Honda GX240 Assembly Information

GX240
PISTON
MARKING
TOP RING (CHROME FACED)
SECOND RING (BLACK FACED)
SPACER
OIL RING
SIDE RAIL (2)
PISTON PIN CLIP (2)
REASSEMBLY:
PISTON
Refer to GX120·GX160·
GX200 Engine Assembly
Information.
PISTON PIN
PISTON PIN
CLIP
CUT OUT
CRANKSHAFT/BALANCER/PISTON
PISTON
REASSEMBLY:
CRANKCASE COVER, CRANKSHAFT, PISTON
Install with the
triangle mark
toward the
pushrod hole.
TRIANGLE MARK
OIL SEAL
30 x 46 x 8 mm
BALL
GREAS
BEARING
10 mm
FLANGE
NUT
10 N·m
(1.0 kgf·m, 7 lbf·ft)
OIL DRAIN
BOLT (2)
23 N·m (2.3 kgf·m, 17 lbf·ft)
DRAIN BOLT WASHER
Replace.
OIL LEVEL SWITCH
CONNECTING ROD BOLT (2)
14 N·m (1.4 kgf·m, 10 lbf·ft)
BALANCER
CONNECTING ROD CAP
REASSEMBLY:
Install with the oil dipper toward the camshaft and
the ribs on the cap and connecting rod aligned.
・
GX270R/RT/T/U/UT Engine Assembly Information
PISTON RINGS
REASSEMBLY:
Refer to GX120·GX160·GX200
Engine Assembly Information.
TOP RING
(CHROME FACED)
10 mm
SECOND RING
(0.4 in)
(BLACK FACED)
OIL RING
(COMBINATION RINGS)
CONNECTING ROD
REASSEMBLY:
Install the connecting rod with the long
end toward the triangle-marked side of
the piston.
CAMSHAFT
REASSEMBLY:
Before installing, inspect for worn and weakened springs
and check that the decompressor weight moves smoothly.
DECOMPRESSOR
WEIGHT
VALVE LIFTER (2)
DISASSEMBLY:
When removing, mark so that the IN
and EX sides can be distinguished.
REASSEMBLY:
Install the lifters immediately before
installing the camshaft.
7 x 7 x 33 mm KEY
(L,S type only)
6.3 x 6.3 x 43 mm KEY
(Q type only)
TIMING GEAR/
BALANCER GEAR
CRANKSHAFT
REASSEMBLY:
Push in until the bearing touches the crankcase.
Be careful not to damage the oil seal.
See the shop manual for additional information.
BALANCER
LOCK PIN
BALANCER
REASSEMBLY:
DRIVE GEAR
· Install the lock pin immediately
(large gear on the
after installing the governor arm
BALANCER
crankshaft)
shaft, and move the shaft to the
cylinder side as shown.
· The lock pin must be installed
with the straight side of the pin
against the groove in the shaft.
GOVERNOR SLIDER
REASSEMBLY:
PUNCH MARKS
Spread the governor weights to
install the slider; then check to be
sure the slider moves smoothly.
TIMING GEAR
(smaller gear on
GOVERNOR WEIGHT (2)
the crankshaft)
REASSEMBLY:
Check that the weights move freely.
GOVERNOR WEIGHT HOLDER
REASSEMBLY:
Before installing, check for wear and
damage of the gear.
PUNCH MARKS
CAMSHAFT
Refer to GX340・GX390K1/R1/T1/U1/UT1 Engine Assembly Information.
WOODRUFF KEY
REASSEMBLY:
After installing the flywheel, check to
be sure that the woodruff key is still
in its slot on the crankshaft.
SPARK PLUG CAP
FLYWHEEL
DISASSEMBLY:
IGNITION COIL
・Remove the ignition coil before
removing the flywheel.
COOLING FAN
・Do not hit the flywheel with a
NOTICE: When disassembling and reassembling,
hammer. Remove with the special
take care not to damage the fan blades.
tool.
REASSEMBLY: REASSEMBLY:
on the rear side of the fan with the three holes
Clean the crankshaft tapered surface
in the flywheel.
before installation.
FLYWHEEL
FLYWHEEL
PULLER
07935-8050004
(Honda's special
tool)
CRANKCASE COVER/GOVERNOR
DOWEL PIN (2)
GOVERNOR
PIN (2)
WASHER
CRANKCASE GASKET
Do not reuse.
CRANKCASE COVER
CYLINDER HEAD/VALVES
FLYWHEEL/IGNITION COIL
BLACK WIRE
REASSEMBLY:
Insert securely into the
two ribs on the crankcase
as shown.
HIGH TENSION CORD
6 x 28 (2)
Attach by aligning the three lugs
STARTER PULLEY
REASSEMBLY:
COOLING FAN
ALIGN Align the hole of the
starter pulley with the
boss of the cooling fan.
HOLE (3) LUG (3)
WASHER
REASSEMBLY:
Install inside the case.
GOVERNOR ARM SHAFT
REASSEMBLY:
After installing, rotate the shaft to
the cylinder barrel side.
6 x 16 mm WASHER (Equipped type)
CLIP
REASSEMBLY:
Install firmly into the shaft groove.
BALL BEARING
GREASE
OIL SEAL
30 x 46 x
8 x 35 (7) 8 mm
24 N·m
(2.4 kgf·m, 17 lbf·ft)
16 mm FLANGE NUT
TORQUE:
115 N·m
(11.5 kgf·m, 83 lbf·ft)
DISASSEMBLY/
REASSEMBLY:
· Apply oil to the threads.
· Hold the flywheel by
placing a screwdriver
into the pulley.
(SD, SN, QD
types only)
© Honda Motor Co., Ltd. 2009