2009 08 24 Engine Assembly GX35

GX35 Engine Assembly Information

CRANKSHAFT/PISTON LOWER CRANKCASE PISTON RING TIMING BELT 4 x 8 mm SCREW (2) 14.8 x 2.4 mm O-RING 5 x 16 mm HEX BOLT (2) REASSEMBLY: INSTALLATION: REASSEMBLY: REASSEMBLY: · Install the second ring with the " • " or "R" mark facing up. Check that the Clean the threads and apply 5 x 53 mm Clean the hex bolt threads · Do not interchange the top ring and the second ring. belt is not worn liquid sealant (Loctite® 648, HEX BOLT (2) and apply liquid sealant · After assembly, check for smooth movement of the or cracked and Hondalock 2 or equivalent) (Loctite® 648, Hondalock 2 piston rings. do not bend or to the threads. or equivalent) to the · Stagger the piston ring end gaps 120° apart. twist the belt. threads. Do not align with the piston pin. OIL OUTLET VALVE PLATE · Space the oil ring side rail end gaps at least 10 mm (0.4 in) INSTALLATION: apart. Coat the oil ring with oil after assembly. Install the oil outlet valve to TOP RING the oil outlet valve plate by (CHROME FACE) aligning the chamfer and SHROUD SECOND RING projections. (BLACK FACE) CARBURETOR SIDE OIL OUTLET OIL OIL RINGS SIDE RAIL VALVE (COMBINATION SPACER FILLER D12 TUBE CLIP PISTON CAP STOPPER PLATE (Color: Gold) RINGS) SIDE RAIL PROJECTIONS REASSEMBLY: OIL TUBE Install with the " △ " CHAMFER " • " or "R" MARK REASSEMBLY: mark on the piston head OIL FILLER CAP PACKING Inspect for cracks or facing the carburetor deterioration before TOP RING PISTON PIN 4 x 10 mm SPRING PIN installation. LOWER CRANKCASE 3.5 mm SCREW SECOND RING REASSEMBLY: D13 TUBE CLIP (Color: Silver) OIL RINGS 10 x 20 x 5 mm Clean the inside of the crankcase " △ " MARK 5 x 20 mm HEX BOLT (2) (COMBINATION OIL SEAL and remove foreign material before 6.4 N·m (0.65 kgf·m, 4.7 lbf・ft) RINGS) 15 x 25 x 6 mm reassembly. OIL SEAL 5 x 32 mm HEX BOLT (4) 10 mm (0.4 in) 6.4 N·m (0.65 kgf·m, 4.7 lbf・ft) CRANKSHAFT

CAM PULLEY/CRANKSHAFT LOWER CRANKCASE/CYLINDER BARREL/VALVES CAM PULLEY ALIGNMENT CAM PULLEY LOWER CRANKCASE VALVE SPRING VALVE SPRING (2) MARKS RETAINER (2) TIMING BELT CYLINDER BARREL VALVE STEM SEAL DISASSEMBLY: CAM PULLEY (Intake valve only) Do not remove the valve TIMING BELT SHAFT Do not reuse. spring retainers while the lower crankcase is VALVE LIFTER (2) installed, or the valves Do not will drop into the cylinder. CAM PULLEY SHAFT HEAD COVER disassemble. SPARK PLUG MATING SURFACE CMR5H (NGK) Loosely tighten each two VALVE ROCKER CYLINDER BARREL FLYWHEEL PISTON LIQUID GASKET 5 x 20 mm and four 5 x 30 mm ARM (2) Viewed from the back APPLICATION AREA hex bolts, and then tighten to Do not (Hondabond 4, disassemble. side: INSTALLATION: the numbered sequence. IN EX ThreeBond® #1216, ・Check that the belt 1216E or equivalent) is not worn or TORQUE: 6.4 N·m (0.65 kgf·m, INTAKE VALVE ・ cracked, and do not 4.7 lbf ft) REASSEMBLY: Assemble within 3 minutes bend or twist the Wait for approximately 60 Do not interchange after applying the liquid belt. minutes after assembly before with the exhaust valve. VALVE HEAD DIAMETER: gasket. filling with oil and starting the ALIGNMENT ・Install with the IN: 15.5 mm (0.61 in) engine. FAN COVER BOLT HOLE ▽ MARK markings as shown. CRANKSHAFT EXHAUST VALVE EX: 14.0 mm (0.55 in)