Honda GX 610 standard Owner'S Manual Download

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Summary of Contents for GX 610 standard

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Page 3: ... of the engine and should remain with the engine if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations are based on the GX620 QDW type Honda Motor Co Ltd reserves the right however to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever No part of...

Page 4: ...That information is intendedtohelpyouavoid damage to your engine other property or the environment We suggestyoureadthewarrantypolicytofullyunderstand its coverage and your responsibilities of ownership The warranty policy is a separate document that should have been given to you by your dealer When your engine needs scheduled maintenance keep in mind that your Hondaservicingdealer is speciallytra...

Page 5: ...ng an engine You must use your own good judgment You willfindimportantsafetyinformationin a varietyofforms including Safety Messages preceded by a safety alert symbol kl and one of three signal words DANGER WARNING or CAUTION These signal wordsmean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be H...

Page 6: ... YOUR ENGINE READY TO GO 14 Checkthe General Condition of the Engine 14 Checkthe Engine 15 Checkthe EquipmentPowered by This Engine 15 OPERATION 16 SAFEOPERATINGPRECAUTIONS 16 STARTINGTHE ENGINE 16 STOPPING THE ENGINE 20 SETTING ENGINESPEED 21 SERVICING YOUR HONDA ENGINE 22 THE IMPORTANCEOF MAINTENANCE 22 MAINTENANCE SAFETY 23 MAINTENANCE SCHEDULE 24 FUEL RECOMMENDATIONS 25 ENGINE OILLEVEL CHECK 2...

Page 7: ...GINEWILL NOT START 45 ENGINE LACKSPOWER 45 FUSE REPLACEMENT 3A charge coil and switch box type 46 TECHNICAL CONSUMER INFORMATION 47 TECHNICAL INFORMATION 47 Serial Number Location 47 Battery Connectionsfor Electric Starter 48 Remote Control Linkage 49 Carburetor Modification for High Altitude Operation 51 Oxygenated Fuels 52 Air Index 55 Specifications 56 Wiring Diagrams 58 CONSUMER INFORMATION 60...

Page 8: ... to operate the engine Keep children and pets away from the area of operation Refuel With Care Gasoline is extremelyflammable andgasolinevapor can explode Refuel outdoors in a well ventilated area with the engine stopped Never smoke near gasoline and keep other flames and sparks away Always store gasoline in an approved container If any fuel is spilled make sure the area is dry before starting the...

Page 9: ...n the engine in a closed garage orconfined 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 10: ...NENT CONTROL LOCATIONS GX61O GX620 FUEL FILTER I AIR CLEANER CHOKE KNOB THROlTLE LEVER ENGINE SWITCH OIL PRESSURESWITCH STARTER GRIP I FLYWHEEL PROTECT PTOTYPE TYPE S T D SCREENGRID RECOIL ARTER optional parts EQUIPPEDTYPE 7 ...

Page 11: ...CONTROLS FEATURES GX61O GX620 SIDE MOUNT MUFFLER HIGH MOUNT MUFFLER A type OIL FILLER CAP HIGH MOUNT MUFFLER B type SPARK OIL DRAIN BOLT ELECTRIC STARTER 8 ...

Page 12: ...CONTROLS FEATURES OIL COOLER 9 ...

Page 13: ...tch 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 The key automatically returns to the ON position whenreleased from theSTART position ENGINE SWITCH 10 ...

Page 14: ...engine The OPEN positionprovidesthecorrectfuelmixtureforoperation after starting and for restarting a warm engine Some engine applications use a remotely mounted choke control rather than the engine mounted choke knob shown here Refer to the instructions provided with the equipment powered by this engine for remote control information CHOKEKNOB CLOSED 11 ...

Page 15: ...slower Someengineapplications use a remotely mountedthrottlecontrol rather than the engine mounted throttle lever shown here Refer to the instructions provided with the equipment powered by this engine for remote control information THROlTLE LEVER Recoil Starter Grip Pulling thestarter grip operates the recoil starter to crank the engine STARTER GRIP 12 ...

Page 16: ... the engine oillevel page 26 before troubleshootingin other areas Fuel cutSolenoid The engine is equipped with a fuel cut solenoid that allows fuel to flow to the carburetor main jetwhentheengineswitchis in the ON or START position and stops the flow of fuel to the main jet when the engine switch isin the OFF position The engine must be connected to the battery to energize the fuel cut solenoid al...

