Honda Automobiles GXV620 User Manual

INTRODUCTION
Thank you for purchasing a Honda engine. We want to help you to
get the best results from your new engine and to operate it safely.		OWNER’S MANUAL
This manual contains information on how to do that; please read it
carefully before operating the engine. If a problem should arise, or
		MANUEL DE L’UTILISATEUR
if you have any questions about your engine, consult an
authorized Honda servicing dealer.		MANUAL DEL PROPIETARIO
All information in this publication is based on the latest product
information available at the time of printing. Honda Motor Co., Ltd.		GXV610 · GXV620 · GXV670
reserves the right to make changes at any time without notice and
without incurring any obligation. No part of this publication may
be reproduced without written permission.
This manual should be considered a permanent part of the engine
and should remain with the engine if resold.
Review the instructions provided with the equipment powered by
this engine for any additional information regarding engine
startup, shutdown, operation, adjustments or any special
maintenance instructions.
United States, Puerto Rico, and U.S. Virgin Islands:
We suggest you read the warranty policy to fully understand its
coverage and your responsibilities of ownership. The warranty
policy is a separate document that should have been given to you		The engine exhaust from this product
by your dealer.		contains chemicals known to the State of
SAFETY MESSAGES		California to cause cancer, birth defects
		or other reproductive harm.
Your safety and the safety of others are very important. We have		CONTENTS
provided important safety messages in this manual and on the
engine. Please read these messages carefully.
		INTRODUCTION........................	1	FUEL FILTER .........................	.9
A safety message alerts you to potential hazards that could hurt		SAFETY MESSAGES.................	1	SPARK PLUG .......................	10
you or others. Each safety message is preceded by a safety alert		SAFETY INFORMATION ...........	2	SPARK ARRESTER ..............	10
symbol	and one of three words, DANGER, WARNING, or	SAFETY LABEL LOCATION ......	2	HELPFUL TIPS &
CAUTION.		COMPONENT & CONTROL		SUGGESTIONS .......................	11
		LOCATION .................................	2	STORING YOUR ENGINE....	11
These signal words mean:		FEATURES.................................	3	TRANSPORTING .................	12
	You WILL be KILLED or SERIOUSLY	BEFORE OPERATION		TAKING CARE OF
	HURT if you don’t follow instructions.	CHECKS .....................................	3	UNEXPECTED PROBLEMS .....	12
		OPERATION...............................	4	TECHNICAL INFORMATION ...	13
	You CAN be KILLED or SERIOUSLY	SAFE OPERATING		Serial Number Location ......	13
	HURT if you don’t follow instructions.	PRECAUTIONS ......................	4	Battery Connections for
		STARTING THE ENGINE .......	4	Electric Starter .....................	13
	You CAN be HURT if you don’t follow	STOPPING THE ENGINE .......	5	Remote Control Linkage......	14
	instructions.	SETTING ENGINE SPEED......	5	Carburetor Modifications for
		SERVICING YOUR ENGINE ......	6	High Altitude Operation ......	14
Each message tells you what the hazard is, what can happen, and		THE IMPORTANCE OF		Emission Control System
what you can do to avoid or reduce injury.		MAINTENANCE .....................	6	Information ..........................	15
		MAINTENANCE SAFETY.......	6	Air Index...............................	16
DAMAGE PREVENTION MESSAGES		SAFETY PRECAUTIONS........	6	Specifications ......................	16
		MAINTENANCE		Tuneup Specifications.........	17
You will also see other important messages that are preceded by		SCHEDULE.............................	6	Quick Reference
the word NOTICE.		REFUELING............................	7	Information ..........................	17
		ENGINE OIL............................	7	Wiring Diagrams .................	17
This word means:		Recommended Oil .............	7	CONSUMER INFORMATION..18
	Your engine or other property can be damaged if you	Oil Level Check...................	7	DISTRIBUTOR/DEALER
	don’t follow instructions.	Oil Change..........................	8	LOCATOR INFORMATION ..	18
		OIL FILTER..............................	8	CUSTOMER SERVICE
The purpose of these messages is to help prevent damage to your		AIR CLEANER.........................	9	INFORMATION ....................	18
engine, other property, or the environment.		Inspection...........................	9
		Cleaning .............................	9
2007 Honda Motor Co., Ltd. All Rights Reserved
	GXV610R1·GXV620R1·GXV670R·GXV610U1·GXV620U1·GXV670U
37Z6E603
00X37-Z6E-6022

ENGLISH

FRANÇAIS

ESPAÑOL

ENGLISH

1

SAFETY INFORMATION

Understand the operation of all controls and learn how to stop the engine quickly in case of emergency. Make sure the operator receives adequate instruction before operating the equipment.

