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1. Owner Responsibilities e 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 e Know how to stop the engine quickly and understand the operation of all controls Never permit anyone to operate the engine without proper instructions e Donotallow 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 e Themuffler 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 e To prevent fire hazards and to provide adequate ventilation for stationary equipment applications keep the engine atleast 3feet 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
2. 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 the engine has been running the muffler will be very hot Allow the muffler to cool before servicing the spark arrester 1 HIGH MOUNT MUFFLER TYPE Remove the special screw from the muffler and remove the spark arrester MUFFLER SPARK ARRESTER SIDE MOUNT MUFFLER TYPE Remove the 6 mm screws from the muffler protector and remove the muffler protector Remove the special screws from the spark arrester and remove the spark arrester from the muffler MUFFLER SPARK ARRESTER SPECIAL SCREWS 6 mm SCREWS 225 MUFFLER 6 mm SCREW PROTECTOR 36 SERVICING YOUR HONDA ENGINE 2 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 HIGH MOUNT MUFFLER TYPE SIDE MOUNT MUFFLER TYPE SPARK ARRESTER SCREEN 3 Install the spark arrester and muffler protector in the reverse order of disassembly 37 HELPFUL TIPS amp SUGGESTIONS STORING YOUR ENGINE Storage Preparation Proper storage preparation is essential for keeping your engine troublefree and looking good The following steps will help to keep rust and corrosion from impairing your engine s functi
3. 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 Office 4475 River Green Parkway Duluth Georgia 30136 2565 Or telephone 770 497 6400 When you write or call please give us this information e Model and serial number see page 46 e Name of dealer who sold the engine to you e Name and address of dealer who services your engine e Date of purchase Your name address and telephone number e A detailed description of the problem 57 Current customer service contact information Servicing dealership personnel are trained professionals They should be able 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 General Manager or Owner can help Almost all problems are solved in this way United States Puerto Rico and U S Virgin Islands If you are dissatisfied with the decision made by the dealership s management contact the Honda Regional Engine Distributor for your area www honda engines com dea htm If you are still dissatisfied after speaking with the Regional Engine Distributor you may contact the Honda Office as shown American Honda Motor Co Inc Power Equi
4. filter from the air cleaner body AIR CLEANER COVER T WING BOLT GASKET 5 mm SCREWS FOAM FILTER ELEMENT CLEAN CHAMBER 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 23 Clean the air filter elements if they are to be reused 32 SERVICING YOUR HONDA ENGINE Paper air 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 element and both gaskets if it is excessively dirty Foam air filter element Clean in warm soapy water rinse and allow to dry thoroughly Or clean in nonflammable 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 if too much oil is left in the foam Wipe dirt from the inside of the air cleaner body and cover using a moist rag Be careful to prevent dirt from entering the air chamber that leads to the carburetor Place the foam air filter elementto the air cleaner body Be sure the gaskets are in place then reinstall the paper air filter element and cover Tighten the air filter wing bolt securely 33 SERVICING YOUR HONDA ENGINE SPARK PLU
5. 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 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 e Safety Labels on the engine e Safety Messages preceded bya safety alert sym bol A and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t fol
6. Allow the used oil to drain completely then reinstall the drain bolt and tighten it 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 down a drain With the engine in a level position fill to the upper limit mark on the dipstick with the recommended oil see page 29 ENGINE OIL REFILL CAPACITIES Without oil filter replacement 1 27 US qt 1 20 2 With oil filter replacement 1 59 US qt 1 50 2 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 the safe limit However to avoid the inconvenience of an unexpected shutdown fill to the upper limit and check the oil level regularly DIPSTICK SERVICING YOUR HONDA ENGINE OIL FILTER CHANGE 1 Drain the engine oil and retighten the drain bolt securely see page 26 2 Remove the oil filter and drain the oil into a suitable container Discard the used oil filter Use an oil filter socket tool rather than a strap wrench to avoid striking and damaging the oil pressure switch OIL FILTER SOCKET TOOL 3 Clean the filter mounting base and coat the seal of the new oil filter with clean engine oil Use only a genuin
