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How to use this manual

A Few Words About Safety
How to use this manual

SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.

Improper service or repairs can create an unsafe

condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.

Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.

Important Safety Precautions

Make sure you have a clear understanding 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 glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.

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How to use this manual

INTRODUCTION OUTLINE OF CHANGES

This supplement covers the construction, function, and SPECIFICATIONS 1
servicing procedures of the Honda GX160T2 CHB3
type, GX200T2 CACK/CHK/CAC1/CHBR/CHB2/CW2/ SERVICE INFORMATION
CW/DHBR/DHB2/DHB3 types engine.
2
For service information that is not covered in this MAINTENANCE
supplement, please refer to the GX160T2/GX200T2
3
base shop manual (part number 82Z4H00). TROUBLESHOOTING 4
All information contained in this manual is based on the COVER 5
latest product information available at the time of
printing. We reserve the right to make changes at FUEL SYSTEM
anytime without notice.
6
CONTROL BASE 7
No part of this publication may be reproduced, stored in
a retrieval system, or transmitted, in any form, by any FLYWHEEL
means, electronic, mechanical, photocopying,
8
recording, or otherwise, without prior written permission
of the publisher. This includes text, figures, and tables.
IGNITION SYSTEM 9
STARTING SYSTEM 10
As you read this manual, you will find information that is
preceded by a symbol. The purpose of this OTHER ELECTRICAL 11
message is to help prevent damage to this Honda
product, other property, or the environment. MUFFLER 12
SAFETY MESSAGES CYLINDER HEAD/VALVES 13

Your safety and the safety of others are very important. CRANKCASE 14
To help you make informed decisions, we have
provided safety messages and other safety information WIRING DIAGRAMS 15
throughout this manual. Of course, it is not practical or
possible to warn you about all the hazards associated INDEX
with servicing these products. You must use your own
good judgement. The marked sections contain no changes.
They are not covered in this supplement.
You will find important safety information in a variety of
forms, including:
· Safety Labels – on the product.
· Safety Messages – preceded by a safety alert symbol
and one of three signal words, DANGER,
WARNING, or CAUTION.
These signal words mean:

You WILL be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow

instructions.

· Instructions – how to service these products correctly

© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: July 2015

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How to use this manual

SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it will be explained specifically in the text without the use of the symbols.

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use marine grease (water resistant urea based grease).

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

Use automatic transmission fluid.

( x )( ) Indicates the diameter, length, and quantity of metric bolts used.

page 1-1 Indicates the reference page.

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How to use this manual

ABBREVIATIONS
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbreviated Full term
term
ACG Alternator
A/F Air Fuel Ratio
API American Petroleum Institute
Approx. Approximately
Assy. Assembly
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
ATT Attachment
BAT Battery
BDC Bottom Dead Center
BTDC Before Top Dead Center
BARO Barometric Pressure
CKP Crankshaft Position
Comp. Complete
CMP Camshaft Position
CYL Cylinder
DLC Data Link Connector
EBT Engine Block Temperature
ECT Engine Coolant Temperature
ECM Engine Control Module
EMT Exhaust Manifold Temperature
EOP Engine Oil Pressure
EX Exhaust
F Front or Forward
GND Ground
HO2S Heated Oxygen Sensor
IAB Intake Air Bypass
IAC Idle Air Control
IAT Intake Air Temperature
I.D. Inside Diameter
IG or IGN Ignition
IN Intake
INJ Injection
L. Left
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
O.D. Outside Diameter
OP Optional Part
PGM-FI Programmed-Fuel Injection
P/N Part Number
Qty Quantity
R. Right
SAE Society of Automotive Engineers
SCS Service Check Signal
STD Standard
SW Switch
TDC Top Dead Center
TP Throttle Position
VTEC Variable Valve Timing & Valve Lift Electronic Control

