A Few Words About Safety: How To Use This Manual
A Few Words About Safety: How To Use This Manual
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.
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62Z6N000.book 2 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 3 ページ 2009年6月16日 火曜日 午後6時17分
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.
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:
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.
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62Z6N000.book 4 ページ 2009年6月16日 火曜日 午後6時17分
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.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
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.
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62Z6N000.book 5 ページ 2009年6月16日 火曜日 午後6時17分
0-5
62Z6N000.book 1 ページ 2009年6月16日 火曜日 午後6時17分
1. SPECIFICATIONS
1-1
62Z6N000.book 2 ページ 2009年6月16日 火曜日 午後6時17分
SPECIFICATIONS
SERIAL NUMBER LOCATION
SPECIFICATIONS
(1)
1-2
62Z6N000.book 3 ページ 2009年6月16日 火曜日 午後6時17分
SPECIFICATIONS
ENGINE SPECIFICATIONS
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 cm3 (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) / 16.0 kW (21.8 PS) / 16.5 kW (22.4 PS) /
3,600 min-1 (rpm) 3,600 min-1 (rpm) 3,600 min-1 (rpm)
Continuous rated power 12 kW (16.3 PS) / 12.5 kW (17.0 PS) / 13 kW (17.7 PS) /
3,600 min-1 (rpm) 3,600 min-1 (rpm) 3,600 min-1 (rpm)
Maximum net torque (SAE J1349)* 48.3 N·m 48.3 N·m 48.3 N·m
(4.93 kgf·m, 35.6 lbf·ft) (4.93 kgf·m, 35.6 lbf·ft) (4.93 kgf·m, 35.6 lbf·ft)
/ 2,500 min-1 (rpm) / 2,500 min-1 (rpm) / 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 6.0 Liters (1.59 US gal, 6.3 Liters (1.66 US gal, 6.7 Liters (1.77 US gal,
power) 1.32 Imp gal) / h 1.39 Imp gal) / h 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
*: 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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62Z6N000.book 4 ページ 2009年6月16日 火曜日 午後6時17分
SPECIFICATIONS
PERFORMANCE CURVES
GX630/GX630R
45 4.5
NET TORQUE
40 30
4.0
25
(KW)
(PS)
18
24
22
16
20
NET POWER
OUTPUT
14
18
12
16
14
10
12
RECOMMENDED OPERATING SPEED RANGE
8
1-4
62Z6N000.book 5 ページ 2009年6月16日 火曜日 午後6時17分
SPECIFICATIONS
GX660/GX660R
45 4.5
NET TORQUE
40 30
4.0
25
(KW)
(PS)
18
24
22
16
NET POWER 20
OUTPUT
14
18
12
16
14
10
12
