GX270T2/UT2 GX390T2/UT2/RT2 Engine Assembly Information
PISTON/CRANKSHAFT/BALANCER
PISTON RING SET
(Use the recommended engine oil, unless otherwise specified.)
MAKER MARK
TOP RING (Chrome plated) SECOND RING SIDE RAIL
LOCK PIN (10 mm) INSTALLATION: Install the lock pin immediately after installing the governor arm shaft in the direction as shown. The 10 mm lock pin must be installed with the straight side of the 10 mm lock pin against the groove of the governor arm shaft.
(Replace the part(s) with new one(s) before assembly.)
PISTON INSTALLATION: Install the piston to the cylinder RIBS barrel with the mark on the piston head toward the push rod hole of the cylinder head. Viewed from cylinder head side VALVE LIFTER REMOVAL: When removing the valve lifters, mark so that the intake and exhaust sides can be distinguished. INSTALLATION: Attach the valve lifters to the cylinder barrel immediately before installing the camshaft. GROOVE CRANKSHAFT INSTALLATION: Before installing the crankshaft, check the oil seal of the cylinder barrel for damage or hardening. Be careful not to damage the oil seal when installing the crankshaft. MARK
ASSEMBLY: Be sure that the top and second ring are not interchanged. Install the top ring and second ring on the piston with the maker mark side facing up. Check that the piston rings rotate smoothly after installing them. Space the piston ring end gaps 120 degrees apart, and do not align the gaps with the piston pin bore. PISTON TOP RING (CHROME PLATED) SECOND RING OIL RING (COMBINATION RING) PISTON PIN CLIP (20 mm) (2) ASSEMBLY: Install by setting one end of the piston pin clip in the groove of the piston pin bore, holding the other end with long needle pliers, and rotating the clip in. Do not align the end gap of the piston pin clip with the cutout of the piston pin bore. END GAP CUTOUT PISTON PIN CLIP PISTON PIN
10 mm (0.4 in)
SPACER SIDE RAIL OIL RING (COMBINATION RING)
10 mm (0.4 in)
MARK
DRAIN PLUG WASHER (12 mm) (2) OIL LEVEL SW JOINT NUT (10 mm) 10 Nm (1.0 kgfm, 7 lbfft) DRAIN PLUG BOLT (2) 22.5 Nm (2.25 kgfm, 17 lbfft) PISTON CONNECTING ROD UPPER ASSEMBLY: Set the connecting rod upper with the long end toward the mark on the piston head. WASHER (8.2 x 17 x 0.8 mm) GOVERNOR ARM SHAFT
PISTON
CAMSHAFT SIDE
LONG END
OIL LEVEL SW (If equipped)
FLANGE BOLT (6 x 12 mm) (2)
BALANCER WEIGHT
CONNECTING ROD BOLT (2) 14 Nm (1.4 kgfm, 10 lbfft) (Apply to the threads and seating surface)
BALANCER/CRANKCASE COVER/GOVERNOR
BALANCER WEIGHT/CAMSHAFT INSTALLATION Install balancer weight to the cylinder barrel by aligning the punch marks of the balancer weight and the crankshaft (marked on the balancer drive gear). CRANKSHAFT BALANCER WEIGHT GOVERNOR HOLDER CLIP ASSEMBLY: Install firmly into the groove of the governor shaft. GOVERNOR WEIGHT PIN (3) GOVERNOR SLIDER ASSEMBLY: Spread the governor weight to install the governor slider. After installing the governor slider, check to be sure it moves smoothly. GOVERNOR WEIGHT (3) REASSEMBLY: After installing the governor weight, check to be sure they move smoothly. EXCEPT E TYPE
DOWEL PIN (8 x 12 mm) (2)
KEY (7 x 7 x 33 mm) (6.3 x 6.3 x 43 mm) (If equipped)
CRANKCASE COVER (Without reduction type)
PUNCH MARKS
BALANCER DRIVE GEAR
OIL FILLER CAP CRANKCASE COVER
Install the camshaft to the cylinder barrel by aligning the punch marks of the camshaft and the crankshaft (marked on the timing gear). CRANKSHAFT TIMING GEAR
PLAIN WASHER
CRANKCASE COVER (With reduction type)
GROOVE
CASE COVER PACKING
PUNCH MARKS CAMSHAFT
OIL FILLER CAP (With oil level gauge)
OIL FILLER PACKING (2)
BOLT (8 x 40 mm) (7) 24 Nm (2.4 kgfm, 17 lbfft)
See the shop manual for additional information.