Do not allow children to operate the engine. Keep children and pets away from the area of operation.

Your engine’s exhaust contains poisonous carbon monoxide. Do not run the engine without adequate ventilation, and never run the engine indoors.

The engine and exhaust become very hot during operation. Keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Keep flammable materials away, and do not place anything on the engine while it is running.

SAFETY LABEL LOCATION

This label warns you of potential hazards that can cause serious injury. Read it carefully.

If the label comes off or becomes hard to read, contact your Honda dealer for replacement.

For Canadian types only: French label comes with the engine.

Gasoline is highly flammable and explosive.

Turn engine off and let cool before refueling.

The engine emits toxic poisonous carbon monoxide gas. Do not run in an enclosed area.

Read Owner’s Manual before operation.

COMPONENT & CONTROL LOCATION

GXV610/GXV620

FAN COVER	PROTECTOR TYPE
PROTECTOR TYPE	(STANDARD)

RECOIL STARTER	SCREEN GRID
EQUIPPED TYPE	(STANDARD TYPE)

	STARTER GRIP
	(applicable types)
	OIL PRESSURE SWITCH
	OIL FILLER CAP/
	DIPSTICK
	OIL DRAIN BOLT
AIR CLEANER	OIL FILTER
FUEL FILTER	SPARK PLUG

ELECTRIC STARTER

SPARK PLUG

MUFFLER

2

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GXV670

OIL PRESSURE SWITCH

OIL FILLER CAP/

DIPSTICK

OIL COOLER

HOSE

OIL FILTER

AIR CLEANER

OIL COOLER

FUEL FILTER

SPARK PLUG

ELECTRIC STARTER

SPARK PLUG

FEATURES

Fuel-cut Solenoid

The engine is equipped with a fuel-cut solenoid that allows fuel to flow to the carburetor main jet when the engine switch is in the 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 fuelcut solenoid, allowing the engine to run. If the battery is disconnected, fuel flow to the carburetor main jet will stop.

Oil Cooler (GXV670)

The GXV670 engine is equipped with an oil cooler to maintain the correct oil temperature.

BEFORE OPERATION CHECKS

IS YOUR ENGINE READY TO GO?

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

Improperly maintaining this engine, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.

Always perform a pre-operation inspection before each operation, and correct any problem.

Before beginning your pre-operation checks, be sure the engine is level and the engine switch is in the OFF position.

Always check the following items before you start the engine:

Check the General Condition of the Engine

1.Look around and underneath the engine for signs of oil or gasoline leaks.

2.Remove any excessive dirt or debris, especially around the muffler and recoil starter.

3.Remove any objects or debris that my block the cooling air intake at the recoil starter/fan cover. Running the engine with a blocked air intake can cause engine damage.

4.Look for signs of damage.

5.Check that all shields and covers are in place, and all nuts, bolts, and screws are tightened.

Check the Engine

1.Check the fuel level. Starting with a full tank will help to eliminate or reduce operating interruptions for refueling.

2.Check the engine oil level (see page 7 ). Running the engine with a low oil level can cause engine damage.

3.Check the air filter element (see page 9 ). A dirty air filter element will restrict air flow to the carburetor, reducing engine performance.

4.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.

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3

OPERATION

SAFE OPERATING PRECAUTIONS

Before operating the engine for the first time, please review the

SAFETY INFORMATION section on page 2 and the BEFORE OPERATION CHECKS on page 3 .

For your safety, do not operate the engine in an enclosed area such as a garage. Your engine’s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an enclosed area and cause illness or death.

Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed areas. Breathing carbon monoxide can cause unconsciousness or death.

Never run the engine in a closed, or even partly closed area where people may be present.

Review the instructions provided with the equipment powered by this engine for any safety precautions that should be observed with engine startup, shutdown or operation.

STARTING THE ENGINE

1.If the fuel tank is equipped with a valve, be sure the fuel valve is in the OPEN or ON position before attempting to start the engine.

2.To start a cold engine, move 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 remote-mounted choke control rather than the engine-mounted choke lever shown here. Refer to the instructions provided with the equipment powered by this engine for remote control information.

CHOKE LEVER

OPEN

CLOSED

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 remote-mounted throttle control 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.

THROTTLE LEVER

FAST

SLOW

4.Turn the engine switch to the ON position.