7. G SERVICE Recommended spark plugs BPR6ES NGk W20EPR U DENSO Incorrect spark plugs can cause engine damage 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 PLUG CAP Inspect the spark plug Replace it if the 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 mm Correct the gap if necessary by care fully bending the side electrode Installthe spark plug carefully by hand to avoid cross threading 34 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 1 4 turn after the spark plug seats If installing a new spark plug tighten 1 2 turn after the spark plug seats 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 35 SERVICING YOUR HONDA ENGINE SPARK ARRESTER SERVICE optional equipment Your engine is not factory equipped with a spark arrester In some areas it is illegal to operate an engine without a spark arrester
8. HONDA ENGINES Owner s Manual 10 GX620 a wi Click here to save this i manual to your computer amp WARNING A 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 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 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
9. 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 96 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 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 6 000 feet 1 800 meters 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 50 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 it is unleaded and meets the minimum octane rating requirement Before using an oxygenated fuel t
10. ace below You will need this serial number when ordering parts and when making technical or warranty inquiries see page 57 Engine serial number 46 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 4a WARNING 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 bat tery 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 STARTER SOLENOID NEGATIVE BATTERY CABLE POSITIVE BATTERY CABLE 47 TECHNICAL amp CONSUMER INFORMATION Remote Control Linkage The thrott
11. al bolts from the control cover and remove the control cover CONTROL COVER A 280 2 6 mm SPECIAL BOLT 2 Check the fuel filter for water accumulation or sediment If no water or sediment is found reinstall the control cover 3 Ifthe fuel filter is found with excessive water accumulation or sediment take the engine to your authorized Honda servicing dealer 30 SERVICING YOUR HONDA ENGINE AIR FILTER INSPECTION Remove the air cleaner cover and inspect the filter Clean or replace dirty filter elements Always replace damaged filter elements Refer to page 32 for instructions that apply to the air cleaner and filter PAPER FILTER ELEMENT AiR CLEANER COVER GASKET CLEAN CHAMBER AIR CLEANER BODY 31 SERVICING YOUR HONDA ENGINE AIR CLEANER SERVICE A dirty air filter 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 1 2 Remove the wing bolt from the air cleaner cover and remove the cover Remove the two 5 mm screws from the air cleaner cover and remove the paper element from the cover Remove the foam
12. e 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 27 SERVICING YOUR HONDA ENGINE 4 Screw the new oil filter by hand until the seal contacts the filter mounting base then use an oil filter socket tool to tighten the filter an additional 7 8 turn Oil filter tightening torque 16 ft lb 22 N m 2 2 kg m 5 Refill the crankcase with the specified amount of the recommended oil see page 29 Reinstall the oil filler cap and dipstick 6 Start the engine and check for leaks 7 Stop the engine and check the oil level as described on page 25 If necessary add oil to bring the oil level to the upper limit mark on the dipstick 28 SERVICING YOUR HONDA 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 general use Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range 30 20 10 0 10 20 30 40 C 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 29 SERVICING YOUR HONDA ENGINE FUEL FILTER INSPECTION 1 Remove the two 6 mm speci
13. e 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 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 WARNING Improperly maintaining this engine or fall ing 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 e Look around and underneath the engine for signs of oil or gasoline leaks e Remove any excessive dirt or debris especially around the muffler and recoil starter e Look for signs of damage e Check that all shields and covers are in place and all nuts bolts and screws are tightened 13 Check the Engine Check the engine o
14. 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 CONTROLS amp FEATURES COMPONENT amp CONTROL LOCATIONS THROTTLE LEVER SPARK PLUG AIR CLEANER o Ao Ww uz m CHOKE KNOB OIL FILTER ENGINE SWITCH DRAIN BOLT STARTER GRIP FAN COVER PROTECTOR PROTECTOR TYPE S T D TYPE FLYWHEEL SCREEN GRID PTO TYPE TYPE CONTROLS amp FEATURES SIDE MOUNT MUFFLER HIGH MOUNT MUFFLER B type OIL FILLER CAP HIGH MOUNT MUFFLER A type SPARK PLUG OIL PRESSURE SWITCH ELECTRIC STARTER CONTROLS amp 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 OFF START ENGINE SWITCH CONTROLS amp FEATURES Choke Knob The choke knob opens and closes the choke valve in the carburetor The CLOSED pos