RECOMMENDED OPERATING SPEED RANGE
8
1-5
62Z6N000.book 6 ページ 2009年6月16日 火曜日 午後6時17分
SPECIFICATIONS
GX690/GX690R
25
(KW)
(PS)
18
24
22
16
20
NET POWER
OUTPUT
14
18
12
16
14
10
12
RECOMMENDED OPERATING SPEED RANGE
8
1-6
62Z6N000.book 7 ページ 2009年6月16日 火曜日 午後6時17分
SPECIFICATIONS
DIMENSIONAL DRAWINGS
Unit: mm (in)
67 (2.6)
287.3 (11.31)
(EXHAUST
PORT END) (EXHAUST PORT CENTER) M8x1.25 DEPTH 18
(2 PLACES)
M8x1.25 DEPTH 18
(2 PLACES)
18° 18°
(2.0
)
50
50
(2.0
)
135 (5.3)
198.5 (7.81) 207 (8.1)
405 (15.9)
245(9.6)
205(8.1) 205(8.1) 81(3.2)
(EXHAUST
PORT END)
438(17.2)
133.5(5.26)
1-7
62Z6N000.book 8 ページ 2009年6月16日 火曜日 午後6時17分
SPECIFICATIONS
HIGH MOUNT MUFFLER TYPE
Unit: mm (in)
275.8(10.86)
380(15.0)
309.5
68(2.7)
130.5
102.5
328
205.8(8.10)
125.5(4.94)
140
166(6.5)
170.5(6.71)
138.5(5.45)
78(3.1)
238.5(9.39) 209(8.2)
280(11.0)
307(12.1)
1-8
62Z6N000.book 9 ページ 2009年6月16日 火曜日 午後6時17分
SPECIFICATIONS
PTO DIMENSIONAL DRAWINGS
MOUNT PART
Unit: mm (in)
30° 30°
125.5 (4.94)
103.5 (4.07)
5/16-24UNF-2B TAP
(4 PLACES)
3/8-16UNF-2B TAP
146 .127
(4 PLACES)
7/16-14UNF-2B TAP
P.D
.05
(4 PLACES)
65.1
P.D.1
18 (0.2)
6.9
P.D.19
4 (0.2)
18(0.7)
45°
45°
Q TYPE
50 (2.0)
35 (1.4)
28 (1.1)
Φ25.4 -0.025 (Φ25.4 -0.0010 )
5 (0.2)
21.82 -0.13 (0.859 -0.005 )
3/8-24UNF2B TAP
0
Φ11.5 (Φ0.45)
+0.05
6.3 0 (0.25 +0.002
0 )
0
0
Φ13 (Φ0.5)
Φ110 (Φ4.3)
(Φ1.3)
Φ32
2 (0.1)
4.5 (0.18)
74 (2.9)
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62Z6N000.book 10 ページ 2009年6月16日 火曜日 午後6時17分
SPECIFICATIONS
T TYPE
Unit: mm (in)
70 (2.8)
)
49 (1.9)
-0.0010
0
43.5 (1.71)
7/16-20UNF2B TAP
Φ11.5 (Φ0.45)
0
+0.05 +0.002
6.3 0 0.25 0
Φ13 (Φ0.5)
Φ110 (Φ4.3)
(Φ1.4)
1.0 -0.005
25 -0.13
Φ36
0
) 5
.0
4.5 (0.18)
(0
2
90 (3.5) 6 (0.2)
1.
B TYPE
92 (3.6)
50 (2.0)
43.5 (1.71)
5 (0.2)
5/8-18UNF2B TAP
Φ16.5 (Φ0.65)
31 -0.13 (1.2 -0.005 )
+0.05
9.53 (0.375 +0.002 )
0
0 0
Φ36.5 -0.025 (Φ1.4 -0.0010 )
0
Φ18.5 (Φ0.73)
Φ110 (Φ4.3)
0
.5
C1 2 (0.1)
4.5 (0.18)
111.2 (4.38)
V TYPE
(GAUGE LINE)
(TAPER GAUGE DIA.)
5/16-24UNF2B TAP
0 (Φ0.9
+0.003
Φ8.5 (Φ0.433)
0
Φ10 (Φ0.4)
Φ22
Φ110 (Φ4.3)
Φ35 (Φ1.4)
4 (0.2)
25 (1.0) 4.5 (0.18)
32 (1.3)
1-10
62Z6N000.book 11 ページ 2009年6月16日 火曜日 午後6時17分
SPECIFICATIONS
S TYPE
Unit: mm (in)
41 (1.6)
35 (1.4)
28 (1.1)
Φ11.5 (Φ0.45)
+0.05
Φ25f8 -0.020
+0.002
7 (0.3 )
M10x1.25
0 0
21 - 0.13 (0.8 -0.005 )
0
Φ110 (Φ4.3)
(Φ1.3)
(Φ0.5)
Φ13
Φ32
0
)
05
4.5 (0.18)
0.
2(
1.