BI Black G Green Br Brown Lg Light green

Y Yellow R Red O Orange P Pink
Bu Blue W White Lb Light blue Gr Gray

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How to use this manual

OUTLINE OF CHANGES
Item Before modification After modification
FAN COVER

AIR GUIDE
STARTER PULLEY

TRIANGLE MARK TRIANGLE MARK

COOLING FAN

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How to use this manual

Item Before modification After modification
FLYWHEEL
KEY SLOT KEY SLOT

RECOIL STARTER

CRANKCASE COVER

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How to use this manual

Item Before modification After modification
PISTON

MARK

MARK

CAMSHAFT

CRANKSHAFT

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1. SPECIFICATIONS

DIMENSIONS AND WEIGHTS PERFORMANCE CURVES··························· 1-5

SPECIFICATIONS ·········································1-2
DIMENSIONAL DRAWINGS························· 1-7
ENGINE SPECIFICATIONS ··························1-3
P.T.O. DIMENSIONAL DRAWINGS ············· 1-8

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SPECIFICATIONS
DIMENSIONS AND WEIGHTS SPECIFICATIONS
SPECIFICATIONS

GX160T2
CHB3 type

P.T.O. type DIMENSIONS AND WEIGHTS

Overall length 311 mm (12.2 in)
Overall width 370 mm (14.6 in)
Overall height C 335 mm (13.2 in)
Dry weight 16.0 kg (35.3 lbs)
Operating weight 18.9 kg (41.7 lbs)

GX200T2
CACK/CHK/CAC1/CHBR/CHB2/CW2/CW types

P.T.O. type DIMENSIONS AND WEIGHTS

Overall length 311 mm (12.2 in)
Overall width CHK/CHBR/
376 mm (14.8 in)
CHB2
CACK/CAC1/
C 430 mm (16.9 in)
CW2/CW
Overall height 335 mm (13.2 in)
Dry weight 16.1 kg (35.5 lbs)
Operating weight 19.0 kg (41.9 lbs)
DHBR/DHB2/DHB3 types

P.T.O. type DIMENSIONS AND WEIGHTS

Overall length 319.5 mm (12.58 in)
Overall width DHBR/DHB2 376 mm (14.8 in)
DHB3 361 mm (14.2 in)
Overall height 335 mm (13.2 in)
D
Dry weight DHBR/DHB2 16.1 kg (35.5 lbs)
DHB3 15.1 kg (33.3 lbs)
Operating weight DHBR/DHB2 19.0 kg (41.9 lbs)
DHB3 18.0 kg (39.7 lbs)

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SPECIFICATIONS
ENGINE SPECIFICATIONS
GX160T2
CHB3 type
Model GX160T2
Description code GCBRT
Type 4 stroke, overhead valve, single cylinder, inclined by 25°
Displacement 163 cm3 (9.9 cu-in)
Bore x stroke 68.0 x 45.0 mm (2.68 x 1.77 in)
Net power (SAE J1349) *1 3.6 kW (4.8 HP)/3,600 min-1 (rpm)
Continuous rated power 2.9 kW (3.9 HP)/3,600 min-1 (rpm)
Maximum net torque (SAE J1349) *1 10.3 N·m (1.05 kgf·m, 7.6 lbf·ft)/2,500 min-1 (rpm)
Compression ratio 9.0 : 1
Fuel consumption (at continuous rated power) *1 1.4 Liters (0.37 US gal, 0.31 Imp gal)/h
Ignition system Transistorized magneto
Ignition timing B.T.D.C. 18° /1,400 min-1 (rpm)
Recommended spark plug BPR6ES (NGK)/W20EPR-U (DENSO)
Lubrication system Forced splash
Oil capacity 0.58 Liter (0.61 US qt, 0.51 Imp qt)
Recommended oil SAE 10W-30 API service classification SE or higher
Cooling system Forced air
Starting system Recoil starter
Stopping system Ignition primary circuit ground
Carburetor Horizontal type, butterfly valve
Air cleaner Dual type
Governor Centrifugal weight system
Breather system Flat valve type
Fuel used Unleaded gasoline with a pump octane rating 86 or higher
Fuel tank capacity 3.1 Liters (0.82 US gal, 0.68 Imp gal)
Reduction method Direct-coupled (gear drive)
Reduction system Reduction ratio 1/2
Lubricant capacity Included
*1: The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine
model and measured in accordance with SAE J1349 at 3,600 min-1 (rpm) (net power) and at 2,500 min-1 (rpm) (max net torque).
Mass production engines may vary from this value. Actual power output for the engine installed in the final machine will vary
depending on numerous factors, including the operating speed of the engine in application, environmental conditions, maintenance,
and other variables.

