 min (rpm) 3,150 ± 150 min (rpm) (QYD, VEP4, VXF types only) 3,200 ± 150 min...
  • Page 20 0.150 – 0.210 (0.0059 – 0.0083) 0.30 (0.012) Outer rotor-to-pump cover clearance 0.04 – 0.09 (0.002 – 0.004) 0.11 (0.004) Carburetor Main jet GX630/630R: #102 (No.1 cylinder) – #105 (No.2 cylinder) GX660/660R: #112 (No.1 / No.2 cylinder) GX690/690R: #118 (No.1 / No.2 cylinder)
  • Page 21: Torque Values

    62Z6N000.book 4 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION TORQUE VALUES ENGINE TORQUE VALUES Torque values Item Tread Dia. (mm) N·m kgf·m lbf·ft Cylinder nut M10 x 1.25 Oil drain plug bolt M20 x 1.5 Oil filter cartridge M20 x 1.5 Connecting rod bolt M7 x 1.0 Tappet adjusting nut M5 x 0.5...
  • Page 22 62Z6N000.book 5 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION LUBRICATION & SEAL POINT Location Material Remarks Crankshaft pin, journal and gear Engine oil Crankcase bearing Crankcase cover bearing Piston outer surface and piston pin hole Piston pin outer surface Piston ring Cylinder inner surface Connecting rod big and small end bearing Connecting rod bolt threads and seating surface Camshaft cam profile, bearing, decompressor and...
  • Page 23 62Z6N000.book 6 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION TOOLS Float level gauge Oil pressure gauge attachment Oil pressure gauge set 07401-0010000 07406-0030000 07506-3000000 Tappet adjusting wrench 3 mm Pilot 17 mm Driver handle 15 x 135L 07708-0030400 07746-0040400 07749-0010000 Seat cutter 27.5 mm Seat cutter 33 mm Flat cutter 30 mm 07780-0010200...
  • Page 24 62Z6N000.book 7 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION Oil seal driver attachment 60 mm Oil filter wrench 64 mm Clutch center holder 07GAD-PG40100 07HAA-PJ70100 07JMB-MN50301 Pilot screw wrench (D) 07KMA-MS60101...
  • Page 25: Harness Routing

    62Z6N000.book 8 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION HARNESS ROUTING FRONT VIEW FUEL CUT SOLENOID HIGH TENSION CORD ENGINE WIRE HARNESS No.1 IGNITION COIL No.2 IGNITION COIL IGNITION COIL 4P CONNECTOR HIGH TENSION FUEL CUT SOLENOID CORD CLIP ENGINE WIRE HARNESS No.1 IGNITION COIL HIGH TENSION CORD...
  • Page 26 62Z6N000.book 9 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION FRONT VIEW (AUTO THROTTLE TYPE) AUTO THROTTLE SOLENOID WIRE BAND UPPER SHROUD HARNESS AUTO THROTTLE No.1 IGNITION COIL Make sure there is no slack. SOLENOID HARNESS HIGH TENSION ENGINE WIRE CORD HARNESS Cut the band end so its length is 10 –...
  • Page 27 62Z6N000.book 10 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION TOP VIEW (AUTO THROTTLE TYPE) AUTO THROTTLE SOLENOID UPPER SHROUD AUTO THROTTLE SOLENOID HARNESS Make sure there is no slack. WIRE BAND ENGINE WIRE HARNESS No.1 IGNITION COIL 2-10...
  • Page 28 62Z6N000.book 11 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION SIDE VIEW (REMOTE CONTROL TYPE) CORD GROMMET CHARGE COIL CORD ENGINE WIRE HARNESS STARTER MOTOR CABLE STRAP OIL LEVEL SWITCH ENGINE WIRE HARNESS CORD GROMMET STARTER MOTOR Pass the engine wire harness over the charge coil cord.
  • Page 29: Side View With Control Box Type

    62Z6N000.book 12 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION SIDE VIEW (WITH CONTROL BOX TYPE) WIRE BAND CHOKE CABLE THROTTLE CABLE ENGINE WIRE HARNESS CHARGE COIL REGULATOR/RECTIFIER CORD (2.7 A) STARTER MOTOR COMBINATION SWITCH 4P CONNECTOR WIRE GROUND TERMINAL HARNESS CLIP HOUR METER OIL LEVEL SWITCH 4P CONNECTOR CORD GROMMET...
  • Page 30: Tube Routing

    62Z6N000.book 13 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION TUBE ROUTING TOP VIEW TUBE CLAMP D10.0 BREATHER TUBE TUBE CLIP C11 TUBE CLAMP D10.0 FUEL FILTER FUEL TUBE A PURGE TUBE GROMMET Clamp the fuel tube A to the hock of FUEL TUBE B the fan cover.
  • Page 31 62Z6N000.book 14 ページ 2009年6月16日 火曜日 午後6時17分 SERVICE INFORMATION RIGHT SIDE VIEW FUEL FILTER FUEL TUBE A TUBE CLAMP D10.0 FUEL PUMP DRAIN TUBE 2-14...
  • Page 32: Valve Clearance Check

