Honda Power Equipment GXV610 Automobile Parts User Manual
Contents
1. PA P UUve 2 To start a cold engine pull the choke lever to the CLOSED position To restart a warm engine leave the choke lever in the OPEN position Some engine applications use a remotely mounted choke control rather than the engine mounted choke lever shown here 3 Movethe 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 contro rather than the engine mounted throttle lever shown here SLOW THROTTLE LEVER 15 OPERATION 4 Turn the engine switch to the ON position 5 Operate the starter RECOIL STARTER Pull the starter grip lightly until you feel resistance then pull briskly Return the starter grip gently ELECTRIC STARTER Turn the key to the START position and hold it there until the engine starts ifthe engine fails to start within 5 seconds release the key and wait atleast 10 seconds before operating the starter again NOTICE Using the electric starter for more than 5 seconds at atime will overheat the starter motor and can damage it When the engine starts release the key allowing it to return to the ON position 6 If the choke lever has been moved to the CLOSED position to start the engine gradually move it to the OPEN position as the engine warms up CHOKE LEVER 16 OPERATION STOPPING THE ENGINE To stop the engine in an eme2. 1 4 turn after the spark plug seats If installing a new spark plug tighten 1 2 turn after the spark plug seats loose spark plug can overheat and damage the engine Overtightening the spark plug can damage threads in the cylinder head 7 Attach the spark plug caps 33 SERVICING YOUR HONDA ENGINE SPARK ARRESTER SERVICE optional equipment Your engine is not factory equipped with a spark arrester In some areas itis illegal to operate an engine without a spark arrester Check local laws and regulations spark arrester is available from authorized Honda servicing dealers The spark arrester must be serviced every 100 hours to keep it functioning as designed If the engine has been running the muffler will be very hot Allow the muffler to cool before servicing the spark arrester 1 Remove the 6 mm screws from the muffler protector and remove the muffler protector 2 Remove the special screws from the spark arrester and remove the spark arrester from the muffler SPECIAL SCREWS 6 mm SCREWS MUFFLER SPARK ARRESTER SCREWS MUFFLER PROTECTOR 34 SERVICING YOUR HONDA ENGINE 3 Use a brush to remave carbon deposits from the spark arrester screen Be careful to avoid damaging the screen The spark arrester must be free of breaks and holes Replace the spark arrester if it is damaged SPARK ARRESTER SCREEN M 4 Install the spark arrester and protecto
3. Fuel cut solenoid type only The engine is equipped with a fuel cut solenoid that allows fuel to flow to the carburetor main jet when the engine switch is inthe ON or START position and stops the flow of fuel to the main jet when the engine switch is in the OFF position The engine must be connected to the battery to energize the fuel cut solenoid allowing the engine to run If the battery is disconnected fuel flow to the carburetor main jet will stop 11 IS YOUR ENGINE READY GO For your safety and to maximize the service life of your equipment it is very important to take a few moments before you operate the engine to check its condition Be sure to take care of any problem you find or have your servicing dealer correct it before you operate the engine 44 WARNING Improperly malntaining this engine or fail ing to correct a problem before operation could cause a malfunction in which you could be serlously injured Always perform a preoperation Inspection before each operation and correct any problem Before beginning your preoperation checks be sure the engine is level andthe engine switch is in the OFF position Check the General Condition of the Engine Look around and underneath the engine for signs of oil or gasoline leaks Remove any excessive dirt or debris especially around the muffler and recoil starter Look for signs of damage Check that all shie
4. fresh gaso refueled with bad line gasoline 3 Take engine to an Fuel filter clogged Replace or repair faulty authorized Honda carburetor malfunction components as neces servicing dealer or ignition malfunction sary refer to shop manual valves stuck etc Fuel filter clogged carburetor malfunction ignition malfunction TECHNICAL CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location ENGINE SERIAL NUMBER ELECTRIC STARTER QWA Record the engine serial number in the space below You will need this serial number when ordering parts and when making technical or warranty inquiries see page 52 Engine serial number 43 TECHNICAL amp CONSUMER INFORMATION Battery Connections Use a 12 volt battery with an ampere hour rating of at least 35 Ah Be careful not to connect the battery in reverse polarity as this will short circuit the battery charging system Always connect the positive battery cable to the battery terminal before connecting the negative battery cable so your tools cannot cause a short circuit if they touch a grounded part while tightening the positive battery cable end 4 WARNING battery can explode if you do not follow the correct procedure serlausty injuring anyone nearby Keep all sparks open flames and smoking materials away from the bat tery 1 Connect the battery positive cable to the starte
