Honda GC160, Service Manual

Page 1: ...of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety g...

Page 2: ...S190LA 2007 emission components GC160 GC190 GS190 Item FUEL TANK Redesigned fuel filler neck FUEL TANK CAP Fuel cap has a charcoal filter tether and ratchet mechanism NEW ANGLE 10 TETHER GC160 book Page iii Tuesday June 5 2007 7 48 AM gc160_gcaha_3599750_3721672 ...

Page 3: ... second rings PISTON RINGS Thickness changed Material changed from cast iron to steel Z2A 01 ZOY 01 GC160LA GC GS190LA 1 0 mm 0 04 in Z2A ZOY 00 GC160 GC GS190 1 5 mm 0 06 in TOP RING 0 95 0 97 mm 0 037 0 038 in SECOND RING 0 038 0 039 in 0 93 0 95 mm 0 97 0 99 mm GC160LA GC GS190LA 0 036 0 037 in TOP RING 1 50 mm 0 06 in SECOND RING 1 50 mm 0 06 in GC160 book Page iv Tuesday June 5 2007 7 48 AM g...

Page 4: ...m 2 71 x 1 97 in Net power in accordance with SAE J1349 3 4 kW 4 6 hp at 3 600 rpm 3 9 kW 5 2 hp at 3 600 rpm Max net torque in accordance with SAE J1349 9 4 N m 6 9 lbf ft at 2 500 rpm 11 2 N m 8 3 lbf ft at 2 500 rpm Compression ratio 8 5 1 Fuel consumption 1 5 hr at 3 600 rpm 1 6 hr at 3 600 rpm Cooling system Forced air Ignition system Transistorized magneto ignition Ignition timing 20 B T D C...

Page 5: ...S GC160 Q 13 3 in 13 6 in 13 3 in 337 mm 347 mm 337 mm P v Overall length Overall width 13 5 kg 29 8 Ibs Operating weight 11 5 kg 25 4 Ibs Dry weight 331 mm 13 0 in Overall height 369 mm 14 5 in gc160_gcaha_3599750_3721672 ...

Page 6: ...GC160 GC190 GS190 2 PERFORMANCE CURVES GC160LA GC190LA GS190LA GC160 book Page 2 Tuesday June 5 2007 7 48 AM gc160_gcaha_3599750_3721672 ...

Page 7: ...text 8 5 03 1 59 PM Page 5 gc160_gcaha_3599750_3721672 ...

Page 8: ...text 8 5 03 1 59 PM Page 6 gc160_gcaha_3599750_3721672 ...

Page 9: ...PECIFICATIONS GC160 GC190 GS190 1 WIRING DIAGRAM 1 WIRING DIAGRAM 1 1 2 WIRE ROUTING 1 2 SPARK PLUG IGNITION COIL IGNITION SWITCH OIL LEVEL SWITCH OIL ALERT UNIT WITH OIL ALERT gc160_gcaha_3599750_3721672 ...

Page 10: ...lear understanding of all basic shop safety practices and that you are wearing appropriate clo and safety equipment When performing maintenance or repairs be especially careful of the following Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely Be sure the engine is off before you begin any maintenance or repairs This will reduce t...

Page 11: ...SERIAL NUMBER LOCATION The engine serial number is stamped onthe cylinder barrel Refer to this when ordering partsor making technical inquiries ENGINE SERIAL gc160_gcaha_3599750_3721672 ...

Page 12: ...pon disassembly Lubricate any sliding surfaces before reassembly After reassembly check all parts for proper installation and operation Many screws used in this machine are self tapping Be aware that cross threading or overtightening these screws will strip the threads and ruin the hole Use only metric tools when servicing this engine Metric bolts nuts and screws are not interchangeable with nonme...

Page 13: ...tem Engine 0 49 MPa 5 0 kgf cm2 71psi at 600 rpm Cylinder compression 1 400 If 150 rpm idle speed 3 850 _ 150 rpm Maximum speed Carburetor Main jet Float height Pilot screw opening GC160 65 9 2 mm 0 36 in GC160 1 3 4 turnsout gc160_gcaha_3599750_3721672 ...

Page 14: ...Part Service limit Standard Item Spark plug Ignition coil 0 7 0 8 mm 0 028 0 031 in Gap 0 2 0 6mm 0 008 0 024 in Air gap at flywheel 1 0 1 2 a Resistance Primary coil Secondary coil 10 6 12 8 k 0 gc160_gcaha_3599750_3721672 ...

