Honda GX630 Workshop Manual Download Page 46

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TROUBLESHOOTING

4-2

TROUBLESHOOTING

BEFORE TROUBLESHOOTING

• Use a known-good battery for troubleshooting.

• Check that the connectors are connected securely.

• Check the sufficient fresh fuel in the fuel tank.

• Read the circuit tester's operation instructions carefully, and observe the instructions during inspection.

• Disconnect the battery cable before continuity inspection.

TROUBLESHOOTING

GENERAL SYMPTOMS AND POSSIBLE CAUSES

Hard starting.

ENGINE OIL level low (oil alert system
applicable types).
Inspect: page 3-3

Poor performance at high
speed.

FUEL FILTER clogged.
Clean: page 3-10

IGNITION COIL faulty.
Replace: page 9-4

SPARK PLUGS faulty
Inspect: page 3-6

AIR FILTER restricted.
Clean: page 3-5

SPARK ARRESTER restricted (applicable
types).
Clean: page 3-7

CARBURETOR problem.
Readjust: page 3-8
Disassemble/inspect: page 6-6 through 8

GOVERNOR out of adjustment.
Readjust: page 7-3, 7-6

VALVE CLEARANCE incorrect.
Readjust: page 3-8

VALVE or VALVE SEATS worn or damaged
Inspect: page 14-7
Correct: page 14-13

CYLINDER, PISTON or PISTON RING
worn
Disassembly: page 14-2, 5, 6
Inspect: page 14-7, 14-10 through 12

Engine lacks power.

Engine will not rev
sufficiently.

Poor performance at low
speed.

<0DQQMࡍ࡯ࠫ㧞㧜㧜㧥ᐕ㧢᦬㧝㧢ᣣޓἫᦐᣣޓඦᓟ㧢ᤨ㧝㧣ಽ

Summary of Contents for GX630

Page 1: ...HONDA GX690 WORKSHOP MANUAL ...

Page 2: ...g 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 ...

Page 3: ...ESHOOTING 4 COVER 5 FUEL SYSTEM 6 GOVERNOR SYSTEM 7 CHARGING SYSTEM 8 IGNITION SYSTEM 9 STARTING SYSTEM 10 OTHER ELECTRICAL 11 MUFFLER 12 LUBRICATION SYSTEM 13 CYLINDER 14 CRANKCASE 15 TECHNICAL FEATURES 16 WIRING DIAGRAMS 17 INDEX 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 4: ...ble to warn you about all the hazards associated with servicing these products You must use your own good judgement Honda Motor Co Ltd SERVICE PUBLICATION OFFICE Date of Issue June 2009 You will find important safety information in a variety of forms including Safety Labels on the product Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION Thes...

Page 5: ...not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the unit SYMBOLS The symbols used throughout this manual show specific service procedures If supplementary information is required pertaining to these symbols it would be explained specifically in the text without the use of the symbols Replace the part s with new one s before assembly Use the recomm...

Page 6: ...e ECM Engine Control Module EMT Exhaust Manifold Temperature EOP Engine Oil Pressure EX Exhaust F Front or Forward GND Ground HO2S Heated Oxygen sensor IAC Idle Air Control IAT Intake Air Temperature I D Inside diameter IG or IGN Ignition IN Intake INJ Injection L Left MAP Manifold Absolute Pressure MIL Malfunction Indicator Lamp O D Outside Diameter OP Optional Part PGM FI Programmed Fuel Injecti...

Page 7: ...ER LOCATION 1 2 DIMENSIONS AND WEIGHTS SPECIFICATIONS 1 2 ENGINE SPECIFICATIONS 1 3 PERFORMANCE CURVES 1 4 DIMENSIONAL DRAWINGS 1 7 PTO DIMENSIONAL DRAWINGS 1 9 ENGINE MOUNT DIMENSIONAL DRAWING 1 11 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 8: ...mm 16 8 in S type 396 mm 15 6 in T type 429 mm 16 9 in B type 442 mm 17 4 in DEN type 371 mm 14 6 in Overall width 410 mm 16 1 in Overall height 438 mm 17 2 in Dry weight Q S types 44 4 kg 97 9 lbs V T types 44 6 kg 98 3 lbs B type 45 0 kg 99 2 lbs DEN type 44 3 kg 97 7 lbs Operating weight Q S types 46 0 kg 101 4 lbs V T types 46 2 kg 101 9 lbs B type 46 6 kg 102 7 lbs DEN type 45 9 kg 101 2 lbs ...

Page 9: ...torque SAE J1349 48 3 N m 4 93 kgf m 35 6 lbf ft 2 500 min 1 rpm 48 3 N m 4 93 kgf m 35 6 lbf ft 2 500 min 1 rpm 48 3 N m 4 93 kgf m 35 6 lbf ft 2 500 min 1 rpm Maximum rpm at no load 3 850 150 min 1 rpm Compression ratio 9 3 0 2 Fuel consumption at continuous rated power 6 0 Liters 1 59 US gal 1 32 Imp gal h 6 3 Liters 1 66 US gal 1 39 Imp gal h 6 7 Liters 1 77 US gal 1 47 Imp gal h Ignition syst...

Page 10: ...630 GX630R N m 50 KW lbf ft kgf m 18 16 14 12 25 4 0 4 5 5 0 30 35 PS 10 8 2000 3600 3000 45 40 12 14 16 18 20 22 24 OUTPUT TORQUE RECOMMENDED OPERATING SPEED RANGE NET POWER NET TORQUE ENGINE SPEED min 1 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 11: ... m 50 KW lbf ft kgf m 18 16 14 12 25 4 0 4 5 5 0 30 35 10 8 2000 3600 3000 45 40 PS 12 14 16 18 20 22 24 TORQUE RECOMMENDED OPERATING SPEED RANGE NET POWER NET TORQUE OUTPUT ENGINE SPEED min 1 TRO 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 12: ... N m 50 KW lbf ft kgf m 18 16 14 12 25 4 0 4 5 5 0 30 35 10 8 2000 3600 3000 45 40 PS 12 14 16 18 20 22 24 TORQUE RECOMMENDED OPERATING SPEED RANGE NET POWER NET TORQUE OUTPUT ENGINE SPEED min 1 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 13: ...133 5 5 26 207 8 1 198 5 7 81 18 5 0 2 0 18 5 0 2 0 M8x1 25 DEPTH 18 287 3 11 31 EXHAUST PORT CENTER 154 5 6 08 EXHAUST PORT CENTER 2 PLACES 2 PLACES M8x1 25 DEPTH 18 81 3 2 EXHAUST PORT END 133 5 5 26 438 17 2 205 8 1 205 8 1 245 9 6 Unit mm in 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 14: ...FFLER TYPE SIDE MOUNT MUFFLER TYPE 275 8 10 86 125 5 4 94 205 8 8 10 380 15 0 68 2 7 140 328 309 5 130 5 102 5 Unit mm in 238 5 9 39 280 11 0 307 12 1 138 5 5 45 170 5 6 71 209 8 2 166 6 5 78 3 1 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 15: ... 4 PLACES 7 16 14UNF 2B TAP 4 PLACES 125 5 4 94 30 30 45 45 P D 1 2 7 P D 1 6 5 1 P D 1 9 6 9 1 4 6 0 5 Unit mm in 5 0 2 28 1 1 50 2 0 35 1 4 4 5 0 18 74 2 9 2 0 1 6 3 0 0 05 0 25 0 0 002 21 82 0 13 0 0 859 0 005 0 0 0 025 3 8 24UNF2B TAP Φ11 5 Φ0 45 Φ25 4 Φ25 4 Φ13 Φ0 5 Φ110 Φ4 3 Φ32 Φ1 3 0 0 0010 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 16: ...010 0 Unit mm in 5 0 2 43 5 1 71 92 3 6 50 2 0 C1 5 4 5 0 18 111 2 4 38 2 0 1 9 53 0 0 05 0 375 0 0 002 31 0 13 0 1 2 0 005 0 0 0 025 5 8 18UNF2B TAP Φ110 Φ4 3 Φ36 5 Φ1 4 Φ18 5 Φ0 73 Φ16 5 Φ0 65 0 0 0010 4 0 2 25 1 0 84 3 3 32 77 5 3 05 GAUGE LINE 8 2 0 32 2 1 4TAPER PER F T ON DIA 32 1 3 0 0 003 4 5 0 18 TAPER GAUGE DIA 5 16 24UNF2B TAP Φ110 Φ4 3 Φ10 Φ0 4 Φ8 5 Φ0 433 Φ22 Φ0 9 Φ35 Φ1 4 0 0 0001 0 ...