Page 17: ...n could cause a malfunction in which you could be seriously injured Always performa preoperation inspection beforeeach operation and correct any problem Before beginning your preoperation checks be sure the engine is level and the engine switch is in the OFF position Check the General Conditionof the Engine Look around and underneath the engine for signs of oil or gasoline leaks Remove any excessi...

Page 18: ...xpectedshutdown always check the engine oil level before startup Check the air filter see page 30 A dirty air filter will restrict airflow to thecarburetor reducing engine performance Check the fuellevel Startingwith a full tank will help to eliminate or reduce operating interruptions for refueling Check the Equipment PoweredbyThis Engine Review the instructions provided with the equipment powered...

Page 19: ...unconsciousness and evenkill you Avoid any areas or actionsthat expose you tocarbon monoxide Review the instructions provided with the equipment powered by this engine for any safety precautions that should be observed in conjunction with engine startup shutdown or operation STARTING THE ENGINE 1 If the fuel tank is equipped witha valve be sure the fuel valve is in the OPEN or ON position before a...

Page 20: ...e Refer to theinstructionsprovidedwiththeequipmentpoweredbythis en gine for remote control information CHOKE KNOB 3 Move the throttle lever away from the SLOW position about 1 3 of the way toward the FAST position Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here Refer to theinstructionsprovidedwith the equipment powered by th...

Page 21: ...WITCH 4 Turn the engine switch to the ON position 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 18 ...

Page 22: ...t 10 secondsbeforeoperating the starter again OFF piEq Using theelectric starter formore than 5 seconds at a timewill overheat the starter motor and can damage it When the enginestarts release the key allowing it to return to theON position 6 If the choke knob has been pulled to the CLOSED position to start the engine graduallypush it to the OPEN position as theengine warms up CHOKEKNOB CLOSED 19 ...

Page 23: ...on Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here Refer to the instructions provided with the equipment powered by this en gine for remote control information THROlTLE LEVER m a 2 Turn the engine switch to the OFF position OF ENGINE SWITCH 3 If the fuel tank is equipped with a valve turn the fuel valve to the CLOSED or OFF ...

Page 24: ... mounted throttle lever shown here For engine speed recommendations referto theinstructions provided with the equipment powered by this engine THROlTLE LEVER Do not disconnect the battery from the engine while the engine is running Disconnecting the battery causes the fuel cut solenoid to shut off the flow of fuel to the carburetor main jet and the engine will stop 21 ...

Page 25: ...cedures andsimple maintenance procedures using basic hand tools Other service tasks that are moredifficult orrequirespecialtools 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 If you operate your engine under unusual conditions such as sustained high load or high temperat...

Page 26: ...onoxide poisoning from engineexhaust Be sure there is adequate ventilation whenever you operate the engine Let the engine and exhaust systemcool before touching Burns from hotparts Injury from moving parts Do not run the engine unless instructedto doso Readthe instructions before you begin and make sure you tools andskills required have the To reduce thepossibilityoffireor explosion becarefulwhen ...

Page 27: ...or or or 20 Hrs 50 Hrs 100 Hrs 300 Hrs 200 Hrs I I I I O 1 I I 0 l o I O 2 I O 2 After every 500 Hrs 2 Emission related items Replacethe paper air filter element only 1 Service more frequently whenused 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 Honda shop manual for service procedures 3 For comm...

Page 28: ...n the fuel tank Occasionally you may hear a light spark knock or pinging metallic rapping noise while operating under heavy loads This is no cause for concern If sparkknock orpinging occursat a steadyengine speed under normal load changebrands of gasoline Ifsparkknock orpinging persists see an authorized Honda servicing dealer m Running the engine with persistent spark knock or pinging can cause e...

Page 29: ...ick then removeit to check the oillevel 5 If the oil level is low remove the oil filler cap and fill to the upper limit mark on the dipstick with the recommended oil see page 29 6 Reinstall the dipstick and filler cap UPPER LIMIT LOWER LIMIT p E q Running the engine with a low oillevel can causeengine damage The Oil Alert system applicable engine types will automatically stop the engine before the...