5. in the MAINTENANCE SCHEDULE page 21 Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine causing rapid engine wear This type of damage is not covered by the Distributor s Limited Warranty 1 Remove the wing bolt from the air cleaner cover and remove the cover 2 Remove the two 5 mm screws from the air cleaner cover and remove the paper filter element from the cover 3 Remove the foam filter element from the air cleaner body GASKET AIR CLEANER COVER WING BOLT 5 mm SCREWS PAPER FILTER ELEMENT 4 Inspect both air filter elements and replace them if they are damaged rz el replace the paper filter element at the scheduled interval see page 121 30 SERVICING YOUR HONDA ENGINE 5 Clean the air filter elements if they are to be reused Paper filter element Tap the filter element several times on a hard surface to remove dirt or blow compressed air not exceeding 30 psi 207 kPa 2 1 kg cm through the filter element from the air cleaner cover side Never try to brush off dirt brushing will force dirt into the fibers Replace the paper filter element and both gaskets if it is excessively dirty Foam filter element Clean in warm soapy water rinse and allow to dry thoroughly Or clean in nonf fammable solvent and allow to dry Dip the filter element in clean engine oil then squeeze out all excess oil The engine will smoke when started
6. of ownership The warranty policy is aseparate document that should have been given to you by your dealer When your engine needs scheduled maintenance keep in mind that your Honda servicing dealer is specially tra ned in servicing Honda engines Your Honda servicing dealer is dedicated to your satisfaction and will be pleased to answer your questions and concerns Best Wishes Honda Motor Co Ltd INTRODUCTION A FEW WORDS ABOUT SAFETY Your safety and the safety of others are very important And using this engine safely is an important responsibility To help you make informed decisions about safety we have provided operating procedures and other information cn labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course is not practical or possible to you about all the hazards associated with operating or maintaining an engine You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels on the engine Safety Messages preceded bya safety alert symbol and one ofthree signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don tfollow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instructions Safety Headings such as IMPORTANT SAFETY I
7. 2 60 in 77 x 66 18 1x 17 9 x 19 2 in 459 x 455 x 487 mm 3XV610 GXV620 Tuneup SPECIFICATION MAINTENANCE Spark gap 0 028 0 031 in 0 7 0 8 mm page 32 Valve clearance cold 0 15 0 02 mm See your authorized EX 0 20 6 02 mm Honda dealer Other speciications No other adjustments needed 20 TECHNICAL 8 CONSUMER INFORMATION CONSUMER INFORMATION Honda Publications These publications will give you additional information for maintaining and repairing your engine You may order them from your Honda engine dealer Shop Manual This manual covers complete maintenance and overhaul procedures It is intended to be used by a skilied technician Parts Catalog This manual provides complete illustrated paris lists 51 TECHNICAL 8 CONSUMER INFORMATION Warranty Service Information Servicing dealership personnel are trained professionals They should be abie to answer any question you may have If you encounter a problem that your dealer does not solve to your satisfaction please discuss it with the dealership s management The Service Manager or General Manager can help Almost all problems are solved in this way If you are dissatisfied with the decision made by the dealership s manage ment contact the Honda Power Equipment Customer Relations Office You can write to American Honda Motor Co Inc Power Equipment Division Customer Relations Offic