Page 17: ... 0 8 0 005 0 7 0 0 13 21 M10x1 25 4 5 0 18 Φ110 Φ4 3 Φ13 Φ0 5 Φ11 5 Φ0 45 Φ25f8 Φ25f8 0 0021 0 0008 Φ32 Φ1 3 Unit mm in 5 0 2 28 1 1 35 1 4 C1 M10X1 25 TAPER 1 10 30 2 1 19 4 5 0 18 7 8 0 31 Φ110 Φ4 3 Φ30 Φ1 2 Φ13 Φ0 5 Φ11 5 Φ0 45 72 2 8 90 5 3 56 105 4 1 2 PLACES 1X27 0 4x1 1 SLOT 16 0 6 16 0 6 86 3 4 4 PLACES 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 18: ...MEMO 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 19: ...2 1 2 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 4 LUBRICATION SEAL POINT 2 5 TOOLS 2 6 HARNESS ROUTING 2 8 TUBE ROUTING 2 13 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 20: ... 0 003 Piston rings Ring side clearance Top 0 050 0 080 0 0020 0 0031 0 15 0 006 Second 0 050 0 080 0 0020 0 0031 0 15 0 006 Ring end gap Top 0 200 0 350 0 0079 0 0138 1 0 0 04 Second 0 200 0 350 0 0079 0 0138 1 0 0 04 Oil side rail 0 20 0 70 0 008 0 028 1 0 0 04 Ring width Top 1 140 1 155 0 0449 0 0455 1 120 0 0441 Second 1 140 1 155 0 0449 0 0455 1 120 0 0441 Connecting rod Small end I D 18 006 ...

Page 21: ...r arm shaft O D 5 960 5 990 0 2346 0 2358 5 953 0 2344 Rocker arm shaft bearing I D 6 000 6 018 0 050 0 077 6 043 0 2379 Oil pump Oil pressure 2 8 kgf cm2 39 8 psi 2 000 min 1 rpm and more Tip clearance 0 15 0 006 0 30 0 012 Outer rotor to housing clearance 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 N...

Page 22: ...aling bolt PT1 8 9 0 9 6 6 Air cleaner wing nut M6 x 1 0 0 8 0 08 0 6 Starter motor terminal nut M8 x 1 25 9 0 9 6 6 Breather valve screw M3 x 0 5 1 0 1 0 7 Hour meter screw M3 tapping screw 0 8 0 08 0 6 Switch box bracket screw M5 tapping screw 4 0 4 3 0 Combination switch nut M22 x 1 0 4 9 0 5 3 6 Fuel cut solenoid 8 8 0 90 6 5 Screen grid cover bolt M6 x 1 0 8 5 0 85 6 3 Screen grid cover nut M...

Page 23: ...ng surface and stem end Valve spring Push rod end Rocker arm bearing and slipper Tappet adjusting screw and nut threads and seating surface Rocker arm shaft Crankshaft thrust washer Flywheel nut threads and seating surface Oil pump gear outer surface rotor and shaft Governor weight holder gear and journal Governor holder shaft Governor slider Governor arm shaft Cylinder nut and bolt threads and se...

Page 24: ... 07746 0040400 Driver handle 15 x 135L 07749 0010000 Seat cutter 27 5 mm 07780 0010200 Seat cutter 33 mm 07780 0010800 Flat cutter 30 mm 07780 0012200 Flat cutter 33 mm 07780 0012900 Interior cutter 30 mm 07780 0014000 Interior cutter 26 mm 07780 0014500 Cutter holder 5 5 mm 07981 VA20101 Valve guide reamer 5 510 mm 07984 2000001 Cleaning brush 07998 VA20100 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 25: ... INFORMATION 2 7 Oil seal driver attachment 60 mm 07GAD PG40100 Oil filter wrench 64 mm 07HAA PJ70100 Clutch center holder 07JMB MN50301 Pilot screw wrench D 07KMA MS60101 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 26: ... CORD ENGINE WIRE HARNESS No 1 IGNITION COIL No 2 IGNITION COIL IGNITION COIL 4P CONNECTOR FUEL CUT SOLENOID HIGH TENSION CORD IGNITION COIL 4P CONNECTOR WIRE BAND HIGH TENSION CORD CLIP Cut the band end so its length is 10 15 mm 0 4 0 6 in ENGINE WIRE HARNESS No 1 IGNITION COIL HIGH TENSION CORD HARNESS BRACKET CHARGE COIL WIRE 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 27: ...HARNESS No 1 IGNITION COIL HIGH TENSION CORD AUTO THROTTLE SOLENOID HARNESS Make sure there is no slack No 1 IGNITION COIL AUTO THROTTLE SOLENOID HARNESS ENGINE WIRE HARNESS AUTO THROTTLE SOLENOID HARNESS AUTO THROTTLE SOLENOID HARNESS TO CHARGE COIL TO IGNITION COIL TO AUTO THROTTLE SOLENOID TO OILLEVEL SWITCH WIRE HARNESS CLIP 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 28: ...ION 2 10 TOP VIEW AUTO THROTTLE TYPE AUTO THROTTLE SOLENOID UPPER SHROUD WIRE BAND AUTO THROTTLE SOLENOID HARNESS Make sure there is no slack No 1 IGNITION COIL ENGINE WIRE HARNESS 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 29: ...rness is not in contact with the bolts ENGINE WIRE HARNESS CORD GROMMET CHARGE COIL CORD CABLE STRAP Pass the engine wire harness over the charge coil cord OIL LEVEL SWITCH ENGINE WIRE HARNESS CORD GROMMET CHARGE COIL CORD CABLE STRAP STARTER MOTOR STARTER MOTOR 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 30: ...ss over the charge coil cord TO STARTER MOTOR TO CHARGE COIL TO IGNITION COIL TO COMBINATION SWITCH TO REGULATOR RECTIFIER TO OILLEVEL SWITCH STARTER MOTOR REGULATOR RECTIFIER OIL LEVEL SWITCH ENGINE WIRE HARNESS CHARGE COIL CORD WIRE HARNESS CLIP STARTER MOTOR REGULATOR RECTIFIER 2 7 A COMBINATION SWITCH 4P CONNECTOR HOUR METER 4P CONNECTOR GROUND TERMINAL THROTTLE CABLE CHOKE CABLE WIRE BAND 0 D...