Page 30: ...t in thetrash pour it on the ground or down adrain 3 With the engine ina level position fill to the upper limit mark on the dipstickwith the recommended oil see page 29 ENGINE OILREFILL CAPACITIES Without oil filter replacement approximately 1 16 US qt 1 10 0 0 97 Imp qt Withoilfilterreplacement approximately1 48 US qt 1 40 0 1 23 Imp qt Running the engine with a low oil level can causeengine dama...

Page 31: ...n oil filtersocket rather than a strap wrench to avoidstriking and damaging the oil pressure switch SEAL OIL FILTER SOCKET v 3 Clean the filter mountingbase and coatthe seal of the new oil filter with clean engine oil 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 cau...

Page 32: ...escribed on page 26 If necessary add oil to bring the oil level to the upper limit mark o dipstick ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting performance and service life Use 4 stroke automotive detergent oil SAE 1OW 30 is recommendedfor general use Other viscositiesshown in the chart maybe usedwhen theaverage temperature in your area is within the recommendedrange SAE Viscosity Gr...

Page 33: ...ean or replace dirty filterelements Always replace damaged filterelements Refer to page31 for instructions that apply to the air cleaner and filter service STANDARD TYPE AIR CLEANER COVER FOAMFILTER ELEMENT PAPER FILTER ELEMENT AIR CLEANER CASE SNORKEL TYPE PAPER FILTER ELEMENT AIR CLEANER COVER AIR CLEANER 30 ...

Page 34: ...the engine causing rapid engine wear This type of damage is not covered by the Distributor s Limited Warranty Standard Type 1 Release four latch tabs from the aircleaner cover and remove the cover 2 Removethe foam filter from the cover 3 Remove the paper filter from the air cleaner case AIR CLEANERCOVER FOAM FILTER ELEMENT PAPER FILTER ELEMENT 4 Inspect bothairfilter elements and replace themifthe...

Page 35: ...y Or clean in nonflammable solvent and allow to dry Do not put oil to the foam element 6 Wipe dirt from the inside of the air cleaner body and cover using a moist rag Be careful to prevent dirt from entering the air chamber that leads to the carburetor 7 Place thefoam airfilterelement totheaircleaner cover then reinstall the paper air filter element and cover to the aircleaner case Hook four latch...

Page 36: ...e dirt or blow compressed air not exceeding 30 psi 207 kPa 2 1 kgkm through the filter element from theinside Never try to brush off dirt brushing will force dirt into the fibers 6 Wipe dirt from the inside of the air cleaner case and cover using a moist rag Be careful to prevent dirt from entering the air duct that leads to the carburetor 7 Reinstall the paper air filter element Tighten the air f...

Page 37: ...om entering the air chamber that leads to the carburetor 3 Pinch off the fuel filter from the air cleanercase 6 rnrn BOLTS 5 rnrnSPECIAL BOLTS AIR CLEANERCASE 4 Check the fuel filter for water accumulation or sediment If no water or sediment is found reinstall the fuel filter and the air cleaner case FUEL FILTER 5 Ifthefuelfilterisfoundwith excessive wateraccumulation or sediment take the engineto...

Page 38: ...g area SPARK PLUG 3 Inspect the sparkplugs Replace them if the electrodes are worn or if the insulator is cracked or chipped Clean the spark plugs with a wirebrushifyou are goingto 0 028 0 031in reuse them 0 70 0 80 rnrn 4 Measurethesparkplugelectrode gap with a suitable gauge The gap should be 0 028 0 031 in 0 70 0 80 mm Correct the gap if neces sary by carefully bending the side electrode SPARK ...

Page 39: ...r If reinstalling the used sparkplugs tighten 1 8 1 4 turn after the spark plug seats If installing a new spark plugs tighten 1 2 turn after the spark plug seats 1 A loose spark plug can overheat and damage the engine Overtighteningthe spark plug can damage thethreads in the cylinder head 7 Attach thespark plug caps 36 ...

Page 40: ...iced every 100 hoursto keep it functioning as designed If the enginehas been running the muffler will be very hot Allow the muffler to cool before servicing the spark arrester 1 HIGH MOUNT MUFFLER TYPE Remove the special screw from the muffler and remove the spark arrester SIDE MOUNT MUFFLER TYPE Remove the 6 mm flange bolts from the muffler protector and remove the muffler protector Remove the sp...

