Honda GX630 GX660 GX690 Engine Complete Workshop Manual

How to use this manual 0-1 How to use this manual A Few Words About Safety SERVICE INFORMATION The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage this Honda product or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use special tools. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer’s Safety Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight while servicing this product can result in faulty operation, damage to the product, or injury to others. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: • Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. • Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around pressurized air, pressurized liquids, springs or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. • Protect yourself and others whenever you have engine-power equipment up in the air. Anytime you lift this product with a hoist, make sure that the hoist hook is securely attached to the product. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. • Burns from hot parts. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gasses from battery are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. • Use only a nonflammable solvent, not gasoline, to clean parts. • Never store gasoline in an open container. • Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts. Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. 62Z6N000.book 1 ページ２００９年６月１６日火曜日午後６時１７分

CONTENTS SPECIFICATIONS 1 SERVICE INFORMATION 2 MAINTENANCE 3 TROUBLESHOOTING 4 COVER 5 FUEL SYSTEM 6 GOVERNOR SYSTEM 7 CHARGING SYSTEM 8 IGNITION SYSTEM 9 STARTING SYSTEM 10 OTHER ELECTRICAL 11 MUFFLER 12 LUBRICATION SYSTEM 13 CYLINDER 14 CRANKCASE 15 TECHNICAL FEATURES 16 WIRING DIAGRAMS 17 INDEX 62Z6N000.book 2 ページ２００９年６月１６日火曜日午後６時１７分

How to use this manual 0-3 INTRODUCTION This manual covers the service and repair procedures for Honda GX630/630R/660/660R/690/690R. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at anytime without notice. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and tables. As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to this Honda product, other property, or the environment. SAFETY MESSAGES Your safety, and the safety of others, are very important. To help you make informed decisions, we have provided safety messages and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing these products. You must use your own good judgement. © Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE Date of Issue: June 2009 You will find important safety information in a variety of forms, including: • Safety Labels – on the product. • Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. • Instructions – how to service these products correctly and safely. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Mo- tor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PER- MISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda products. 62Z6N000.book 3 ページ２００９年６月１６日火曜日午後６時１７分

How to use this manual 0-4 SERVICE RULES • Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product. • Install new gaskets, O-rings, etc. when reassembling. • When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless a particular sequence is specified. • Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. • After reassembly, check all parts for proper installation and operation. • Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the threads and ruin the hole. Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. The use of incorrect tools and fasteners will damage the unit. SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use the recommend engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use water resistant molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: UNILITE M No.2 manufactured by KYODO YUSHI, Japan Apply a locking agent. Use a medium strength locking agent unless otherwise specified. Apply sealant. Use automatic transmission fluid. ( x ) ( ) Indicates the diameter, length, and quantity of metric bolts used. page 1-1 Indicates the reference page. 62Z6N000.book 4 ページ２００９年６月１６日火曜日午後６時１７分

How to use this manual 0-5 ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems Abbrev. term Full term ACG Alternator API American Petroleum institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center ATF Automatic Transmission Fluid ATT Attachment BAT Battery BDC Bottom Dead Center BTDC Before Top Dead Center BARO Barometric Pressure CKP Crankshaft Position Comp. Complete CMP Camshaft Position CYL Cylinder DLC Data Link Connector EBT Engine Block Temperature ECT Engine Coolant Temperature ECM Engine Control Module EMT Exhaust Manifold Temperature EOP Engine Oil Pressure EX Exhaust F Front or Forward GND Ground HO2S Heated Oxygen sensor IAC Idle Air Control IAT Intake Air Temperature I.D. Inside diameter IG or IGN Ignition IN Intake INJ Injection L. Left MAP Manifold Absolute Pressure MIL Malfunction Indicator Lamp O.D. Outside Diameter OP Optional Part PGM-FI Programmed-Fuel Injection P/N Part Number Qty Quantity R. Right SAE Society of Automotive Engineers SCS Service Check Signal STD Standard SW Switch TDC Top Dead Center TP Throttle Position VTEC Variable Valve Timing & Valve Lift Electronic Control BI Black G Green Br Brown Lg Light green Y Yellow R Red O Orange P Pink BU Blue W White Lb Light blue Gr Gray 62Z6N000.book 5 ページ２００９年６月１６日火曜日午後６時１７分

1-1 1 1. SPECIFICATIONS SERIAL NUMBER LOCATION ······················ 1-2 DIMENSIONS AND WEIGHTS SPECIFICATIONS ·········································· 1-2 ENGINE SPECIFICATIONS ··························· 1-3 PERFORMANCE CURVES ···························· 1-4 DIMENSIONAL DRAWINGS···························1-7 PTO DIMENSIONAL DRAWINGS ··················1-9 ENGINE MOUNT DIMENSIONAL DRAWING ·····················································1-11 62Z6N000.book 1 ページ２００９年６月１６日火曜日午後６時１７分