Page 31: ...BE CLAMP D10 0 TUBE CLIP C11 FUEL PUMP GROMMET Clamp the fuel tube A to the hock of the fan cover DRAIN TUBE FUEL FILTER TUBE CLAMP D10 0 FUEL TUBE A GROMMET TUBE CLAMP D10 0 TUBE CLIP C11 FUEL TUBE B PURGE TUBE PULSE TUBE BREATHER TUBE CLIP FUEL PUMP Clamp the fuel tube A to the hock of the fan cover 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 32: ...SERVICE INFORMATION 2 14 RIGHT SIDE VIEW DRAIN TUBE FUEL FILTER TUBE CLAMP D10 0 FUEL TUBE A FUEL PUMP 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 33: ...EANER CHECK CLEANING 3 5 AIR CLEANER REPLACEMENT 3 6 SPARK PLUG CHECK ADJUSTMENT 3 6 SPARK PLUG REPLACEMENT 3 7 SPARK ARRESTER CLEANING 3 7 IDLE SPEED CHECK ADJUSTMENT 3 8 VALVE CLEARANCE CHECK ADJUSTMENT 3 8 COMBUSTION CHAMBER CLEANING 3 10 FUEL FILTER REPLACEMENT 3 10 FUEL TUBE CHECK 3 11 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 34: ... hrs Refer to page ITEM Perform at every indicated month or operating hour interval whichever comes first к Engine oil Check level 3 3 Change 3 4 к Engine oil filter Replace Every 200 hours 3 4 к Air cleaner Check 3 5 Clean 1 3 5 Replace 3 6 к Spark plug Check adjust 3 6 Replace 3 7 Spark arrester applicable types Clean 3 7 к Idle speed Check adjust 3 8 к Valve clearance Check adjust 3 8 к Combust...

Page 35: ... and fill with recommended oil to the upper level mark 5 of the level dipstick Oil is a major factor affecting performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 or 5W 30 is recommended for general use Use a full synthetic 5W 30 for starting operating temperatures between 15 C and 5 C Other viscosities shown in the chart may be used when the average temperature in your a...

Page 36: ...ller cap and install the oil level dipstick securely OIL FILTER REPLACEMENT Drain the engine oil Remove the oil filter 1 using the special tool 2 Apply a light coat of grease to the O ring 3 of the new oil filter Install the new oil filter and tighten to the specified torque Fill with recommended oil to the upper level mark of the oil level dipstick page 3 3 Start the engine and warm up for 1 to 2...

Page 37: ...able solvent 2 and allow to dry thoroughly Dip the filter in clean engine oil 3 and squeeze out all the excess oil Excess oil will restrict air flow through the foam element and may cause the engine to smoke at startup 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 cm2 30 psi or less through the paper filter from...

Page 38: ...is cracked or chipped Remove carbon or other deposits with wire brush Check the sealing washer 2 for damage Replace the spark plug if the sealing washer is damaged page 3 7 Measure the plug gap with a wire type feeler gauge If the measurement is out of the specification adjust by bending the side electrode Install the spark plug finger tight to seat the washer and then tighten 1 8 1 4 turn with a ...

Page 39: ...ds in the cylinder block Install the spark plug cap securely SPARK ARRESTER CLEANING Remove the flange bolts 1 and muffler protector 2 side mount type only Remove the tapping screw s 3 and spark arrester 4 If the engine has been running the engine will be very hot Allow it to cool before proceeding SPARK PLUG ZFR5F NGK The muffler becomes very hot during operation and remains hot for a while after...

Page 40: ...flange bolts 1 and the each valve cover 2 Remove the fan cover protector or screen grid page 5 2 Disconnect the spark plug caps 3 from the spark plugs Set the piston of the No 1 cylinder at the top dead center of the cylinder compression stroke both valves fully closed by rotating the flywheel 1 clockwise slowly When the No 1 piston is at the top dead center of the compression stroke the T mark 2 ...

Page 41: ...djusting screw 1 and loosen the tappet adjusting nut 2 Turn the tappet adjusting screw to obtain the specified clearance Hold the tappet adjusting screw and retighten the tappet adjusting nut to the specified torque Recheck the valve clearance and if necessary readjust the clearance Check the valve cover packing for damage or deterioration and install it on the valve cover Attach the cylinder valv...

Page 42: ...ion chamber Do not press the cleaning brush with force against the combustion chamber FUEL FILTER REPLACEMENT Check the fuel filter 1 for water accumulation or sediment If necessary replace it Install the commercially available tube clamps 1 on the fuel tubes 2 on both sides of the fuel filter 3 Disconnect the fuel tube from the fuel filter to remove the fuel filter Install a new fuel filter with ...

Page 43: ...acks or signs of leakage If necessary replace it Install the air cleaner case page 6 3 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 1 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 44: ...MEMO 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 45: ...4 1 4 4 TROUBLESHOOTING BEFORE TROUBLESHOOTING 4 2 TROUBLESHOOTING 4 2 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 46: ...e 3 3 Poor performance at high speed FUEL FILTER clogged Clean page 3 10 IGNITION COIL faulty Replace page 9 4 SPARK PLUGS faulty Inspect page 3 6 AIR FILTER restricted Clean page 3 5 SPARK ARRESTER restricted applicable types Clean page 3 7 CARBURETOR problem Readjust page 3 8 Disassemble inspect page 6 6 through 8 GOVERNOR out of adjustment Readjust page 7 3 7 6 VALVE CLEARANCE incorrect Readjus...

Page 47: ...Perform the STARTING SYSTEM TROUBLESHOOTING page 10 2 Perform the FUEL SYSTEM TROUBLESHOOTING page 6 2 Disassemble the carburetor to clean the carburetor ports jets and nozzles page 6 6 6 7 Perform the cylinder compression test page 14 6 Check the valve clearance page 3 8 and then perform the cylinder compression test If the cylinder compression is too high remove carbon deposit in the combustion ...

Page 48: ... wire harness connecting the combination switch and ignition coils Yellow Replace the engine wire harness Check the continuity between IGN terminal Black of the combination switch and the engine ground at ON position page 11 4 Replace the combination switch page 7 10 Replace the ignition coil with a new one and recheck 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 49: ...5 1 5 5 COVER FAN COVER REMOVAL INSTALLATION 5 2 LOWER SHROUD REMOVAL INSTALLATION 5 5 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 50: ...AN COVER PROTECTOR SPECIAL SCREW 4 x 10 mm 4 BOLT 6 x 20 mm 4 SPECIAL SCREW 6 x 15 mm 2 4 N m 0 4 kgf m 3 0 lbf ft 1 7 N m 0 17 kgf m 1 3 lbf ft TAPPING SCREW 5 x 20mm 2 4 4 N m 0 45 kgf m 3 2 lbf ft FUEL TUBE A Clamp the fuel tube A to the hock of the fan cover 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 51: ...f ft NUT 6 mm 2 SCREEN GRID SCREEN GRID HOLDER BOLT 6 x 20 mm 2 SPECIAL SCREW 6 x 15 mm 2 TAPPING SCREW 5 x 20mm 2 BOLT 8 x 18 mm 3 SCREW 6 x 16 mm 3 BOLT 6 x 38 mm 3 FUEL TUBE A Clamp the fuel tube A to the hock of the fan cover 12 N m 1 2 kgf m 9 lbf ft 8 5 N m 0 85 kgf m 6 3 lbf ft 8 5 N m 0 85 kgf m 6 3 lbf ft 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 52: ... 0 lbf ft 4 4 N m 0 45 kgf m 3 2 lbf ft SCREEN GRID SCREEN GRID HOLDER BOLT 6 x 20 mm 4 SPECIAL SCREW 6 x 15 mm 2 TAPPING SCREW 5 x 20mm 2 BOLT 6 x 12 mm 3 SCREW 6 x 16 mm 3 BOLT 8 x 50 mm 3 FUEL TUBE A Clamp the fuel tube A to the hock of the fan cover 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 53: ...BOLT 6 x 20 mm BOLT 6 x 16 mm 2 1 2 R LOWER SHROUD HIGH TENSION CORD GROMMET ENGINE WIRE HARNESS GROMMET ENGINE WIRE HARNESS INSTALLATION Pass the engine wire harness through the R lower shroud and align the BOLT 6 x 20 mm 3 INSTALLATION Clamp the high tension cord 1 to the inside of the R lower shroud 2 and align the grommet 3 with the cutout in the shroud as shown 3 2 2 1 BOLT 6 x 16 mm 0 DQQM ࡍ...