8. A ENGINE ENGINE OIL RECOMMENDATIONS Oil is a major factor affecting performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 is recommended for generat use Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range 10401 Bie eee 30 20 10 0 109 20 30 40 AMBIENT TEMPERATURE The SAE oil viscosity and service classification are in the API label on the oil container Honda recommends that you use API SERVICE category SF or SG oil 27 SERVICING YOUR HONDA ENGINE FUEL FILTER INSPECTION 1 Check the fuel filter for water accumulation or sediment FUEL FILTER 2 ifthe fuel filteris found with excessive water accumulation or sediment take the engine to your authorized Honda servicing dealer 28 SERVICING YOUR HONDA ENGINE AIR FILTER INSPECTION Remove the air cleaner cover and inspect the filter elements Clean or replace dirty filter elements Always replace damaged filter elements Refer 30 for instructions that apply to the air cleaner and filter GASKET CLEAN FILTER CLEANER BODY LEMENT 220 7 WING BOLT 29 SERVICING YOUR HONDA ENGINE AIR CLEANER SERVICE air filter will restrict air flow to the carburetor reducing engine performance if you operate the engine in very dusty areas ciean the air filter more often than specified
9. Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates ETHANOL ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohofl MTBE methyl tertiary butyl ether 15 by volume You may use gasoline containing up to 15 MTBE by volume METHANOL methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rub ber and plastic parts of your fuel system lf you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates men tioned above are not covered under warranty 47 TECHNICAL amp CONSUMER INFORMATION Emission Control System Information Source of Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very imp
10. HONDA ENGINES Owners Manual GXV610 GX V620 manual to your computer WARNING engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Keep this owner s manual handy so you can refer to it at any time This owner s manual is considered a permanent part 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 GXV610 QWA 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 this publication may be repro duced without written permission INTRODUCTION Congratulations on your selection of a Honda engine We are certain you will be pleased with your purchase of one of the finest engines on the market We want to help you get the best results from your new engine and to operate it safely This manual contains the information on how to do that please read it carefully As you read this manual you will find information preceded by a symbol Thatinformation is intendedto help you avoid damage to your engine other property or the environment We suggest you read the warranty policy to fully understand its coverage and yourresponsibilities
11. NFORMATION Safety Section such as ENGINE SAFETY Instructions how to use this engine correctly and safely This entire book is filled with important safety information please read it carefully 2 CONTENTS 5 IMPORTANT SAFETY 1 1 5 T TE 7 COMPONENT amp CONTROL LOCATIONS eere m 7 se eR c 9 chore LENG 9 Thote LEVEI ETT 10 FAC Ol ro 10 5 11 Fueren Solenoid E 11 12 15 YOUR ENGINE READY TOGO T 12 Check the General Condition of the Engine sese 12 Check ENGNG seirinin 13 Check the Equipment Powered by This Engine 13 14 SAFE OPERATING PRECAUTIONS WW 14 STARTING THE 14 STOPPING THE ENGINE up o Ri debat o E da 17 SETTING ENGINE 1016 66 nnne nnn 218 MAINTENANCE SAFETY 2 a
12. URETOR 1 Disconnect the fuel line to the engine and drain the fuel tank into approved gasoline container If the fuel tank is equipped with a valve turn the fuel valve to the OPEN or ON position to enable draining After draining is completed reconnect the line 2 Remove the contro page 45 loosen the carburetor drain screw and drain the carburetor info an approved gasoline container After draining is completed tighten the carburetor drain screw and reinstall the control cover aa WARNING Gasoline is highiy fiammable and explosive You be burned or seriously injured when handiing fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately CARBURETOR 38 HELPFUL TIPS 8 SUGGESTIONS Engine 1 Change the engine oil 2 Hemove the spark plugs see page 32 3 Pour a tablespoon 5 10 cc of clean engine oil into the cylinders 4 Pull the starter rope several times to distribute the oil in the cylinders 5 Reinstall the spark plugs storage Precautions If your engine will be stored with gasoline in the fuel tank and carburetor it is important to reduce the hazard of gasoline vapor ignition Select a well ventilated storage area away from any appliance that operates with 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 opera