Page 15: ...eat width Spring free length Valve head diameter EX IN EX IN EX IN EX IN EX IN EX 0 20 rt 0 04 mm 5 48 mm 0 216 in 5 44 mm 0 214 in 5 50 mm 0 217 in 0 7 mm 0 028 in 34 0 mm 1 34 in 25 mm 0 98 in 24 mm 0 94 in 5 318 mm 0 2094 in 5 275 mm 0 2077 in 5 572 mm 0 2194 in 1 8 mm 0 07 in 32 5 mm 1 28in gc160_gcaha_3599750_3721672 ...

Page 16: ...ght 9 987 mm 0 3932 in Cam pulley shaft0 D 10 027 mm 0 3948 in Cam pulley 1 D Bearing 37 394 mm 1 4722 in Rocker arm Rocker arm 1 D 6 000 mm 0 2362 in Rocker arm shaft 0 D 5 990 mm 0 2358 in Rocker arm shaft bearing I D 6 000mm 0 2362in Rocker arm shaft bearing to rocker arm shaft clearance 0 010 0 058 mm 0 0004 0 0023 in Service limit 13 07 mm 0 515 in 26 066 mm 1 0262 in 0 12 mm 0 005 in 0 8 mm ...

Page 17: ...to cylinder clearance Piston ring 0 15 mm 0 006 in 0 015 0 045 mm 0 0006 0 0018 in Ringside clearanceTop second oil 2 37 mm 0 093 in 2 5 mm 0 10 in Oil 1 37 mm 0 054 in 1 5 mm 0 06in Ring width Top second Ring end gap Top 0 20 0 35 mm 0 008 0 014 in 1 0 mm 0 04 in Second 0 30 0 45 mm 0 012 0 018 in 1 0 mm 0 04 in 0 15 0 35 mm 0 006 0 014 in Oil 1 0 mm 0 04 in Crankshaft axial clearance 0 15 0 75 m...

Page 18: ...LA 0 95 0 97 mm 0 037 0 038 in 0 93 mm 0 036 in Second ring 0 97 0 99 mm 0 038 0 039 in 0 95 mm 0 037 in Standard Service limit Top ring GC160LA 0 055 0 089 mm 0 002 0 004 in 0 150 mm 0 006 in Top ring GC GS190LA 0 035 0 069 mm 0 001 0 003 in 0 150 mm 0 006 in Second ring 0 015 0 049 mm 0 0006 0 0019 in 0 150 mm 0 006 in Standard Service limit Top ring 0 20 0 35 mm 0 008 0 014 in 1 00 mm 0 040 in ...

Page 19: ...T M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M5 x 0 8 M6 x 1 0 M6 x 1 0 CT MI4 x 1 25 Use standardtorque values of fasteners that are not listed inthis table CT indicatesa self tappingbolt STANDARD TORQUE VALUE Nom 12 12 8 12 24 52 10 12 10 12 8 5 12 12 10 3 12 12 20 Torque kgf m 1 2 1 2 0 8 1 2 2 4 5 3 1 o 1 2 1 o 1 2 0 85 1 2 1 2 1 o 0 3 1 2 1 2 2 0 Ibf ft 9 9 5 8 9 17 38 7 9 7 9 6 1 9 9 7 2 2 9 9 14 I...

Page 20: ...ent 62 28 radial ball bearing removal V andP types only 62 28 radial ball bearing installation V and P types only 62 28 radial ball bearing removaI installation V and Ptypes only Driver for tools3 4 and 5 Valve seat reconditioning IN EX Valve seat reconditioning Combustion chamber cleaning 0 n Tool number 07701 0010000 07708 0030400 07746 0010100 07746 0010400 07746 0041100 07749 0010000 07780 001...

Page 21: ...nd FUEL TUBE Inspect clogged DIAPHRAGM TUBE d Connect the tubeproperly I I I FUEL PUMPclogged Replace I Clean FUEL STRAINERclogged CARBURETOR out ofadjustment Readjust _ Disassemble and inspect I I I IGNITIONCOIL air gap incorrect IGNITIONCOIL faulty 1 Inspect SPARK PLUG faulty Inspect GOVERNORout of adjustment Inspect t Clean 1 t GOVERNOR out of adjustment Readjust gc160_gcaha_3599750_3721672 ...