Page 54: ...MEMO 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 55: ...AIR CLEANER REMOVAL INSTALLATION 6 3 FUEL PUMP REMOVAL INSTALLATION 6 4 CARBURETOR REMOVAL INSTALLATION 6 5 CARBURETOR DISASSEMBLY ASSEMBLY 6 6 PILOT SCREW REMOVAL INSTALLATION 6 7 CARBURETOR BODY CLEANING 6 7 CARBURETOR INSPECTION 6 8 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 56: ...is ON Add fresh gasoline Check for clogged fuel filter fuel tube and fuel strainer screen If they are normal replace the fuel pump page 6 4 Check the continuity between LO terminal Black yellow and BAT terminal White of the combination switch in the ON position page 11 4 Replace the combination switch page 7 10 Check the continuity of the wire harness connecting the combination switch and fuel cut...

Page 57: ...INSTALLATION AIR CLEANER COVER OUTER FILTER FOAM WING NUT INNER FILTER PAPER AIR CLEANER CASE AIR CLEANER ELEMENT STAY AIR CLEANER CASE PACKING 0 8 N m 0 08 kgf m 0 6 lbf ft NUT 6 mm BOLT 6 x 18 mm 4 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 58: ...ured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately FUEL FILTER FUEL TUBE B PURGE TUBE FUEL TUBE A TUBE CLIP C11 2 PULSE TUBE FUEL PUMP FUEL PUMP STAY 3 N m 0 3 kgf m 2 2 lbf ft SCREW 6 x 12 mm 2 BOLT 6 x 12 mm 2 TUBE CLAMP D10 0 4 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 59: ...LATION Install the fuel tube grommet stay 1 in contact with each projection 2 of stay and inlet manifold 3 REMOVAL Unhook the throttle return spring 1 from the carburetor throttle linkage 2 Then push off the carburetor throttle linkage to unsnap from the governor rod 3 Disconnect the governor rod from the throttle linkage BREATHER TUBE BREATHER TUBE CLIP AIR CLEANER CASE SEAL AIR CLEANER ELBOW AIR...

Page 60: ...stop screw 4 to secure the float pin as shown FUEL STRAINER SCREEN MAIN JET FLOAT PIN O RING DRAIN SCREW FUEL CUT SOLENOID STOP SCREW 4 2 FLOAT VALVE 1 3 PILOT JET PLATE FROAT CHAMBER FLOAT PILOT SCREW ASSEMBLY Before installing clean thoroughly with low compressed air 207 kPa 2 11 kgf cm2 30 psi or less Lightly lubricate the O ring 1 to ensure easy installation into the carburetor body 1 SCREW 4 ...

Page 61: ...and ports Clean the carburetor body with non flammable solvent Clean thoroughly the following passages and ports with low compressed air Pilot jet hole 1 Main air jet 2 Main nozzle holder 3 Pilot air jet 4 Bypass ports 5 Pilot outlet ports 6 Internal vent port 7 TOOL PILOT SCREW WRENCH D 2 07KMA MS60101 PILOT SCREW OPENING GX630 GX630R L side No 1 cylinder 2 turns out R side No 2 cylinder 1 7 8 tu...

Page 62: ...AT VALVE Check a worn float valve 1 Check the float valve and valve seat 2 for contamination Check for wear or a weak spring 3 After installation check the operation of float valve FUEL CUT SOLENOID Remove the fan cover page 5 2 Disconnect the wire harness 1 from the fuel cut solenoid 2 Apply 12V battery voltage between the terminal of the fuel cut solenoid 3 and engine ground and check the soleno...

Page 63: ... Without auto throttle type 7 3 GOVERNOR SPRING INSTALLATION 7 4 AUTO THROTTLE SOLENOID REMOVAL 7 5 AUTO THROTTLE SOLENOID GOVERNOR ARM INSTALLATION 7 6 CONTROL BOX REMOVAL INSTALLATION 7 8 THROTTLE CABLE INSTALLATION 7 9 CHOKE CABLE INSTALLATION 7 9 CONTROL BOX DISASSEMBLY ASSEMBLY 7 10 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 64: ...le linkage 2 Then push off the carburetor throttle linkage to unsnap from the governor rod 3 Disconnect the governor rod from the throttle linkage CONTROL PAN SCREW MAXIMUM SPEED ADJUSTING SCREW RECESSED BOLT 3 CABLE HOLDER PAN SCREW IDLING SPEED ADJUSTING SCREW CONTROL ADJUST SPRING GOVERNOR SPRING START SPRING GOVERNOR ROD THROTTLE RETURN SPRING 2 1 3 2 3 RETURN SPRING GOVERNOR ARM GOVERNOR ARM ...

Page 65: ...nd throttle return spring 5 to the governor arm and carburetor Loosen the governor sub arm nut 6 Rotate the governor arm counterclockwise to fully open the carburetor throttle valve Rotate the governor sub arm 7 counterclockwise as far as it will go Hold the governor arm and governor sub arm tighten the governor sub arm nut securely MAXIMUM SPEED 3 850 150 min 1 rpm 3 150 150 min 1 rpm GX630R QYD ...

Page 66: ...n the governor arm 3 The engine type is stamped on the crankcase near the engine serial number page 1 2 Model Type Spring position GX630 All types 1 GX630R Except QYD VEP4 VXD8 VXE1 VXF 1 QYD VEP4 VXD8 VXE1 VXF 2 GX660 All types 1 GX660R Except VXE1 1 VXE1 2 GX690 All types 1 GX690R Except VXE 1 VXE 2 1 2 3 SPRING POSITION 1 SPRING POSITION 2 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 67: ...ge 6 3 Disconnect the choke rod from the control page 7 2 Unhook the governor spring and start spring from the governor arm page 7 2 AUTO THROTTLE SOLENOID SPECIAL CAP NUT 2 SOLENOID STAY SOLENOID PLATE BOLT 6 x 14 mm 3 CONTROL BOLT 6 x 14 mm 2 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 68: ...onnect the governor rod 4 and throttle return spring 5 to the governor arm and carburetor Install the auto throttle solenoid 1 and solenoid plate 2 on the solenoid stay 3 and loosely tighten the two special cap nuts 4 Install the solenoid stay on the control 5 and tighten the two bolts 6 TORQUE 11 N m 1 1 kgf m 8 lbf ft 1 2 3 4 5 1 2 3 4 5 6 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 69: ...nd the pin 5 of the governor sub arm 6 is in the specified clearance Do not rotate the governor sub arm during this procedure Tighten the special cap nuts 7 to secure the auto throttle solenoid Check the clearance between the auto throttle lever and the governor sub arm pin Take up the slack of the auto throttle solenoid harness and route the crankcase page 2 9 Rotate the governor arm to fully ope...

Page 70: ...ble and the choke cable from the control Disconnect the combination switch terminals and con nector from the starter motor and regulator rectifier CONTROL BOX TERMINAL NUT 9 N m 0 9 kgf m 6 6 lbf ft BOLT 6 x 20 mm 2 CHOKE CABLE THROTTLE CABLE 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 71: ...nd CHOKE CABLE INSTALLATION Install the choke cable 1 on the control box bracket 2 Pull the choke knob 3 of the control box 4 to the fully closed position Hook the choke cable to the choke lever 5 of the control Pull the choke cable until the choke lever of the control touches with the control to fully close the carburetor choke valve Set the choke cable to the cable holder 6 of the control and be...

Page 72: ...L THROTTLE LEVER TAPPING SCREW 3 x 8 mm 2 CHOKE KNOB SOCKET BOLT 5 x 9 mm 2 CONTROL BOX BRACKET SPECIAL SCREW 6 x 8 mm CONTROL COVER CONTROL BOX GROMMET CHOKE CABLE BLADE FUSE FUSE COVER LOCK NUT 4 9 N m 0 5 kgf m 3 6 lbf ft 4 N m 0 4 kgf m 3 0 lbf ft 0 8 N m 0 08 kgf m 0 6 lbf ft TAPPING SCREW 5 x 14 mm COMBINATION SWITCH 1 2 SWITCH BOX BRACKET SPECIAL SCREW 5 x 10 5 mm 2 SCREW 5 x 8 mm 0 DQQM ࡍ ...