Page 41: ...en Be careful to avoid damaging the screen Thesparkarrester must be free of breaks and holes Replace the spark arresterif it is damaged HIGH MOUNTMUFFLER TYPE SIDE MOUNT MUFFLER TYPE SPARK ARRESTERSCREEN 3 Install thespark arrester and muffler protector in the reverse order of disassembly 38 ...

Page 42: ...ler can enter the cylinder causing damage Water contacting ahot engine can cause damage If the enginehas been running allow it tocoolforat least half an hour before washing Fuel Gasoline will oxidize and deteriorate in storage Oldgasoline will cause hard starting and it leaves gum depositsthatclogthefuel system Ifthe gasolinein yourengine deteriorates during storage you may need to have the carbur...

Page 43: ...E When adding a fuel stabilizer fill the fuel tank with fresh gasoline If onlypartiallyfilled airinthe tank willpromotefueldeterioration during storage If you keep a container of gasoline for refueling be sure thatit contains only fresh gasoline 1 Add fuel stabilizer following the manufacturer s instructions 2 After addinga fuel stabilizer run the engine outdoors for 10 minutes to be sure that tre...

Page 44: ...position to enable draining After draining is completed reconnect the fuel line 2 Loosen the carburetor drainscrew and drain the carburetor into an approvedgasolinecontainer Afterdraining is completed tighten the carburetor drain screw Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparksand flameaway Handle fuel only outdoors Wipe up...

Page 45: ...e in thefueltankand carburetor it isimportantto reduce the hazard of gasolinevapor ignition Select a well ventilated storagearea away from any appliance that operateswith a flame such as a furnace water heater or clothes dryer Also avoid any area with a spark producing electric motor or where power tools are operated If possible avoidstorage areas withhighhumidity because that promotes rust and co...

Page 46: ...e it in a cool dry place Rechargethe batteryonce a month while the engine is in storage This i will help to extendtheservicelifeofthebattery Removal From Storage Check your engineas described in the BEFOREOPERATIONchapter of this manual If the fuel was drained during storage preparation fill the tank with freshgasoline If you keep a container of gasoline for refueling be sure that it contains only...

Page 47: ...s before loading the engine powered equipment on the transport vehicle A hot engine and exhaust system can burn you andcan ignite some materials Keep the engine level when transporting to reduce the possibility of fuel leakage If the fuel tank is equipped with a fuel valve move the fuel valve lever to OFF 44 ...

Page 48: ... Oil spark plugs or improperly gapped spark plugs p 35 Spark plugs wetwith Dry and reinstallspark fuel floodedengine plugs Start engine with throttle lever in FAST position 6 Take engine toan valves stuck etc refer to shop manual as necessary ignition malfunction servicing dealer or faulty components carburetormalfunction authorized Honda Replace or repair Fuel filter clogged ENGINE LACKS Clean or...

Page 49: ...of the engine switch box 2 Remove the fuse cover and inspect the fuse If the fuse is burnt out remove the fuse cover then pull out and discard the burnt out fuse Install a new 25 ampere fuse and reinstall the fuse cover p5q Never use a fuse with a rating greater than 25 amperes Serious damage to the electrical system or a fire could result 3 Reinstall the fuse cover Install the 6 X 12 mm screw and...

Page 50: ...L INFORMATION Serial Number Location SERIAL NUMBER ENGINETYPE Record the engine serial number in the space below Youwill need this serial numberwhenordering parts andwhenmakingtechnicalor warranty inquires see page 61 Engine serial number 47 ...

Page 51: ...e positive battery cable end A battery can explode if you do not follow the correct procedure seriously injuring anyone nearby Keep all sparks open flames and smoking materials away from the battery 1 Connectthebatterypositive cabletothestartersolenoid terminal as shown 2 Connect the battery negative cable to an engine mountingbolt frame bolt or other good engine ground connection terminal as show...

Page 52: ...l cable attachment 1 The following illustrations show installation examples for a solid wire cable and fora braided wirecable REMOTETHROTTLE AND REMOTECHOKE BRAIDEDWIRE CABLE TYPE 5 X 16 m m 2 CONTROL HOLDER 2 LEVER LEFTSIDE CONTROL RIGHT SIDE CONTROL SOLID WIRE CABLE TYPE BLE HOLDER 2 LEFTSIDE CONTROL RIGHT SIDE CONTROL 49 ...