15. f spark knock or pinging persists see an authorized Honda servicing dealer Running the engine with persistent spark knock or pinging can cause engine damage Running the engine with persistent spark knock or pinging is misuse and the Distributor s Limited Warranty does not cover parts damaged by misuse 24 SERVICING YOUR HONDA ENGINE ENGINE OIL LEVEL CHECK Check the engine oil level with the engine stopped and in a level position 1 Remove the dipstick and wipe it clean 2 Fully insert the dipstick then remove it to check the oil level 3 If the oil level is low fill to the upper limit mark on the dipstick with the recommended oil see page 29 4 Reinstall the dipstick and screw in the filler cap securely FILLER CAP _ _ UTILIZA UPPER LIMIT LOWER LIMIT DIPSTICK 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 25 SERVICING YOUR HONDA ENGINE ENGINE OIL CHANGE Drain the used oil while the engine is warm Warm oil drains quickly and completely 1 26 Reinstall the filler cap and dipstick securely FILLER CAP Place a suitable container below the engine to catch the used oil then remove the filler cap and the drain bolt
16. gine to an authorized Honda servicing dealer or refer to shop manual Replace or repair faulty components as necessary 44 UNEXPECTED PROBLEMS FUSE REPLACEMENT 3A charge coil and switch box type The electric starter relay circuit and battery charging circuit are protected by a25 ampere fuse If the fuse burns out the electric starter will not operate The engine can be started manually if the fuse burns out but running the engine will not charge the battery 1 Remove the 6 x 12 mm screw from the rear cover of the engine switch box 2 Remove the fuse cover and inspect the fuse Ifthe fuse is burnt out remove the fuse cover then pull out and discard the burnt out fuse Install a new 25 ampere fuse and reinstall the fuse cover Never use a fuse with a rating greater than 25 amperes Serious damage to the electrical system or a fire could result 3 Reinstall the fuse cover Install the 6 x 12 mm screw and tighten it securely FUSE COVER SWITCH BOX COVER lt 2 25 FUSE 6 X 12 mm SPECIAL SCREW Frequent fuse failure usually indicates a short circuit or an overload in the electrical system If the fuse burns out frequently take the engine to a servicing Honda dealer for repair 45 TECHNICAL amp CONSUMER INFORMATION TECHNICAL INFORMATION Serial Number Location ELECTRIC STARTER SERIAL NUMBER amp ENGINE TYPE Record the engine serial number in the sp
17. il 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 e Check the air filter see page 31 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 14 OPERATION SAFE OPERATING PRECAUTIONS Before operating the engine for the first time please review the IMPORTANT SAFETY INFORMATION on page 5 and the chapter titted BEFORE OPERA TION 4a WARNING Carbon monoxide gas is 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 in the OPEN or ON position bef
18. ine oil filter Replace O or 200 Air fiter Replace Spark plug Clean Readust O Jx Replace e Idie speed Chekadst E Valve clearance Check Readjust Lb Replace Ed cu T quus e Fuelline Chek 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 23 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 Unleaded 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 I
19. ine was not fresh when you filled the fuel tank 38 HELPFUL TIPS amp SUGGESTIONS The Distributor s Limited Warranty does not cover fuel system damage engine performance problems resulting 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 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 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 Stop the engine and if the fuel tank is equipped with a fuel valve move the fuel valve to the CLOSED or OFF position 39 HELPFUL TIPS amp SUGGESTIONS DRAINING THE FUEL TANK AND CARBURETOR 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 Remove the contr
20. ions 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 U S 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 e Removal or alteration of any part of the intake fuel or exhaust systems e Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters 52 TECHNICAL amp 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 e Hard starting or stalling after starting e Rough idle e Misfiring or backfiring under load e Afterburning backfiring e Black exhaust smoke or high fuel consumption Replacement Parts The emission control systems on your Honda engi
21. ition 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 THROTTLE LEVER 4 SAN Non UN NA SH SITS SLOW 2 wy Recoil Starter Grip Pulling the starter grip operates the recoil starter to crank the engine STARTER GRIP 11 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 engin