50 (2.0) 3 (0.1)
DEN TYPE
35 (1.4)
28 (1.1)
5 (0.2)
TAPER 1/10
M10X1.25
Φ11.5 (Φ0.45)
Φ110 (Φ4.3)
Φ30 (Φ1.2)
Φ13 (Φ0.5)
C1 4.5 (0.18)
30.2 (1.19) 7.8 (0.31)
72 (2.8)
86 (3.4)
)
ES
L AC
(4P
(0.6)
16
1-11
62Z6N000.book 12 ページ 2009年6月16日 火曜日 午後6時17分
MEMO
62Z6N000.book 1 ページ 2009年6月16日 火曜日 午後6時17分
2. SERVICE INFORMATION
2-1
62Z6N000.book 2 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
MAINTENANCE STANDARDS
SERVICE INFORMATION
Unit: mm (in)
Part Item Standard Service limit
Engine Maximum speed (at no load) GX630: 3,850 ± 150 min-1 (rpm)
GX630R: 3,850 ± 150 min-1 (rpm)
3,150 ± 150 min-1 (rpm)
(QYD, VEP4, VXF types only)
3,200 ± 150 min-1 (rpm)
(VXD8, VXE1 types only)
GX660: 3,850 ± 150 min-1 (rpm)
–
GX660R: 3,850 ± 150 min-1 (rpm)
3,200 ± 150 min-1 (rpm)
(VXE1 type only)
GX690: 3,850 ± 150 min-1 (rpm)
GX690R: 3,850 ± 150 min-1 (rpm)
3,200 ± 150 min-1 (rpm)
(VXE type only)
Idle speed 1,400 ± 150 min-1 (rpm) –
Cylinder compression 0.5 – 0.7 MPa –
(5.09 – 7.14 kgf/cm2, 73 – 102 psi)
/ 500 min-1 (rpm)
Cylinder Sleeve I.D. 78.000 – 78.015 (3.0709 – 3.0715) 78.150
(3.0768)
Piston Skirt O.D. 77.985 – 77.995 (3.0703 – 3.0707) 77.850
(3.0650)
Piston-to-cylinder clearance 0.005 – 0.030 (0.0002 – 0.0012) 0.10 (0.004)
Piston pin bore I.D. 18.002 – 18.008 (0.7087 – 0.7090) 18.042
(0.7103)
Piston pin Pin O.D. 17.994 – 18.000 (0.7084 – 0.7087) 17.95
(0.707)
Piston pin-to-piston pin bore clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.08 (0.003)
Piston rings Ring side clearance Top 0.050 – 0.080 (0.0020 – 0.0031) 0.15 (0.006)
Second 0.050 – 0.080 (0.0020 – 0.0031) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 1.0 (0.04)
Ring width Top 1.140 – 1.155 (0.0449 – 0.0455) 1.120
(0.0441)
Second 1.140 – 1.155 (0.0449 – 0.0455) 1.120
(0.0441)
Connecting rod Small end I.D. 18.006 – 18.018 (0.7089 – 0.7094) 18.07
(0.711)
Big end I.D. 44.988 – 45.012 (1.7712 – 1.7721) 45.050
(1.7736)
Big end oil clearance 0.005 – 0.039 (0.0002 – 0.0015) 0.070
(0.0028)
Big end side clearance 0.2 – 0.4 (0.008 – 0.016) 1.000
(0.0394)
Crankshaft Crank pin O.D. 44.973 – 44.983 (1.7706 – 1.7710) 44.920
(1.7685)
Main journal O.D. 39.984 – 40.000 (1.5742 – 1.5748) 39.930
(1.5720)
Thrust washer thickness 0.95 – 1.05 (0.037 – 0.041) 0.8 (0.03)
Crankcase Camshaft bearing I.D. 17.016 – 17.027 (0.6699 – 0.6704) 17.06
(0.672)
Main journal I.D. 40.025 – 40.041 (1.5758 – 1.5764) 40.06
(1.577)
Crankshaft axial clearance 0.05 – 0.45 (0.002 – 0.018) 1.0 (0.04)
Crankcase cover Camshaft bearing I.D. 17.016 – 17.027 (0.6699 – 0.6704) 17.06
(0.672)
Main journal I.D. 40.025 – 40.041 (1.5758 – 1.5764) 40.06
(1.577)
2-2
62Z6N000.book 3 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
Part Item Standard Service limit
Valves Valve clearance IN 0.08 ± 0.02 –
EX 0.10 ± 0.02 –
Valve stem O.D. IN 5.475 – 5.490 (0.2156 – 0.2161) 5.400
(0.2126)
EX 5.435 – 5.450 (0.2140 – 0.2146) 5.300
(0.2087)
Valve guide I.D. IN/EX 5.500 – 5.512 (0.2165 – 0.2170) 5.560
(0.2189)
Guide-to-stem clear- IN 0.010 – 0.037 (0.0004 – 0.0015) 0.110