13. YOUR HONDA ENGINE ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position 1 Remove the oil filler cap dipstick and wipe it clean 2 insert and remove the dipstick without screwing it into the filler neck Check the oil level shown on the dipstick 3 If the oil level is near or below the lower limit mark on the dipstick and fili with the recommended oil to the upper limit mark see page 27 4 Reinstall the oil filler cap DIL FILLER CAP bIPSTICK UPPER LIMIT LOWER OIL ALLER CAP DIPSTICK Running the engine with a low oil level can cause engine damage 23 SERVICING YOUR HONDA ENGINE ENGINE OIL CHANGE Drain the used oil while the engine is warm Warm oil drains quickly and completely 1 Place a suitable container below the engine to catch the used oil then remove the oil filler cap dipstick and the drain bolt 2 Allow the used oil io drain completely then reinstall the drain bolt and tighten it securely 3 Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation Do not throw it tn the trash pour it on the ground or down a drain 4 With the engine in a leve position fill to the upper limit mark on the dipstick with the recommended oil see page 27 ENGINE OIL REFILL CAPACITIES Without oil fil
14. air fuel mixture will be too rich Performance will decrease and fuel consumption will increase A very rich mixture will also foul the spark plug and cause hard starting High altitude performance can be improved by specific modifications to the carburetor If you always operate your engine at altitudes above 6 000 feet 1 800 meters have your servicing dealer perform this carburetor modifica tion Even with carburetor modification engine horsepower will decrease about 3 5 for each 1 000 foot 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification 15 made When the carburetor has been modified for high altitude operation the air fuel mixture will be too lean for low altitude use Operation at altitudes below 6 000 feet 1 800 meters with a modified carburetor may cause the engine to overheat and resuit in serious engine damage For use at low altitudes have your servicing dealer return the carburetor to original factory specifications 46 TECHNICAL amp CONSUMER INFORMATION Oxygenated Fuels Some conventional gasolines are being blended with alcohol or an ether compound These gasolines are collectively referred to as oxygenated fuels To meet clean air standards some areas of the United States and Canada use oxygenated fuels to help reduce emissions if you use an oxygenated fuel be sure itis unleaded and meets the mininum octane rating requirement
15. e 4475 River Green Parkway Duluth Georgia 30136 2565 Or telephone 770 497 6400 When you write or call please give us th s information Model and serial number page 43 Name of dealer who sold the engine to you Name and address of dealer who services your engine Date of purchase Your name address and telephone number detailed description of the problem 52 QUICK REFERENCE INFORMATION me O Unleaded gasoline with a pump octane rating of 86 or higher page 22 Il SG general Engine Without oil filter replacement ce 2 2 US qt 2 1 2 NGK BPRSES DENSO W16EPR U 0 028 0 031 in 0 70 0 80 mm page 32 Before Check engine oil level each use Check air filter Maintenance First 20 Change engine oil hours Ss 1 fe IT CHEESE 3 EET
16. es teen Eau caue 42 HNICAIL 8 INFORMATION 12 43 TECHNICAL 1 1 43 Serial Number Location 43 Battery Connections sessi eene enne nennen nnns 44 Remote Contro Linkage esee 45 Carburetor Modification for High Altitude Operation 46 Oxygenated Fuels 47 Emission Control System Information 48 Specifications rna eem n tameu nena nuper tata same a atn 50 CONSUMER INFORMATION 1 nne nene nenne 51 Honda Publications errechnet 51 Warranty Service Information scene mn 52 QUICK REFERENCE INFORMATION 40 Inside back cover ENGINE SAFETY IMPORTANT SAFETY INFORMATION Most accidents with engines can be prevented if you follow all instructions in this manual and on the engine Some of tha most common hazards discussed below along with the best way to protect yourself and others Owner Responsibilities Honda engines are designed to give safe and dependable service if operated according to instructions Head and understand this owner s manual before operating the engi
17. fety precautions that should be observed in conjunction with engine startup shutdown or operation or protective apparel that may be needed to operate the equipment CONTROLS FEATURES COMPONENT amp CONTROL LOCATIONS PROTECTOR FAN COVER TYPE PROTECTOR STANDARD SCREEN GRID TYPE STARTER GRIP OIL FILLER CAP OIL FILTER FUEL FILTER AIR CLEANER OIL DRAIN BOLT SPARK PLUG CONTROLS 8 FEATURES SPARK PLUG OIL DRAIN BOLT MUFFLER OIL DRAIN BOLT ELECTRIC STARTER QWA type CONTROLS 8 FEATURES CONTROLS Choke Lever The choke lever opens and closes the choke valve in the carburetor The CLOSED position enriches the fuel mixture for starting a cold engine The OPEN position provides the correct fuel mixture for operation after starting and for restarting a warm engine some engine applications use a remotely mounted choke control rather than the engine mounted choke lever shown here CONTROLS 8 FEATURES neeaaea Throttle Lever The throttle lever controls engine speed Moving the throttle lever in the directions shown makes the engine run faster or slower some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here Recoil Starter Grip Pulling the starter grip operates the recoil starter to crank the engine 10 CONTROLS amp FEATURES FEATURES Fuel cut Solenoid