22. ition the equipment so the engine is level 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 Anonporous cover will trap moisture around the engine promoting rust and corrosion Remove the battery and store itin 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 If the cylinders were coated with oil during storage preparation the engine may smoke briefly at startup This is normal 42 HELPFUL TIPS amp SUGGESTIONS 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 43 TAKING CARE OF UNEXPECTED PROBLEMS ENGINE WILL NOT START Possible Cause Cor
23. ke overhead valve 2 cylinders 90 V Twin Bore x Stroke 3 03 x 2 60 in 77 x 66 mm Max output 20bhp i49KW 203PS at3600rpm 32 5 ft lb 44 13 Nem 4 50 kg m at 2 500 rpm GX610 GX620 Tuneup SPECIFICATION MAINTENANCE Spark plug gap 0 7 0 8 mm 0 028 0 031 in Refer to page 34 Valve clearance cold IN 0 15 0 02 mm See your authorized EX 0 20 0 02 mm Honda dealer Other specifications No other adjustments needed 54 TECHNICAL amp CONSUMER INFORMATION Wiring Diagrams 3A Charge Coil and Switch Box Type IGHT GREEN ENGINE STOP DIODE 55 TECHNICAL amp 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 skilled technician Parts Catalog This manual provides complete illustrated parts lists 56 TECHNICAL amp CONSUMER INFORMATION Warranty Service Information Servicing dealership personnel are trained professionals They should be able 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
24. le and choke control levers are provided with holes for optional cable attachment 1 Remove the two 6 mm special bolts from the contro cover and remove control cover lt CEE CONTROL COVER v XM al CEA 6 mm SPECIAL BOLTS 2 Thefollowing illustrations show installation examples for a solid wire cable and for a braided wire cable If using a braided wire cable add a return spring as shown 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 yo T 5 mmSCREW FRICTION NUT MEA 4 mm SCREW 5 3 RETURN SPRING e 3 EIS CHOKE CABLE CHOKE CABLE 5 mm SCREW 5 mm SCREW 48 BRAIDED WIRE CABLE TYPE SOLID WIRE CABLE TYPE TECHNICAL amp CONSUMER INFORMATION REMOTE THROTTLE AND MANUAL CHOKE 5 mm SCREW FRICTION NUT E S 5 v Fs 22525 pA Y deccm BRAIDED WIRE CABLE FRICTION NUT RETURN SPRING SOLID WIRE CABLE TYPE 3 Reinstall the control cover Install the throttle cable or the choke cable to the control base after guiding the cable through the hole in the control cover 49 TECHNICAL amp CONSUMER INFORMATION Carburetor Modification tor High Altitude Operation At high altitude the standard carburetor air fuel mixture will be too rich
25. low instructions Safety Headings such as SAFETY INFORMATION e Safety Section such as ENGINE SAFETY e Instructions how to use this engine correctly and safely This entire book is filled with important safety information please read it carefully 2 5 Oil Alert System applicable engine types 12 12 STARTING THE ENGINE STOPPING THE ENGINE NGINE OIL RECOMMENDATIONS 29 FUEL FILTERANSPEGTIODNL aen Fait ato Ea qus 30 CONTENTS SERVICING YOUR HONDA ENGINE continued AIR FILTER INSPECTION 31 38 Md 38 38 Storage 8 2121242020020 41 JN laelupnuimme 56 K S 56 Warranty Service 2 1 57 QUICK REFERENCE INFORMATION 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 the most common hazards are discussed below along with the best way to protect yourself and others
26. ne were designed built and certified to conform with EPA and California emission regulations We recom mend 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 23 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 53 TECHNICAL amp CONSUMER INFORMATION Specifications GX610 QZE Type 17 6 x 19 3 x 17 8 in Length x Width x Height 447 x 490 x 452 mm Dry weight 94 8 Ib 43 0 kg Engine type 4 stroke overhead valve 2 cylinders 90 V Twin Displacement 37 5 cu in 614 cm Bore x Stroke 3 03 x 2 60 in 77 x 66 mm 18 bhp 13 4 KW 18 3 PS at 3 600 rpm GX620 QDF Type 4 stro
27. ol cover see page 30 loosen the carburetor drain screw and drain the carburetor into an approved gasoline container After draining is completed tighten the carburetor drain screw and reinstall the control cover 44 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately CARBURETOR 40 HELPFUL TIPS amp SUGGESTIONS Engine 1 Change the engine oil see page 26 2 Remove the spark plugs see page 34 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 operated 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 41 HELPFUL TIPS amp SUGGESTIONS Pos
28. on 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 e Usinga 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 e 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 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 deteriora tion Very warm storage temperatures accelerate fuel deterioration Fuel deterioration problems may occur within a few months or even less if the gasol
