Honda GC135/160/190 GS190 Assembly Instructions

GC135 ・ GC160 ・ GC190 ・ GS190 Engine Assembly Information
CRANKCASE COVER/GOVERNOR
MODEL MARK
GOVERNOR ARM SHAFT
6 mm WASHER
TOP RING
(CHROME PLATED)
OIL RING
(COMBINATION
RINGS)
CRANKCASE
COVER
SPACER
10 mm (0.4 in)
SIDE RAIL (2)
PISTON
PISTON PIN
OIL
OIL
PISTON PIN CLIP (2)
REASSEMBLY:
Do not align the
CLIP
end gap of the
clip with the
cutout in the
piston pin
bore.
CUTOUT
CONNECTING
ROD
CONNECTING
ROD WITH THE
LONG END
NOTICE:
Take care not to
break the piston
ring when installing
the piston
assembly in the
cylinder.
8 mm
LOCK PIN
GROOVE
VALVE GUIDE
GOVERNOR HOLDER CLIP
(Apply grease to the oil seal lips.)
GOVERNOR
SLIDER
TIMING BELT
Specified belt: 84HU7 G-200
INSTALLATION: Check that the
belt is not worn or cracked and do
not bend or twist the belt.
PISTON ASSEMBLY
INSTALLATION:
Install with the model
mark and connecting
rod long end to the
right side of the cylinder.
OIL
CYLINDER BARREL
GREASE
PROJECTIONS
OIL
OIL
DIPPER
THRUST
WASHER
(Hondabond HT, ThreeBond 1207,
or equivalent)
Assemble within 10 minutes after
applying the liquid gasket.
TIMING
BELT
CAM
PULLEY
6.8 x 1.9 mm O-RING
CONNECTING
ROD BOLT (2)
12 N·m
(1.2 kgf·m,
9 lbf·ft)
Do not reuse.
ROCKER
ARM
SHAFT (2)
CYLINDER HEAD
COVER VIEWED
FROM BACK SIDE:
CYLINDER
BARREL
"▽" MARK
Loosely tighten each bolt, then
tighten to the specified torque in
the numbered sequence.
(Apply grease to the oil seal lips.)
See the shop manual for additional information.
LIQUID GASKET
APPLICATION AREA
CAM
PULLEY
CYLINDER
HEAD
COVER
MATING
SURFACE
CRANKSHAFT
KEY GROOVE
・Set the cam pulley on the timing belt
with care not to turn the crankshaft.
・Install the cam pulley shaft on the
cylinder barrel.
TIMING BELT
CAM PULLEY SHAFT
CAM PULLEY
CRANKSHAFT
"I" MARK
25 x 18 mm SPECIAL
WOODRUFF KEY
When installing the
flywheel, check to be
sure that the woodruff
key remains in its slot
on the crankshaft.
VIEW FROM PTO SIDE:
ALIGNMENT
MARKS
VALVE
ADJUSTING
LOCK NUT (2)
INTAKE
ROCKER
ARM
OIL DIPPER
CRANKSHAFT
INSTALLATION:
・Be careful not to damage the
oil seal.
・After installation, clean the
crankshaft tapered surface.
6 x 12 (4)
12 N·m (1.2 kgf·m,
9 lbf·ft)
VALVE
ADJUSTING
SCREW (2)
EXHAUST
ROCKER ARM
CONNECTING
ROD CAP
8 x 20 mm
DOWEL PIN (2)
CYLINDER HEAD
COVER
OIL
THRUST WASHER
25.4 x 62 x 6 mm
OIL SEAL
CYLINDER
BARREL
OIL
OIL DRAIN
PLUG
WASHER
(Replace)
OIL DRAIN PLUG BOLT
24 N·m (2.4 kgf·m, 17 lbf·ft)
EXHAUST VALVE
VALVE HEAD
DIAMETER:
IN: 25 mm (0.98 in)
EX: 24 mm (0.94 in)
6 mm THRUST
WASHER
CRANKCASE
COVER
PACKING
74 N·m (7.5 kgf·m, 54 lbf·ft)
CAM PULLEY/ROCKER ARM/CYLINDER HEAD COVER
LIQUID GASKET
APPLICATION
AREA
GREASE
INSTALLATION:
6 x 25 (8)
CRANKCASE
COVER,
CRANKSHAFT,
PISTON
Be careful not to damage the lip of the
12 N·m (1.2 kgf·m, 9 lbf·ft)
oil seal when installing the crankcase
cover with the oil seal.
OIL FILLER CAP
INTAKE
VALVE
Be careful
not to
damage the
valve stem
seal when
installing.
GOVERNOR WEIGHT
HOLDER ASSEMBLY
6 mm
WASHER
GROOVE
GOVERNOR HOLDER
SHAFT
14 mm SPECIAL NUT
Aluminum flywheel:
52 N·m (5.3 kgf·m, 38 lbf·ft)
Cast iron flywheel:
CYLINDER BARREL
LOCK PIN
CRANKCASE COVER/CRANKSHAFT/CYLINDER BARREL
28 x 41.25 x 6 mm OIL SEAL
VALVE STEM
SEAL (Intake
valve only)
SPARK
PLUG
BPR6ES
(NGK)
OIL
10 mm
SECOND
RING
(BLACK FACE)
VALVE SPRING (2)
OIL
SECOND
RING
REASSEMBLY:
Install inside the
cover.
VALVE SPRING
RETAINER (2)
NOTICE:
Do not remove the
valve spring retainer
while the piston is
installed, or the valves
will drop into the
cylinder.
REASSEMBLY:
The lock pin must be installed
with the straight side of the pin
against the groove in the shaft.
GOVERNOR
ARM
SHAFT
OIL
MARK
OIL
TOP RING (CHROME FACE)
PISTON RINGS
VALVES/FLYWHEEL
OIL
PISTON
・Apply a liquid gasket
(Hondabond HT, ThreeBond
1207, or equivalent) to the
cylinder head cover.
・Assemble within 10 minutes
after applying the liquid gasket.
・Wait for approximately 20 minutes
after assembly before filling with
oil and starting the engine.
ROCKER
ARM
SHAFT
Install the rocker arm shaft from
the opposite side from the cam
pulley as shown.
© Honda Motor Co., Ltd. 2009