18. heck Every 2 years Replace if necessary 2 Emission related items Replace the paper air filter element only 1 Service more frequently when used in dusty areas 2 These items should be serviced by your servicing dealer unless you have the proper tools and are mechanically proficient Refer to the Honda shop manual for service procedures 3 For commercial use log hours of operation to determine proper mainte nance intervals 21 SERVICING YOUR HONDA ENGINE FUEL RECOMMENDATIONS Use unleaded gasoline with a pump octane rating of 86 or higher These engines are certified to operate on unleaded gasoline Unieaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt or water in 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 spark knock or pinging occurs at a steady engine speed under normal load change brands of gasoline spark knock or pinging persists see authorized Honda servicing dealer Running the engine with persistent spark knock or pinging can cause engine damage Hunning the engine with persistent spark knock or pinging is misuse and the Distributors Limited Warranty does not cover parts damaged by misuse 22 SERVICING
19. if too much oil is left in the foam 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 clean chamber that leads to the carburetor 7 Place the foam filter element to the air cleaner body Be sure the gaskets are in place then reinstall the paper filter element and cover Tighten the wing bolt securely 31 SERVICING YOUR HONDA ENGINE SPARK PLUG SERVICE Recommended spark plugs BPRSES W16EPR U DENSO Incorrect spark plugs can cause engine damage 1 Disconnectthe spark plug caps and remove any dirt from around the spark plug area 2 Remove the spark plugs with a 13 16 inch spark plug wrench H a DA SPARK PLUG WRENCH PLUG CAP 3 Inspect the spark plug Replace it ifthe electrodes are worn or if the insulator is cracked or chipped Clean the spark plug with a wire brush if you are going to reuse it 0 028 0 031 In 0 70 0 80 mm 4 Measure the spark plug electrode gap with a suitable gauge The gap should be 0 028 0 031 in 0 70 0 80 Correct the gap if necessary by care fully bending the side electrode 5 Installthe spark plug carefully by hand to avoid cross threading 32 SERVICING YOUR HONDA ENGINE 6 After the spark plug seats tighten with a 13 16 inch spark plug wrench to compress the washer If reinstalling the used spark plug tighten 1 8
20. lds and covers are in place and all nuts bolts and screws are tightened 12 BEFORE OPERATION Check the Engine e Check the engine oil level see page 23 Running the engine with a low oil level can cause engine damage Check the air filter see page 29 A dirty air filter will restrict air flow to the carburetor reducing engine performance Check the fuel level Starting with a full tank will help to eliminate or reduce operating interruptions for refueling Check the Equipment Powered by This Engine Review the instructions provided with the equipment powered by this engine for any precautions and procedures that should be followed before engine Startup 13 OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time please review the IMPORTANT SAFETY INFORMATION on page 58 nd the chapter titled BEFORE OPERA TION WARNING Carbon monexide gas 15 toxic Breathing it can cause unconsciousness and even kill you Avoid any areas or actions that expose you to carbon 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 Ifthe fuel tank is equipped with a valve be sure the fuel valve is inthe OPEN or ON position before attempting to start the engine 14 OPERATION