ance (0.0043)
EX 0.050 – 0.077 (0.0020 – 0.0030) 0.130
(0.0051)
Valve seat width 1.0 – 1.2 (0.04 – 0.05) 2.1 (0.08)
Valve spring free length 38.3 (1.51) 36.8 (1.45)
Valve spring perpendicularity 2° max. –
Camshaft Cam height IN 29.506 – 29.706 (1.1617 – 1.1695) 29.36
(1.156)
EX 29.410 – 29.610 (1.1579 – 1.1657) 29.26
(1.152)
Camshaft O.D. 16.982 – 17.000 (0.6686 – 0.6693) 17.100
(0.6732)
Valve lifter Valve lifter I.D. 6.010 – 6.040 (0.2366 – 0.2378) 6.070
(0.2390)
Valve lifter shaft O.D. 5.970 – 6.000 (0.2350 – 0.2362) 5.940
(0.2339)
Rocker arm Rocker arm I.D. 6.000 – 6.018 (0.050 – 0.077) 6.043
(0.2379)
Rocker arm shaft O.D. 5.960 – 5.990 (0.2346 – 0.2358) 5.953
(0.2344)
Rocker arm shaft bearing I.D. 6.000 – 6.018 (0.050 – 0.077) 6.043
(0.2379)
Oil pump Oil pressure 2.8 kgf/cm2 (39.8 psi) / –
2,000 min-1 (rpm) and more
Tip clearance 0.15 (0.006) 0.30 (0.012)
Outer rotor-to-housing clearance 0.150 – 0.210 (0.0059 – 0.0083) 0.30 (0.012)
Outer rotor-to-pump cover clearance 0.04 – 0.09 (0.002 – 0.004) 0.11 (0.004)
Carburetor Main jet GX630/630R: #102 (No.1 cylinder) –
#105 (No.2 cylinder)
GX660/660R: #112
(No.1 / No.2 cylinder)
GX690/690R: #118
(No.1 / No.2 cylinder)
Pilot screw opening GX630/630R: 2 turns out –
(No.1 cylinder)
1 - 7/8 turns out
(No.2 cylinder)
GX660/660R: 1 - 3/4 turns out
(No.1 cylinder)
1 - 7/8 turns out
(No.2 cylinder)
GX690/690R: 1 - 7/8 turns out
(No.1 cylinder)
1 - 3/4 turns out
(No.2 cylinder)
Float height 15.5 (0.61) –
Spark plug Gap 0.7 – 0.8 (0.028 – 0.031) –
Ignition Coil Air gap 0.2 – 0.6 (0.01 – 0.02) –
Starter motor Brush length 10 (0.4) 6 (0.2)
Mica depth – 0.2 (0.01)
Charge coil Resistance 2.7A 1.95 - 2.93 Ω –
17A 0.18 - 0.28 Ω –
26A 0.17 - 0.25 Ω –
2-3
62Z6N000.book 4 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
TORQUE VALUES
ENGINE TORQUE VALUES
Torque values
Item Tread Dia. (mm)
N·m kgf·m lbf·ft
Cylinder nut M10 x 1.25 37 3.8 27
Oil drain plug bolt M20 x 1.5 45 4.5 33
Oil filter cartridge M20 x 1.5 12 1.2 9
Connecting rod bolt M7 x 1.0 22 2.2 16
Tappet adjusting nut M5 x 0.5 7.5 0.75 5.5
Governor arm nut M6 x 1.0 11 1.1 8
Flywheel nut M20 x 1.5 235 24 173
Fuel pump cover screw M5 tapping screw 4 0.4 3.0
Fan cover protector screw M4 special screw 1.7 0.17 1.3
Fan cover screw M6 x 1.0 special screw 4.4 0.45 3.2
Fuel pump screw M6 x 1.0 3 0.3 2.2
Oil pressure switch PT1/8 9 0.9 6.6
Sealing bolt PT1/8 9 0.9 6.6
Air cleaner wing nut M6 x 1.0 0.8 0.08 0.6
Starter motor terminal nut M8 x 1.25 9 0.9 6.6
Breather valve screw M3 x 0.5 1 0.1 0.7
Hour meter screw M3 tapping screw 0.8 0.08 0.6
Switch box bracket screw M5 tapping screw 4 0.4 3.0
Combination switch nut M22 x 1.0 4.9 0.5 3.6
Fuel cut solenoid - 8.8 0.90 6.5
Screen grid cover bolt M6 x 1.0 8.5 0.85 6.3
Screen grid cover nut M6 x 1.0 8.5 0.85 6.3
Screen grid cover stud bolt M6 x 1.0 12 1.2 9
2-4
62Z6N000.book 5 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
LUBRICATION & SEAL POINT
Location Material Remarks
