Honda GX610, GX620 Owner's Manual
ENGINES’
Owner’s Manual
GX610 l GX620
The 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 GX610-QZE
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 reproduced 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 -1
symbol. That information is intended to 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
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
Honda servicing dealer is specially trained 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.
1
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 on labels and in this manual. This
information alerts you to potential hazards that could hurt you or others.
Of course, it is not practical or possible to warn 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:
l
Safety Labels - on the engine.
.
Safety Messages - preceded by a safety alert symbol A and one of three
signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
B You WILL be KILLED
or SERIOUSLY HURT if you don’t follow
instructions.
m You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
m You CAN be HURT if you don’t follow instructions.
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Safety Headings -
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Safety Section -
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Instructions - how to use this engine correctly and safely.
such as IMPORTANT SAFETY INFORMATION.
such as ENGINE SAFETY.
This entire book is filled with important safety information - please read it
carefully.
2
CONTENTS
ENGINE
CONTROLS
BEFORE
OPERATION
SAFETY ......................................................................................
IMPORTANT
COMPONENT
CONTROLS ..........................................................................................
Engine Switch
Choke Knob.. ...................................................................................
Throttle Lever ..................................................................................
Recoil Starter Grip.. .........................................................................
FEATURES
Oil Alert System (applicable engine types)
Fuel-cut Solenoid ............................................................................
OPERATION .............................................................................
IS YOUR
Check the General Condition of the
Check the Engine ............................................................................
Check the Equipment Powered by This Engine
SAFE
STARTING
STOPPING
SETTING
OPERATING PRECAUTIONS.. .................................................
SAFETY INFORMATION
& FEATURES
& CONTROL
..................................................................................
..........................................................................................
ENGINE READY TO GO?.
.............................................................................................
THE ENGINE ....................................................................
THE ENGINE..
ENGINE SPEED..
.......................................................................
LOCATIONS ...........................................
..................................................................
...............................................................
................................................
.....................................
...................................................
Engine.. ..................................
..............................
.5
.5
.7
.7
.9
.9
10
11
11
12
12
12
13
13
13
14
14
15
15
15
19
.20
SERVICING
IMPORTANCE OF MAINTENANCE.. .........................................
THE
MAINTENANCE
MAINTENANCE
FUEL
ENGINE
ENGINE
OIL
ENGINE
FUEL
RECOMMENDATIONS.. ...........................................................
FILTER CHANGE..
FILTER INSPECTION.. .............................................................
YOUR HONDA ENGINE .....................................................
SAFETY
SCHEDULE
OIL LEVEL CHECK.. ............................................................
OIL CHANGE
OIL RECOMMENDATIONS .................................................
...................................................................
.............................................................
.......................................................................
.......................................................................
.21
.21
.22
.23
.24
.25
.26
.27
.29
.30
3
CONTENTS
SERVICING YOUR HONDA ENGINE (continued)
FILTER INSPECTION
AIR
AIR CLEANER SERVICE
SPARK PLUG SERVICE
SPARK ARRESTER
..................................................................
...................................................................
.................................................................... .34
MAINTENANCE
(optional part) .........................
.31
.32
.36
HELPFUL TIPS
STORING
Storage Preparation .......................................................................
Storage Precautions.. .....................................................................
Removal From Storage
TRANSPORTING
TAKING
TECHNICAL & CONSUMER
CARE OF UNEXPECTED
ENGINE
ENGINE
FUSE REPLACEMENT (3A charge coil and switch box type).
TECHNICAL
Serial Number Location.. ................................................................
Battery Connections for Electric Starter .........................................
Remote Control Linkage ................................................................
Carburetor Modification for High Altitude .......................................
Oxygenated Fuels
Emission Control System
Specifications
Wiring Diagrams
CONSUMER INFORMATION
Honda Publications
Warranty Service Information.. .......................................................
& SUGGESTIONS
YOUR ENGINE..
.................................................................................
WILL NOT START.. ..............................................................
LACKS POWER ...................................................................
INFORMATION
INFORMATION.. ............................................................
..........................................................................
..................................................................................
..............................................................................
.........................................................................
.........................................................
................................................................
..................................................................
PROBLEMS
Information
..............................................................
....................................
.........................................
............................................
...........
.38
.38
.38
.41
.42
44
.44
.44
.44
.45
.46
.46
.46
.47
.48
.50
.51
.52
54
55
56
56
.57
QUICK
4
REFERENCE INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside
back cover
IMPORTANT SAFETY INFORMATION
Most accidents with engines can be prevented if you follow all instructions in
this manual and on the engine. Some of the most common hazards are
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. Read and understand this owner’s
manual before operating the engine. Failure to do so could result in
personal injury or equipment damage.