21. lend your storage temperatures and whether the fuel tank is partially or completely filled The air in a partially filled fuel tank promotes fuel deteriora tion Very warm storage temperatures accelerate fuel deterioration Fuel detertoration problems may occur within a few months or even less if the gasoline was not fresh when you fillad the fuel tank 36 HELPFUL TIPS 8 SUGGESTIONS The Distributor s Limited Warranty does not cover fuel system damage or engine performance problems resuiting from neglected storage preparation You can extend fuel storage life by adding a fuel stabilizer that is formulated for that purpose or you can avoid fuel deterioration problems by draining the fuel tank and carburetor ADDING A FUEL STABILIZER TO EXTEND FUEL STORAGE LIFE When adding a fuel stabilizer fill the fue tank with fresh gasoline If only partially filled air in the tank will promote fuel deterioration during storage If you keep a container of gasoline for refueling be sure that it contains only fresh gasoline 1 Add fuel stabilizer following the manufacturer s instructions 2 After adding a fuel stabilizer run the engine outdoors for 10 minutes to be sure that treated gasoline has replaced the untreated gasoline in the carburetor 3 Stop the engine and if the fuel tank is equipped with a fuel valve move the fuel valve 10 the CLOSED or OFF position 37 HELPFUL TIPS amp SUGGESTIONS DRAINING THE FUEL TANK AND CARB
22. n and malnte nance recommendations and schedules in this owner s manual To help you properly care for your engine the following pages include a maintenance schedule routine inspection procedures and simple mainte nance procedures using basic hand tools Other service tasks that are more difficult or require special tools best handled by professionals and 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 temperature operation or use in unusually wet or dusty conditions consult your servicing dealer for recommendations applicable to your indi vidual needs and use Maintenance replacement or repair of emission control devices and systems may be done by any engine repair establishment or individual using parts that are certified to EPA standards 19 SERVICING YOUR HONDA ENGINE MAINTENANCE SAFETY Sorne of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise performing mainte nance Only you can decide whether or not you should perform a given task 44 WARNING Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions in the owner s manuat Safety Precauti
23. ne Failure to do so could result in personal injury or equipment damage Know how fo stop the engine quickly and understand the operation of alf controls Never permit anyone to operate the engine without proper instructions Do not allow children to operate the engine Keep children and pets away from the area of operation Refuel With Care Gasoline is extremely flammable and gasoline vapor can explode 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 fuelis spilled make sure the area is dry before starting the engine Hot Exhaust The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful notto touch the muffler while it is hot Let the engine cool before storing it indoors To prevent fire hazards and to provide adequate ventilation for stationary equipment applications keep the engine at least 3 feet 1 meter away from building walls and other equipment during operation Do not place flam mable objects close to the engine ENGINE SAFETY Carbon Monoxide Hazards Exhaust gas contains poisonous carbon monoxide Avoid inhalation of ex haust gas Never run the engine in a closed garage or confined area Other Equipment Review the instructions provided with the equipment powered by this engine for any additional sa
24. on control systems on your Honda engine were designed built and certified to conform with EPA and California emission regulations We recom mendthe use of genuine Honda parts whenever you have maintenance done These original design replacement parts are manufactured to the same standards 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 of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations Maintenance Follow the maintenance schedule 21 Remember that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature operation or use in unusu ally wet or dusty conditions will require more frequent service 49 TECHNICAL 8 CONSUMER INFORMATION Specifications GXV610 QWA Type 4 stroke overhead valve 2 cylinders 90 V Twin Bora Stroke 3 03 2 60 in 77 66 mm GXV620 QWA Type Length x Width x Height 93 Ib 42 kg Engine type 4 stroke overhead valve 2 cylinders 90 V Twin Displacemant 37 5 614 crm Bore x Stroke 3 03 x
25. ons Make sure the engine is off before you begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching Injury from moving parts Do not run the engine unless instructed to do 50 Read the instructions before you begin make sure you have the tools and skilis required e To reduce the possibility of fire or explosion be careful when working around gasoline Use only a nonflammable solvent not gasoline to clean parts Keep cigarettes sparks and flames away from all fuei related parts Remember that your servicing dealer knows your engine best and is fully equipped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair and replacement 20 SERVICING YOUR HONDA ENGINE MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD 3 at every indicated month ar operating hour interval whichever comas first Engine cil Check level Change Aur filtar Spark plug Clean Readjust Replace Spark arrester optional part Clean idie speed Check adjust df Om e Valve ctearance Check Readjust Fuel Replace 21 11 199 e Fucttine C
