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