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SPECIFICATIONS
GX200T2
CACK/CHK/CAC1/CHBR/CHB2/CW2/CW/DHBR/DHB2/DHB3 types
Model GX200T2
Description code GCBUT
Type 4 stroke, overhead valve, single cylinder, inclined by 25°
Displacement 196 cm3 (12.0 cu-in)
Bore x stroke 68.0 x 54.0 mm (2.68 x 2.13 in)
Net power (SAE J1349) *1 4.1 kW (5.5 HP)/3,600 min-1 (rpm)
Continuous rated power 3.7 kW (5.0 HP)/3,600 min-1 (rpm)
Maximum net torque (SAE J1349) *1 12.4 N·m (1.26 kgf·m, 9.1 lbf·ft)/2,500 min-1 (rpm)
Compression ratio 8.5 : 1
Fuel consumption (at continuous rated power) *1 1.7 Liters (0.45 US gal, 0.37 Imp gal)/h
Ignition system Transistorized magneto
Ignition timing B.T.D.C. 20° /1,400 min-1 (rpm)
Recommended spark plug BPR6ES (NGK)/W20EPR-U (DENSO)
Lubrication system Forced splash
Oil capacity 0.60 Liter (0.63 US qt, 0.53 Imp qt)
Recommended oil SAE 10W-30 API service classification SE or higher
Cooling system Forced air
Starting system Recoil starter
Stopping system Ignition primary circuit ground
Carburetor Horizontal type, butterfly valve
Air cleaner Dual silent, Cyclone, Semi dry types
Governor Centrifugal weight system
Breather system Flat valve type
Fuel used Unleaded gasoline with a pump octane rating 86 or higher
Fuel tank capacity 3.1 Liters (0.82 US gal, 0.68 Imp gal)
Reduction method Direct-coupled (gear drive)
Reduction system Reduction ratio 1/2
Lubricant capacity Included
*1: The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine
model and measured in accordance with SAE J1349 at 3,600 min-1 (rpm) (net power) and at 2,500 min-1 (rpm) (max net torque).
Mass production engines may vary from this value. Actual power output for the engine installed in the final machine will vary
depending on numerous factors, including the operating speed of the engine in application, environmental conditions, maintenance,
and other variables.

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SPECIFICATIONS
PERFORMANCE CURVES
GX160T2

(N·m) (lbf·ft) (kgf·m)

11
8 1.1
NET TORQUE
TORQUE

10 7.5
1
7
9 0.9

(kW)

4 (HP) (PS)

5
5

NET POWER
3 4 4
OUTPUT

3 3
2

2 2

1
1 1

RECOMMENDED OPERATING SPEED RANGE

0 0 0

2,000 3,000 3,600

ENGINE SPEED (min-1 (rpm))

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SPECIFICATIONS
GX200T2

(N·m) (lbf·ft) (kgf·m)

13 9.5
NET TORQUE 1.3
TORQUE

9
12
1.2
8.5
11 8 1.1

10

(kW)

5
(HP) (PS)

6 6

4
NET POWER
5 5
OUTPUT

3 4 4

3 3
2

2 2

1 1

RECOMMENDED OPERATING SPEED RANGE

0 0 0

2,000 3,000 3,600

ENGINE SPEED (min-1 (rpm))

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SPECIFICATIONS
DIMENSIONAL DRAWINGS
*1: P.T.O. type (page 1-2).