Page 73: ... SYSTEM TROUBLESHOOTING 8 3 COOLING FAN FLYWHEEL REMOVAL INSTALLATION 8 4 CHARGE COIL REMOVAL INSTALLATION 8 6 CHARGE COIL INSPECTION 8 7 REGULATOR RECTIFIER SYSTEM INSPECTION 8 7 REGULATOR RECTIFIER INSPECTION 8 8 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 74: ...BATTERY Gr Gr W Bl Gr Gr Gr Gr Gr CHARGE COIL 17 A REGULATOR FUSE 30 A RECTIFIER W W W Gr Bl Y Bl Y Bl Y LO BAT Bl Y W COMBINATION SWITCH BATTERY Gr Gr W Bl Gr Gr Gr Gr Gr REGULATOR FUSE 40 A RECTIFIER W W W CHARGE COIL 26 A Gr Gr Gr Gr Gr 2 7 A CHARGE COIL TYPE 17 A CHARGE COIL TYPE 26 A CHARGE COIL TYPE 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 75: ...ace the charge coil page 8 6 Check the regulator rectifier system page 8 7 Replace the wire harness connecting the regulator rectifier and combination switch charge coil Check the regulator rectifier page 8 8 If necessary replace it page 10 3 Replace the combination switch page 7 10 No continuity Continuity Check the continuity of the sub harness between combination switch and regulator rectifier ...

Page 76: ...wheel 1 with the special tool 2 and remove the special nut 3 TOOL Clutch center holder 2 07JMB MN50301 1 3 2 REMOVAL Hold the flywheel 1 with a commercially available strap wrench 2 and use a commercially available flywheel puller 3 to remove the flywheel FLYWHEEL COOLING FAN COOLING FAN SETTING PLATE SPECIAL NUT SPECIAL WOODRUFF KEY 1 3 2 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 77: ...ning the holes 4 with projections 5 as shown Attach the cooling fan setting plate 1 to the cooling fan 2 by aligning the claws of the cooling fan setting plate with the projections of the cooling fan Rotate the cooling fan setting plate clockwise to touch the claw of the cooling fan setting plate with projections of the cooling fan Apply a light coat of oil to the threads and the seating surface o...

Page 78: ...age 8 4 CHARGE COIL 17A CHARGE COIL 2 7A CHARGE COIL 26A CABLE STRAP HARNESS BRACKET INSTALLATION Be sure not to pinch the charge coil wire 1 with the harness bracket 2 1 2 BOLT 6 x 32 mm 4 BOLT 6 x 32 mm 4 BOLT 6 x 32 mm 3 BOLT 6 x 12 mm 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 79: ...l page 8 6 REGULATOR RECTIFIER SYSTEM INSPECTION Disconnect the regulator rectifier connector 1 and check the regulator rectifier connector terminals wire harness side as follows Resistance 2 7 A 1 95 2 93 ǡ 17 A 0 18 0 28 ǡ 26 A 0 17 0 25 ǡ 2 7 A 17 A TYPES 26 A TYPE Inspect between each terminals Item Terminal Specification Battery charging line White and ground Battery voltage should register C...

Page 80: ...1 п 290 22k ACG2 п 290 22k BAT п п SENSE 80k п 80k п 120k п CHG M 150k п 150k п 300k п GND п п п probe SENSE CHG M GND probe ACG1 п п п ACG2 п п п BAT п п п SENSE 2k 150k 8k 150k CHG M 300 30k 20k 300k GND п п 26 A Unit ǡ probe ACG1 ACG2 ACG3 probe ACG1 30k 420k 30k 420k ACG2 30k 420k 30k 420k ACG3 30k 420k 30k 420k BAT 30k 420k 30k 420k 30k 420k LAMP п п п GND 30k 950k 30k 950k 30k 950k probe BAT...

Page 81: ...9 1 9 9 IGNITION SYSTEM SYSTEM DIAGRAM 9 2 IGNITION SYSTEM TROUBLESHOOTING 9 2 IGNITION COIL REMOVAL INSTALLATION 9 4 SPARK TEST 9 5 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 82: ...rform the spark test page 9 5 Inspect the oil level switch page 11 3 Check the continuity of the wire harness connecting the oil level switch and ignition coils Yellow oil level switch applicable types Replace the engine wire harness Check the continuity between IGN terminal Black and GND terminal Green of the combination switch in the ON position page 11 4 Replace the combination switch page 7 10...

Page 83: ... Check the continuity of the wire harness connecting the combination switch and ignition coils Black Replace the engine wire harness Replace the ignition coil with a new one and recheck page 9 4 From page 9 2 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 84: ...ess gauge 3 of proper thickness between the ignition coil and the flywheel 4 Adjust the ignition coil air gap equally at both side Push the ignition coil firmly against the flywheel and tighten the flange bolts Remove the thickness gauge IGNITION COIL HIGH TENSION CORD CLAMP BOLT 6 x 32 mm 4 IGNITION COIL AIR GAP 0 2 0 6 mm 0 01 0 02 in 1 2 0 2 0 6 mm 0 01 0 02 in 0 2 0 6 mm 0 01 0 02 in 1 2 3 4 0...

Page 85: ...plug 2 Connect a known good spark plug 3 to the spark plug cap and ground the spark plug to the head cover bolt 4 Crank the engine by operating the starter motor several seconds and check whether sparks jump across the electrode Do not operate the starter motor for more than 5 seconds at a time When operating the starter motor several times in a row wait 10 20 seconds between operation to recover ...

Page 86: ...MEMO 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 87: ... SYSTEM DIAGRAM 10 2 STARTING SYSTEM TROUBLESHOOTING 10 2 STARTER MOTOR REMOVAL INSTALLATION 10 3 STARTER MOTOR DISASSEMBLY ASSEMBLY 10 4 STARTER MOTOR INSPECTION 10 5 BRUSH REPLACEMENT 10 8 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 88: ...ace the combination switch page 7 10 Replace the blade fuse Replace the magnetic switch page 10 4 Perform the starter motor performance test page 10 5 If necessary disassemble the starter motor page 10 4 and check the each parts page 10 6 7 Check the battery condition Check the battery voltage between the starter motor side positive battery cable terminal and engine ground Check the continuity bet...

Page 89: ...TARTER MOTOR REMOVAL INSTALLATION Disconnect the starter motor wires from the starter motor STARTER MOTOR REGULATOR RECTIFIER REGULATOR RECTIFIER BRACKET BOLT 6 x 32 mm BOLT 10 x 40 mm 2 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 90: ...a clean lint free cloth If rusted or damaged dress with a fine emery paper YOKE ASSEMBLY Make sure that there is no obstruction on the magnets COMMUTATOR END FRAME NEEDLE BEARING BRUSH HOLDER INSULATOR BRUSH HOLDER BRUSH SPRING BRUSH THROUGH BOLT 2 OVERRUNNING CLUTCH CLUTCH STOP COLLAR A CLUTCH STOP COLLAR B DISASSEMBLY Hold the armature 1 upright and drive the clutch stop collar A 2 Then remove t...

Page 91: ... cutout of the commutator end frame Tighten the through bolts to secure the drive housing and commutator end frame STARTER MOTOR INSPECTION PERFORMANCE TEST Measure starter performance while cranking the engine To get accurate results the test must be operated in the normal ambient temperature Battery 55B24 12 V 36 AH 5 HR Battery cable 15 sq x 1 5 m 4 9 ft each for battery positive cable and batt...

Page 92: ...ushes There should be continuity between both the negative brushes There should be no continuity between both the positive and negative brushes If the correct continuity is not obtained replace the yoke page 10 4 OVERRUNNING CLUTCH Hold the armature 1 as shown and check that the overrunning clutch 2 turns clockwise and slides smoothly If necessary apply oil or replace the overrunning clutch page 1...

