Honda GX610 Owner's Manual
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Honda GX610 Owner's Manual

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Summary of Contents for Honda GX610

  • Page 1 ENGINES’ Owner’s Manual GX610 GX620...
  • Page 2 The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the GX610-QZE type. Honda Motor Co., Ltd. reserves the right, however, to discontinue change specifications or design at any time without notice and without incurring any obligation whatever.
  • Page 3 Honda servicing dealer is specially trained in servicing Honda engines. Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns. Best Wishes, Honda Motor Co., Ltd.
  • Page 4 INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important. And using this engine safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual. This information alerts you to potential hazards that could hurt you or others.

  • Page 5: Table Of Contents

    Check the Equipment Powered by This Engine ......OPERATION ..................... SAFE OPERATING PRECAUTIONS........... STARTING THE ENGINE ..............STOPPING THE ENGINE..............SETTING ENGINE SPEED..............SERVICING YOUR HONDA ENGINE ............. THE IMPORTANCE OF MAINTENANCE........... SAFETY ..............MAINTENANCE SCHEDULE .............
  • Page 6 CONTENTS SERVICING YOUR HONDA ENGINE (continued) AIR FILTER INSPECTION ..............AIR CLEANER SERVICE ..............SPARK PLUG SERVICE ..............(optional part) ......36 SPARK ARRESTER MAINTENANCE HELPFUL TIPS & SUGGESTIONS ............STORING YOUR ENGINE..............Storage Preparation ............... Storage Precautions...............

  • Page 7: Important Safety Information

    Some of the most common hazards are discussed below, along with the best way to protect yourself and others. Owner Responsibilities Honda engines are designed to give safe and dependable service if operated according to instructions.

  • Page 8: Engine Safety

    ENGINE SAFETY Carbon Monoxide Hazards Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of ex- haust gas. Never run the engine in a closed garage or confined area. Other Equipment Review the instructions provided with the equipment powered by this engine for any additional safety precautions that should be observed in conjunction with engine startup, shutdown, or operation, or protective apparel that may be needed to operate the equipment.

  • Page 9: Controls & Features

    CONTROLS & FEATURES COMPONENT & CONTROL LOCATIONS THROTTLE LEVER SPARK\PLUG AIR CLEANER FUEL FILTER CHOKE KNOB OIL DRAIN BOLT STARTER &RIP PROTECTOR FAN COVER TYPE (S.T.D) PROTECTOR TYPE FLYWHEEL PTO TYPE...
  • Page 10 CONTROLS & FEATURES SIDE-MOUNT MUFFLER HIGH-MOUNT MUFFLER !B type) OIL FILLER CAP HIGH-MOUNT MUFFLER (A type) OIL LEVEL DIPS SWITCH ELECTRIC STARTiR...

  • Page 11: Controls

    CONTROLS & FEATURES CONTROLS Engine Switch The engine switch enables and disables the ignition system. The engine switch must be in the ON position for the engine to run. Turning the engine switch to the OFF position stops the engine. Turning the engine switch to the START position operates the electric starter to crank the engine.

  • Page 12: Choke Knob

    CONTROLS & FEATURES Choke Knob The choke knob opens and closes the choke valve in the carburetor. The CLOSED position enriches the fuel mixture for starting a cold engine. The OPEN position provides the correct fuel mixture for operation after starting, and for restarting a warm engine.

  • Page 13: Throttle Lever

    CONTROLS & FEATURES Throttle Lever The throttle lever controls engine speed. Moving the throttle lever in the directions shown makes the engine run faster or slower. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here. Recoil Starter Grip Pulling the starter grip operates the recoil starter to crank the engine.

  • Page 14: Features

    CONTROLS & FEATURES FEATURES Oil Alert System (applicable engine types) The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert system will automatically stop the engine (the engine switch will remain in the ON position).

  • Page 15: Before Operation

    BEFORE OPERATION IS YOUR ENGINE READY TO GO? For your safety, and to maximize the service life of your equipment, it is very important to take a few moments before you operate the engine to check its condition. Be sure to take care of any problem you find, or have your servicing dealer correct it, before you operate the engine.

  • Page 16: Check The Engine

    BEFORE OPERATION Check the Engine Check the engine oil level (see page 25). Running the engine with a low oil level can cause engine damage. The Oil Alert system (applicable engine types) will automatically stop the engine before the oil level falls below safe limits. However, to avoid the inconvenience of an unexpected shutdown, always check the engine oil level before startup.