GX160T2: 83 (3.3) Unit: mm (in)

GX200T2: 87 (3.4)

*2: : AIR CLEANER TYPE:

Silent : GX160T2: CHB3
Dual silent : GX200T2: CHK, CHB2, DHB2
Semi dry : GX200T2: CHBR, DHBR
Cyclone : GX200T2: CACK, CAC1, CW2, CW

*3: : WITHOUT MUFFLER TYPE:

GX200T2: DHB3

GX160T2: 370 (14.6)

GX200T2: GX160T2: 160 (6.3)
Dual silent, Semi dry*2: 376 (14.8) GX200T2:
Cyclone*2: 430 (16.9) Dual silent*2: 160 (6.3)
Without muffler type*3: 361 (14.2) Semi dry*2: 157 (6.2)
106 (4.2)
2
(Except DHB3 type) Cyclone* : 168 (6.6)
123 (4.8)

GX160T2:
337 (13.3)
335
(13.2) GX200T2:
339 (13.3)

73
(2.9)

75.5
(2.97)
51.46
(2.026)
162 (6.4)
5 (0.2)
96 (3.8) C type*1: 311 (12.2)
39.5 (1.56) D type*1: 319.5 (12.58)

80 (3.1)

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SPECIFICATIONS
P.T.O. DIMENSIONAL DRAWINGS
Unit: mm (in)

M8 x 1.25 (8 PLACES)

65.1 (2.56) 36.54(1.439)

GX160T2:
33.12 (1.304)
GX200T2:
33.13 (1.304) 62 (2.4)
65.1
(2.56)

CAMSHAFT (P.T.O.)
51.46 (2.026)

50.1 (1.97)

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SPECIFICATIONS
C type
Unit: mm (in)

M8 X 1.25
52.5 (2.07)

5.000 – 5.030 50.0 (1.97)

(0.1969 – 0.1980)

23.0 (0.91)
16.90 – 17.00
(0.6654 – 0.6693)
Φ 19.972 – 19.993 (0.7863 – 0.7871)

D type
Unit: mm (in)

5/16-24UNF-2B
61.0 (2.40)

4.730 – 4.780 58.5 (2.30)

(0.1862 – 0.1882)

17.0 (0.67)
16.260 – 16.360
(0.6402 – 0.6441)
Φ 19.025 – 19.050 (0.7490 – 0.7500)

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2. SERVICE INFORMATION

MAINTENANCE STANDARDS ·····················2-2 TOOL ····························································· 2-3

TORQUE VALUES ········································2-2

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SERVICE INFORMATION
MAINTENANCE STANDARDS
SERVICE INFORMATION

Unit: mm (in)
Part Item Standard Service limit
Engine Maximum speed GX160T2 3,900 ± 100 min-1 (rpm) –
(at no load) GX200T2 3,850 ± 150 min-1 (rpm) –
Idle speed + 200
1,400 min-1 (rpm) –
– 150
Cylinder GX160T2 0.49 – 0.69 MPa (5.0 – 7.0 kgf/cm2,
compression –
71 – 100 psi)/600 min-1 (rpm)
GX200T2 0.35 MPa (3.6 kgf/cm2,51 psi)/
–
600 min-1 (rpm)
Cylinder Camshaft journal I.D.
14.000 – 14.018 (0.5512 – 0.5519) 14.048 (0.5531)
barrel
Camshaft Cam height GX160T2 IN 27.500 – 27.900 (1.0827 – 1.0984) 27.450 (1.0807)
EX 27.546 – 27.946 (1.0845 – 1.1002) 27.500 (1.0827)
GX200T2 IN 27.500 – 27.900 (1.0827 – 1.0984) 27.450 (1.0807)
EX 27.547 – 27.947 (1.0845 – 1.1003) 27.500 (1.0827)
Camshaft O.D. 13.966 – 13.984 (0.5498 – 0.5506) 13.916 (0.5479)
Crankshaft Crankpin O.D. 29.970 – 29.980 (1.1799 – 1.1803) 29.92 (1.178)
Runout – 0.10 (0.004)
Valves Valve clearance GX160T2 IN 0.08 ± 0.02 (0.003 ± 0.001) –
EX 0.10 ± 0.02 (0.004 ± 0.001) –
GX200T2 IN 0.15 ± 0.02 (0.006 ± 0.001) –
EX 0.20 ± 0.02 (0.008 ± 0.001) –
Carburetor Main jet GX160T2 #68 –
GX200T2 #75 –
Pilot screw GX160T2 CHB3 2-1/2 turns out –
opening GX200T2 CACK
CAC1
CHBR
CW2 2-1/4 turns out –
CW
DHBR
DHB3
CHK
CHB2 1-7/8 turns out –
DHB2
Float height 13.7 (0.54) –