Page 22: ...ct sufficiently L 1 I CARBURETOR out of adjustment Disassemble and inspect I I I t SPARK PLUG faulty Inspect L l GOVERNOR out of adjustment 1 Readjust 1 I I I I Disassemble and inspect t SPARK PLUG faulty Inspect AIR CLEANER restricted Clean GOVERNOR out of adjustment Readjust C A Disassemble and inspect AIR CLEANER restricted Clean GOVERNOR out of ad Readjust Readjust gc160_gcaha_3599750_3721672 ...

Page 23: ...system faulty NO spark or weak spark I I Good spark 4 Check the cylinder compres Abnormal compression Normal compression I 1 5 Install the spark plug and restart the engine CYLINDER COMPRESSIONCHECK 1 Remove the spark plug and install a compression gauge in the spark plug hole 2 Pull the recoil starter several times withforce and measure the cylinder compression L Compression Check that the valve ...

Page 24: ...OUBLESHOOTING 2 1 Perform the spark test P 2 11 of the base shop manual Sparks Refer to HARD STARTING P 2 8 of the base shop manual Disconnect the oil level switch yellow lead from the Oil Alert unit yellow red lead Perform the spark test P 2 11 of the base shop manual Sparks Faulty oil level switch Replace the oil level switch P 8 12 of the base shop manual Proceed to next page No spark OIL ALERT...

Page 25: ...ck lead from the ignition coil Perform the spark test P 2 11 of the base shop manual Sparks Faulty engine stop switch or stop switch lead Replace the engine stop switch P 6 8 of the base shop manual or stop switch lead P 7 1 See IGNITION SYSTEM troubleshooting P 2 11 of the base shop manual OIL ALERT UNIT OIL ALERT UNIT BLACK RED LEAD OIL ALERT UNIT BLACK LEAD No spark ENGINE STOP SWITCH BLACK LEA...

Page 26: ...nd seconrary coils of transistorized ignitioncoil Primary coil Secondary coil SPARK PLUGTEST 1 Remove the spark plug attach it to thespark plug cap and ground the side electrode against the cylinder head cover bolt 2 Move the ignition switchlever to the ON position pull the recoil starter and check to see if sparks jump across the electrodes Abnormal Replace transistorized ignition 1 coil If ignit...

Page 27: ... Check the ignition system Good spark If thecarburetor is loose tighten the bolts Check the carburetor insulatorfor damage securely and proper installation Replacethe spark plug with a new one and Checkfor leaking current caused by damaged Check ignition coil check for spark high tension cord insulation Abnormal Check that the valve clearance is correct Normal Start the engine accordingto thestart...

Page 28: ...k t Abnormal I Measure the C Normal t Start the engineaccording to the starting procedure Clean the spark plug andadjust the spark Replace the spark plug if necessary Plug gap Replace the spark plug with a new one and check for spark Check for leaking current caused by damaged high tension cord insulation Check ignition coil Check that the valve clearance is correct Check to see whether excessive ...

Page 29: ...rk I electrodes for carbonand spark plug gap I Plug gap Replace the spark plug if necessary Normal t Abnormal Check for blockage in the main jet or nozzle of the carburetor Clean and replace if necessary INormal Abnormal If thecarburetor is loose tighten the bolts and for secondary air being drawn through the carburetor insulator Normal securely and proper installation Check the carburetor insulat...

Page 30: ...HARNESSROUTING HIGH TENSION CORD SWITCH IGNITIONC O I L gc160_gcaha_3599750_3721672 ...

Page 31: ...nce Check Adjust 0 Idle speed Check Adjust Fuel line Check 0 Replaceif necessary 0 Emission related items BEFORE USE 0 0 FIRST 25 HRS 5 HRS OR OR SEASON MONTH EVERY 0 0 2 I100 HRS OR 1150 HRS SEASON EVERY EVERY EVERY 50 HRS Every 2 years 1 Change engine oil every 25 hours when used under heavy load or in high ambient temperature 2 Service more frequently when used in dustyareas 3 For commercial us...

Page 32: ... oildrained from the crankcase and the oil level switch wires disconnected check continuity between the yellow oil level switchwire and ground There should be continuity Oil levelcheck Check the engine oil level with theengine stopped and engine on a level surface 1 Remove the oil fillercap and wipe thedipstick clean 2 Insert the dipstick in the oil filler neck but donot screw it in Remove the dip...