29. ore attempting to start the engine 15 OPERATION 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 1 3 of the way toward the FAST position Some engine applications use a remotely mounted throttle control rather than the engine mounted throttle lever shown here THROTTLE LEVER 16 OPERATION 4 Turn the engine switch to the ON position 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 17 OPERATION ELECTRIC STARTER all engine types Turn the key to the START position and hold it there the engine starts Ifthe 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 ENGINE SWITCH 6 If the choke knob has been pulled to the CLOSED position to start the engine gradually push it to
30. pment Division Customer Relations Office 4900 Marconi Drive Alpharetta GA 30005 8847 Or telephone 770 497 6400 M F 8 30 am 7 00 pm EST When you write or call please provide the following information e Equipment manufacturer s name and model number that the engine is mounted on e Engine model serial number and type e Name of the dealer who sold the engine to you Name address and contact person of the dealer who services your engine e Date of purchase e Your name address and telephone number Adetailed description of the problem 58 59 60 QUICK REFERENCE INFORMATION Unleaded gasoline with a pump octane om SS of 86 or higher page 24 we page 29 Without oil filter replacement 1 27 US qt 1 20 2 pacity With oil filter replacement 1 59 US qt 1 50 NGK BPR6ES DENSO W20EPR U Spark Plug 0 028 0 031 in 0 70 0 80 mm page 34 Idle speed 1 400 150 rpm Before Check engine oil level each use Check air filter Maintenance First 20 Change engine oil hours Refer to the maintenance schedule on page 23 Subsequent LLLLLLLLLLLLLI
31. rection 1 Check battery and Battery discharged Recharge battery fuse Replace fuse p 45 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 ON 3 Check fuel Out of fuel j Refue Bad fuel engine Drain fuel tank and stored without treating carburetor p 40 or draining gasoline Refuel with fresh or refueled with bad gasoline gasoline 4 Remove and Spark plugs faulty Clean gap or replace fouled or improperly spark plugs p 34 gapped inspect spark plugs Spark plugs wet with Dry and reinstall spark fuel flooded engine plugs Start engine with throttle lever in FAST position Replace or repair faulty components as necessary 5 Take engine to an Fuel filter clogged authorized Honda carburetor malfunc servicing dealer or tion ignition malfunc refer to shop manual tion valves stuck etc 1 Check air filter Filter element s Clean or replace filter clogged element s p 32 2 Check fuel Bad fuel engine Drain fuel tank and stored without treating carburetor p 40 or draining gasoline Refuel with fresh or refueled with bad gasoline gasoline Fuel filter clogged carburetor malfunc tion ignition malfunc tion valves stuck etc 3 Take en
32. ry 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 Gasohol 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 If 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 51 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 impor tant because under certain condit
33. 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 manual Safety Precautions 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 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 fuel 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 22 SERVICING YOUR HONDA ENGINE MAINTENANCE SCHEDULE REGULAR SERVICE PERIOD 3 ITEM Perform at every indicated month or operating hour interval whichever comes first Engine oil Check level Change Eng
34. the OPEN position as the engine warms up 18 OPERATION 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 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 M 2 Turn the engine switch to the OFF position ENGINE SWITCH N ENGINE SW 4 r4 d THROTILE LEVER oS gt 3 If the fuel tank is equipped a valve turn the fuel valve to the CLOSED or OFF position 19 OPERATION SETTING ENGINE SPEED Position the throttle lever for the desired engine speed Some engine applications use 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 THROTTLE LEVER SXFAST a 5 5 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 20 SERVICING YOUR HONDA ENGINE THE IMPORTANCE OF MAINTENANCE Good maintenance is essential for safe economical and trouble free opera
35. tion It will also help reduce air pollution WARNING 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 follow the inspection and mainte 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 are best handled by professionals and are normally performed by a Honda technician or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your engine under unusual conditions such as sustained high load or high 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 21 SERVICING YOUR HONDA ENGINE MAINTENANCE SAFETY Some of the most important safety precautions follow However we cannot warn you of every conceivable hazard that can arise in performing mainte nance Only you can decide whether or not you

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