GX120 ·GX160 ·GX200 Engine Assembly Information

PISTON CYLINDER HEAD/VALVES

GX120/GX160: VALVE SPRING RETAINER EXHAUST VALVE
PISTON RING MARKING
DISASSEMBLY: REASSEMBLY:
REASSEMBLY: Push down and slide the retainer to the side, so the valve ・Before installation, remove carbon deposits
TOP RING (CHROME FACED)
· Install all rings with the markings facing upward. stem slips through the hole at the side of the retainer. and inspect the valve.
· Be sure that the top and second rings are not interchanged. SECOND RING (BLACK FACED) REASSEMBLY: ・Do not interchange with the intake valve.
· Check that the rings rotate smoothly after installation. The exhaust valve retainer has a larger center recess than VALVE HEAD DIAMETER
· Space the piston ring end gaps 120 degrees apart, and OIL RING (COMBINATION RINGS)
the intake valve retainer so it can accept the valve rotator. GX120: IN: 22 mm (0.87 in)
do not align the gaps with the piston pin bore. PISTON PISTON PIN CLIP NOTICE: EX: 19 mm (0.75 in)
· Space the oil ring side rail end gaps at least 10 mm (0.4 in) REASSEMBLY: Do not remove the valve spring retainers while the cylinder GX160: IN: 25 mm (0.98 in)
apart. Coat the oil ring with oil after assembly. Install by setting one end of the clip in
PISTON PIN head is installed, or the valves will drop into the cylinder. EX: 24 mm (0.94 in)
the piston groove, holding the other
end with long-nosed pliers, and CYLINDER HEAD
TOP RING VALVE ROTATOR (Exhaust valve only)
CONNECTING rotating the clip in. VALVE GUIDE (2)
(CHROME FACED) NOTICE:
ROD Do not align the end gap of the clip
SECOND RING If the valve rotator is not installed, the VALVE SPRING (2) INTAKE VALVE
REASSEMBLY: Install the with the cutout in the piston pin bore.
(BLACK FACED) exhaust valve may drop into the cylinder PUSH ROD (2)
connecting rod with the CLIP
when starting the engine. REASSEMBLY:
OIL RING long end toward the
triangle-marked side of Check both ends for wear,
(COMBINATION RINGS) ROCKER ARM PIVOT (2)
CUT-OUT and check the rod for
the piston.
ROCKER ARM straightness.
PIVOT LOCK NUT (2) Be sure the rod ends are
10 N·m (1.0 kgf·m, 7 lbf·ft) firmly seated in the lifters.
CRANKCASE COVER/CRANKSHAFT/PISTON
PISTON ROCKER ARM PIVOT BOLT (2) 24 N·m (2.4 kgf·m, 17 lbf·ft)
VALVE LIFTER CAMSHAFT
REASSEMBLY: ROCKER ARM (2)
REASSEMBLY: REASSEMBLY:
Install with the GX200: Refer to the above for information not shown below.
Install the lifters ・With the crankshaft in place, align the REASSEMBLY:
triangle mark Before installing, check for wear on the surfaces which contact VALVE STEM SEAL (Intake valve only)
immediately before timing punch mark on the cam gear with
toward the the pivot bolt, the push rod, and the rocker arm pivot.
installing the camshaft. the punch mark on the crankshaft gear. Replace with a new one
pushrod hole. ・Before installing, inspect for worn and when reassembling.
TRIANGLE MARK weakened springs and check that the
decompressor weight moves smoothly. INTAKE VALVE
PUSH ROD HOLE
REASSEMBLY:
OIL SEAL 22 x 35 x 6 mm (GX120) · Do not interchange with the exhaust valve.
25 x 41 x 6 mm Valve head diameter: Intake: 25 mm (0.98 in) Exhaust: 24 mm (0.94 in)
(GX160/GX200) · Be careful not to damage the valve stem seal when installing.
GOVERNOR DRIVE
GEAR PUNCH MARKS
PUNCH MARKS CYLINDER HEAD GOVERNOR
CRANKCASE
6 x 28 (GX120)
COVER 8 x 55 (4) (GX120), 8 x 60 (4) (GX160/GX200)
12 N·m (1.2 kgf·m, 9 lbf·ft) GOVERNOR WEIGHT GOVERNOR SLIDER WASHER
GASKET 24 N·m (2.4 kgf·m, 17 lbf·ft)
8 x 32 (GX160/GX200) GASKET REASSEMBLY: Be sure REASSEMBLY:
GREAS Do not reuse. REMOVAL/INSTALLATION: WASHER (2)
24 N·m (2.4 kgf·m, 17 lbf·ft) Do not reuse. to install the governor Install inside
Loosen and tighten the weight before installing
OIL SEAL the case.
bolts in a crisscross pattern the crankshaft.
CRANKCASE 22 x 41 x 6 mm (GX120) in 2-3 steps.
25 x 41 x 6 mm (GX160/GX200) LOCK PIN
CLIP GOVERNOR REASSEMBLY:
OIL DRAIN
REASSEMBLY: ARM SHAFT The lock pin must be
BOLT
Insert firmly installed with the
18 N·m
into the shaft straight side of the pin
(1.8 kgf·m,
groove. against the groove in
13 lbf·ft)
BALL the shaft.
DRAIN BOLT WASHER BEARING DOWEL PINS
6 x 12 (2)
Replace. TIMING GEAR CYLINDER BARREL 10 mm NUT
CONNECTING ROD BOLT CYLINDER HEAD
12 N·m (1.2 kgf·m, 9 lbf·ft) CRANKSHAFT REMOVAL/INSTALLATION: Green ( To side plate)
CONNECTING ROD CAP REASSEMBLY: · Before installation, remove any carbon deposits
OIL LEVEL SWITCH
REASSEMBLY: from the combustion chamber and inspect the Yellow ( To engine switch) O-RING
Push in until the bearing touches GREAS
Install with the oil dipper toward the camshaft and the the crankcase. Be careful not to valve seats.
· Measure the cylinder compression after reassembly. REASSEMBLY: Install firmly in the groove.
ribs on the cap and connecting rod are aligned. damage the oil seal. CRANKCASE COVER

See the shop manual for additional information. © Honda Motor Co., Ltd. 2009