Page 33: ...text 8 5 03 2 00 PM Page 25 ...

Page 34: ...nk side of the air cleaner cover and removethe cover Inspect the air filter and replace if damaged Tap the filterseveral times ona hardsurface to remove dirt or blowcompressed air not exceeding 207 kPa 2 1 kgf cm2 30 psi through the filter from the clean side that faces the engine Never try to brush off dirt brushing will force dirt into the fibers Wipe dirt from the inside of the air cleaner cove...

Page 35: ...ug gap I If necessary adjust the gap by bending the side electrode Make sure the sealing washer is in good condition replace the plug ifnecessary Install the plug fingertight to seat the washer then tighten with a plug wrench an additional 1 2 turn ifa new plug to coppress the sealingwasher If you are reusing a plug tighten 1 8 1 4 turn after the plugseats CAUTION A loose spark plug can become ver...

Page 36: ... cover with force It Replacethe cylinder head cover if it is deformed can deformthe cylinder headcover 3 Set the piston at top dead center of thecompression stroke both valves fully closed Topdeadcenter of thecompression strokeisinthe position where the cylinder head cover mating surface is in line with the cam pulley alignment marks CYLINDER HEAD COVER CORNER 6 x 12 4 I CORNER CYLINDER HEADCOVER ...

Page 37: ...intake and exhaust valve clearance c Hold the adjusting screw using the special tool and tighten thelock nut TORQUE 6 Recheckvalve clearance after tightening thelock nut 7 Apply a liquid packing Three Bond 1207 Honda Bond 4 or equivalent to the cylinder head cover installation surface and install the cylinder headcover S TOOL VALVE ADJUSTING WRENCH B VALVE ADJUSTING LOCK NUT VALVE STEM To increase...

Page 38: ...ercap for pilotscrew adjust ment Thelimiter cap cannot be removedwithout breaking the pilot screw Pilot screw adjustmentmust be performed only whenit is dis assembled Throttle stop screw 1 Start the engine and allow it to warm up to normal operat ing temperature 2 With theengine idling turn the throttle stop screwto obtain the standard idle speed I Standard idle speed I I THROTTLE gc160_gcaha_3599...

Page 39: ...ith the controllever in theSLOW position check to see whether the carburetor throttle valve is fullyclosed Check to see whether the governor arm and the carburetor throttle valve operate smoothly Start the engine and warm it up to the normal operating temperature Move the control lever to the maximum engine speed position and check the maximumengine speed I Maximum speed no load I IO Adjustment is...

Page 40: ...be burnedor seriously injuredwhen handling fuel Keep heat sparks and flame away Handlefuel only outdoors Wipe up spillsimmediately 1 Drain the fuel intoa suitable container and remove the fuel tank FUElL rANK 6 x 25 mm BOLT WASHER 2 FUEL TUBE 6 mm FLANGE NUT gc160_gcaha_3599750_3721672 ...

Page 41: ...INE Check 1 Gasoline is highly flammable and explosive You canbe burned or seriously injuredwhen handling fuel Keep heat sparks and flameaway Handle fuelonly outdoors I Wipe upspills immediately 1 Check the fuel lines for deterioration cracks or sings of leakage 2 Check the fuel pump for dirt and otherforeign material 3 Drain the fuel into a suitable container 4 Replacethe fuel lines and fuel pump...

Page 42: ...ove the three6 x 12 mm flange bolts from the muffler protector and removethe mufflerprotector Removethe 4 x 6 mm tapping screw from the spark arrester and remove the spark arrester from themuffler Check for carbon deposits around the exhaust port and spark arrester Clean if necessary with a wire brush Replacethe spark arrester if there are any breaks or tears Install the spark arrester and muffler...

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Page 44: ...mblethe recoil starter assembly FAN COVER INSTALLATION Checkwhether thehigh tension cord is securely setin the groove inthe fan cover as shown GROOVE HIGHTENSION I 6 mm FLANGE NUT 3 TORQUE STARTER ROPE REPLACEMENT 1 Pull the starter grip fully untilthe starter rope is pulled out fully RECOIL STARTER ASSEMBLY gc160_gcaha_3599750_3721672 ...

