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62Z6P000.book 2 ページ 2009年7月9日 木曜日 午後1時35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 practices, 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 equipment hoisted 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 batteries 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 HQRP GXV630R

  • Page 1 62Z6P000.book 2 ページ 2009年7月9日 木曜日 午後1時35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.
  • Page 2: Table Of Contents

    62Z6P000.book 3 ページ 2009年7月9日 木曜日 午後1時35分 CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING COVER FUEL SYSTEM GOVERNOR SYSTEM CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM OTHER ELECTRICAL LUBRICATION SYSTEM CYLINDER CRANKCASE TECHNICAL FEATURES WIRING DIAGRAMS INDEX...
  • Page 3 How to use this manual INTRODUCTION This manual covers the service and repair procedures for the Honda GXV630R/660R/690R. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice.
  • Page 4 62Z6P000.book 5 ページ 2009年7月9日 木曜日 午後1時35分 How to use this manual SERVICE RULES • Use Honda Genuine 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 62Z6P000.book 6 ページ 2009年7月9日 木曜日 午後1時35分 How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated Full term term Alternator American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Battery...
  • Page 6: Specifications

    62Z6P000.book 1 ページ 2009年7月9日 木曜日 午後1時35分 1. SPECIFICATIONS SERIAL NUMBER LOCATION ······················ 1-2 PERFORMANCE CURVES·····························1-4 DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS···························1-7 SPECIFICATIONS ·········································· 1-2 ENGINE MOUNT / PTO DIMENSIONAL ENGINE SPECIFICATIONS ··························· 1-3 DRAWINGS ·····················································1-8...
  • Page 7 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 GXV630R GXV660R GXV690R Overall length 443 mm (17.4 in) Screen grid cover type: 449 mm (17.7 mm) Overall width 420 mm (16.5 in)
  • Page 8: Ignition System

    62Z6P000.book 3 ページ 2009年7月9日 木曜日 午後1時35分 SPECIFICATIONS ENGINE SPECIFICATIONS Model GXV630R GXV660R GXV690R Description code GJAKK GJAPK GJARK 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 62Z6P000.book 4 ページ 2009年7月9日 木曜日 午後1時35分 SPECIFICATIONS PERFORMANCE CURVES GXV630R (N•m) (lbf•ft) (kgf•m) NET TORQUE (KW) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE (min 2000 3000 3600 ENGINE SPEED...
  • Page 10 62Z6P000.book 5 ページ 2009年7月9日 木曜日 午後1時35分 SPECIFICATIONS GXV660R (N·m) (lbf·ft) (kgf·m) NET TORQUE (KW) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE (min 2000 3000 3600 ENGINE SPEED...
  • Page 11 62Z6P000.book 6 ページ 2009年7月9日 木曜日 午後1時35分 SPECIFICATIONS GXV690R (N•m) (lbf•ft) (kgf•m) NET TORQUE (KW) (PS) NET POWER RECOMMENDED OPERATING SPEED RANGE (min 2000 3000 3600 ENGINE SPEED...
  • Page 12 62Z6P000.book 7 ページ 2009年7月9日 木曜日 午後1時35分 SPECIFICATIONS DIMENSIONAL DRAWINGS 443 (17.4) 205.8 (8.10) 138 (5.4) 154.5 (6.08) (EXHAUST PORT 133.5 (5.26) M8x1.25 DEPTH 18 CENTER) 91 (3.6) (2 PLACES) 154.5 (6.08) (EXHAUST PORT CENTER) 144 (5.7) 25 (1.0) 70 (2.8) 133.5 (0.6) 15 (0.6)
  • Page 13 62Z6P000.book 8 ページ 2009年7月9日 木曜日 午後1時35分 SPECIFICATIONS ENGINE MOUNT / PTO DIMENSIONAL DRAWINGS ENGINE MOUNT BASE Unit: mm (in) Φ11 (Φ0.4) (ENGINE MOUNT HOLE) (4 PLACES)
  • Page 14 62Z6P000.book 9 ページ 2009年7月9日 木曜日 午後1時35分 SPECIFICATIONS Q TYPE Unit: mm (in) ENG MOUNT LINE Φ32 (Φ1.3) 7/16-20UNF2B TAP Φ11.5 (Φ0.45) Φ13 (Φ0.5) Φ25.4 (Φ25.4 -0.025 -0.0010 Φ70 (Φ2.8) 21.82 -0.13 (0.859 -0.005 T TYPE ENG MOUNT LINE Φ35 (Φ1.4) Φ36 (Φ1.4) 7/16-20UNF2B TAP Φ11.5 (Φ0.45) Φ13 (Φ0.5)
  • Page 15 62Z6P000.book 10 ページ 2009年7月9日 木曜日 午後1時35分 MEMO...
  • Page 16 62Z6P000.book 1 ページ 2009年7月9日 木曜日 午後1時35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············································2-10...
  • Page 17 62Z6P000.book 2 ページ 2009年7月9日 木曜日 午後1時35分 SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION Unit: mm (in) Service Part Item Standard limit Engine Maximum speed (at no load) – 3,400 ± 150 min (rpm) Idle speed – 1,400 ± 150 min (rpm) Cylinder compression 0.5 –...
  • Page 18 #115 (No.2 cylinder) GXV690R: #115 (No.1 cylinder) #125 (No.2 cylinder) Pilot screw opening GXV630R: 2 turns out (No.1 cylinder) – 2 - 1/8 turns out (No.2 cylinder) GXV660R: 2 turns out (No.1 cylinder) 2 - 1/8 turns out (No.2 cylinder) GXV690R: 1 - 7/8 turns out (No.1 cylinder)
  • Page 19 62Z6P000.book 4 ページ 2009年7月9日 木曜日 午後1時35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 20: Cylinder

