HQRP GXV630R, Instruction Manual

Page 1: ...ng 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...

Page 2: ...OUBLESHOOTING 4 COVER 5 FUEL SYSTEM 6 GOVERNOR SYSTEM 7 CHARGING SYSTEM 8 IGNITION SYSTEM 9 STARTING SYSTEM 10 OTHER ELECTRICAL 11 LUBRICATION SYSTEM 12 CYLINDER 13 CRANKCASE 14 TECHNICAL FEATURES 15 WIRING DIAGRAMS 16 INDEX 62Z6P000 book 3 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 3: ...o 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 July 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 sig...

Page 4: ...t 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 will 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...

Page 5: ...ne Control Module EMT Exhaust Manifold Temperature EOP Engine Oil Pressure EX Exhaust F Front or Forward GND Ground HO2S Heated Oxygen sensor IAB Intake Air Bypass 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 ...

Page 6: ...ERIAL NUMBER LOCATION 1 2 DIMENSIONS AND WEIGHTS SPECIFICATIONS 1 2 ENGINE SPECIFICATIONS 1 3 PERFORMANCE CURVES 1 4 DIMENSIONAL DRAWINGS 1 7 ENGINE MOUNT PTO DIMENSIONAL DRAWINGS 1 8 62Z6P000 book 1 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 7: ...pe 446 mm 17 6 in Q type screen grid cover type 475 mm 18 7 in T type 463 mm 18 2 in T type screen grid cover type 492 mm 19 4 in Dry weight Q type 45 7 kg 100 8 lbs Q type screen grid cover type 46 5 kg 102 5 lbs T type 45 9 kg 101 2 lbs T type screen grid cover type 46 7 kg 103 0 lbs Operating weight Q type 47 6 kg 104 9 lbs Q type screen grid cover type 48 4 kg 106 7 lbs T type 47 8 kg 105 4 lb...

Page 8: ...349 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 3 400 150 min 1 rpm Compression ratio 9 3 0 2 Fuel consumption at continuous rated power 4 7 Liters 1 24 US gal 1 03 Imp gal h 5 3 Liters 1 40 US gal 1 17 Imp gal h 5 6 Liters 1 48 US gal 1 23 Imp gal h Ignition system C D I Capa...

Page 9: ...V630R 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 62Z6P000 book 4 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 10: ...0 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 TRO 62Z6P000 book 5 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 11: ... 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 62Z6P000 book 6 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 12: ... 205 8 8 10 EXHAUST PORT CENTER 154 5 6 08 EXHAUST PORT CENTER 2 PLACES M8x1 25 DEPTH 18 SCREEN GRID TYPE 371 14 6 FAN COVER PROTECTOR TYPE 366 14 4 133 5 0 6 25 1 0 15 0 6 167 5 6 59 16 5 0 65 T TYPE 265 10 4 Q TYPE 247 5 9 74 EXHAUST PORT END 67 316 12 4 SCREEN GRID COVER TYPE 395 15 6 167 5 6 59 67 2 6 70 2 8 16 5 0 65 81 3 2 EXHAUST PORT END 144 5 7 62Z6P000 book 7 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 13: ...SPECIFICATIONS 1 8 ENGINE MOUNT PTO DIMENSIONAL DRAWINGS ENGINE MOUNT BASE 45 35 35 45 4 PLACES Φ11 Φ0 4 ENGINE MOUNT HOLE P D 2 5 4 Unit mm in 62Z6P000 book 8 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 14: ... 0 13 21 82 0 859 0 0 005 0 0 002Φ13 Φ0 5 Φ25 4 0 0 0010 Φ25 4 0 0 025 ENG MOUNT LINE Unit mm in Φ36 Φ1 4 Φ70 Φ2 8 43 5 1 71 96 5 3 80 14 0 6 265 10 4 1 0 04 49 1 9 5 0 2 76 5 3 01 ENG MOUNT LINE Φ35 Φ1 4 Φ11 5 Φ0 45 7 16 20UNF2B TAP 0 0 05 6 3 0 25 0 0 13 25 0 1 0 0 0 005 0 0 002 Φ1 1250 0 0 025 Φ28 575 0 0 025 Φ13 Φ0 5 97 5 3 84 62Z6P000 book 9 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 15: ...MEMO 62Z6P000 book 10 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 16: ...2 1 2 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 4 LUBRICATION SEAL POINT 2 5 TOOLS 2 6 HARNESS ROUTING 2 8 TUBE ROUTING 2 10 62Z6P000 book 1 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 17: ...00 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 00...

Page 18: ...m 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 GXV630R 105 No 1 cyl...

Page 19: ...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 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 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 Item Tread Dia mm Torque val...

Page 20: ...urface 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 seatin...

Page 21: ...7746 0040400 Driver handle 15 x 135L 07749 0010000 Seat cutter 27 5 mm 07780 0010200 Seat cutter 33 mm 07780 0010800 Flat cutter 30 mm 07780 0012200 Flat cutter 33 mm 07780 0012900 Interior cutter 30 mm 07780 0014000 Interior cutter 26 mm 07780 0014500 Cutter holder 5 5 mm 07981 VA20101 Valve guide reamer 5 510 mm 07984 2000001 Cleaning brush 07998 VA20100 62Z6P000 book 6 ページ ２００９年７月９日 木曜日 午後１時３５分...