Page 93: ... 10 4 ARMATURE CONTINUITY CHECK COMMUTATOR TO CORE Check for continuity between the commutator segments and the armature coil core Replace the armature if continuity exists between any of the commutator segments and the armature coil core page 10 4 ARMATURE CONTINUITY CHECK COMMUTATOR TO SHAFT Check for continuity between the commutator and the armature shaft Replace the armature if continuity exi...

Page 94: ...minal 3 and press it using a pair of pliers as shown Solder the plate on the terminal Before soldering heat the pressed part of the plate well to make sure solder reaches the end of the pressed part Prevent solder from flowing down the brush lead Do not allow solder to run down onto the field winding of the yoke File the brush so that the brush and commutator can fit using an emery paper 500 or 60...

Page 95: ...OMPONENT LOCATION 11 2 OIL LEVEL SWITCH INSPECTION 11 3 OIL PRESSURE SWITCH INSPECTION 11 3 AUTO THROTTLE SOLENOID INSPECTION 11 3 COMBINATION SWITCH INSPECTION 11 4 HOUR METER INSPECTION 11 5 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 96: ...OTHER ELECTRICAL 11 2 OTHER ELECTRICAL COMPONENT LOCATION OIL LEVEL SWITCH Control box type COMBINATION SWITCH HOUR METER OIL PRESSURE SWITCH AUTO THROTTLE SOLENOID 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 97: ...el switch page 15 4 OIL PRESSURE SWITCH INSPECTION With the combination switch OFF check continuity between the switch terminal and switch body There should be continuity Start the engine and check continuity between the switch terminal and switch body There should be no continuity If the correct continuity is not obtained replace the oil pressure switch page 13 3 AUTO THROTTLE SOLENOID INSPECTION...

Page 98: ...ination switch 4P connector 1 Remove the combination switch 4P connector and open the wire harness clip 2 to remove the wire harness Remove the special screw 3 and the control cover 4 Remove the blade fuse 5 from the fuse box 6 Visually inspect the blade fuse Check continuity between the blades of the fuse If there is not continuity replace the blade fuse OFF ON IGN GND ST BAT LO ST ST IGN Bl BAT ...

Page 99: ...ly a 9 V battery voltage between the PULSE terminal Yellow and GND terminal Green The hour meter should start counting time Apply a 4 5 V battery voltage between the LED terminal Blue and GND terminal Green The oil indicator should come on 1 GND G LED Bu PULSE Y 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 100: ...MEMO 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 101: ...IGH MOUNT MUFFLER REMOVAL INSTALLATION 12 2 SIDE MOUNT MUFFLER REMOVAL INSTALLATION 12 3 EXHAUST PIPE STUD BOLT REPLACEMENT 12 5 HIGH MOUNT MUFFLER MOUNTING STUD BOLT REPLACEMENT 12 5 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 102: ...the engine Be careful not to touch the muffler while it is hot Al low it to cool before proceeding MUFFLER PROTECTOR INSTALLATION Make sure the HOT mark on the protector is in an upward direction HOT MARK MUFFLER EXHAUST PIPE GASKET SPARK ARRESTER TAPPING SCREW 4 x 6 mm BOLT 6 x 8 mm 6 BOLT 8 x 20 mm 2 NUT 8 mm 6 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 103: ... while it is hot Al low it to cool before proceeding MUFFLER PROTECTOR OUTSIDE MUFFLER MUFFLER BAND EXHAUST PIPE GASKET SPARK ARRESTER MUFFLER PROTECTOR INSIDE MUFFLER STAY EXHAUST PIPE MUFFLER DEFLECTOR TAPPING SCREW 4 x 8 mm 3 BOLT 6 x 8 mm 4 NUT 8 mm 4 TAPPING SCREW 4 x 8 mm 2 BOLT 8 x 60 mm BOLT 8 x 20 mm 2 BOLT 6 x 12 mm 4 BOLT 8 x 30 mm BOLT 6 x 8 mm 2 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 104: ...l the two exhaust muffler gaskets 4 and exhaust pipe to the cylinders then slide the exhaust pipe to mark B Tighten the three bolts 5 to secure the muffler Tighten the four nuts 6 to secure the exhaust pipe Tighten the muffler band Install the muffler protector outside 7 and tighten the four bolts 8 35 mm 1 4 in 55 mm 2 2 in MARK B MARK A 1 1 8 5 6 4 2 7 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 105: ...MOUNT MUFFLER MOUNTING STUD BOLT REPLACEMENT Thread two nuts onto the stud bolt and tighten them together then use a wrench to turn the stud bolt out Install new stud bolts SPECIFIED LENGTH 22 mm 0 87 in 22 mm 0 9 in SPECIFIED LENGTH No 1 cylinder 60 mm 2 36 in No 2 cylinder 45 mm 1 77 in No 1 cylinder 60 mm 2 36 in No 2 cylinder 45 mm 1 77 in 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 106: ...MEMO 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 107: ...13 1 13 13 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 13 2 OIL PRESSURE TEST 13 3 OIL PUMP INSPECTION 13 4 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 108: ...LUBRICATION SYSTEM 13 2 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ROCKER ARM PISTON CRANKSHAFT OIL PRESSURE SWITCH OIL FILTER OIL PUMP OIL STRAINER 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 109: ... engine and allow it to warm up for 10 minutes While the engine is at idle measure the oil pressure If the oil pressure is less than the specification inspect the oil pump page 13 4 Remove the special tools 1 2 FRONT MOUNT TYPE SIDE MOUNT TYPE 1 2 TOOLS Oil pressure gauge attachment 1 07406 0030000 Oil pressure gauge set 2 07506 3000000 TORQUE 9 N m 0 9 kgf m 6 6 lbf ft OIL PRESSURE 2 8 kgf cm2 39...

Page 110: ... the inner rotor and outer rotor page 15 7 OUTER ROTOR TO HOUSING CLEARANCE Remove the crankcase cover page 15 2 Remove the oil pump cover page 15 7 Measure the oil pump outer rotor to housing clearance If the measurement is more than the service limit replace the outer rotor page 15 7 OUTER ROTOR TO PUMP COVER CLEARANCE Remove the crankcase cover page 15 2 Remove the oil pump cover page 15 7 Remo...

Page 111: ...ON INSTALLATION 14 3 CYLINDER INSTALLATION 14 3 CYLINDER DISASSEMBLY ASSEMBLY 14 5 PISTON DISASSEMBLY ASSEMBLY 14 6 CYLINDER PISTON INSPECTION 14 6 VALVE SEAT RECONDITIONING 14 13 CYLINDER STUD BOLT REPLACEMENT 14 14 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 112: ...r page 5 2 L R lower shroud page 5 5 Ignition coil page 9 4 Starter motor page 10 3 Oil level pipe page 15 2 Head cover page 3 8 REMOVAL Insert a screwdriver into the recess 1 as shown and remove the cylinder from the crankcase CYLINDER 1 ENGINE WIRE HARNESS PISTON PISTON PIN PISTON PIN CLIP DOWEL PIN 12 x 20 mm 2 PUSH ROD OIL PASSAGE PACKING UPPER SHROUD SPARK PLUG NUT 10 mm 4 BOLT 6 x 20 mm 2 RO...

Page 113: ...n clips 5 into the grooves in the piston pin hole Make sure the piston pin clips are seated securely Do not align the piston pin clip end gap 6 with the piston cutout 7 CYLINDER INSTALLATION Clean the mating surfaces of the cylinder and crankcase of old liquid gasket oil and other foreign material Loosely install the fan cover and set the piston near top dead center by rotating the crankshaft slow...