  • Page 17: Operation

    OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time, please review the IMPORTANT SAFETYlNFORMATlONon page 5 and the chapter titled BEFOREOPERA- T/ON. Carbon monoxide gas is toxic. Breathing itcancauseunconsciousnessandeven kill you. Avoid any areas or actions that expose you to carbon monoxide.
  • Page 18 2. To start a cold engine, pull the choke knob out to the CLOSED position. To restart a warm engine, leave the choke knob in the OPEN position. Some engine applications use a remotely-mounted choke control rather than the engine-mounted choke knob shown here.
  • Page 19 OPERATION 4. Turn the engine switch to the ON position. SWITCH ENGINE 5. Operate the starter. RECOIL STARTER (applicable engine types): Pull the starter grip lightly until you feel resistance, then pull briskly. Return the starter grip gently. -_7_ STARTER GRIP...
  • Page 20 OPERATION ELECTRIC STARTER (all engine types): Turn the key to the START position, and hold it there until the engine starts. If the engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again. Using the electric starter for more than 5 ENGINE seconds at a time will overheat the starter...

  • Page 21: Stopping The Engine

    STOPPING THE ENGINE To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. 1. Move the throttle lever to the SLOW position. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here.

  • Page 22: Setting Engine Speed

    OPERATION SElTlNG ENGINE SPEED Position the throttle lever for the desired engine speed. Some engine applications use a remotely-mounted throttle control rather than the engine-mounted throttle lever shown here. For engine speed recommendations, refer to the instructions provided with the equipment powered by this engine.

  • Page 23: Servicing Your Honda Engine

    Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic. The maintenance schedule applies to normal operating conditions.

  • Page 24: Maintenance Safety

    Keep cigarettes, sparks, and flames away from all fuel-related parts. Remember that your servicing dealer knows your engine best and is fully equipped to maintain and repair it. To ensure the best quality and reliability, use only new, genuine Honda parts or their equivalents for repair and replacement.

  • Page 25: Maintenance Schedule

    (1) Service more frequently when used in dusty areas. (2) These items should be serviced by your servicing dealer, unless you have the proper tools and are mechanically proficient. Refer to the Honda shop manual for service procedures. (3) For commercial use, log hours of operation to determine proper mainte-...

  • Page 26: Fuel Recommendations

    SERVICING YOUR HONDA ENGINE FUEL RECOMMENDATIONS Use unleaded gasoline with a pump octane rating of 86 or higher. These engines are certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life.

  • Page 27: Engine Oil Level Check

    SERVICING YOUR HONDA ENGINE ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position. 1. Remove the dipstick and wipe it clean. 2. Fully insert the dipstick, then remove it to check the oil level.

  • Page 28: Engine Oil Change

    SERVICING YOUR HONDA ENGINE ENGINE OIL CHANGE Drain the used oil while the engine is warm. Warm oil drains quickly and completely. 1. Place a suitable container below the engine to catch the used oil, then remove the filler cap and the drain bolt.

  • Page 29: Oil Filter Change

    1 NOTICE ) Use only a genuine Honda oil filter or a filter of equivalent quality specified for your model. Using the wrong filter, or a non-Honda filter which is not of equivalent quality, may cause engine damage.
  • Page 30 SERVICING YOUR HONDA ENGINE 4. Screw on the new oil filter by hand until the seal contacts the filter mounting base, then use an oil filter socket tool to tighten the filter an additional 7/8 turn. Oil filter tightening torque: 16 ft-lb (22 Nom, 2.2 kg-m).

  • Page 31: Engine Oil Recommendations

    AMBIENT TEMPERATURE The SAE oil viscosity and service classification are in the API label on the oil container. Honda recommends that you use API SERVICE category SF or SG oil.

  • Page 32: Fuel Filter Inspection

    2. Check the fuel filter for water accumulation or sediment. If no water or sediment is found, reinstall the control cover. FUEL 3. If the fuel filter is found with excessive water accumulation or sediment, take the engine to your authorized Honda servicing dealer.