5.Operate the starter. ELECTRIC STARTER:

Turn the key to the START position, and hold it there until the engine starts.

If the engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before operating the starter again.

Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it.

When the engine starts, release the key, allowing it to return to the ON position.

4

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RECOIL STARTER (applicable types):

Pull the starter grip lightly until you feel resistance, then pull briskly in the direction of the arrow as shown below. Return the starter grip gently.

Direction to pull

STARTER GRIP

Do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.

6.If the choke lever was moved to the CLOSED position to start the engine, gradually move it to the OPEN position as the engine warms up.

CHOKE LEVER

OPEN

CLOSED

STOPPING THE ENGINE

To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure. Refer to the instructions provided by the equipment manufacturer.

1. Move the throttle lever to the SLOW position.

Some engine applications use a remote-mounted throttle control 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.

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.

SETTING ENGINE SPEED

Position the throttle lever for the desired engine speed.

Some engine applications use a remote-mounted throttle control rather than the engine-mounted throttle lever shown here. Refer to the instructions provided by the equipment manufacturer.

For engine speed recommendations, refer to the instructions provided with the equipment powered by this engine.

THROTTLE LEVER

FAST

SLOW

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.

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5

SERVICING YOUR ENGINE

THE IMPORTANCE OF MAINTENANCE

Good maintenance is essential for safe, economical and troublefree operation. It will also help reduce pollution.

Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed.

Always follow the inspection and maintenance 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 maintenance procedures using basic hand tools. Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions. If you operate your engine under severe 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 individual needs and use.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are ‘‘certified’’ to EPA standards.

MAINTENANCE SAFETY

Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed.

Always follow the procedures and precautions in this owner’s manual.

SAFETY PRECAUTIONS

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 so.

Read the instructions before you begin, and make sure you have the tools and skills required.

To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a non-flammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and flames away from all fuel related parts.

Remember that an authorized Honda 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 Honda Genuine parts or their equivalents for repair and replacement.

MAINTENANCE SCHEDULE

	REGULAR SERVICE PERIOD (3)			Each	First	Every 3	Every 6	Every	Refer
	Perform at every			use	month	months	months	year	to
	indicated month or				or	or	or	or	page
	operating hour interval,				20 Hrs	50 Hrs	100 Hrs	300 Hrs
	whichever comes first.
	ITEM
	Engine oil	Check level							7
		Change							8
	Engine oil filter	Replace						Every	8
								200 Hrs.
	Air cleaner	Check							9
		Clean				(1)			9
		Replace
	Spark plugs	Check-adjust							10
		Replace
	Spark arrester	Clean							10
	(applicable types)
	Idle speed	Check-adjust						(2)
	Valve clearance	Check-adjust						(2)
	Combustion	Clean			After every 500 Hrs. (2)
	chamber
	Fuel filter	Check							9
		Replace						(2)
	Fuel tank	Clean			Every year (2)
	Fuel tube	Check		Every 2 years (Replace if necessary) (2)

Replace the paper air filter element only.Refer to the Shop Manual.

(1)Service more frequently when used in dusty areas.

(2)These items should be serviced by your Honda 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 maintenance intervals.

Failure to follow this maintenance schedule could result in nonwarrantable failures.

6

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REFUELING

Recommended Fuel

Unleaded gasoline

U.S.	Pump octane rating 86 or higher
Except U.S.	Research octane rating 91 or higher
	Pump octane rating 86 or higher

This engine is certified to operate on unleaded gasoline with a pump octane rating of 86 or higher (a research octane rating of 91 or higher).

Refuel in a well-ventilated area with the engine stopped. If the engine has been running, allow it to cool first. Never refuel the engine inside a building where gasoline fumes may reach flames or sparks.

You may use unleaded gasoline containing no more than 10% ethanol (E10) or 5% methanol by volume. In addition, methanol must contain cosolvents and corrosion inhibitors. Use of fuels with content of ethanol or methanol greater than shown above may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system. Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty.

If your equipment will be used on an infrequent or intermittent basis, please refer to the fuel section of the HELPFUL TIPS & SUGGESTIONS chapter (see page 11 ) for additional information regarding fuel deterioration.

Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling.

Stop engine and keep heat, sparks, and flame away.

Refuel only outdoors.

Wipe up spills immediately.

Fuel can damage paint and some types of plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under the Distributor’s Limited Warranty.

Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.

1.With the engine stopped and on a level surface, remove the fuel filler cap and check the fuel level. Refill the tank if the fuel level is low.