Page 45: ...de and the starter reel side and removethe starter rope 4 When the starter rope has broken or thestarter reel has re wound align therope holein thestarter case with the rope hole in the starter reel by turning the starter reel 5 turns in the direction of thearrow STARTER REEL STARTER REEL STARTER ROPE L STARTER GRIP ALIGN THE HOLES STARTER CASE I STARTER REEL gc160_gcaha_3599750_3721672 ...

Page 46: ...f the starter rope through the rope hole in the starter case and through the rope hole in the starter reel and makea slip knot at the rope end STARTER GRIP KNOT 7 Wind the starter rope slowlyon the starter reel 8 Check the operationof the ratchets by pulling the starter rope several times gc160_gcaha_3599750_3721672 ...

Page 47: ...spills immediately FUEL TANK FUEL CAPACITY CLEANING INSTALLATION Wash with solvent to remove the sediment and dry throughly before installing i FUEL TANK Make sure that the air 6 mm SPECIAL WASHER TUBE CLIPB10 FUEL TANK TUBE CHECK INSTALLATION vent hole is clean and unclogged Blow with compressedairif necessary ING SETTING COLLAR INSTALLATION Check to be sure thestrainer isclean andundamaged befor...

Page 48: ...tank tube to the fuel tank 2 Connect the smaller diameterend of the fuel tank tube to the fuel pump on the side marked with I A FUEL PUMP VIEWED FROM BACK SIDE FUEL MARK FUEL TANK TUBE CONNECTOR FUEL TANK TUBE SMALLER0 D J LARGER 0 D TO FUEL TANK gc160_gcaha_3599750_3721672 ...

Page 49: ... RETURN SPRING REMOVAL I INSTALLATION CARBURETOR CARBURETOR INSULATOR Do not reuse Blow out the passages INSTALLATION Replace the packing if it is damaged DISASSEMBLY r Y J w a REASSEMBLY y 4 INSPECTION ADJUSTMENT STAY A n n n n m n c CHOKE ROD CHOKE ROD U n u l V l l V l e I I REMOVAL REPLACEMENT AIR CLEANER ASSEMBLY DISASSEMBLY REASSEMBLY INSTALLATION 9 INSTALLATION 5 x 14 mm WASHER SCREW TORQUE...

Page 50: ...s overhauled CARBURETOR BODY I REASSEMBLY FLOAT VALVE PILOT SCREW REPLACEMENT LIMITER CAP REPLACEMENT Clean internal passages and I orifices with compressed air before installation REASSEMBLY Check for worn float valve seat float valve orweak spring before installation I VALVE SEAT FLOAT VALVE P A OK REPLACE THROTTLE STOP SCREW ADJUSTMENT MAIN NOZZLE FLOAT U REASSEMBLY t e Clean thoroughly with 4 ...

Page 51: ...r cap requires breaking the pilotscrew A new pilotscrew and limitercap must be installed 1 When the limitercap has been broken off remove the bro ken pilot screw 2 Placethe spring on thereplacement pilot screw and install it on thecarburetor 3 Turn the pilotscrew in untilit is lightlyseated then turn the screw out therequired number ofturns Pilot screw opening 4 Apply LOCTITE 638 to the inside of ...

Page 52: ...ok the governor rod from the carburetor throttle valve INSTALLATION 1 Set the choke rod on the carburetor chokevalve 2 Hook the governor rodin thelarger hole in the carburetor throttle valve Hookthe throttle return spring inthe smaller holeinthe car buretor throttlevalve 3 Install the insulatorpacking carthretor insulator air guide fuel tank stayA carburetor packing air cleaner packingand air clea...

Page 53: ...ect the smaller diameter end of the diaphragm tube to the fuel pump of the side marked with P Connect the larger diameter end of the diaphragm tube to the crankcase cover 0 AIR CLEANER INSTALLATION Install the air cleaner so that the stop switch wire passesthrough the guide on the air cleaner case FUEL PUMP VIEWD FROM BACK SIDE PUMP P MARK 2 DIAPHRAGMTUBE CONNECTOR FUELTUBE 0 D TO CARBURETOR LARGE...

Page 54: ...t the governor small holes in the governor arm and throttle GOVERNOR SPRING STOP SWITCH WIRE I CLIPA Install the spring with the long end on thecarburetor nstallwith the shortend idetowardthe governor GOVERNOR ARM NUT TORQUE GOVERNOR ENGINESTOP SWITCH INSPECTION 4 x 12 mm SCREW WASHER TORQUE TROL LEVER SPACER ONTROL BASE 6 mm SELF LOCKING NUT CONTROL asewith the groove inthe control 1lever washer ...

