2010 06 07 PART 1 Engine Assembly GXV630 660

GXV630 ・ GXV660 ・ GXV690 Engine Assembly Information

PISTON MARK PISTON PISTON RING SET TOP RING INSTALLATION: ASSEMBLY: (CHROME PLATED) FLYWHEEL SIDE Position the connecting rod of the cylinder near The top ring (1) and second ring (2) are not top dead center by rotating the crankshaft slowly. interchangeable. SECOND RING (2) Install the top and second ring on the piston with Install the piston (1) on the connecting rod (2) (6) the mark side facing up. (5) SIDE RAIL with triangle mark (3) of the piston pointing Check that the piston rings rotate smoothly after OIL RING toward the flywheel side as shown. (7) installing them. (COMBINATION Space the piston ring end gaps 120 degrees (5) RING) Apply oil to the piston pin (4) outer surface, (4) apart, and do not align the ring end gaps with connecting rod small end and piston pin bore. the piston pin bore. SPACER Install the piston pin through the piston and FLYWHEEL SIDE 10 mm (0.4 in) connecting rod. (1) Install new piston pin clips (5) into the grooves (2) in the piston pin hole. ・ Make sure the piston pin clips are seated securely. ・ Do not align the piston pin clip and gap (6) (3) CYL #1 CYL #2 with the piston cutout (7). (1)

CRANKSHAFT/CONNECTING ROD/CAMSHAFT BREATHER BOLT (6 x 45 mm) OIL LEVEL CONNECTING ROD BEARING CAMSHAFT Clean the mating surfaces CONNECTING GAUGE OIL FILLER INSTALLATION: INSTALLATION: of the breather cover ROD UPPER EXTENSION CONNECTING Install the connecting rod bearing (1) Open the valve lifters in the crankcase. and crankcase of old liquid (CYL #1) ROD UPPER on the connecting rod upper (2) and Install the camshaft (1) into the crankcase (2) by gasket, oil and other foreign (CYL #2) lower (3) in the direction as shown. aligning the punch marks (3) on the camshaft material. Each connecting rod upper and and the crankshaft (4) (marked on the timing lower are not interchangeable. gear). Apply a bead (Ø1.0 - 1.5 mm DOWEL PIN VALVE (Ø0.04 - 0.06 in) of liquid (8 x 10 mm) (2) gasket (Threebond TB1207B, LIFTER (2) (1) Hondabond HT, Hondabond 4 BOLT LOCK PIN or equivalent) to the mating (6 x 22 mm) surface of the crankcase as shown.

(1)

BOLT (6 x 14 mm) (3) (3) BREATHER COVER

CAMSHAFT SCREW (3 x 8 mm) GOVERNOR ARM SHAFT 1 N•m (0.1 kgf•m) (3) INSTALLATION: (4) STOPPER PLATE Install the governor arm shaft (1), and then install the lock pins (2) in CRANKSHAFT OIL OUTLET the direction as shown. INSTALLATION: VALVE (2) Before installing the crankshaft, Install the breather cover and tighten the three flange bolts securely. CONNECTING check the crankcase oil seal for BREATHER FILTER (2) ROD damage or hardening. ・ Be sure not to catch the breather filter between INSTALLATION: LOWER Be careful not to damage the oil seal the breather cover and crankcase. Install the breather when installing the crankshaft. ・ Assemble the breather cover within 3 minutes after applying liquid gasket. filter until it is fully seated on the end. CRANKSHAFT THRUST ・ Wait for 30 minutes after assembly before filling (1) CONNECTING ROD BOLT (4) WASHER with oil and starting the engine. 22 N•m (2.2 kgf•m)

See the shop manual for additional information. © Honda Motor Co., Ltd. 2010 GXV630 ・ GXV660 ・ GXV690 Engine Assembly Information