Refer to the instructions provided with the equipment powered by this engine for refuelling.

Refuel carefully to avoid spilling fuel. It may be necessary to lower the fuel level depending on operating conditions. After refueling, tighten the fuel tank cap securely.

Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc.

Spilled fuel is not only a fire hazard, it causes environmental damage. Wipe up spills immediately.

ENGINE OIL

Oil is a major factor affecting performance and service life. Use 4-stroke automotive detergent oil.

Recommended Oil

Use 4-stroke motor oil that meets or exceeds the requirements for API service category SJ or later (or equivalent). Always check the API service label on the oil container to be sure it includes the letters SJ or later (or equivalent).

AMBIENT TEMPERATURE

SAE 10W-30 is recommended for general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range.

Oil Level Check

Check the engine oil level with the engine stopped and in a level position.

1.GXV670 ONLY: Start the engine and let it idle for 1 or 2 minutes. Stop the engine and wait for 2 or 3 minutes.

2.Remove the oil filler cap/dipstick and wipe it clean.

3.Insert and remove the oil filler cap/dipstick without screwing it into the oil filler neck, then remove it to check the oil level shown on the dipstick.

4.If the oil level is near or below the lower limit mark on the dipstick, fill with the recommended oil to the upper limit mark.

5.Reinstall the oil filler cap/dipstick.

OIL FILLER CAP/DIPSTICK

OIL FILLER CAP/

DIPSTICK

UPPER LIMIT

LOWER LIMIT

Running the engine with a low oil level can cause engine damage. This type of damage is not covered by the

Distributor’s Limited Warranty.

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7

Oil Change

Drain the used oil when 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, drain bolt and washer.

2.Allow the used oil to drain completely, then reinstall the drain bolt and new washer, and tighten the drain bolt securely.

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 in the trash, pour it on the ground, or pour it down a drain.

3.With the engine in a level position, fill with the recommended oil to the upper limit mark on the dipstick.

SEALING WASHER

UPPER

LIMIT

LOWER

LIMIT

OIL DRAIN BOLT

OIL FILLER CAP/DIPSTICK

Running the engine with a low oil level can cause engine damage. This type of damage is not covered by the Distributor’s Limited Warranty.

4. Reinstall the oil filler cap/dipstick securely.

OIL FILTER

Change

1.Drain the engine oil, and retighten the drain bolt securely.

2.Remove the oil filter with an oil filter wrench and drain the remaining oil into a suitable container. Dispose the used oil and filter in a manner compatible with the environment.

Use an oil filter socket, rather than a strap wrench, to avoid striking and damaging the oil filter.

	OIL FILTER
OIL FILTER SOCKET	FILTER MOUNTING BASE

SEAL

3.Clean the filter mounting base, and coat the seal of the new oil filter with clean engine oil.

Use only a Honda Genuine 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.

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.

Oil filter tightening torque: 22 N·m (2.2 kgf·m , 16 lbf·ft)

GXV610 QYC4, QYF4 type and GXV620 QYC4 type

Oil filter tightening torque: 12 N·m (1.2 kgf·m , 9 lbf·ft)

5.Refill the crankcase with the specified amount of the recommended oil (see page 7 ). Reinstall the oil filler cap/ dipstick.

6.Start the engine, and check for leaks.

7.Stop the engine, and check the oil level as described on page 7 . If necessary, add oil to bring the oil level to the upper limit mark on the dipstick.

8

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AIR CLEANER

A dirty air cleaner will restrict air flow to the carburetor, reducing engine performance. If you operate the engine in very dusty areas, clean the air filter more often than specified in the MAINTENANCE SCHEDULE.

Operating the engine without an air filter, or with a damaged air filter, will allow dirt to enter the engine, causing rapid engine wear. This type of damage is not covered by the Distributor’s Limited Warranty.

Inspection

Remove the air cleaner cover and inspect the filter elements. Clean or replace dirty filter elements. Always replace damaged filter elements.

Cleaning

1.Release the four spring tabs from the air cleaner cover, and remove the cover.

2.Remove the foam filter element.

3.Remove the paper filter element.

	AIR CLEANER BASE
SPRING TABS
PAPER FILTER ELEMENT	SPRING TABS
FOAM FILTER ELEMENT

CHAMBER

AIR CLEANER COVER

4.Inspect both air filter elements, and replace them if they are damaged. Always replace the paper air filter element at the scheduled interval (see page 6 ).

