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HONDA ENGINES OWNER’S MANUAL GX640 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. 0 Honda Motor Co., Ltd. 1995 31ZG8611 c9 0 5009704 00X31-ZG8-6110 ~ 1 @) PRINTED IN JAPAN
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Thank you for purchasing a Honda engine. 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. This manual covers the operation and maintenance of GX640 engines and is based on the SD4 Type. All information in this publication is based on the latest product information available at the time of printing. Honda Motor Co., Ltd. reserves the right to make changes at any time wi
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Safety Messages Your safety and the safety of others is very important. We have provided important safety messages in this manual and on the engine. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or ot ers. Each safety message is preceded by a safety alert symbol . and one of three words: DANGER, WARNING, or P; CAUTION. These words mean: B You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILL
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1. ENGINE SAFETY l Honda engines are designed to give safe and dependable service if operated according to instructions. Read and under- stand this Owner’s Manual before operating the engine. Failure to do so could result in personal injury or equipment damage. l To prevent fire hazards and to provide adequate ventilation, keep the engine at least 1 meter (3 feet) away from building walls and other equipment during operation. Do not place flammable objects close to the engine. l Do not
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ENGINE OIL IR CLEANER E SERIAL NUMBER RADIATOR SPARK PLUGS RADIATOR OIL DRAIN PLUG SCREEN 5
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3. PRE-OPERATION CHECK RADIATOR SCREEN and RADIATOR CORE 1. Allow the radiator to cool, then remove the screen from the front of the radiator. 2. Clean debris from the screen and radiator core. 3. Reinstall the radiator screen. RADIATOR SCREEN CORE 6
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ENGINE OIL p5YZE-J l Engine oil is a major factor affecting engine performance and service life. Nondetergent oils and 2-stroke engine oils are not recommended because they have inadequate lubricating characteristics. l Check the oil level with the engine on a level surface and the engine stopped. Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SF or SG. Always check the API SERVICE label on the oil container to be sure it includes the lett
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FUEL Use unleaded gasoline with a pump octane rating of 86 or higher. This engine is certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life. Gasoline is highly flammable and explosive, and you can be burned or seriously injured when refueling. l Stop engine and keep heat, sparks, and flame away. l Refuel only outdoors. l Wipe up spills immediately. Fuel can damage paint and some types of plastic. Be c
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1 NOTICE ] 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. 9
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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 Sates 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, try to confirm the fuel’s contents. Some states/provinces require this in
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COOLANT If there is no coolant in the reserve tank, check the cooling system for leaks and repair if necessary. Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. Add coolant to the radiator and the reserve tank, then check the coolant level in the reserve tank after the engine reaches operating temperature. When the engine is at operating temperatu
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AIR CLEANER Check that the air cleaner elements are clean and in good condi- tion. A dirty air cleaner will restrict air flow to the carburetor, reduc- ing engine performance. 1 NOTICE 1 Operating the engine without air filters, or damaged filters, 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. Remove the wing nuts to remove the air cleaner cover and air cleaner elements. 2. Inspect the air cl
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4. OPERATION HIGH ALTITUDE OPERATION At high altitude, the standard carburetor air-fuel mixture will be too rich. Performance will decrease, and fuel consumption will in- crease. A very rich mixture will also foul the spark plugs and cause hard starting. High altitude performance can be improved by specific modifica- tions to the carburetor. If you always operate your engine at altitudes above 1,800 meters (6,000 feet), have your dealer per- form this carburetor modification. Even with
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5. MAINTENANCE THE OMPORTANCE OF MAINTENANCE Good maintenance is essential for safe, economical, and trouble- free operation. It will also help reduce air pollution. Improper maintenance, 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 maintenance recommendations and schedules in this owner’s manual. To help you properly care for your engine, the following pages include a maintena
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MAINTENANCE SAFETY Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task. Failure to properly follow mainte- nance instructions and precautions can cause you to be seriously hurt or killed. Always follow the procedures and precautions in this owner’s manual. Safety Precautions l Make sure the en ine is off before you begi
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EMISSION CONTROL SYSTEM Source of Emissions The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, 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 hyd
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Replacement Parts The emission control systems on your Honda engine were de- signed, built, and certified to conform with EPA and California emission regulations. We recommend 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 effective
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MAINTENANCE SCHEDULE - 0 - - - - 0 Air cleaner - 0 - -i G s - 0 Fuel filter G - 0 Emission related items. (*) Replace the paper element only. (1) Service more frequently when used in dusty areas. (2) These items should be serviced by an authorized Honda servicing dealer, unless the owner has the proper tools and is mechanically proficient. See the Honda Shop Manual. (3) For commercial use, log hours of operation to determine proper maintenance intervals. 18
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ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. 1. Remove the oil filler cap and drain bolt, and drain the oil into a suitable container. 2. Retighten the drain plug securely. 3. Refill to the upper limit mark on the dipstick with the recom- mended oil (see page 7). Tighten the oil filler cap securely. ENGINE OIL REFILL CAPACITY Without oil filter change : 2.0 e (2.1 US qt, 1.8 Imp qt) With oil filter change : 2.3 @ (2.4 US qt, 2.0 Imp qt