TORQUE VALUES
Torque values
Item Tread Dia. (mm)
N·m kgf·m lbf·ft
Crankcase cover bolt M8 x 1.25 24 2.4 18
Connecting rod bolt GX160T2 M6 x 1.0 9.8 1.0 7
GX200T2 M7 x 1.0 12 1.2 9
Rocker arm pivot lock nut M6 x 0.5 (Special nut) 10 1.0 7
Air cleaner elbow nut M6 x 1.0 9 0.9 6.6
Recoil starter center screw M6 x 1.0 (Special bolt) 5.4 0.6 4.0

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SERVICE INFORMATION
TOOL
Bearing remover shaft set, 25 mm
07936-ZV10100

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3. MAINTENANCE

VALVE CLEARANCE CHECK/

ADJUSTMENT···············································3-2

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MAINTENANCE
VALVE CLEARANCE CHECK/
MAINTENANCE

ADJUSTMENT

Inspect and adjust the valve clearance while the engine

is cold.
CHECK
Disconnect the spark plug cap [1] and remove the
[4] [1] [2]
following:
– Breather tube [2]
– Head cover bolt (6 x 12 mm) [3] (4)
– Head cover [4]
– Head cover packing [5]

[3] [5]

Set the piston near top dead center of the cylinder

[1] [3]
compression stroke (both valves fully closed) by pulling
the recoil starter slowly. When the piston is near top
dead center of the compression stroke, the triangle
mark [1] on the starter pulley [2] will align with the top
hole [3] on the recoil starter case [4]. Pull slowly.

If the exhaust valve is open, use the recoil starter to turn

the crankshaft one additional turn and align the triangle
mark with the top hole again.

[4] [2]
Insert a feeler gauge [1] between the valve rocker arm
[2] and valve stem [3] to measure the valve clearance. [1] [3] [2]

VALVE CLEARANCE:
GX160T2:
IN: 0.08 ± 0.02 mm (0.003 ± 0.001 in)
EX: 0.10 ± 0.02 mm (0.004 ± 0.001 in)
GX200T2:
IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in)
EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in)
If adjustment is necessary, proceed as follows.

[2]

[3]

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MAINTENANCE
ADJUSTMENT
Hold the rocker arm pivot [1] and loosen the pivot lock
[3] [1]
nut [2].
Insert a feeler gauge [3] between the valve rocker arm
and the valve stem.
Adjust by turning the rocker arm pivot until there is a
slight drag on the feeler gauge.
VALVE CLEARANCE:
GX160T2:
IN: 0.08 ± 0.02 mm (0.003 ± 0.001 in)
EX: 0.10 ± 0.02 mm (0.004 ± 0.001 in)
GX200T2:
IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in)
EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in) [2]
[1]
Hold the rocker arm pivot and retighten the pivot lock
nut to the specified torque. [2]

TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

Recheck the valve clearance, and if necessary, readjust
the clearance.
Replace the head cover packing with a new one and
install the removed parts in the reverse order of
removal.

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10. STARTING SYSTEM

RECOIL STARTER RECOIL STARTER

REMOVAL/INSTALLATION························10-2 DISASSEMBLY/ASSEMBLY ······················ 10-3

10

10-1
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STARTING SYSTEM
RECOIL STARTER
STARTING SYSTEM

REMOVAL/INSTALLATION

RECOIL STARTER

RECOIL MOUNT SPACER

BOLT (6 x 18 mm) (3)

10-2
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STARTING SYSTEM
RECOIL STARTER
DISASSEMBLY/ASSEMBLY

• Wear gloves and eye protection.