26. or tant because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide oxides of nitrogen and hydrocarbons The 0 5 and California Clean Air Acts EPA and California regulations require all manufacturers to furnish written instructions describing 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 emission control system may increase emis sions beyond the legal limit Among those acts that constitute tampering are Removal or alteration of any part of the intake fuel or exhaust systems Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters 48 TECHNICAL 8 CONSUMER INFORMATION Problems That May Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer Hard starting or stalling after starting Rough idle Misfiring or backfiring under load Afterburning backfiring Black exhaust smoke or high fuel consumption Heplacement Parts The emissi
27. r in the reverse order of disassembly 35 HELPFUL TIPS 8 SUGGESTIONS STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine troubiefree andlooking good The following steps will help to keep rust and corrosion from impairing your engine s function and appearance and will make the engine easier to start when you use it again Cleaning If the engine has been running allow it to cool for at least half an hour before cleaning Clean all exterior surfaces touch up any damaged paint and coat other areas that may rust with a light film of oil Using a garden hose or pressure washing equipment can force water into the air cleaner or muffler opening Water in the air cleaner will soak the air filter and water that passes through the air filter or muffler can enter the cylinder causing damage Water contacting a hot engine can cause damage If the engine has been running allow it to cool for at least half an hour before washing Fuel Gasoline will oxidize and deteriorate in storage Old gasoline will cause hard starting and it leaves qum deposits that clog the fus system the gasoline in your engine deteriorates during storage you may need to have the carburetor and other fuel system components serviced or replaced The length of time that gasoline can be left in your fuel tank and carburetor without causing functional problems will vary with such factors as gasoline b
28. r solenoid terminal as shown 2 Connect the battery negative cable to an engine mounting bolt frame bolt or other good engine ground connection 3 Connect the battery positive cable to the battery positive terminal as shown 4 Connect the battery negative cable to the battery negative terminal as shown 5 Coat the terminals and cable ends with grease NEGATIVE BATTERY CABLE POSITIVE i BATTERY CABLE STARTER SOLENOID 44 TECHNICAL amp CONSUMER INFORMATION Remote Control Linkage The throttle and choke contro levers are provided with holes for optional cable attachment 1 Remove the two 6 mm special bolts from the control cover and remove the control cover eT 6 mm SPECIAL BOLTS CONTROL COVER 2 The following illustrations show installation examples for a solid wire cable Do not use a braided wire cable It is necessary to loosen the throttle lever friction nut when operating the throttle with a remote cable REMOTE THROTTLE AND REMOTE CHOKE 5 mm SCREW CHOKE LEVER CHOKE CABLE SOLID WIRE THROTTLE CABLE SOLID WIRE THHOTTLE LEVER 4 FRICTION NUT 5 mm SCREW 3 Reinstall the control cover Install the throttle cable or the choke cable to the contro base after guiding the cable through the hole in the control cover 45 TECHNICAL amp CONSUMER INFORMATION Carburetor Modification for High Altitude Operation At high altitude the standard carburetor
29. rgency simply turn the engine switch to the OFF position Under normal conditions use the following procedure 1 Move the throttle lever to the SLOW position Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here THROTTLE LEVER SLOW 2 Turn the engine switch to the OFF position 3 if the fuel tank is equipped with a valve turn the fuel valve to the CLOSED or OFF position 17 OPERATION SETTING ENGINE SPEED Position the throttle lever for the desired engine speed Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here For engine speed recommendations refer to the instructions provided with the equipment powered by this engine SLOW THROTTLE LEVER Fual cut solenoid type only 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 18 SERVICING YOUR HONDA ENGINE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe economical and trouble free opera tion It will also help reduce air pollution WARNING Improperly maintaining this engine or failure to correct a problem before operation can cause malfunction in which you can be seriously hurt or killed Always fotlow the inspectio