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 207 kPa (2.1 kgf/cm, 30 psi)] through the filter element from the clean side that faces the engine. Never try to brush off dirt; brushing will force dirt into the fibers. Replace the paper filter element if it is excessively dirty.

Foam air filter element: Clean in warm soapy water, rinse, and allow to dry thoroughly. Or clean in non-flammable solvent and allow to dry. Do not put oil on the foam element.

6.Wipe dirt from the inside of the air cleaner base and cover, using a moist rag. Be careful to prevent dirt from entering the chamber that leads on the carburetor.

7.Place the foam air filter element in the air cleaner cover, then reinstall the paper air filter element and cover to the air cleaner base. Hook the four spring tabs securely.

FUEL FILTER

Inspection

1. Check the fuel filter for water accumulation or sediment.

FUEL FILTER

2.If the fuel filter is found with excessive water accumulation or sediment, take the engine to your authorized Honda servicing dealer.

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9

SPARK PLUG

Recommended Spark Plugs: ZGR5A (NGK)

J16CR-U (DENSO)

The recommended spark plugs have the correct heat range for normal engine operating temperatures.

Incorrect spark plugs can cause engine damage.

For good performance, the spark plugs must be properly gapped and free of deposits.

1.Disconnect the 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.

SPARK PLUG CAP

3.Inspect the spark plugs. Replace them if damaged, badly fouled, if the sealing washer is in poor condition, or if the electrode is worn.

4.Measure the spark plug electrode gaps with a wire-type feeler gauge. Correct the gap, if necessary, by carefully bending the side electrode.

The gap should be:

0.7 0.8 mm (0.028 0.031 in)

5.Install the spark plugs carefully, by hand, to avoid crossthreading.

SPARK PLUG WRENCH

0.7 0.8 mm

(0.028 0.031 in)

SEALING

WASHER

6.After the spark plug is seated, tighten with a 13/16-inch spark plug wrench to compress the sealing washer.

When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer.

When reinstalling the original spark plug, tighten 1/8 1/4 turn after the spark plug seats to compress the washer.

A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head.

7.Attach the spark plug caps to the spark plugs.

SPARK ARRESTER (applicable types)

Your engine is not factory-equipped with a spark arrester. The spark arrester is optional part. In some areas, it is illegal to operate an engine without a spark arrester. Check local laws and regulations. A spark arrester is available from authorized Honda servicing dealers.

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 hot. Allow it to cool before servicing the spark arrester.

Cleaning & Inspection

1.Remove the 6 mm flange bolts 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 FLANGE BOLTS

MUFFLER

SPARK ARRESTER

SPECIAL SCREWS

MUFFLER	6 mm FLANGE BOLT
PROTECTOR

3.Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen.

The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged.

SPARK ARRESTER

SCREEN

4.Install the spark arrester and muffler protector in the reverse order of disassembly.

10

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HELPFUL TIPS & SUGGESTIONS

STORING YOUR ENGINE

Storage Preparation

Proper storage preparation is essential for keeping your engine trouble-free and looking good. The following steps will help to keep rust and corrosion from impairing your engine’s function and appearance, and will make the engine easier to start when you use it again.

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.

Fuel

Depending on the region where you operate your equipment, fuel formulations may deteriorate and oxidize rapidly. Fuel deterioration and oxidation can occur in as little as 30 days and may cause damage to the carburetor and/or fuel system. Please check with your servicing dealer for local storage recommendations.

Gasoline will oxidize and deteriorate in storage. Deteriorated gasoline will cause hard starting, and it leaves gum deposits that clog the fuel system. If 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 blend, your storage temperatures, and whether the fuel tank is partially or completely filled. The air in a partially filled fuel tank promotes fuel deterioration. Very warm storage temperatures accelerate fuel deterioration. Fuel deterioration problems may occur within a few months, or even less if the gasoline was not fresh when you filled the fuel tank.

Fuel system damage or engine performance problems resulting from neglected storage preparation are not covered under the

Distributor’s Limited Warranty.

You can extend fuel storage life by adding a gasoline stabilizer that is formulated for that purpose, or you can avoid fuel deterioration problems by draining the fuel tank and carburetor.

Adding a Gasoline Stabilizer to Extend Fuel Storage Life

When adding a gasoline stabilizer, fill the fuel 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 gasoline stabilizer following the manufacturer’s instructions.

2.After adding a gasoline 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 to the CLOSED or OFF position.

Draining the Fuel Tank and Carburetor

Gasoline is highly flammable and explosive, and you can be burned or seriously injured when handling fuel.

