GX100 Engine Assembly Information

PISTON CRANKCASE COVER/GOVERNOR VALVES/FLYWHEEL

TOP RING MARK PISTON RINGS 6 mm WASHER VALVE SPRING RETAINER (2) 12 mm FLANGE NUT
8 mm LOCK PIN 6204 RADIAL

OIL
TOP RING "FW " MARK REASSEMBLY: NOTICE: Do not remove the 42 N·m (4.3 kgf·m,
LOCK PIN BALL BEARING 31 lbf·ft)

OIL
(CHROME FACE) PISTON Install inside valve spring retainer while the
GROOVE 20 x 32 x 6 mm VALVE SPRING (2)
ASSEMBLY the cover. piston is installed, or the valves Apply oil to the threads
SECOND SECOND OIL SEAL VALVE STEM SEAL will drop into the cylinder. and seat surface of the
MARK RING RING (Intake valve only) nut, and tighten the nut.
(BLACK SPARK PLUG
OIL Do not reuse. FLYWHEEL
FACE) CR5HSB (NGK)
RING Be sure that there is
GOVERNOR
20 mm (0.8 in) (COMBINATION OIL RING VALVE GUIDE CLIP
ARM SHAFT no foreign material on
RINGS)

OIL
(COMBINATION RINGS) (Exhust valve only) the magnetic part.
GOVERNOR
"Z0D" PISTON PIN INTAKE
PISTON PIN CLIP (2) CONNECTING ROD ARM SHAFT

OIL
MARK VALVE
Install so that the end gap LONG END 6 mm WASHER
GUIDE
does not face the notch in NOTICE: EXHAUST
6 mm THRUST GROOVE
the piston. Take care not to break VALVE GUIDE
OIL

END GAP WASHER GOVERNOR

the piston ring when INTAKE VALVE 12 mm WASHER
GOVERNOR HOLDER SHAFT CYLINDER BARREL
PISTON installing the piston VALVE HEAD DIAMETER:
SLIDER CRANKCASE COVER WOODRUFF KEY
assembly in the IN: 23 mm EX: 21 mm

OIL
GOVERNOR OIL LEVEL SWITCH (0.9 in) (0.8 in) REASSEMBLY:
cylinder. GOVERNOR WEIGHT
OIL

NOTCH HOLDER CLIP (OPTIONAL) When installing the

CONNECTING ROD HOLDER ASSEMBLY EXHAUST INTAKE
EXHAUST VALVE flywheel, check to be
SIDE: SIDE:
REASSEMBLY: sure that the woodruff
CRANKCASE COVER/CRANKSHAFT/CYLINDER BARREL Before installation, remove carbon
deposits and inspect the valve.
key remains in its slot
on the crankshaft.

Printed In Belgium - Published by: Honda Motor Europe Logistics NV - Specifications can be changed without notice - Edition: 8301 Sept. 2017
6 x 25 (8)
CRANKCASE
CRANKCASE
COVER, CRANKSHAFT,
GREASE PISTON
(Apply grease to
CONNECTING
ROD CAP
the oil seal lips.)
COVER ASSEMBLY
TIMING BELT
CAM PULLEY/ROCKER ARM/CYLINDER HEAD COVER
Specified belt: 8 x 25 (4) VALVE HEAD COVER FAN COVER TOP HOLE
61 YU7 G-200 [Q and VEL types] ADJUSTING

OIL
CUTOUT
INSTALLATION: 8 x 18 (4) SCREW (2)
Check that the belt is not [S and W types] ALIGNMENT ROCKER

OIL
VALVE
worn or cracked and do MARKS CONNECTING ARM
ADJUSTING
not bend or twist the belt. ROD BOLT (2) CYLINDER SHAFT (2)

OIL
LOCK NUT (2)
BARREL LIQUID GASKET FLYWHEEL

OIL
APPLICATION AREA EXHAUST ROCKER ARM ALIGNMENT TIMING
OIL

CYLINDER (Hondabond HT, ThreeBond 1207 or MARKS BELT

"I" MARK BARREL equivalent)
ENGINE BED FLANGE

OIL
Assemble within 10 minutes after
INTAKE

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

PISTON applying the liquid gasket. VIEWED

CRANKSHAFT CAM ROCKER
ASSEMBLY FROM
INSTALLATION: PULLEY ARM PTO SIDE:
Be careful not to damage TIMING BELT ALIGNMENT CAM
8 x 20 mm PULLEY

OIL
the oil seal. 6.8 x 1.9 mm MARKS
OIL

DOWEL PIN (2) After installation, clean the O-RING

OIL
crankshaft tapered surface. Do not
TIMING BELT
" " MARK reuse.
CONNECTING ROD CAP CRANKSHAFT HEAD COVER
CAM PULLEY SHAFT
MATING SURFACE
CONNECTING ROD Apply a liquid gasket Install the cam pulley shaft in the
HEAD COVER
BOLT (2) (Hondabond HT, cylinder after setting the timing belt
VIEWED FROM
5 N·m (0.5 kgf·m, 3.6 lbf·ft) ThreeBond 1207 or on the cam pulley.
BACK SIDE:
MARKS equivalent) to the head CAM PULLEY
cover.
OIL

6204 RADIAL BALL BEARING Assemble within 10

OIL

Loosely tighten each 6 x 25 mm minutes after applying the

20 x 32 x 6 mm OIL SEAL
flange bolts, then tighten in the liquid gasket.
INSTALLATION: Be careful not to damage the numbered sequence.
oil seal lips when installing the crankcase Wait for approximately 20
Wait for approximately 20 minutes minutes after assembly ROCK ARM SHAFT
CYLINDER cover with the oil seal. after assembly before filling with
TIMING LIQUID GASKET before filling with oil Install the rocker arm shaft from the
BARREL oil and starting the engine.
GREASE (Apply grease to the oil seal lips.) BELT APPLICATION AREA and starting the engine. opposite side of the cam pulley.

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