  • Page 33: Air Filter Inspection

    SERVICING YOUR HONDA ENGINE AIR FILTER INSPECTION Remove the air cleaner cover and inspect the filter. Clean or replace dirty filter elements. Always replace damaged filter elements. Refer to page 32 for instructions that apply to the air cleaner and filter.

  • Page 34: Air Cleaner Service

    AIR CLEANER SERVICE A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If you operate the engine in very dusty areas, clean the air filter more often than specified in the MAINTENANCE SCHEDULE. Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear.
  • Page 35 SERVICING YOUR HONDA ENGINE Paper air filter element: Tap the filter element several times on a hard surface to remove dirt, or blow compressed air [not exceeding 30 psi (207 kPa, 2.1 kg/cm2)] through the filter element from the air cleaner cover side.

  • Page 36: Spark Plug Service

    SERVICING YOUR HONDA ENGINE SPARK PLUG SERVICE Recommended spark plugs: BPRGES (NGK) W20EPR-U (DENSO) Incorrect spark plugs can cause engine damage. Disconnect the spark plug caps, and remove any dirt from around the spark plug area. Remove the spark plugs with a 13/l 6-inch spark plug wrench.
  • Page 37 SERVICING YOUR HONDA ENGINE 6. After the spark plug seats, tighten with a 13/l 6-inch spark plug wrench to compress the washer. If reinstalling the used spark plug, tighten l/8-1/4 turn after the spark plug seats. If installing a new spark plug, tighten l/2 turn after the spark plug seats.

  • Page 38: Spark Arrester Maintenance (Optional Part)

    SERVICING YOUR HONDA ENGINE SPARK ARRESTER SERVICE (optional equipment) Your engine is not factory-equipped with a spark arrester. In some areas, it is illegal to operate an engine without a spark arrester. Check local laws and regulations. A spark arrester is available from authorized Honda servicing dealers.
  • Page 39 2. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen. The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged. SIDE-MOUNT MUFFLER TYPE HIGH-MOUNT MUFFLER TYPE SPARK...

  • Page 40: Helpful Tips & Suggestions

    HELPFUL TIPS & SUGGESTIONS STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine troublefree and looking good. The following steps will help to keep rust and corrosion from impairing your engine’s function and appearance, and will make the engine easier to start when you use it again.
  • Page 41 HELPFUL TIPS 81 SUGGESTIONS The Distributor’s Limited Warranty does not cover fuel system damage or engine performance problems resulting from neglected storage preparation. You can extend fuel storage life by adding a fuel stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor.
  • Page 42 HELPFUL TIPS & SUGGESTIONS DRAINING THE FUEL TANK AND CARBURETOR 1. Disconnect the fuel line to the engine, and drain the fuel tank into an approved gasoline container. If the fuel tank is equipped with a valve, turn the fuel valve to the OPEN or ON position to enable draining. After draining is completed, reconnect the fuel line.

  • Page 43: Storage Precautions

    HELPFUL TIPS & SUGGESTIONS Engine Oil 1. Change the engine oil (see page 26). 2. Remove the spark plugs (see page 34). 3. Pour a tablespoon (5-10 cc) of clean engine oil into the cylinders. 4. Pull the starter rope several times to distribute the oil in the cylinders. 5.

  • Page 44: Removal From Storage

    HELPFUL TIPS & SUGGESTIONS Position the equipment so the engine is level. Tilting can cause fuel or oil leakage. With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials. Do not use sheet plastic as a dust cover.

  • Page 45: Transporting

    HELPFUL TIPS & SUGGESTIONS TRANSPORTING If the engine has been running, allow it to cool for at least 15 minutes before loading the engine-powered equipment on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials. Keep the engine level when transporting to reduce the possibility of fuel...

  • Page 46: Taking Care Of Unexpected Problems

    Start engine with throttle lever in FAST position. Fuel filter clogged, Replace or repair 5. Take engine to an faulty components authorized Honda carburetor malfunc- servicing dealer, or tion, ignition malfunc- necessary. refer to shop manual. tion, valves stuck, etc.

  • Page 47: Fuse Replacement (3A Charge Coil And Switch Box Type)

    3. Reinstall the fuse cover. Install the 6 x 12 mm screw and tighten it securely. SWITCH BOX COVER 6X12mm SPECIAL SCREW Frequent fuse failure usually indicates a short circuit or an overload in the electrical system. If the fuse burns out frequently, take the engine to a servicing Honda dealer for repair.