    62Z6P000.book 5 ページ 2009年7月9日 木曜日 午後1時35分 SERVICE INFORMATION LUBRICATION & SEAL POINT Location Material Remarks Crankshaft pin, journal and gear Engine oil Crankcase bearing Oil pan 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 21 62Z6P000.book 6 ページ 2009年7月9日 木曜日 午後1時35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 22 62Z6P000.book 7 ページ 2009年7月9日 木曜日 午後1時35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 23 62Z6P000.book 8 ページ 2009年7月9日 木曜日 午後1時35分 SERVICE INFORMATION HARNESS ROUTING TOP VIEW HIGH TENSION CORD HIGH TENSION CORD CLIP No.2 IGNITION COIL FUEL PUMP STAY IGNITION COIL 4P CONNECTOR ENGINE WIRE HARNESS Pass the harness between the fuel cut solenoid and the inlet manifold packing.
  • Page 24 62Z6P000.book 9 ページ 2009年7月9日 木曜日 午後1時35分 SERVICE INFORMATION SIDE VIEW CABLE STRAP CORD GROMMET STARTER MOTOR ENGINE WIRE HARNESS Pass the engine wire harness over the charge coil cord. CHARGE COIL CORD...
  • Page 25 62Z6P000.book 10 ページ 2009年7月9日 木曜日 午後1時35分 SERVICE INFORMATION TUBE ROUTING TOP VIEW TUBE CLIP C11 BREATHER TUBE PULSE TUBE FUEL TUBE A FUEL TUBE B FUEL FILTER PURGE TUBE TUBE CLIP C11 TUBE CLAMP D10.0 FUEL PUMP TUBE CLAMP D10.0 TUBE CLAMP D10.0 GROMMET Clamp fuel tube A to the hook on the fan cover.
  • Page 26 62Z6P000.book 11 ページ 2009年7月9日 木曜日 午後1時35分 SERVICE INFORMATION BOTTOM VIEW FUEL TUBE A TUBE CLIP B8 FUEL FILTER TUBE CLAMP D10.0 DRAIN TUBE Clamp the drain tube on the ribs of the L. lower shroud. RIBS 2-11...
  • Page 27 62Z6P000.book 12 ページ 2009年7月9日 木曜日 午後1時35分 MEMO...
  • Page 28 62Z6P000.book 1 ページ 2009年7月9日 木曜日 午後1時35分 3. MAINTENANCE MAINTENANCE SCHEDULE························· 3-2 SPARK PLUG REPLACEMENT ·····················3-6 ENGINE OIL LEVEL CHECK ························· 3-3 IDLE SPEED CHECK/ADJUSTMENT ············3-6 ENGINE OIL CHANGE··································· 3-3 VALVE CLEARANCE CHECK/ ADJUSTMENT ················································3-7 OIL FILTER REPLACEMENT ························ 3-4 COMBUSTION CHAMBER CLEANING ·········3-8 AIR CLEANER CHECK/CLEANING ··············...