    62Z6N000.book 1 ページ 2009年6月16日 火曜日 午後6時17分 3. MAINTENANCE MAINTENANCE SCHEDULE························· 3-2 SPARK PLUG REPLACEMENT ·····················3-7 ENGINE OIL LEVEL CHECK ························· 3-3 SPARK ARRESTER CLEANING····················3-7 ENGINE OIL CHANGE··································· 3-4 IDLE SPEED CHECK/ADJUSTMENT ············3-8 OIL FILTER REPLACEMENT ························ 3-4 VALVE CLEARANCE CHECK/ ADJUSTMENT ················································3-8 AIR CLEANER CHECK/CLEANING ··············...
  • Page 33: Maintenance Schedule

    62Z6N000.book 2 ページ 2009年6月16日 火曜日 午後6時17分 MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE REGULAR SERVICE PERIOD (2) Each First Every Every Every Refer month year 2 years ITEM Perform at every indicated months page month or operating hour 20 hrs. 300 hrs. 500 hrs. interval, whichever comes 100 hrs.
  • Page 34: Engine Oil Level Check

    62Z6N000.book 3 ページ 2009年6月16日 火曜日 午後6時17分 MAINTENANCE ENGINE OIL LEVEL CHECK Place the engine on a level surface. Start the engine and allow it to warm up for 1 to 2 minutes. Remove the oil level dipstick (1), and wipe it clean. Insert the oil level dipstick into the oil level pipe (2).
  • Page 35: Engine Oil Change

    62Z6N000.book 4 ページ 2009年6月16日 火曜日 午後6時17分 MAINTENANCE ENGINE OIL CHANGE Drain the oil in the engine while the engine is warm. Warm oil drains quickly and completely. Place the engine on a level surface and place a suitable container under the drain plug bolt (1). Remove the oil filler cap (2) from the head cover (3) and the drain plug bolt to drain the oil into a suitable container.
  • Page 36 62Z6N000.book 5 ページ 2009年6月16日 火曜日 午後6時17分 MAINTENANCE AIR CLEANER CHECK/CLEANING A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If the engine is operated in dusty areas, clean the air cleaner more often than specified in the MAINTENANCE SCHEDULE. Operating the engine without the air filters or with the filter installed loosely will allow dirt to enter the engine, causing rapid engine wear.
  • Page 37: Air Cleaner Replacement

    62Z6N000.book 6 ページ 2009年6月16日 火曜日 午後6時17分 MAINTENANCE AIR CLEANER REPLACEMENT Remove the air cleaner cover (page 3-5). Remove the wing nut and air cleaner filters (page 3-5). Wipe dirt from the inside of the air cleaner case and the air cleaner cover, using a rag. Check the air cleaner case packing for deterioration or damage.
  • Page 38: Muffler

    62Z6N000.book 7 ページ 2009年6月16日 火曜日 午後6時17分 MAINTENANCE SPARK PLUG REPLACEMENT If the engine has been running, the engine will be very hot. Allow it to cool before proceeding. Remove the spark plug cap, and then remove the spark plug using a spark plug wrench (page 3-6). Verify the new spark plug gap is correct (page 3-6).
  • Page 39: Cylinder

    62Z6N000.book 8 ページ 2009年6月16日 火曜日 午後6時17分 MAINTENANCE Clean the carbon deposits from the spark arrester screen (1) with a wire brush. Check the spark arrester screen for damage. If the screen is damaged, replace the spark arrester. Reinstall the spark arrester to the muffler. Install the muffler protector (side mount type only).
  • Page 40 62Z6N000.book 9 ページ 2009年6月16日 火曜日 午後6時17分 MAINTENANCE Insert a thickness gauge between the valve rocker arm (1) and valve stem (2) to measure the valve clearance. VALVE CLEARANCE: IN: 0.08 ± 0.02 mm EX: 0.10 ± 0.02 mm Set the piston of the No.2 cylinder at the top dead center of the cylinder compression stroke (both valves fully closed) by rotating the flywheel (1) 270 degrees clockwise slowly.
  • Page 41: Fuel Filter Replacement

    62Z6N000.book 10 ページ 2009年6月16日 火曜日 午後6時17分 MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the cylinder (page 14-2). Prepare a cylinder of a thick paper or equivalent material (1), which diameter is as large as to fit against the inner wall of the cylinder, and insert the paper into the cylinder.
  • Page 42: Fuel Tube Check

    62Z6N000.book 11 ページ 2009年6月16日 火曜日 午後6時17分 MAINTENANCE FUEL TUBE CHECK Gasoline is highly flammable and explosive. You can be burned or seriously injured when han- dling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the air cleaner case (page 6-3).

This manual is also suitable for:

Gx660Gx630rGx660rGx690Gx690r