Crankshaft pin, journal and gear Engine oil
Crankcase bearing
Crankcase cover bearing
Piston outer surface and piston pin hole
Piston pin outer surface
Piston ring
Cylinder inner surface
Connecting rod big and small end bearing
Connecting rod bolt threads and seating surface
Camshaft cam profile, bearing, decompressor and
gear
Valve lifter shaft and slipper
Valve stem seal contact area of seal lip
Valve stem sliding surface and stem end
Valve spring
Push rod end
Rocker arm bearing and slipper
Tappet adjusting screw and nut threads and seating
surface
Rocker arm shaft
Crankshaft thrust washer
Flywheel nut threads and seating surface
Oil pump gear outer surface, rotor and shaft
Governor weight holder gear and journal
Governor holder shaft
Governor slider
Governor arm shaft
Cylinder nut and bolt threads and seating surface
Oil seal outer surface
Oil filter cartridge O-ring Multi-purpose grease
Oil seal lip
O-ring
Cylinder Liquid sealant
Crankcase cover (Threebond®1207B)
Breather cover
Oil pressure switch Liquid sealant
Sealing bolt (Threebond®1207B, 1141G,
1215)
2-5
62Z6N000.book 6 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
TOOLS
Float level gauge Oil pressure gauge attachment Oil pressure gauge set
07401-0010000 07406-0030000 07506-3000000
2-6
62Z6N000.book 7 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
Oil seal driver attachment 60 mm Oil filter wrench 64 mm Clutch center holder
07GAD-PG40100 07HAA-PJ70100 07JMB-MN50301
2-7
62Z6N000.book 8 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
HARNESS ROUTING
FRONT VIEW
IGNITION COIL
4P CONNECTOR
HIGH
TENSION FUEL CUT SOLENOID
CORD CLIP ENGINE WIRE HARNESS
IGNITION COIL 4P
CONNECTOR
IGNITION COIL
4P CONNECTOR
No.2
IGNITION HARNESS BRACKET
COIL
CHARGE
COIL
WIRE BAND WIRE
2-8
62Z6N000.book 9 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
FRONT VIEW (AUTO THROTTLE TYPE)
AUTO THROTTLE SOLENOID WIRE BAND
UPPER SHROUD HARNESS
Make sure there is no slack. No.1 IGNITION COIL AUTO THROTTLE
SOLENOID
HARNESS
TO AUTO
THROTTLE
SOLENOID
TO TO
CHARGE IGNITION
COIL COIL
TO
OIL LEVEL
SWITCH
2-9
62Z6N000.book 10 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
TOP VIEW (AUTO THROTTLE TYPE)
2-10
62Z6N000.book 11 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
SIDE VIEW (REMOTE CONTROL TYPE)
CORD GROMMET
CHARGE COIL CORD ENGINE WIRE HARNESS
STARTER MOTOR
CABLE STRAP
CHARGE COIL
CORD
CABLE STRAP
2-11
62Z6N000.book 12 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
SIDE VIEW (WITH CONTROL BOX TYPE)
WIRE BAND
CHOKE CABLE
THROTTLE CABLE
STARTER MOTOR
COMBINATION
SWITCH
4P CONNECTOR
WIRE
HARNESS GROUND TERMINAL
CLIP
TO TO TO
COMBINATION REGULATOR/ OIL LEVEL
SWITCH RECTIFIER SWITCH
2-12
62Z6N000.book 13 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
TUBE ROUTING
TOP VIEW
TUBE CLAMP
D10.0
FUEL FILTER
FUEL TUBE A
PURGE TUBE
GROMMET Clamp the fuel tube A to the hock of FUEL TUBE B
the fan cover. FUEL PUMP
FRONT VIEW
Clamp the fuel tube A to the hock of
FUEL FILTER TUBE CLAMP GROMMET the fan cover.