Stop engine and keep heat, sparks, and flame away.

Handle fuel only outdoors. Wipe up spills immediately.

1.Disconnect the fuel line to the engine, and drain the fuel tank into an approved gasoline container. If the fuel tank is equipped with a valve, turn the fuel valve to the OPEN or ON position to enable draining. After draining is completed, reconnect the fuel line.

2.Loosen the carburetor drain screw, and drain the carburetor into an approved gasoline container. After draining is completed, tighten the carburetor drain screw.

CARBURETOR

DRAIN SCREW

Engine Oil

1.Change the engine oil (see page 8 ).

2.Remove the spark plugs (see page 10 ).

3.Pour a tablespoon 5 10 cm (5 10 cc) of clean engine oil into each cylinder.

4.Turn the engine for a few seconds by turning the engine switch to the START position to distribute the oil in the cylinders.

5.Reinstall the spark plugs.

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11

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 sparkproducing electric motor, or where power tools are operated.

If possible, avoid storage areas with high humidity, because that promotes rust and corrosion.

Keep the engine level in storage. Tilting can cause fuel or oil leakage.

With the engine and exhaust system cool, cover the engine to keep out dust. A hot engine and exhaust system can ignite or melt some materials. Do not use sheet plastic as a dust cover. 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 CHECKS section of this manual (see page 3 ).

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 it contains only fresh gasoline. Gasoline oxidizes and deteriorates over time, causing hard starting.

If the cylinders were coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal.

TRANSPORTING

If the engine has been running, allow it to cool for at least 15 minutes before loading the engine-powered equipment on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some materials.

Keep the engine level when transporting to reduce the possibility of fuel leakage. If the fuel tank is equipped with a fuel valve, move the fuel valve lever to CLOSED or OFF position.

TAKING CARE OF UNEXPECTED PROBLEMS

ENGINE WILL	Possible Cause	Correction
NOT START
1. Electric	Battery	Recharge battery.
starting:	discharged.
Check battery
and fuse.	Fuse burnt out.	Replace fuse.
2. Check control	Fuel valve	Move lever to
positions.	CLOSED or OFF	OPEN or ON
	(If equipped).	position.
	Choke open.	Move lever to
		CLOSED position
		unless the engine
		is warm.
	Engine switch	Turn engine switch
	OFF.	to ON position.
3. Check fuel.	Out of fuel.	Refuel (p. 7).
	Bad fuel; engine	Drain fuel tank and
	stored without	carburetor (p. 11).
	treating or	Refuel with fresh
	draining	gasoline(p. 7).
	gasoline, or
	refueled with
	bad gasoline.
4. Remove and	Spark plugs	Gap, or replace
inspect spark	faulty, fouled, or	spark plugs (p. 10).
plugs.	improperly
	gapped.
	Spark plugs wet	Dry and reinstall
	with fuel	spark plugs. Start
	(flooded engine).	engine with
		throttle lever in
		FAST position.
5. Take engine to	Fuel filter	Replace or repair
an authorized	restricted,	faulty components
Honda	carburetor	as necessary.
servicing	malfunction,
dealer, or refer	ignition
to shop	malfunction,
manual.	valves stuck, etc.

ENGINE LACKS	Possible Cause	Correction
POWER
1. Check air filter.	Filter element(s)	Clean or replace
	restricted.	filter element(s)
		(p. 9).
2. Check fuel.	Bad fuel; engine	Drain fuel tank and
	stored without	carburetor (p. 11).
	treating or	Refuel with fresh
	draining	gasoline (p. 7).
	gasoline, or
	refueled with
	bad gasoline.
3. Take engine to	Fuel filter	Replace or repair
an authorized	restricted,	faulty components
Honda	carburetor	as necessary.
servicing	malfunction,
dealer, or refer	ignition
to shop	malfunction,
manual.	valves stuck, etc.

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TECHNICAL INFORMATION

Serial Number Location

Record the engine serial number, type and purchase date in the space below. You will need this information when ordering parts and when making technical or warranty inquiries.

ENGINE SERIAL NUMBER &

ENGINE TYPE LOCATION

Engine serial number: __ __ __ __ __ __ __ __ __ __ __

Engine type: ___ ___ ___ ___

Date Purchased: ______ / ______ / ______

Battery Connections for Electric Starter

Recommended Battery

GXV610

GXV620 12 V 45 Ah

GXV670

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.

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.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds. Wash hands after handling.