  • Page 29 62Z6P000.book 2 ページ 2009年7月9日 木曜日 午後1時35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 30 62Z6P000.book 3 ページ 2009年7月9日 木曜日 午後1時35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. Stop the engine and wait 2 or 3 minutes. Remove the oil level gauge (1), and wipe it clean. Insert the oil level gauge into the oil filler extension (2), but do not screw in.
  • Page 31 62Z6P000.book 4 ページ 2009年7月9日 木曜日 午後1時35分 MAINTENANCE OIL FILTER REPLACEMENT Drain the engine oil. Remove the oil filter (1) using the special tool (2). TOOLS: Oil filter wrench 65 mm (2) 07HAA-PJ70101 or 07AAA-PLCA100 Apply a light coat of engine oil to the O-ring (3) of the new oil filter.
  • Page 32 62Z6P000.book 5 ページ 2009年7月9日 木曜日 午後1時35分 MAINTENANCE Tap the inner filter (1) lightly several times on a hard surface to remove excess dirt or blow compressed air lightly (207 kPa (2.11 kgf/cm , 30 psi) or less) through the paper filter from the inside out. Never try to brush the dirt off;...
  • Page 33 62Z6P000.book 6 ページ 2009年7月9日 木曜日 午後1時35分 MAINTENANCE Measure the plug gap with a wire-type feeler gauge. If the measurement is out of the specification, adjust by 0.7 – 0.8 mm bending the side electrode. (0.028 – 0.031 in) PLUG GAP: 0.7 – 0.8 mm (0.028 – 0.031 in) Install the spark plug finger-tight to seat the washer, and then tighten 1/8 –...
  • Page 34 62Z6P000.book 7 ページ 2009年7月9日 木曜日 午後1時35分 MAINTENANCE VALVE CLEARANCE CHECK/ ADJUSTMENT Remove the four flange bolts (1) and the each valve cover (2). Remove the fan cover protector or screen grid (page 5- Disconnect the spark plug caps (3) from the spark plugs.
  • Page 35 62Z6P000.book 8 ページ 2009年7月9日 木曜日 午後1時35分 MAINTENANCE Hold the tappet adjusting screw (1) and loosen the tappet adjusting nut (2). TOOL: Tappet adjusting wrench 3 mm (3) 07908-KE90200 Turn the tappet adjusting screw to obtain the specified clearance. VALVE CLEARANCE: IN: 0.08 ± 0.02 mm EX: 0.10 ±...
  • Page 36 62Z6P000.book 9 ページ 2009年7月9日 木曜日 午後1時35分 MAINTENANCE FUEL FILTER REPLACEMENT Gasoline is highly flammable and explosive.You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Check the fuel filter (1) for water accumulation or sediment.
  • Page 37 62Z6P000.book 10 ページ 2009年7月9日 木曜日 午後1時35分 MAINTENANCE FUEL TUBE CHECK Gasoline is highly flammable and explosive.You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the air cleaner case (page 3-4).

This manual is also suitable for:

Gxv660rGxv690r