D10.0
PURGE TUBE
FUEL TUBE A
2-13
62Z6N000.book 14 ページ 2009年6月16日 火曜日 午後6時17分
SERVICE INFORMATION
RIGHT SIDE VIEW
FUEL FILTER
FUEL TUBE A
FUEL PUMP
DRAIN TUBE
2-14
62Z6N000.book 1 ページ 2009年6月16日 火曜日 午後6時17分
3. MAINTENANCE
3-1
62Z6N000.book 2 ページ 2009年6月16日 火曜日 午後6時17分
MAINTENANCE
MAINTENANCE SCHEDULE
MAINTENANCE
REGULAR SERVICE PERIOD (2) Each First Every Every Every Refer
ITEM Perform at every indicated use month 6 year 2 years to
month or operating hour or months or or page
interval, whichever comes 20 hrs. or 300 hrs. 500 hrs.
first. 100 hrs.
Engine oil Check level 3-3
∙
Change 3-4
∙ Engine oil filter Replace Every 200 hours 3-4
Air cleaner Check 3-5
∙ Clean (1) 3-5
Replace * 3-6
Spark plug Check–adjust 3-6
∙
Replace 3-7
Spark arrester Clean 3-7
(applicable types)
∙ Idle speed Check–adjust 3-8
∙ Valve clearance Check–adjust 3-8
∙ Combustion chamber Clean After every 1,000 hours 3-10
∙ Fuel filter Replace 3-10
∙ Fuel tube Check Every 2 years (Replace if necessary) 3-11
3-2
62Z6N000.book 3 ページ 2009年6月16日 火曜日 午後6時17分
MAINTENANCE
ENGINE OIL LEVEL CHECK
Place the engine on a level surface.
Start the engine and allow it to warm up for 1 to 2
(1)
minutes.
Remove the oil level dipstick (1), and wipe it clean.
Insert the oil level dipstick into the oil level pipe (2).
(5)
Remove the oil level dipstick and check oil level shown
on the tip of the level dipstick. (3)
If the oil level is near or below the lower level mark (3)
on the oil level dipstick, remove the oil filler cap (4) from
the head cover and fill with recommended oil to the
upper level mark (5) of the level dipstick. (2)
(4)
Tighten the oil filler cap and install the oil level dipstick
securely.
AMBIENT TEMPERATURE
3-3
62Z6N000.book 4 ページ 2009年6月16日 火曜日 午後6時17分
MAINTENANCE
ENGINE OIL CHANGE
Drain the oil in the engine while the engine is warm.
Warm oil drains quickly and completely.
Place the engine on a level surface and place a suitable
container under the drain plug bolt (1). (4)
Remove the oil filler cap (2) from the head cover (3) and (1)
the drain plug bolt to drain the oil into a suitable
container.
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 into the ground, or down a drain.
(2)
Used engine oil contains substances that have
been identified as carcinogenic.
If repeatedly left in contact with the skin for pro-
longed periods, it may cause skin cancer. (3)
Wash your hands thoroughly with soap and water
as soon as possible after contact with used engine
oil.
Install a new drain plug washer (4) and tighten the drain
plug bolt to the specified torque.
TORQUE: 45 N·m (4.5 kgf·m, 33 lbf·ft)
Fill with recommended oil to the upper level mark of the
oil level dipstick (page 3-3).
Tighten the oil filler cap and install the oil level dipstick
securely.
TOOLS:
Oil filter wrench 64 mm (2) 07HAA-PJ70100
Apply a light coat of grease to the O-ring (3) of the new
oil filter.
Install the new oil filter and tighten to the specified
torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Fill with recommended oil to the upper level mark of the (2)
oil level dipstick (page 3-3).
(3)
Start the engine and warm up for 1 to 2 minutes.
(1) (1)
Check the oil level and if necessary, fill the
recommended oil to the upper mark of the oil level SIDE MOUNT
dipstick (page 3-3). TYPE:
(2)
(3)
(1)
3-4
62Z6N000.book 5 ページ 2009年6月16日 火曜日 午後6時17分
MAINTENANCE
AIR CLEANER CHECK/CLEANING
A dirty air filter will restrict air flow to the carburetor,
reducing engine performance. If the engine is operated
in dusty areas, clean the air cleaner more often than (1)
specified in the MAINTENANCE SCHEDULE.