Page 114: ...ts 5 and tighten them to the specified torque Assemble the cylinder within 3 minutes after applying liquid gasket Wait for 30 minutes after assembly before filling with oil and starting the engine Apply oil to the both end of the two push rods 6 and insert them into the cylinder Apply oil to the bearing and slipper of the rocker arms 1 and install them to the cylinder Apply oil to the rocker arm s...

Page 115: ...e the cylinder is installed to the crankcase or the valve will drop into the cylinder VALVE SPRING RETAINER 1 2 VALVE SPRING VALVE STEM SEAL CYLINDER ASSEMBLY Do not interchange with the exhaust valve The inlet valve is larger than the exhaust valve INLET VALVE ASSEMBLY Do not interchange with the inlet valve The exhaust valve is smaller than the inlet valve EXHAUST VALVE VALVE GUIDE CLIP ENGINE H...

Page 116: ... compression Do not operate the starter motor for more than 5 seconds at a time When operating the starter motor several times in a row wait 10 20 seconds between operation to recover the battery voltage ASSEMBLY The top ring 1 and second ring 2 are not interchangeable Install the top ring and second ring on the piston with the mark side facing up Check that the piston rings rotate smoothly after ...

Page 117: ... on the seat The transferred marking compound will show any area of the valve face that is not concentric Measure the valve seat width of the cylinder If the measurement is more than the service limit recondition the valve seat page 14 13 Check whether the valve seat contact area of the valve is too high If the valve seat is too high recondition the valve seat page 14 13 VALVE GUIDE I D Ream the v...

Page 118: ...f the calculated clearance is more than the service limit replace the following Valve page 14 5 Cylinder page 14 5 VALVE SPRING FREE LENGTH Measure the valve spring free length If the measured length is less than the service limit replace the valve spring page 14 5 STANDARD 5 500 5 512 mm 0 2165 0 2170 in SERVICE LIMIT 5 560 mm 0 2189 in STANDARD IN 5 475 5 490 mm 0 2156 0 2161 in EX 5 435 5 450 m...

Page 119: ...place the push rod page 14 2 ROCKER ARM I D Measure the rocker arm I D If the measurement is more than the service limit replace the rocker arm page 14 4 ROCKER ARM SHAFT O D Measure the rocker arm shaft O D If the measurement is less than the service limit replace the rocker arm shaft page 14 4 STANDARD 2 max STANDARD 6 000 6 018 mm 0 050 0 077 in SERVICE LIMIT 6 043 mm 0 2379 in STANDARD 5 960 5...

Page 120: ... CLEARANCE Subtract the piston skirt O D from the cylinder sleeve I D to obtain the piston to cylinder clearance If the calculated clearance is more than the service limit replace the piston page 14 6 and recheck the clearance If the clearance is still more than the service limit with the new piston replace the cylinder page 14 5 STANDARD 6 000 6 018 mm 0 050 0 077 in SERVICE LIMIT 6 043 mm 0 2379...

Page 121: ...E Measure the clearance between each piston ring and ring groove of the piston using feeler gauge If any of the measurements is more than the service limit inspect the piston ring width If necessary replace the piston rings top second oil as a set page 14 6 and reinspect the clearance If any of the measurements is still more than the service limit with the new piston rings replace the piston page ...

Page 122: ...e piston rings top second oil as a set page 14 6 CONNECTING ROD SMALL END I D Measure the connecting rod small end I D If the measurement is more than the service limit replace the connecting rod page 15 4 STANDARD Top 1 140 1 155 mm 0 0449 0 0455 in Second 1 140 1 155 mm 0 0449 0 0455 in SERVICE LIMIT Top 1 120 mm 0 0441 in Second 1 120 mm 0 0441 in STANDARD Top 0 200 0 350 mm 0 0079 0 0138 in Se...

Page 123: ...y Prussian Blue compound or erasable felt tipped marker ink to the valve seat Insert the valve and snap it closed against its seat several times Be sure the valve does not rotate on the seat The seating surface as shown by the transferred marking compound should have good contact all the way around Thoroughly clean the cylinder to remove any cutting residual TOOLS Cutter holder 5 5 mm 1 07981 VA20...

Page 124: ...remove all lapping compound from the engine before reassembly Adjust the valve clearance after reassembly page 3 8 CYLINDER STUD BOLT REPLACEMENT Thread two nuts onto the stud bolt and tighten them together then use a wrench to turn the stud bolt out Install new stud bolts 1 SPECIFIED LENGTH Upper side 1 40 5 mm 1 59 in Lower side 2 30 5 mm 1 20 in 30 5 mm 1 20 in 40 5 mm 1 59 in 1 2 0 DQQM ࡍ ࠫ 㧞㧜...

Page 125: ...LY 15 5 BREATHER COVER INSTALLATION 15 6 GOVERNOR OIL PUMP OIL FILTER DISASSEMBLY ASSEMBLY 15 7 VALVE LIFTER DISASSEMBLY ASSEMBLY 15 8 CRANKCASE COVER CRANKCASE CRANKSHAFT CONNECTING ROD CAMSHAFT VALVE LIFTER INSPECTION 15 8 CRANKSHAFT OIL SEAL REPLACEMENT CRANKCASE COVER SIDE 15 13 CRANKSHAFT GOVERNOR ARM SHAFT OIL SEAL REPLACEMENT CRANKCASE SIDE 15 14 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 126: ...MOVAL Drain the engine oil page 3 4 O RING OIL LEVEL PIPE DOWEL PIN 8 x 14 mm 2 CRANKCASE COVER REMOVAL Insert a screwdriver into the recess 1 as shown and remove the crankcase cover from the crankcase 1 BOLT 8 x 45 mm 9 O RING 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 127: ... as shown Apply grease to the O ring 1 Install the two dowel pins 2 and O ring to the crankcase Apply a light coat of oil to the main journal part of the crankshaft and crankcase cover 3 Install the crankcase cover and tighten the nine flange bolts 4 securely Assemble the crankcase cover within 3 minutes after applying liquid gasket Wait for 30 minutes after assembly before filling with oil and st...

Page 128: ...er and lower are not interchangeable GOVERNOR ARM SHAFT 1 2 DRAIN PLUG BOLT 20 mm 2 DRAIN PLUG WASHER 20 mm 2 OILLEVEL SWITCH O RING LOCK PIN CONNECTING ROD BOLT 4 22 N m 2 2 kgf m 16 lbf ft CONNECTING ROD LOWER CRANKSHAFT THRUST WASHER CRANKSHAFT INSTALLATION Before installing the crankshaft check the crankcase oil seal for damage or hardening Be careful not to damage the oil seal when installing...

Page 129: ...mshaft and the crankshaft 4 marked on the timing gear BREATHER DISASSEMBLY ASSEMBLY Remove the charge coil page 8 6 1 2 3 4 BREATHER COVER BREATHER FILTER OIL OUTLET VALVE STOPPER PLATE 1 N m 0 1 kgf m 0 7 lbf ft BOLT 6 x 14 mm 3 SCREW 3 x 8 mm INSTALLATION Install the breather filter until it is fully seated on the end 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 130: ...eebond TB1207B to the mating surface of the crankcase as shown Install the breather cover 1 and tighten the three flange bolts 2 securely Be sure not to catch the breather filter between the breather cover and crankcase Assemble the breather cover within 3 minutes after applying liquid gasket Wait for 30 minutes after assembly before filling with oil and starting the engine 1 2 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝...

Page 131: ...FT OIL PUMP OUTER ROTOR RELIEF VALVE SPRING STEEL BALL GOVERNOR SLIDER GOVERNOR HOLDER CLIP GOVERNOR WEIGHT PIN O ring OIL FILTER BASE SIDE MOUNT TYPE BOLT 6 x 35 mm 2 BOLT 6 x 28 mm BOLT 6 x 90 mm 2 BOLT 6 x 28 mm BOLT 6 x 20 mm WASHER 6 x 16 mm BOLT 6 x 20 mm 3 INSTALLATION Install the inner rotor with the punch mark side facing up INSTALLATION Install the outer rotor with the punch mark side fa...