Page 53: ...E 5 X 16mm CABLE HOLDER LINKAGE BUSH CONTROL LEVER MANUALTHROTTLE AND MANUAL CHOKE LOCK PIN Install the lock pin in the direction as shown CHOKE LEVER THROlTLE ROD CHOKE KNOB LINKAGE BUSH 2 Install the throttle cable rod or thechoke cable rod to the control base 50 ...

Page 54: ...aler performthis carburetor modification This engine when operated at high altitude with thecarburetor modifications for high altitude use will meet each emission standard throughout itsuesful life Even with carburetor modification engine horsepower will decrease about 3 5 for each1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carbure...

Page 55: ...may use gasoline containing up to 10 ethanolbyvolume Gasolinecontainingethanol may be marketed under the name Gasohol methyl tertiary butyl ether 15 by volume You may use gasoline containing up to15 MTBE by volume methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanolbyvolume as long as it also contains cosolvents and corrosion inhibitors to protect the fuelsystem Gaso...

Page 56: ...ydrocarbons The U S and California Clean Air Acts EPA andCaliforniaregulationsrequire all manufacturerstofurnish written instructions describi ng the operation and maintenance of emission control systems 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...

Page 57: ...ementparts are manufacturedtothe samestandards as the original parts so you can be confident of their performance The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system A manufacturer ofan aftermarket partassumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebu...

Page 58: ...ed to provide you with information relating tothe engine s emissiondurabilityperiod Thedescriptive term indicates the useful life period for theengine s emission control system See your Emission Control Warranty for additional information Descriptive Term 50 hours 0 65 cc Moderate Applicable to Emissions Durability Period 125 hours greaterthan 65 cc Intermediate 125 hours 0 65 cc 250 hours greater...

Page 59: ...ckwise GX620 QDW Type Length X Width X Height 37 5cu in 614cm3 Displacement 4 stroke overhead valve 2 cylinders 90 V Twin Engine type 92 6 Ibs 42 0 kg Dry weight 15 3 X 18 0 X 17 8 in 388X 457 X 452 mm Bore X Stroke 0 51 Ib hph 313g kWh 230 g PSh Fuel consumption 32 5 Ibfdi 44 13N m 4 50 kgf m at2 500 rpm Max torque 20 bhp 14 9 kW 20 3 PS at 3 600 rpm Max output 3 03 X 2 60 in 77 X 66 mm I Cooling...

Page 60: ...tation Transistorized magneto Ignition system Forced air Cooling system 0 59 Ib hph 360 g kWh 265 g PSh Fuel consumption 31 8 I b f 4 43 1 N m 4 4 kgf m at 2 500 rpm Max torque 24 bhp 17 6 kW 24 PS at 3 600 rpm Max output 3 03 X 2 83 in 77 X 72 mm GX670 Tuneup ITEM MAINTENANCE SPECIFICATION Spark plug gap No other adjustments needed Other specifications See yourauthorized IN 0 15 0 02 mm Valve cle...

Page 61: ...TECHNICAL CONSUMER INFORMATION Wiring Diagrams I I 58 ...

Page 62: ...TECHNICAL CONSUMER INFORMATION Wiring Diagrams X P I 59 ...

Page 63: ...u additional information for maintainingandrepairingyourengine Youmayorderthemfrom your Honda engine dealer Shop Manual This manual covers complete maintenance and overhaul procedures It is intended to be used bya skilled technician Parts Catalog This manual provides complete illustrated parts lists 60 ...

Page 64: ...way If you are dissatisfied with the decisionmade bythe dealership s management contact the Honda Power Equipment Customer Relations Office You can writeto American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta Georgia 30005 8847 Or telephone 770 497 6400 When you write or call please give us this information Model andserial number see page 47 ...

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Page 68: ...97 Imp qt With oil filter replacement atmroximatelv Engine Oil SAE 1OW 30 API SJ for general TYPe 1 48 US qt 1 40 J 1 23 Impqt Spark Plug NGK ZGR5A TYPe DENSO J16CR U GaD 0 028 0 031 in 0 70 0 80 mm page35 Carburetor Maintenance 1 400 150 rpm Idle speed Check engine oillevel Each use Check air filter First 20 Refer to the maintenance Subsequent hours Change engine oil schedule on page 24 ...

Page 69: ...Printed on Recycled Paper 31ZJ1623 00X31 ZJ1 6230 EM3 K1 POM53094 C 500 2002 07 PRINTED IN U S A KINKOS ...

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