  • Page 48: Technical & Consumer Information

    TECHNICAL & CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location ELECTRIC STARTEk SERIAL NUMBER & ENGINE TYPE Record the engine serial number in the space below. You will need this serial number when ordering parts, and when making technical or warranty inquiries (see page 57).

  • Page 49: Battery Connections For Electric Starter

    TECHNICAL & CONSUMER INFORMATION Battery Connections Use a 12-volt battery with an ampere-hour rating of at least 35 Ah. Be careful not to connect the battery in reverse polarity, as this will short circuit the battery charging system. Always connect the positive (+) battery cable to the battery terminal before connecting the negative (-) battery cable, so your tools cannot cause a short circuit if they touch a grounded part while tightening the positive (+) battery cable end.

  • Page 50: Remote Control Linkage

    TECHNICAL & CONSUMER INFORMATION Remote Control Linkage The throttle and choke control levers are provided with holes for optional cable attachment. 1. Remove the two 6 mm special bolts from the control cover and remove the control cover. CONTROL COVER 2.
  • Page 51 TECHNICAL & CONSUMER INFORMATION REMOTE THROlTLE AND MANUAL CHOKE 5 mm SCREW FRICTION NUT mm SCREW THROlTLE BRAIDED WIRE CABLE TYPE FRICTION NUT THROlTLE SOLID WIRE CABLE TYPE 3. Reinstall the control cover. Install the throttle cable or the choke cable to the control base, after guiding the cable through the hole in the control cover.

  • Page 52: Carburetor Modification For High Altitude

    TECHNICAL & CONSUMER INFORMATION Carburetor Modification tor High Altitude Operation At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. High altitude performance can be improved by specific modifications to the...

  • Page 53: Oxygenated Fuels

    TECHNICAL & CONSUMER INFORMATION OXYGENATED FUELS Some conventional gasolines are being blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States and Canada use oxygenated fuels to help reduce emissions.

  • Page 54: Emission Control System Information

    The following instructions and procedures must be followed in order to keep the emissions from your Honda engine within the emission standards. Tampering and Altering Tampering with or altering the emission control system may increase emis- sions beyond the legal limit.
  • Page 55 Black exhaust smoke or high fuel consumption. Replacement Parts The emission control systems on your Honda engine were designed, built, and certified to conform with EPA and California emission regulations. We recom- mend the use of genuine Honda parts whenever you have maintenance done.

  • Page 56: Specifications

    TECHNICAL & CONSUMER INFORMATION Specifications GX610-QZE Type 17.6x19.3x17.8in Length x Width x Height (447 x 490 x 452 mm) Dry weight 94.8 lb (43.0 kg) Engine type 4-stroke, overhead valve, 2 cylinders (90’ V-Twin) Displacement 37.5 cu-in (614 cm3) [Bore x Stroke] [3.03x 2.60 in (77 x 66 mm)]...

  • Page 57: Wiring Diagrams

    TECHNICAL & CONSUMER INFORMATION Wiring Diagrams 3A Charge Coil and Switch Box Type I-- --*I;-j+-+...

  • Page 58: Consumer Information

    CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining repairing your engine. You may order them from your Honda engine dealer. Shop Manual This manual covers complete maintenance and overhaul procedures. It is intended to be used by a skilled technician.

  • Page 59: Warranty Service Information

    The Service Manager or General Manager can help. Almost all problems are solved in this way. If you are dissatisfied with the decision made by the dealership’s manage- ment, contact the Honda Power Equipment Customer Relations Office. You can write to: American Honda Motor Co., Inc. Power Equipment Division...
  • Page 60 If you are dissatisfied with the decision made by the dealership's management, contact the Honda Regional Engine Distributor for your area (www.honda-engines.com/dea.htm). If you are still dissatisfied after speaking with the Regional Engine Distributor, you may contact the Honda Office as shown.
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  • Page 64: Quick Reference Information

    QUICK REFERENCE INFORMATION Unleaded gasoline with a pump octane Fuel Type rating of 86 or higher (page 24) SAE lOW-30, API SF or SG, for general Type use (page 29) Engine Oil Without oil filter replacement: 1.27 US qt (1.20 JZ) Capacity With oil filter replacement: 1.59 us qt (1.50 e)

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Gx620

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