Page 22: ...NFORMATION 2 7 Oil seal driver attachment 60 mm 07GAD PG40100 Oil filter wrench 64 mm 07HAA PJ70100 Clutch center holder 07JMB MN50301 Pilot screw wrench D 07KMA MS60101 62Z6P000 book 7 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 23: ...IGH TENSION CORD CLIP Cut the band end so its length is 10 15 mm 0 4 0 6 in ENGINE WIRE HARNESS No 1 IGNITION COIL HIGH TENSION CORD HARNESS BRACKET CHARGE COIL WIRE IGNITION COIL 4P CONNECTOR No 1 IGNITION COIL FUEL PUMP STAY Pass the harness between the fuel cut solenoid and the inlet manifold packing Clamp the wire harness on the fuel pump stay INLET MANIFOLD PACKING HIGH TENSION CORD CLIP FUEL...

Page 24: ...RVICE INFORMATION 2 9 SIDE VIEW ENGINE WIRE HARNESS CORD GROMMET CHARGE COIL CORD CABLE STRAP Pass the engine wire harness over the charge coil cord STARTER MOTOR 62Z6P000 book 9 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 25: ...n the fan cover TUBE CLIP C11 TUBE CLAMP D10 0 PULSE TUBE BREATHER TUBE BREATHER TUBE FUEL FILTER TUBE CLAMP D10 0 FUEL TUBE A FUEL TUBE B PURGE TUBE TUBE CLAMP D10 0 TUBE CLIP C11 FUEL PUMP GROMMET Clamp fuel tube A to the hook on the fan cover DRAIN TUBE Clamp the drain tube on the ribs of the upper shroud RIBS PULSE TUBE TUBE CLAMP D10 0 BREATHER TUBE CLIP 62Z6P000 book 10 ページ ２００９年７月９日 木曜日 午後１...

Page 26: ...ERVICE INFORMATION 2 11 BOTTOM VIEW DRAIN TUBE FUEL FILTER TUBE CLAMP D10 0 FUEL TUBE A TUBE CLIP B8 Clamp the drain tube on the ribs of the L lower shroud RIBS 62Z6P000 book 11 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 27: ...MEMO 62Z6P000 book 12 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 28: ...NT 3 4 AIR CLEANER CHECK CLEANING 3 4 AIR CLEANER REPLACEMENT 3 5 SPARK PLUG CHECK ADJUSTMENT 3 5 SPARK PLUG REPLACEMENT 3 6 IDLE SPEED CHECK ADJUSTMENT 3 6 VALVE CLEARANCE CHECK ADJUSTMENT 3 7 COMBUSTION CHAMBER CLEANING 3 8 FUEL FILTER REPLACEMENT 3 9 FUEL TUBE CHECK 3 10 62Z6P000 book 1 ページ ２００９年７月９日 木曜日 午後１時３５分 ...

Page 29: ...300 hrs Every 2 years or 500 hrs Refer to page ITEM Perform at every indicated month or operating hour interval whichever comes first Engine oil Check level 3 3 Change 3 3 Engine oil filter Replace Every 200 hours 3 4 Air cleaner Check 3 4 Clean 1 3 4 Replace 3 5 Spark plug Check adjust 3 5 Replace 3 6 Idle speed Check adjust 3 6 Valve clearance Check adjust 3 7 Combustion chamber Clean After ever...

Page 30: ...e 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 Remove the oil level gauge 2 and 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 rec...

Page 31: ...g the engine without the air filters or with the filter installed loosely will allow dirt to enter the engine causing rapid engine wear Install the air filters securely Remove the air cleaner cover 1 Remove the outer filter Foam 2 from the element holder 3 Remove the element holder and inner filter Paper 4 from the air cleaner case 5 Carefully check both filters for holes or tears and replace if d...

Page 32: ...cover page 3 4 Remove the outer filter element holder and inner filter page 3 4 Wipe dirt from the inside of the air cleaner case element holder and air cleaner cover using a rag Install new air cleaner filters and element holder Install the air cleaner cover SPARK PLUG CHECK ADJUSTMENT Remove the spark plug cap 1 and then remove the spark plug 2 using a spark plug wrench 3 Visually check the spar...

Page 33: ...erify the new spark plug gap is correct page 3 5 Install a new spark plug finger tight to seat the washer and then tighten 1 2 turn with a spark plug wrench A loose spark plug can become very hot and can damage the engine Overtightening can damage the threads in the cylinder block Install the spark plug cap securely IDLE SPEED CHECK ADJUSTMENT Start the engine and allow it to warm up to normal ope...

Page 34: ...on the cooling fan with the alignment mark on the fan cover again Insert a thickness gauge between the valve rocker arm 1 and valve stem 2 to measure the valve clearance Set the piston of the No 2 cylinder at the top dead center of the cylinder compression stroke both valves fully closed by rotating the flywheel 1 270 degrees clockwise slowly When the No 2 piston is at the top dead center of the c...

Page 35: ...ch 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 Do not remove valves from the cylinder while cleaning the combustion chamber Be sure to insert a thick paper into the cylinder to protect the inner wall of the cylinder...

Page 36: ...ect the fuel tube from the fuel filter to remove the fuel filter Install a new fuel filter with the arrow mark toward the carburetor side Check the connecting parts for any sign of fuel leakage 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 1 2 1 3 2 62Z6P000 b...

Page 37: ...ks or signs of leakage If necessary replace it Install the air cleaner case page 3 4 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 1 62Z6P000 book 10 ページ ２００９年７月９日 木曜日 午後１時３５分 ...