1.Connect the battery positive ( ) cable to the starter 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.

POSITIVE ( )

BATTERY CABLE

NEGATIVE ( )

BATTERY CABLE

STARTER SOLENOID

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13

Remote Control Linkage

The throttle and choke control levers are provided with holes for optional cable attachment. The following illustrations show installation examples for a solid wire cable and for a flexible, braided wire cable.

LEFT SIDE CONTROL

CONTROL LEVER

CHOKE CABLE

CABLE

HOLDER

CONTROL LEVER

CABLE
5 mm SCREWS HOLDER	THROTTLE CABLE

RIGHT SIDE CONTROL

CONTROL LEVER

CONTROL LEVER

CHOKE CABLE

CABLE

HOLDER

5 mm SCREWS

CABLE HOLDER

THROTTLE CABLE

Carburetor Modifications for High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions.

High altitude performance can be improved by specific modifications to the carburetor. If you always operate your engine at altitudes above 1,500 meters (5,000 feet), have your servicing dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life.

Even with carburetor modification, engine horsepower will decrease about 3.5% for each 300-meter (1,000-foot) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is 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 1,500 meters (5,000 feet) with a modified carburetor may cause the engine to overheat and result in serious engine damage. For use at low altitudes, have your servicing dealer return the carburetor to original factory specifications.

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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 important 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 appropriate air/fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide, oxides of nitrogen and hydrocarbons.

Additionally, Honda fuel systems utilize components and control technologies to reduce evaporative emissions.

The U.S., California Clean Air Acts and Environment Canada

EPA, California and Canadian 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 emissions 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.

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.

Replacement Parts

The emission control systems on your Honda engine were designed, built, and certified to conform with EPA, California (models certified for sale in California), and Canadian emission regulations. We recommend the 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 on page 6 . Remember that this schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load or hightemperature operation, or use in unusually wet or dusty conditions, will require more frequent service.

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15

Air Index

(Models certified for sale in California)

An Air Index Information label is applied to engines certified to an emission durability time period in accordance with the requirements of the California Air Resources Board.

The bar graph is intended to provide you, our customer, the ability to compare the emissions performance of available engines. The lower the Air Index, the less pollution.

The durability description is intended to provide you with information relating to the engine’s emission durability period. The descriptive term indicates the useful life period for the engine’s emission control system. See your Emission Control System Warranty for additional information.

Descriptive Term	Applicable to Emissions Durability Period
Moderate	50 hours [0 80 cm (0 80 cc) inclusive]
	125 hours [greater than 80 cm	(80 cc)]
Intermediate	125 hours [0 80 cm (0 80 cc) inclusive]
	250 hours [greater than 80 cm	(80 cc)]
Extended	300 hours [0 80 cm (0 80 cc) inclusive]
	500 hours [greater than 80 cm	(80 cc)]
	1,000 hours [225 cm (225 cc) and greater]

Specifications

GXV610 (QAF-Type)

Length × Width ×	459 × 457 × 431 mm
Height	(18.1 × 18.0 × 17.0 in)
Dry mass [weight]	43.8 kg (96.6 lbs)
Engine type	4-stroke, overhead valve, 2 cylinders (90° V-Twin)
Displacement	614 cm (37.5 cu-in)
[Bore × Stroke]	[77.0 × 66.0 mm (3.03 × 2.60 in)]
Net power	12.1 kW (16.5 PS, 16.2 bhp)
(in accordance with SAE J1349 )	at 3,600 rpm
Max. Net torque	39.4 N·m (4.02 kgf·m, 29.1 lbf·ft) at
(in accordance with SAE J1349 )	2,500 rpm
Engine oil capacity	Without oil filter replacement:
	1.7 (1.8 US qt , 1.5 Imp qt)
	With oil filter replacement:
	2.2 (2.3 US qt , 1.9 Imp qt)
Cooling system	Forced air
Ignition system	Transistor magneto
PTO shaft rotation	Counterclockwise
GXV620 (QAF-Type)
Length × Width ×	459 × 457 × 431 mm
Height	(18.1 × 18.0 × 17.0 in)
Dry mass [weight]	43.8 kg (96.6 lbs)
Engine type	4-stroke, overhead valve, 2 cylinders (90° V-Twin)
Displacement	614 cm (37.5 cu-in)
[Bore × Stroke]	[77.0 × 66.0 mm (3.03 × 2.60 in)]
Net power	13.3 kW (18.1 PS, 17.8 bhp)
(in accordance with SAE J1349 )	at 3,600 rpm
Max. Net torque	41.1 N·m (4.19 kgf·m, 30.3 lbf·ft) at
(in accordance with SAE J1349 )	2,500 rpm
Engine oil capacity	Without oil filter replacement:
	1.7 (1.8 US qt , 1.5 Imp qt)
	With oil filter replacement:
	2.2 (2.3 US qt , 1.9 Imp qt)
Cooling system	Forced air
Ignition system	Transistor magneto
PTO shaft rotation	Counterclockwise
GXV670 (TAF-Type)
Length × Width ×	464 × 473 × 449 mm
Height	(18.3 × 18.6 × 17.7 in)
Dry mass [weight]	45.3 kg (99.9 lbs)
Engine type	4-stroke, overhead valve, 2 cylinders (90° V-Twin)
Displacement	670 cm (40.9 cu-in)
[Bore × Stroke]	[77.0 × 72.0 mm (3.03 × 2.83 in)]
Net power	15.5 kW (21.1 PS, 20.8 bhp)
(in accordance with SAE J1349 )	at 3,600 rpm
Max. Net torque	44.4 N·m (4.53 kgf·m, 32.7 lbf·ft) at
(in accordance with SAE J1349 )	2,500 rpm
Engine oil capacity	Without oil filter replacement:
	2.0 (2.1 US qt , 1.8 Imp qt)
	With oil filter replacement:
	2.5 (2.6 US qt , 2.2 Imp qt)
Cooling system	Forced air
Ignition system	Transistor magneto
PTO shaft rotation	Counterclockwise