Honda Motor Co., Ltd. 2010
GX270T2/UT2 GX390T2/UT2/RT2 Engine Assembly Information
CRANKCASE COVER/REDUCTION UNIT/COOLING FAN/FLYWHEEL
E TYPE DOWEL PIN (8 x 12 mm) (2) BOTTOM RUBBER (LARGE) (2) REDUCTION TYPE PRIMARY DRIVE GEAR WASHER (8 mm) BOLT (8 x 25 mm) DISASSEMBLY/ASSEMBLY: Hold the 16 mm special nut of the flywheel and remove/install the 8 x 25 mm flange bolt. TORQUE: 24 Nm (2.4 kgfm, 17 lbfft) 16 mm SPECIAL NUT KEY (7 x 7 x 33 mm/ 6.3 x 6.3 x 43 mm) SPECIAL WOODRUFF KEY (25 x 18 mm) FLYWHEEL (With starter) STARTER PULLEY (With screen)
CASE COVER PACKING CASE COVER
STARTER PULLEY (With screen)
DOWEL PIN (8 x 14 mm) (2)
FLYWHEEL (Without starter) COOLING FAN
BOLT (8 x 40 mm) (7) 24 Nm (2.4 kgfm, 17 lbfft) BOTTOM RUBBER (SMALL) OIL FILLER CAP GEAR CASE COVER OIL FILLER CAP PACKING DUCT COVER (If equipped) BOLT (5 x 10 mm) (3) (If equipped) FLANGE BOLT (8 x 40 mm) (6) 24 Nm (2.4 kgfm, 17 lbfft)
P.T.O. SHAFT COUNTER SHAFT
FLYWHEEL REMOVAL: Hold the flywheel with a commercially available strap wrench and use the special tool to remove the flywheel. Do not hit the flywheel with a hammer. FLYWHEEL PULLER SET 07935-8050004
SPECIAL NUT (16 mm) REMOVAL: Hold the flywheel with a commercially available strap wrench and remove the 16 mm special nut. Take care not to damage the cooling fan. FLYWHEEL STRAP WRENCH (Commercially available) SPECIAL NUT (16 mm)
CHAIN CASE COVER PACKING
STRAP WRENCH (Commercially available)
FLYWHEEL
COOLING FAN/FLYWHEEL/CYLINDER HEAD/VALVES
INSTALLATION: Clean the tapered parts of dirt, oil, grease, and other foreign material before installation. Be sure there are no metal parts or other foreign material on the magnet part of the flywheel. "TAPERED PARTS" Align FLYWHEEL STARTER PULLEY Align COOLING FAN Apply a light coat of oil to the threads and the seating surface of the 16 mm special nut, and loosely tighten the nut. Hold the flywheel with a commercially available strap wrench, and tighten the 16 mm special nut to the specified torque. TORQUE: 170 Nm (17.3 kgfm, 125 lbfft) STRAP WRENCH (Threads and seating surface) FLYWHEEL INTAKE/EXHAUST VALVE SPRING RETAINER "MAGNET PART" DISASSEMBLY: Push down and slide the valve spring retainer to the side so that the valve stem slips through the hole at the side of the valve spring retainer. Do not remove the valve spring retainer while the cylinder head is installed to the cylinder barrel, or the valve will drop into the cylinder. (Apply to the tappet surface and pivot) VALVE ROCKER ARM ASSEMBLY: Before installing the rocker arm, check for wear on the surface of the rocker arm that contact the pivot bolt, push rod, and valve stem. PIVOT ADJUSTING NUT (2) 10 Nm (1.0 kgfm, 7 lbfft) VALVE SPRING SEAT VALVE GUIDE CLIP EXHAUST VALVE GUIDE SPARK PLUG HEAD COVER HEAD COVER BOLT HEAD COVER EXHAUST VALVE ASSEMBLY: Do not interchange with the intake valve. VALVE HEAD DIAMETER: 31 mm HEAD COVER PACKING INSTALLATION: Note the installation direction.
HEAD COVER PACKING
DOWEL PIN (12 x 20 mm) (2)
INTAKE VALVE ASSEMBLY: Do not interchange with the exhaust valve. VALVE HEAD DIAMETER: 33 mm INTAKE VALVE GUIDE SHROUD
FAN COVER CYLINDER HEAD GASKET CYLINDER HEAD (Apply to the threads and INSTALLATION: FLANGE BOLT (10 x 80) (4) seating surface) Before installing the cylinder head, remove any carbon deposits from the combustion REMOVAL/INSTALLATION: chamber, and inspect the valve seat. Loosen and tighten the four 10 x 80 mm flange After installing the cylinder head, measure bolts in a crisscross pattern in 2 - 3 steps. the cylinder compression. TORQUE: 35 Nm (3.5 kgfm, 26 lbfft) HEAD COVER WASHER
CT BOLT (6 x 12 mm) ROCKER ARM 8 mm PIVOT BOLT (2) PIVOT (2) 24 Nm (2.4 kgfm, (Apply to 17 lbfft) the threads PUSH ROD GUIDE PLATE and pivot) PUSH ROD (2)
VALVE STEM SEAL ASSEMBLY: Before installing the push rods, check the ends of the push rods for wear. Be sure the ends of the push rods are firmly seated in the valve lifters.
VALVE SPRING (2)
See the shop manual for additional information.
Honda Motor Co., Ltd. 2010