Page 55: ...ROTTLE TYPE Qtype Solid wire cable 5 x 16 mm SCREW 0 CONTROL ROD LEVER HOLDER ENGINE STOP SWITCH INSPECTION MANUAL THROTTLE V type ADJUSTING SCREW ENGINE STOP SWITCH INSPECTION CONTROL gc160_gcaha_3599750_3721672 ...

Page 56: ...de and set the spring on the control lever as shown 3 Set the shorter straight side of the governor spring on the governor arm INSPECTION ENGINE STOP SWITCH There should be continuity when the plunger is pushed in There should be no continuity when the plu nger is released Replacethe engine stop switch if the correct continuity test re sults are not obtained CONTROL LEVER CONTROL LEVER J gc160_gca...

Page 57: ...tion IGNITION COIL INSPECTION ADJUSTMENT PSWITCH WIRE CLAMPER h oil level switch 6 X 12 2 With oil level switch WIRE CLAMPER With oil level switch FLYWHEEL REMOVAL INSTALLATION TORQUE When installing the flywh check to be sure that FAN COVER STUD BOLT 3 TORQUE 25 x 18 mm SPECIAL WOODRUFF KEY I REASSEMBLY STOP SWITCH WIRE With oil level switch INSTALLATION When disassembling and re I4 mm SPECIAL NU...

Page 58: ... Remove the ignition coil 2 Holding the flywheel with a commercially available strap wrench remove the 14 mm special nut I CAUTION Do not loosenthe nut by using a screw driveror equiva lent toolon the fan bladeor projection 3 Set the magnetic parts of the flywheelinthe positionshown PROJECTIONS I I I I I 14 mm SPECIAL NUT MAGNETIC PARTS gc160_gcaha_3599750_3721672 ...

Page 59: ...STALLATION CAUTION Make sure the tapered part is free of dirt oil grease and Make sure that there is no washer or foreign material on other foreign material before installation the magnetic part 1 Be sure that the woodruff key is set in thekey groove proper ly 2 Install the flywheel 3 Apply oil to the threads 4 Holding the flywheel with a commercially available strap wrench tighten the 14 mm speci...

Page 60: ... Secondary side resistance I ADJUSTMENT IGNITION COIL AIR GAP Adjustment is required only when the ignition coil or the fly wheel has been removed Loosen the ignition coil bolts Insert along feeler gauge of the proper thickness between the ignition coiland the flywheel Both gaps should be adjusted simultaneously Pushthe ignition coil firmly toward the flywheel and tighten the bolts I Specified cle...

Page 61: ...eaner and carburetor 2 Remove the governorspring REATHER VALVE INSTALLATION Be sure that the breather valve is set inside the three tabs o fthe breather cover as shown TABS I BREATHER VALVE I BREATHER COVER I COVER 6 x 14 TORQUE gc160_gcaha_3599750_3721672 ...

Page 62: ...VAL INSTALLATION VALVE ADJUSTING SCREW 2 ADJUSTMENT EXHAUST ROCKERARM VALVE ADJUSTING LOCK NUT 2 TORQUE 6 8 x 1 9 mm O RING IDO not reuse I ROCKERARM SHAFT 2 INSPECTION I INSTALLATION INTAKE ROCKERARM INSPECTION CAM PULLEY SHAFT INSPECTION TIMING BELT I I gc160_gcaha_3599750_3721672 ...

Page 63: ... the cam pulley on the timing belt with care not to turn thecrankshaft 3 Apply oil to the 6 8 x 1 9 mm O ring and install it on thecam pulley shaft 4 Install thecam pulley shaft in the cylinder barrel 5 Holding thecam pulley alignmentmarks in line with the cyl inder head cover mating surface check again whether the crankshaft key groove is facing up 6 If thekey groove is not facingup repeatthe pro...

Page 64: ...n shop towel Apply a liquid packing Three Bond 1207 Honda Bond 4 or equivalent to thecylinder head cover specifically to the in ner wall of the groove and bolt hole in the cylinder head cover NOTE Assemble within 10 minutes after applying the liquid packing Wait for approximately 20 minutes after assembly before filling oiland starting theengine ROCKER ARM SHAFT CYLINDER HEAD COVERVIEWED FROM BACK...