Clean the outer filter (1) in warm soapy water (2), rinse
and allow to dry thoroughly, or clean with a non- (1)
flammable solvent (2) and allow to dry thoroughly. Dip (3)
the filter in clean engine oil (3) and squeeze out all the Squeeze
excess oil. Excess oil will restrict air flow through the and dry
foam element and may cause the engine to smoke at
startup.
(2)
Squeeze thoroughly
Tap the inner filter (1) lightly several times on a hard
surface to remove excess dirt or blow compressed air (1)
lightly (207 kPa (2.11 kgf/cm2, 30 psi) or less) through
the paper filter from the inside out. Never try to brush
the dirt off; brushing will force dirt into the fibers.
Wipe dirt from the inside of the air cleaner case and the
air cleaner cover, using a rag.
Check the air cleaner case packing for deterioration or
damage. Make sure the air cleaner packing installed
securely.
Attach the outer filter on the inner element, and then
install the air filter assembly and tighten the wing nut
securely.
TORQUE: 0.8 N·m (0.08 kgf·m, 0.6 lbf·ft)
Install the air cleaner cover.
3-5
62Z6N000.book 6 ページ 2009年6月16日 火曜日 午後6時17分
MAINTENANCE
AIR CLEANER REPLACEMENT
Remove the air cleaner cover (page 3-5).
Remove the wing nut and air cleaner filters (page 3-5).
Wipe dirt from the inside of the air cleaner case and the
air cleaner cover, using a rag.
Check the air cleaner case packing for deterioration or
damage. Make sure the air cleaner packing installed
securely.
Install a new air cleaner filters and tighten the wing nut
securely.
TORQUE: 0.8 N·m (0.08 kgf·m, 0.6 lbf·ft)
Install the air cleaner cover.
Remove the spark plug cap (1), and then remove the
spark plug (2) using a spark plug wrench (3).
(3)
(2)
(1)
(1)
3-6
62Z6N000.book 7 ページ 2009年6月16日 火曜日 午後6時17分
MAINTENANCE
SPARK PLUG REPLACEMENT
Remove the spark plug cap, and then remove the spark
plug using a spark plug wrench (page 3-6).
Verify the new spark plug gap is correct (page 3-6).
Install a new spark plug finger-tight to seat the washer,
and then tighten 1/2 turn with a spark plug wrench.
SPARK PLUG: ZFR5F (NGK)
(3) (4)
(1)
(2)
(4)
(3)
3-7
62Z6N000.book 8 ページ 2009年6月16日 火曜日 午後6時17分
MAINTENANCE
Clean the carbon deposits from the spark arrester
screen (1) with a wire brush.
Check the spark arrester screen for damage. If the (1)
screen is damaged, replace the spark arrester.
Reinstall the spark arrester to the muffler.
Install the muffler protector (side mount type only).
(2)
(3)
(2)
3-8
62Z6N000.book 9 ページ 2009年6月16日 火曜日 午後6時17分
MAINTENANCE
Insert a thickness gauge between the valve rocker arm
(1) and valve stem (2) to measure the valve clearance. (2)
(1)
VALVE CLEARANCE:
IN: 0.08 ± 0.02 mm
EX: 0.10 ± 0.02 mm
3-9
62Z6N000.book 10 ページ 2009年6月16日 火曜日 午後6時17分
MAINTENANCE
COMBUSTION CHAMBER CLEANING
Remove the cylinder (page 14-2).
(1)
Prepare a cylinder of a thick paper or equivalent
material (1), which diameter is as large as to fit against
the inner wall of the cylinder, and insert the paper into
the cylinder.
Attach the cleaning brush (special tool) (2) to an electric
drill and clean any carbon deposits from the combustion
chamber.
TOOL:
Cleaning brush (2) 07998-VA20100 (2)
(1)
Install a new fuel filter with the arrow mark toward the
carburetor side.
Check the connecting parts for any sign of fuel leakage.
(3)
3-10
62Z6N000.book 11 ページ 2009年6月16日 火曜日 午後6時17分
MAINTENANCE
FUEL TUBE CHECK
3-11