Page 132: ...RANCE Remove the connecting rods page 15 4 Reinstall the crankcase cover Measure the crankshaft axial clearance If the measurement is more than the service limit inspect the crankshaft thrust washer page 15 10 VALVE LIFTER SHAFT VALVE LIFTER COLLAR VALVE LIFTER VALVE LIFTER SPRING CLIP STANDARD 0 05 0 45 mm 0 002 0 018 in SERVICE LIMIT 1 0 mm 0 04 in 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 133: ...ng I D of the crankcase cover If the measurement is more than the service limit replace the crankcase cover page 15 7 CAMSHAFT BEARING I D CRANKCASE SIDE Measure the camshaft bearing I D of the crankcase If the measurement is more than the service limit replace the crankcase page 15 4 STANDARD 40 025 40 041 mm 1 5758 1 5764 in SERVICE LIMIT 40 06 mm 1 577 in STANDARD 40 025 40 041 mm 1 5758 1 5764...

Page 134: ... 15 4 CONNECTING ROD BIG END SIDE CLEARANCE Measure the clearance between the connecting rod big end and crankshaft using a feeler gauge If the measurement is more than the service limit replace the connecting rod page 15 4 and recheck the clearance If the clearance is still more than the service limit with the new connecting rod replace the crankshaft page 15 4 STANDARD 44 973 44 983 mm 1 7706 1 ...

Page 135: ...haft while the plastigauge is in place Remove the connecting rod and measure the plastigauge If the clearance is more than the service limit replace the connecting rod bearings page 15 4 and recheck the clearance If the clearance is still more than the service limit with the new connecting rod bearings replace the crankshaft page 15 4 CAMSHAFT CAM HEIGHT Measure the cam height of the camshaft If t...

Page 136: ...rrectly replace the camshaft page 15 5 VALVE LIFTER I D Measure the valve lifter I D If the measurement is more than the service limit replace the valve lifter page 15 8 VALVE LIFTER SHAFT O D Measure the valve lifter shaft O D If the measurement is less than the service limit replace the valve lifter shaft page 15 8 STANDARD 16 982 17 000 mm 0 6686 0 6693 in SERVICE LIMIT 17 100 mm 0 6732 in 1 2 ...

Page 137: ...m the crankcase cover 2 Apply oil to the outer surface of a new oil seal Drive the new oil seal in the position as shown using the special tools Apply grease to the lip of a new oil seal TOOLS Driver handle 15 x 135L 3 07749 0010000 Oil seal driver attachment 60 mm 4 07GAD PG40100 CRANKSHAFT OIL SEAL 38 x 58 x 9 mm 1 2 3 4 1 0 mm 0 04 in 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 138: ...pply oil to the outer surface of a new oil seal Drive the new oil seal in the position as shown using the special tools Apply grease to the lip of a new oil seal TOOLS Driver handle 15 x 135L 3 07749 0010000 Oil seal driver attachment 60 mm 4 07GAD PG40100 CRANKSHAFT OIL SEAL 38 x 58 x 9 mm GOVERNOR ARM SHAFT OIL SEAL 10 x 16 x 5 mm 1 2 3 4 1 0 1 5 mm 0 04 0 06 in 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢...

Page 139: ...l 1 from the crankcase 2 Apply oil to the outer surface of a new oil seal Drive the new oil seal until it is fully seated on the end using the special tools Apply grease to the lip of a new oil seal TOOLS Driver handle 15 x 135L 3 07749 0010000 Pilot 17 mm 4 07746 0040400 1 3 4 2 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 140: ...MEMO 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 141: ...16 1 16 16 TECHNICAL FEATURES HIGH COMPRESSION ENGINE 16 2 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 142: ...the spark plug closer to the center of the combustion chamber Intake exhaust efficiency improvement Arranging the valves in a radial pattern allows the cylinder to have smoother intake and exhaust ports and the port angle has been narrowed Cooling efficiency improvement The cylinder block has been integrated with the cylinder head It eliminates the use of the low thermal conductivity steel cylinde...

Page 143: ...hamber The GX630 GX630R GX660 GX660R GX690 GX690R engines are equipped with the C D I ignition coil that sets the optimum ignition timing in accordance with the engine speed to prevent knocking The ignition coil also is equipped with the engine speed limiter and an oil alert function that shuts down the engine if it senses signal from the oil level switch 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 144: ...MEMO 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 145: ...CHARGE COIL REMOTE CONTROL TYPE 17 2 2 7A CHARGE COIL CONTROL BOX TYPE 17 2 17A CHARGE COIL REMOTE CONTROL TYPE 17 3 17A CHARGE COIL CONTROL BOX TYPE 17 3 26A CHARGE COIL REMOTE CONTROL TYPE 17 4 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 146: ... No 1 IGNITION SPARK PLUG OIL LEVEL SOLENOID COIL SWITCH No 2 IGNITION SPARK PLUG COIL COMBINATION SWITCH Black Yellow Blue Green Red White Gray Pink Light green Light blue Orange Brown W R G Bu Y Bl Gr P Lg Lb O Br Y Gr Bl W Gr Bl BAT ST LO GND IGN W Bl Y Bl W W G Bl Y Bl Bu Y Bl Bl Y Bu Bl Y Bl Y Bu Bl Y Bl Gr Bu Y Bl Y G Bu Y Bl Y G Bl Y W Bl W W W G OFF ON IGN GND ST BAT LO ST Gr Bl W Bl CHARG...

Page 147: ...ITION SPARK PLUG OIL LEVEL SOLENOID COIL SWITCH No 2 IGNITION SPARK PLUG COIL COMBINATION SWITCH Black Yellow Blue Green Red White Gray Pink Light green Light blue Orange Brown W R G Bu Y Bl Gr P Lg Lb O Br Gr Y Gr W Bu Bl Y W Bl Gr Gr W Bu Bl Y W Bl Gr Gr Bl Y W Gr Gr Bl Y BAT ST LO GND IGN W Bl Y Bl W W G Bl Y Bl Bu Y Bl Bl Y Bu Bl Y Bl Y Bu Bl Y Gr Gr Bu Y Bl Y G Bu Y Bl Y G Bl Y W Bl W W W G O...

Page 148: ...Bl Gr Gr W Gr Gr BAT ST LO GND IGN W Bl Y Bl W W G Bl Y Bl Y Bl Bl Bl Y Bl Bl Y Gr Gr Bl Y W Bl W W W G OFF ON IGN GND ST BAT LO ST Gr Gr Gr Gr CHARGE COIL 26 A REGULATOR RECTIFIER FUSE 40 A COMBINATION SWITCH STARTER MOTOR BATTERY FUEL CUT No 1 IGNITION SPARK PLUG OIL LEVEL SOLENOID COIL SWITCH No 2 IGNITION SPARK PLUG COIL COMBINATION SWITCH 0 DQQM ࡍ ࠫ 㧞㧜㧜㧥ᐕ㧢㧝㧢ᣣ ޓ Ἣᦐᣣ ޓ ඦᓟ㧢ᤨ㧝㧣ಽ ...

Page 149: ...NOR ARM CONTROL REMOVAL INSTALLATION 7 2 GOVERNOR SPRING INSTALLATION 7 4 GOVERNOR OIL PUMP OIL FILTER DISASSEMBLY ASSEMBLY 15 7 H HARNESS ROUTING 2 8 HIGH MOUNT MUFFLER REMOVAL INSTALLATION 12 2 HIGH COMPRESSION ENGINE 16 2 HOUR METER INSPECTION 11 5 I IDLE SPEED CHECK ADJUSTMENT 3 8 IGNITION COIL REMOVAL INSTALLATION 9 4 L LOWER SHROUD REMOVAL INSTALLATION 5 5 LUBRICATION SEAL POINT 2 5 LUBRICAT...

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Honda GX630, Workshop Manual

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