Page 65: ...base shop manual INSTALLATION Be careful not to damage the oil seal After installation clean the crankshaft tapered surface THRUST WASHER INSTALLATION P 8 6 of the base shop manual CRANKCASE COVER DISASSEMBLY REASSEMBLY P 8 11 of the base shop manual INSPECTION P 8 20 of the base shop manual REMOVAL P 8 20 of the base shop manual 6 x 25 mm FLANGE BOLT 8 INSTALLATION P 8 5 of the base shop manual T...

Page 66: ...be at the topdead center of thecompression stroke CAUTION Take carenotto breakthe piston ringwhen installingthe piston assembly in thecylinder Install thecrankshaft in thecylinder barrel Apply oil to the connecting rod big end bearing and the crank pin then connect the connecting rod to the crank pin Apply oil to the connecting rod cap bearing Install so that the projection by the oil dipper and t...

Page 67: ...01 5 2 0 mm 00 06 0 08 in of liquid packing Three Bond 1207 Honda Bond 4 or equivalent tothecrankcasecovermatingsurface of the cylinder barrel 6 Install the crankcase cover on the cylinderbarrel NOTE Assemble within 10 minutes after applying the liquid If it is hard to install the crankcase cover securely as packing semble by turning the crankshaft a little I 7 Loosely tighten each 6 x 25mm flange...

Page 68: ...ng Do not align with the piston pin PISTON PIN CUP 2 ASSEMBLY nstall by setting one end f the clip inxthe piston Iroove holding the other md with longnosedpliers Ind rotating the clip in 10 not align the end gap f the clip with the cutout n the piston pin bore CLIP CUTOUT TOP RING Chrome plated Do not interchange I MAKER MARK SECOND RING OIL RING I PISTON INSPECTION REASSEMBLY PISTON PIN INSPECTIO...

Page 69: ...oints down 3 Set the connecting rod in the piston so that the model mark by the piston pin hole and the longer side of the connecting rod large end face to the right handside 4 Apply oil to the piston pin and install it in the piston 5 Install new piston pin clips 6 Install the piston connecting rod assembly in the cylinder barrel PISTON PISTON PIN CONNECTING ROD gc160_gcaha_3599750_3721672 ...

Page 70: ...iner CAUTION Do not remove thevalve spring retainerwhilethepistonis installed or the valves will drop into thecylinder VALVE GUIDE INSPECTION EXHAUSTVALVE Before installation remove carbon deposits and inspect the valve INSPECTION h VALVE SPRING 2 INSPECTION INTAKE VALVE REASSEMBLY interchange with the exhaust IVALVE HEAD DIAMETER I Be careful not todamage the valve stem seal when installing INSPE...

Page 71: ...ll of the cylinder andinsert it into the cylinder for protection 2 Attach the cleaning brush special tool to an electric drill and clean the combustionchamber TOOL Cleaning brush CAUTION tect the inner wall of the cylinder during cleaning of the combustion chamber Do not press the cleaning brush with force againstthe CLEANING BRUSH gc160_gcaha_3599750_3721672 ...

Page 72: ...lled with the straight side of the pin against thegroove in the shaft GOVERNOR L GOVERNOR HOLDER SHAFT GOVERNOR HOLDER Insert firmly into the shaft groove GOVERNOR SLIDER REASSEMBLY Spread the governor weights to install the slider then check to be sure the slider moves smoothly gc160_gcaha_3599750_3721672 ...

Page 73: ...With oil levelswitch oilfiller extension and bearingonly 62 28 RADIAL BALL BEARING REMOVAL INSTALLATION 6 x 2 8 13 8 x 14 5 AR TORQUE OIL LEVEL SWITCH INSPECTION mm gc160_gcaha_3599750_3721672 ...

Page 74: ...mm Pilot 28mm INSTALLATION 1 Apply engine oil to the circumference of a new radial ball bearing 2 Install the 62 28radial ball bearing in the crankcase cover using the special tools as shown TOOLS Driver Attachment 52x 55 mm Pilot 28mm G DRIVER e ATTACHME NT 32 x 35 mm l I BEARING k PILOT 28 mm 3 c DRIVER gc160_gcaha_3599750_3721672 ...