SPECIFICATIONS 1-2 SPECIFICATIONS SERIAL NUMBER LOCATION The engine serial number (1) is stamped on the crankcase. Refer to it when ordering parts or making technical inquiries. DIMENSIONS AND WEIGHTS SPECIFICATIONS (1) Model GX630 GX630R GX660 GX660R GX690 GX690R Overall length Q type: 405 mm (15.9 in) V type: 426 mm (16.8 in) S type: 396 mm (15.6 in) T type: 429 mm (16.9 in) B type: 442 mm (17.4 in) DEN type: 371 mm (14.6 in) Overall width 410 mm (16.1 in) Overall height 438 mm (17.2 in) Dry weight Q, S types: 44.4 kg (97.9 lbs) V, T types: 44.6 kg (98.3 lbs) B type: 45.0 kg (99.2 lbs) DEN type: 44.3 kg (97.7 lbs) Operating weight Q, S types: 46.0 kg (101.4 lbs) V, T types: 46.2 kg (101.9 lbs) B type: 46.6 kg (102.7 lbs) DEN type: 45.9 kg (101.2 lbs) Maximum angle of inclination Forward and backward: 20° Left and right: 20° 62Z6N000.book 2 ページ２００９年６月１６日火曜日午後６時１７分

SPECIFICATIONS 1-3 ENGINE SPECIFICATIONS *: 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. Model GX630 GX630R GX660 GX660R GX690 GX690R Description code GCBBK GCBEK GCBCK GCBFK GCBDK GCBGK Type 4 stroke, overhead valve, 90° V–twin cylinder Displacement 688.0 cm 3 (41.97 cu–in) Bore x stroke 78.0 x 72.0 mm (3.07 x 2.83 in) Net power (SAE J1349)* 15.5 kW (21.1 PS) / 3,600 min -1 (rpm) 16.0 kW (21.8 PS) / 3,600 min -1 (rpm) 16.5 kW (22.4 PS) / 3,600 min -1 (rpm) Continuous rated power 12 kW (16.3 PS) / 3,600 min -1 (rpm) 12.5 kW (17.0 PS) / 3,600 min -1 (rpm) 13 kW (17.7 PS) / 3,600 min -1 (rpm) Maximum net torque (SAE J1349)* 48.3 N·m (4.93 kgf·m, 35.6 lbf·ft) / 2,500 min -1 (rpm) 48.3 N·m (4.93 kgf·m, 35.6 lbf·ft) / 2,500 min -1 (rpm) 48.3 N·m (4.93 kgf·m, 35.6 lbf·ft) / 2,500 min -1 (rpm) Maximum rpm (at no load) 3,850 ± 150 min-1 (rpm) Compression ratio 9.3 ± 0.2 Fuel consumption (at continuous rated power) 6.0 Liters (1.59 US gal, 1.32 Imp gal) / h 6.3 Liters (1.66 US gal, 1.39 Imp gal) / h 6.7 Liters (1.77 US gal, 1.47 Imp gal) / h Ignition system C.D.I.(Capacitor Discharge Ignition) type magneto Ignition timing B.T.D.C. 9° / 1,000 min-1 (rpm) Spark advancer type Electronic type Spark advancer performance B.T.D.C. 9° – 23° Spark plug ZFR5F (NGK) Lubrication system Forced feed Oil capacity Without oil filter replacement: 1.5 Liters (1.59 US qt, 1.32 Imp qt) With oil filter replacement: 1.7 Liters (1.80 US qt, 1.50 Imp qt) Recommended oil SAE 10W-30 API service classification SE or later Cooling system Forced air Starting system Starter motor Stopping system Ignition primary circuit open Carburetor 2 barrel horizontal type, butterfly valve Air cleaner Dual type Governor Mechanical centrifugal Breather system Reed valve type, PCV (Positive Crankcase Ventilation) type Fuel used Unleaded gasoline with a pump octane rating 86 or higher 62Z6N000.book 3 ページ２００９年６月１６日火曜日午後６時１７分

SPECIFICATIONS 1-4 PERFORMANCE CURVES GX630/GX630R (N•m) 50 (KW) (lbf•ft) (kgf•m) 18 16 14 12 25 4.0 4.5 5.0 30 35 (PS) 10 8 2000 3600 3000 45 40 12 14 16 18 20 22 24 OUTPUT TORQUE RECOMMENDED OPERATING SPEED RANGE NET POWER NET TORQUE ENGINE SPEED (min -1 [ ]) 62Z6N000.book 4 ページ２００９年６月１６日火曜日午後６時１７分

SPECIFICATIONS 1-5 GX660/GX660R (N·m) 50 (KW) (lbf·ft) (kgf·m) 18 16 14 12 25 4.0 4.5 5.0 30 35 10 8 2000 3600 3000 45 40 (PS) 12 14 16 18 20 22 24 TORQUE RECOMMENDED OPERATING SPEED RANGE NET POWER NET TORQUE OUTPUT ENGINE SPEED (min -1 [ ]) 62Z6N000.book 5 ページ２００９年６月１６日火曜日午後６時１７分

Honda GX630 GX660 GX690 Engine Complete Workshop Manual

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