GOVERNOR/PUMP/OIL FILTER/CRANKCASE COVER COOLING FAN/FLYWHEEL

OIL PUMP GEAR Clean the mating surfaces of the oil Apply grease to the O-ring (1). FLYWHEEL HOLDER OIL PUMP COVER GOVERNOR BOLT (6 x 20 mm) (3) pan and crankcase of old liquid gasket, Install the two dowel pins (2) and O- (07APB-Z6LA100) SLIDER OIL PUMP O-RING DOWEL PIN oil and other foreign material. ring to the crankcase. 8 x 20 mm BOLT (3) (8 x 10 mm) (2) SPECIAL NUT Apply a bead (Ø1.0 - 1.5 mm (Ø0.04 - Apply a light coat of oil to the main GOVERNOR TORQUE: 235 N•m 0.06 in) of liquid gasket (Threebond journal part of the crankshaft and oil OIL FILTER WEIGHT (24 kgf•m) OIL PUMP INNER ROTOR TB1207B, Hondabond HT, Hondabond pan (3). INSTALLATION: OIL 4 or equivalent) to the mating surface Install the oil pan and tighten the nine SPECIAL COOLING FAN SETTING Install the inner rotor with the PUMP of the oil pan as shown. flange bolts (4) securely. NUT PLATE COOLING FAN punch mark side facing up. SHAFT GOVERNOR ・ Assemble the oil pan within HOLDER CLIP 3 minutes after applying liquid OIL PUMP OUTER ROTOR gasket. FLYWHEEL ・ Wait for 30 minutes after assembly INSTALLATION: GOVERNOR REMOVAL: before filling with oil and starting the Install the outer rotor WEIGHT Hold the flywheel (1) with a engine. with the punch mark HOLDER commercially available strap side facing up. wrench (2) and use a commercially available BOLT (6 x 20 mm) (2) flywheel puller (3) to remove GOVERNOR (4) the flywheel. OIL STRAINER WEIGHT PIN O-RING WASHER (6 x 16 mm) SPECIAL (2) WOODRUFF (3) (1) RELIEF VALVE KEY SPRING

STEEL BALL DRAIN PLUG (1) WASHER (3) DRAIN PLUG OIL PAN BOLT 20 mm (3) (3)

CYLINDER/VALVES/CRANKCASE VALVE SPRING RETAINER BOLT (8 x 16 mm) ENGINE HANGER Apply a bead (Ø1.0 - 1.5 mm (Ø0.04 - 0.06 Apply grease to the oil passage packing (1). DISASSEMBLY: VALVE SPRING in) of liquid gasket (Threebond TB1207B, Install the dowel pins (2) and oil passage packing on the crankcase. Push down and slide the Hondabond HT, Hondabond 4 or valve spring retainer (1) to (2) equivalent) to the mating surface of the Apply oil to the cylinder inner surface, piston outer surface and the side so that the valve cylinder as shown. piston rings. stem (2) slips through the VALVE STEM hole at the side of the valve No. 1 CYLINDER: SEAL Install the cylinder (3) over the piston (4) while compressing spring retainer. (Seal lip) the piston rings with your fingers. Do not remove the valve spring retainer while the Apply a light coat of oil to the threads and the seating surface of cylinder is installed to the (Seal lip) VALVE GUIDE the four flange nuts (5) and tighten them to the specified torque. crankcase, or the valve will CLIP TORQUE: 37 N•m (3.8 kgf•m) drop into the cylinder. (4) ・ Assemble the cylinder within 3 minutes after applying (1) liquid gasket. (3) (5) ・ Wait for 30 minutes after assembly before filling (6) No. 2 CYLINDER: (2) with oil and starting the engine. CYLINDER Apply oil to both end of the two push rods (6) and insert them into the cylinder. ROCKER INLET VALVE ARM ASSEMBLY: Apply oil to the bearing and slipper of the rocker Do not interchange with the exhaust arms and install them to the cylinder. ROCKER valve. The inlet valve is larger than Apply oil to the rocker arm shaft and insert into the ARM the exhaust valve. SHAFT EXHAUST VALVE cylinder in the direction as shown. Install the valve cover.