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GC135 ・ GC160 ・ GC190 ・ GS190 Engine Assembly Information

PISTON CRANKCASE COVER/GOVERNOR VALVES/FLYWHEEL


TOP RING (CHROME FACE) MODEL MARK VALVE SPRING 14 mm SPECIAL NUT
PISTON RINGS MARK GOVERNOR ARM SHAFT REASSEMBLY: VALVE SPRING (2) Aluminum flywheel:

OIL
6 mm WASHER The lock pin must be installed RETAINER (2)
TOP RING VALVE STEM 52 N·m (5.3 kgf·m, 38 lbf·ft)
REASSEMBLY: with the straight side of the pin NOTICE: Cast iron flywheel:
(CHROME PLATED) SEAL (Intake
Install inside the against the groove in the shaft. Do not remove the 74 N·m (7.5 kgf·m, 54 lbf·ft)
SECOND valve only)
SECOND cover. GOVERNOR valve spring retainer
RING SPARK
RING 10 mm ARM while the piston is
(BLACK FACE) PLUG
CRANKCASE SHAFT installed, or the valves
OIL RING SPACER BPR6ES
10 mm (0.4 in) will drop into the
(COMBINATION COVER (NGK)
SIDE RAIL (2) cylinder.
RINGS)
PISTON CONNECTING CYLINDER BARREL
8 mm GROOVE LOCK PIN
PISTON PIN CLIP (2) PISTON PIN ROD WITH THE
LOCK PIN VALVE GUIDE INTAKE
LONG END GOVERNOR WEIGHT
REASSEMBLY: 25 x 18 mm SPECIAL
NOTICE: VALVE
Do not align the HOLDER ASSEMBLY
CLIP Be careful WOODRUFF KEY
OIL

end gap of the Take care not to


GOVERNOR HOLDER CLIP EXHAUST VALVE not to When installing the
clip with the break the piston
6 mm 6 mm THRUST VALVE HEAD damage the flywheel, check to be
OIL

cutout in the ring when installing

OIL
the piston GROOVE WASHER WASHER DIAMETER: valve stem sure that the woodruff
piston pin GOVERNOR HOLDER IN: 25 mm (0.98 in)
CONNECTING assembly in the seal when key remains in its slot
bore. GOVERNOR
CUTOUT ROD SHAFT EX: 24 mm (0.94 in) installing. on the crankshaft.
cylinder. SLIDER

CRANKCASE COVER/CRANKSHAFT/CYLINDER BARREL CAM PULLEY/ROCKER ARM/CYLINDER HEAD COVER


28 x 41.25 x 6 mm OIL SEAL (Apply grease to the oil seal lips.) LIQUID GASKET 6 x 12 (4)
CYLINDER HEAD VIEW FROM PTO SIDE:
INSTALLATION: GREASE CYLINDER 12 N·m (1.2 kgf·m,
CRANKCASE
Be careful not to damage the lip of the
COVER, CRANKSHAFT,
6 x 25 (8) PISTON APPLICATION
BARREL
COVER ALIGNMENT CAM

OIL
12 N·m (1.2 kgf·m, 9 lbf·ft) AREA 9 lbf·ft) MARKS PULLEY
oil seal when installing the crankcase VALVE
cover with the oil seal. ADJUSTING
SCREW (2)
OIL FILLER CAP PACKING CRANKCASE EXHAUST CYLINDER
COVER ROCKER ARM HEAD

OIL
OIL PROJECTIONS COVER
OIL DRAIN VALVE

OIL
OIL DRAIN PLUG BOLT DIPPER MATING
PLUG ADJUSTING
24 N·m (2.4 kgf·m, 17 lbf·ft) SURFACE
WASHER LOCK NUT (2)

OIL
THRUST WASHER (Replace) CRANKSHAFT
CAM KEY GROOVE

OIL
THRUST ROCKER
TIMING BELT (Hondabond HT, ThreeBond 1207, PULLEY
WASHER ARM
Specified belt: 84HU7 G-200 or equivalent)
INSTALLATION: Check that the Assemble within 10 minutes after SHAFT (2)
PISTON ASSEMBLY
INSTALLATION: belt is not worn or cracked and do applying the liquid gasket. INTAKE
Install with the model not bend or twist the belt. ROCKER
mark and connecting ARM ・Set the cam pulley on the timing belt
TIMING

OIL
rod long end to the with care not to turn the crankshaft.
CONNECTING BELT
right side of the cylinder. ・Install the cam pulley shaft on the
ROD CAP
cylinder barrel.
OIL DIPPER TIMING BELT
8 x 20 mm 6.8 x 1.9 mm O-RING
DOWEL PIN (2) CAM PULLEY SHAFT
CONNECTING Do not reuse.
CRANKSHAFT CAM PULLEY
ROD BOLT (2)
12 N·m CYLINDER HEAD
・Apply a liquid gasket
(1.2 kgf·m, COVER VIEWED
CYLINDER (Hondabond HT, ThreeBond
9 lbf·ft) FROM BACK SIDE:
CRANKSHAFT BARREL 1207, or equivalent) to the
OIL

"▽" MARK cylinder head cover. ROCKER


INSTALLATION:
・Assemble within 10 minutes ARM
・Be careful not to damage the
after applying the liquid gasket. SHAFT
oil seal.
・After installation, clean the "I" MARK ・Wait for approximately 20 minutes Install the rocker arm shaft from
CYLINDER BARREL Loosely tighten each bolt, then
crankshaft tapered surface. tighten to the specified torque in after assembly before filling with the opposite side from the cam
25.4 x 62 x 6 mm LIQUID GASKET oil and starting the engine.
the numbered sequence. pulley as shown.
OIL SEAL GREASE (Apply grease to the oil seal lips.) APPLICATION AREA

© Honda Motor Co., Ltd. 2009