30. ted If possible avoid storage areas with high humidity because that promotes rust and corrosion Unless all fuel has been drained from the fuel tank leave the fuel valve lever in the OFF position to reduce the possibility of fuel leakage 39 HELPFUL TIPS 8 SUGGESTIONS Position the equipment so the engine is level Tilting can cause fuel or leakage With the engine and exhaust system cool cover the engine to keep out dust A hot engine and exhaust system can ignite or melt some materials Do not use sheet plastic as a dust cover A nonporous cover will trap moisture around the engine promoting rust and corrosion Remove the battery and store it in a cool dry place Recharge the battery once a month while the engine is in storage This will help to extend the service life of the battery Removal From Storage Check your engine as described in the BEFORE OPERATION chapter of this manual If the fuel was drained during storage preparation fill the tank with fresh gasoline if you keep a container of gasoline for refueling be sure that it contains only fresh gasoline Gasoline oxidizes and deteriorates over time causing hard starting the cylinders were coated with oil during storage preparation the engine may smoke briefly at startup This is normal 40 HELPFUL TIPS 8 SUGGESTIONS TRANSPORTING If the engine has been running allow it to cool for at least 15 minutes before loading the engine powered eq
31. ter replacement 1 9 US qt 1 8 With oil filter replacement 2 2 US qt 2 1 Running the engine with a low oil level can cause engine damage 5 Reinstall the oil filler cap dipstick securely FIELER CAP DIPSTICK OIL DRAIN BOLT 24 SERVICING YOUR HONDA ENGINE OIL FILTER CHANGE 1 Drain the engine and retighten the drain bolt securely see page 24 2 Remove the oil filter with a filter wrench and drain the remaining oil into a suitable container Discard the used oil filter OIL FILTER 3 Clean the filter mounting base and coat the 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 cause engine damage 25 SERVICING YOUR HONDA ENGINE 4 Screw on the new oil filter by hand until the seal contacts the filter mounting base then use an oil filter wrench to tighten the filter an additional 7 8 turn filter tightening torque 16 ft lb 22 Nem 2 2 kg m 5 Refillthe crankcase with the specified amount of the recommended oil page 27 Reinstall the filler cap dipstick 6 Start the engine and check for leaks 7 Stop the engine and check the level as described on page 23 1 necessary add to bring the oil level to the upper limit mark on the dipstick 26 SERVICING YOUR HOND
32. tus eo atat b 20 MAINTENANCE SCHEDULE ER ERE S 21 FUEL 22 ENGINE OIL LEVEL CHEG K cresceret tr oda eene Eras ra aes 23 ENGINE OIL dies Una Da e PEDIR 24 FILTER CHANGE A e 25 ENGINE OIL RECOMMENDATIONS eene nnn 27 FUEC FILTER INSPEC TION 28 5 AIR FILTER 29 AIR CLEANER SERVICE 30 SPARK PLUG SERVICE 32 SPARK ARRESTER MAINTENANCE optional equipment 34 P se 36 STORING YOUR ENGINE eere mmm 36 Storage Preparation assesses eene nennen enean 36 Storage Precautions eese enne nennen 39 Removal From Storage 1 enne 40 TRANSPORTING 41 42 ENGINE WILL NOT 5 42 ENGINE LACKS POWER tt
33. uipment on the transport vehicle A hot engine and exhaust sysiem can burn you and can ignite some materials Keep the engine level when transporting to reduce the possibility of fuel leakage 41 TAKING CARE UNEXPECTED PROBLEMS 1 Gheck battery and Battery discharged Recharge battery fuse Fuse burnt cut Replace fuse if equipped 2 Check control Fuel valve OFF Move lever to ON positions if equipped Choke OPEN Move lever to CLOSED unless engine is warm Engine switch OFF Turn engine switch to if equipped OWN 3 Check fuel Qut of fuel Refuel Bad fuel engine stored Drain fuel tank and without treating or carburetor draining gasoline or Refuel with fresh gaso refueled with bad line gasoline 4 Remove and inspect Spark plugs faulty Clean replace spark plugs fouled or improperly spark plugs p gapped Spark plugs wet with fuel flooded engine Dry and reinstall spark plugs Start engine with throttle lever in FAST position Replace or repair faulty components as neces 5 Take engine to authorized Honda servicing dealer or refer to shop manual valves stuck etc 1 Check air filter Filter 5 Clean or replace filter clogged element s p 30 2 Check fuel Bad fuel engine stored Drain fuel tank and without treating or carburetor draining gasoline or Refuel with
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