Page 75: ...e ohmmeter should read zero resistance 2 Hold the switch upside down The ohmmeter should read infinite 00 resistance 3 Inspectthe float by dipping the switch into a container of oil The ohmmeter reading should go fromzero to infinity as the switch is lowered YELLOW FLOAT Upside down Normal position Infinite 00 Q Zero Q gc160_gcaha_3599750_3721672 ...

Page 76: ...rvice limit CAM PULLEY I D BEARING I Standard I Service limit I CAM PULLEY SHAFT O D I Standard I Service limit I ROCKERARM I D I Standard I Service limit I ROCKER ARM SHAFT BEARING I D I Standard Service limit I L II gc160_gcaha_3599750_3721672 ...

Page 77: ...text 8 5 03 2 01 PM Page 66 gc160_gcaha_3599750_3721672 ...

Page 78: ... 0 97 mm 0 037 0 038 in 0 93 mm 0 036 in Second ring 0 97 0 99 mm 0 038 0 039 in 0 95 mm 0 037 in Standard Service limit Top ring GC160LA 0 055 0 089 mm 0 002 0 004 in 0 150 mm 0 006 in Top ring GC GS190LA 0 035 0 069 mm 0 001 0 003 in 0 150 mm 0 006 in Second ring 0 015 0 049 mm 0 0006 0 0019 in 0 150 mm 0 006 in Standard Service limit Top ring 0 20 0 35 mm 0 008 0 014 in 1 00 mm 0 040 in Second ...

Page 79: ...DGAP Standard Service limit NOTE Use the topof the piston to position the ring horizontally in the cylinder PISTON PIN O D Standard Service limit PISTON PIN BORE I D Standard Service limit gc160_gcaha_3599750_3721672 ...

Page 80: ...L END I D Standard Service limit CONNECTING ROD BIG END I D Standard Service limit CRANKSHAFT MAIN JOURNAL O D I Standard Service limit CRANK PIN O D r Standard I Service limit I FLYWHEEL SIDE gc160_gcaha_3599750_3721672 ...

Page 81: ...andcap and tighten the connecting rod bolts to the specified torque TORQUE NOTE Placethe plastigauge axially Tighten the two bolts equally while holding the crank shaft to keep it from turning Removethe connecting rodcap and measurethe plastigauge with thescale Standard Service limit If the clearance exceeds the service limit replace the con necting rod andrecheck the clearance CYLINDER BARREL MAI...

Page 82: ... service limit replacethe crankcasecover and cylin der barrel VALVE SPRING FREE LENGTH Measure the free length of the valve springs Standard Service limit Replacethe springs if they are shorter than the service limit VALVE FACE STEM O D Inspect each valve face for pitting or wear irregularities Inspect each valve stem for bending or abnormal stem wear Replace the valve if necessary Measure and rec...

Page 83: ... marker ink to thevalve faces Insert the valves and thenlift them andsnap them closed against their seats several times Be sure the valve does not rotate on theseat The transfered marking compound will show any area of theseat that is notconcentric Measure the valve seat width I Standard I Service limit I If the valveseat width is under the standard or over the service limit or if the valve seat i...

Page 84: ...rclockwise Continue to turn the cutter as you liftit from thevalve seat TOOLS Valve seat cutter 45 027 2 VALVE FACE L I CUlTER HOLDER VALVE SEAT Cutter holder 1 VALVE SEATWIDTH Standard Service limit 5 After resurfacing the seats inspect for even valve seating Apply PrussianBluecompound orerasablefelt tipped marker ink to the valve faces Insert the valves and then lift them and snapthem closed aga...

Page 85: ... Operation When the crankshaft turns the timing belt rotates the single lobe cam which cause the L shaped rocker arms to operate the valves The engine oil in the crank chamber gets on the timing belt surface which is then transmitted to the rocker arm chamber INTAKE ROCKERARM L SHAPE ROCKERARM ROCKERARM CHAMBER I CAM PULLEY CAMSHAFT ONE TOP INTAKE VALVE CRANKSHAFT gc160_gcaha_3599750_3721672 ...

Page 86: ...he fuel tank at high ambient temperature is absorbed and stored by the charcoal in the canister which is built into the fuel tank cap PURGING When the pressure in the fuel tank decreases because of low ambient temperature or consumption of gasoline the air drawn through the canister releases the stored gasoline vapor from the charcoal The released gasoline vapor returns to the fuel tank 1 FUEL TAN...