Know how to stop the engine quickly, and understand the operation of all
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. 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 engine.
Hot Exhaust
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The muffler becomes very hot during operation and remains hot for a while
after stopping the engine. Be careful not to touch the muffler while it is hot.
Let the engine cool before storing it indoors.
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To prevent fire hazards and to provide adequate ventilation for stationary
equipment applications, keep the engine at least 3feet (1 meter) away from
building walls and other equipment during operation. Do not place flam-
mable objects close to the engine.
5
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 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.
6
CONTROLS & FEATURES
COMPONENT & CONTROL LOCATIONS
THROTTLE LEVER
SPARK\PLUG
CHOKE KNOB
I
AIR CLEANER
FUEL FILTER
OIL DRAIN BOLT
STARTER &RIP
FAN COVER
PROTECTOR
TYPE
FLYWHEEL
PTO TYPE
PROTECTOR
TYPE (S.T.D)
\
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CONTROLS & FEATURES
SIDE-MOUNT
MUFFLER
HIGH-MOUNT
MUFFLER
!B type)
OIL FILLER CAP
OIL LEVEL DIPS
ELECTRIC STARTiR
HIGH-MOUNT MUFFLER (A type)
\
SWITCH
8
CONTROLS & FEATURES
CONTROLS
Engine Switch
The engine switch enables and disables the ignition system.
The engine switch 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 when
released from the START position.
OF
NGINE SWITCH
9
CONTROLS & FEATURES
Choke Knob
The choke knob 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 knob shown here.
CHOKE KNOB
10
CONTROLS & FEATURES
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.
STARTERGRIP - --
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CONTROLS & FEATURES
FEATURES
Oil Alert System (applicable engine types)
The Oil Alert system is designed to prevent engine damage caused by an
insufficient amount of oil in the crankcase. Before the oil level in the crankcase
can fall below a safe limit, the Oil Alert system will automatically stop the
engine (the engine switch will remain in the ON position).
If the engine stops and will not restart, check the engine oil level (page 25).
before troubleshooting in other areas.
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 fuel-cut solenoid,
allowing the engine to run. If the battery is disconnected, fuel flow to the
carburetor main jet will stop.
12
BEFORE OPERATION
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, orfalling to correct a problem before operation,
could cause a malfunction in which you
could be seriously injured.
Always perform a preoperation inspection
before each 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 Condition of the Engine
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Look around and underneath the engine for signs of oil or gasoline leaks.
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Remove any excessive dirt or debris, especially around the muffler and
recoil starter.
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Look for signs of damage.
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Check that all shields and covers are in place, and all nuts, bolts, and
screws are tightened.
13
BEFORE OPERATION
Check the Engine
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Check the engine oil level (see page 25). Running the engine with a low oil
level can cause engine damage.
The Oil Alert system (applicable engine types) will automatically stop the
engine before the oil level falls below safe limits. However, to avoid the
inconvenience of an unexpected shutdown, always check the engine oil
level before startup.
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Check the air filter (see page 31). A dirty air filter will restrict air flow to the
carburetor, reducing engine performance.
l
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.
14
OPERATION
SAFE OPERATING PRECAUTIONS
Before operating the engine for the first time, please review the IMPORTANT
SAFETYlNFORMATlONon page 5 and the chapter titled BEFOREOPERA-
T/ON.
Carbon monoxide gas is toxic. Breathing
itcancauseunconsciousnessandeven
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. 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.
15
2. To start a cold engine, pull the choke knob out to the CLOSED position.
To restart a warm engine, leave the choke knob in the OPEN position.
Some engine applications use a remotely-mounted choke control rather
than the engine-mounted choke knob shown here.
CHOKE KNOB
3. Move the throttle lever away from the SLOW position, about i/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.
THROTTLE LEVER
16
4. Turn the engine switch to the ON position.
OPERATION
ENGINE
SWITCH
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.
STARTER GRIP
-_7_
17
OPERATION
ELECTRIC STARTER (all engine types):
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
OFF
seconds before operating the starter again.
Using the electric starter for more than 5
seconds at a time will overheat the starter
ENGINE
SWITCH
motor and can damage it.
When the engine starts, release the key,
allowing it to return to the ON position.
6. If the choke knob has been pulled to the CLOSED position to start the
engine, gradually push it to the OPEN position as the engine warms up.
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