The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine model and measured in accordance with SAE J1349 at 3,600 rpm (Net Power) and at 2,500 rpm (Max. Net Torque). Mass production engines may vary from this value.

Actual power output for the engine installed in the final machine will vary depending on numerous factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables.

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Tuneup Specifications		GXV610/620/670		Wiring Diagrams
ITEM		SPECIFICATION	MAINTENANCE	3 A Charge Coil and Switch Box Type
Spark plug gap		0.7 0.8 mm	Refer to page 10.
		(0.028 0.031 in)	See your authorized
Idle speed		1,400 ± 150 rpm		OFF
Valve clearance	IN: 0.15 ± 0.02 mm		Honda dealer	ON
(cold)	EX: 0.20 ± 0.02 mm			START
Other specifications		No other adjustments needed.
				Bl	Black		Br	Brown
				Y	Yellow		O	Orange
				Bu Blue			Lb Light blue
Quick Reference Information				G	Green		Lg	Light green
				R	Red		P	Pink
Fuel	Unleaded gasoline (Refer to page 7).			W White			Gr Gray
	U.S.	Pump octane rating 86 or higher
	Except Research octane rating 91 or higher			(A)		MAIN FUSE
	U.S.	Pump octane rating 86 or higher		(B)		ENGINE SWITCH
Engine oil	SAE 10W-30, API SJ or later, for general use.			(C)		ENGINE GROUND
	Refer to page 7.			(D)		FUEL CUT
Spark plug	ZGR5A (NGK)					SOLENOID
	J16CR-U (DENSO)			(E)		STARTER MOTOR
Maintenance	Before each use:			(F)		BATTERY
	Check engine oil level. Refer to page 7.			(G)		CHARGE COIL (3A)
	Check air filter. Refer to page 9.			(H)		LEFT IGNITION
	First 20 hours:					COIL
	Change engine oil. Refer to page 8.			(I)		LEFT SPARK PLUG
	Subsequent:			(J)		RIGHT IGNITION
	Refer to the maintenance schedule on page 6.					COIL
				(K)		RIGHT SPARK PLUG
				(L)		ENGINE STOP DIODE
				(M)		RECTIFIER

20 A Charge Coil and Switch Box Type

OFF

ON

START

Bl	Black	Br	Brown
Y	Yellow	O	Orange
Bu	Blue	Lb	Light blue
G	Green	Lg	Light green
R	Red	P	Pink
W	White	Gr	Gray

(A) MAIN FUSE

(B) ENGINE SWITCH

(C) ENGINE GROUND

(D) FUEL CUT SOLENOID

(E) STARTER MOTOR

(F) BATTERY

(G) CHARGE COIL (20A)

(H) LEFT IGNITION COIL

(I) LEFT SPARK PLUG

(J) RIGHT IGNITION COIL

(K) RIGHT SPARK PLUG

(L) ENGINE STOP DIODE

(M) REGULATOR/

RECTIFIER

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17