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Honda GX630, Service Manual

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Honda GX630 Service Manual Download Page 32

3-1

3

3. MAINTENANCE

MAINTENANCE SCHEDULE························· 3-2

ENGINE OIL LEVEL CHECK ························· 3-3

ENGINE OIL CHANGE··································· 3-4

OIL FILTER REPLACEMENT ························ 3-4

AIR CLEANER 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

62Z6N000.book  1 ページ  ２００９年６月１６日　火曜日　午後６時１７分

Summary of Contents for GX630

Page 1: ...afety 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...

Page 2: ...HOOTING 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 62Z6N000 book 2 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 3: ...e 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 These ...

Page 4: ... 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 recommend...

Page 5: ...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 Injection...

Page 6: ...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 62Z6N000 book 1 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 7: ... 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 Ma...

Page 8: ...rque 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 system...

Page 9: ... 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 62Z6N000 book 4 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 10: ... 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 62Z6N000 book 5 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

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 62Z6N000 book 6 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 12: ... 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 62Z6N000 book 7 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 13: ...LER 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 62Z6N000 book 8 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 14: ... 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 96 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 62Z6N000 book 9 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 15: ... 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 62Z6N...

Page 16: ...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 62Z6N000 book 11 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 17: ...MEMO 62Z6N000 book 12 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 18: ...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 62Z6N000 book 1 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 19: ...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 18 ...

Page 20: ...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 No ...

Page 21: ...ing 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 M6 ...

Page 22: ...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 seati...

Page 23: ...7746 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 62Z6N000 book 6 ページ ２００９年６月１６日 火曜日 午後６時１７...

Page 24: ...FORMATION 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 62Z6N000 book 7 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 25: ...RD 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 62Z6N000 book 8 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 26: ...NESS 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 62Z6N000 book 9 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 27: ... 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 62Z6N000 book 10 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 28: ...ss 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 62Z6N000 book 11 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 29: ...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 62Z6N0...

Page 30: ...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 62Z6N000 book 13 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 31: ...SERVICE INFORMATION 2 14 RIGHT SIDE VIEW DRAIN TUBE FUEL FILTER TUBE CLAMP D10 0 FUEL TUBE A FUEL PUMP 62Z6N000 book 14 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 32: ...ER 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 62Z6N000 book 1 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

Page 33: ...r 500 hrs Refer to page ITEM Perform at every indicated month or operating hour interval whichever comes first Engine oil Check level 3 3 Change 3 4 Engine oil filter Replace Every 200 hours 3 4 Air cleaner Check 3 5 Clean 1 3 5 Replace 3 6 Spark plug Check adjust 3 6 Replace 3 7 Spark arrester applicable types Clean 3 7 Idle speed Check adjust 3 8 Valve clearance Check adjust 3 8 Combustion chamb...

Page 34: ...nd 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 are...

Page 35: ...er 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 m...

Page 36: ...e 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 th...

Page 37: ...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 spa...

Page 38: ... 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 s...

Page 39: ...nge 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 on ...

Page 40: ...sting 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 valve c...

Page 41: ... 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 the...

Page 42: ...s 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 62Z6N000 book 11 ページ ２００９年６月１６日 火曜日 午後６時１７分 ...

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