• During disassembly/assembly, take care not to
allow the spring to come out.

DISASSEMBLY
Remove the recoil starter (page 10-2).

RECOIL STARTER CENTER SCREW

5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
RATCHET GUIDE

FRICTION SPRING
FRICTION PLATE

STARTER RATCHET (2)

RETURN SPRING (2)

RECOIL STARTER ROPE

RECOIL STARTER REEL

REINFORCEMENT GRIP

RECOIL STARTER SPRING

RECOIL STARTER KNOB

RECOIL STARTER CASE

10-3
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14. CRANKCASE

TOOL ···························································14-2 CYLINDER BARREL/CRANKSHAFT/

CAMSHAFT INSPECTION·························· 14-6
CRANKCASE COVER
REMOVAL/INSTALLATION························14-3 CAMSHAFT BEARING/OIL SEAL
REPLACEMENT ········································· 14-7
CRANKSHAFT/CAMSHAFT/PISTON
REMOVAL/INSTALLATION························14-4 CRANKSHAFT BEARING
REPLACEMENT ········································· 14-8
PISTON DISASSEMBLY/ASSEMBLY········14-5

14

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CRANKCASE
TOOL
CRANKCASE

Bearing remover shaft set, 25 mm

07936-ZV10100

14-2
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CRANKCASE
CRANKCASE COVER
REMOVAL/INSTALLATION
Drain the engine oil (base shop manual : page 3-4).

BEARING (6205)

KEY

OIL FILLER CAP

OIL FILLER CAP

PACKING
DOWEL PIN (2) CHECK:
Replace if necessary.

OIL FILLER CAP

(With oil level gauge)

OIL SEAL
(Lips)
OIL FILLER CAP PACKING
CHECK:
Replace if necessary.
CRANKCASE COVER BOLT (8 x 32 mm) (6)
24 N·m (2.4 kgf·m, 18 lbf·ft)

CRANKCASE COVER
INSTALLATION:
Be careful not to damage the oil seal lips.
Clean the mating surface and apply a bead (2.0 – 2.5 mm (0.08 – 0.10 in))
of liquid sealant (Threebond® 1207B or equivalent) as shown.
Install the cover within 3 minutes after application. Pouring the engine oil is
performed after 30 minutes have elapsed from assembling.

GX160T2 GX200T2

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CRANKCASE
CRANKSHAFT/CAMSHAFT/PISTON
REMOVAL/INSTALLATION
Remove the following:
– Fuel tank (base shop manual : page 6-3).
– Flywheel (base shop manual : page 8-2).
– Cylinder head (base shop manual : page 13-3).
– Crankcase cover (page 14-3).

PISTON
(Outer surface and big end bearing)
INSTALLATION: [1]
CYLINDER BARREL
Install with the mark [1]
(Cylinder inner surface)
on the piston head
INSPECTION: page 14-6 toward away from the
(base shop manual : page 14-7) push rod hole [2]. [2]

OIL SEAL
(Lips)
VALVE LIFTER
(Pivot, pivot end and slipper surface)
REMOVAL:
Mark the valve lifters so that the
intake and exhaust sides can be
distinguished.
INSTALLATION:
Attach the valve lifters to the
cylinder barrel immediately before
installing the camshaft.
THRUST WASHER

CRANKSHAFT
BEARING (6205)
CONNECTING ROD LOWER
(Big end bearing)
INSTALLATION:
Set the connecting rod CAMSHAFT
lower with the oil dipper (Cam profile and journal)
toward the camshaft. INSPECTION: page 14-6
INSTALLATION:
Install the timing gear [1] of the
crankshaft and camshaft [2] by
aligning the punch marks [3].

[3]
CONNECTING ROD BOLT (2)
CRANKSHAFT
(Threads and seating surface)
(Pin and gear teeth)
GX160T2: (6 x 34 mm)
9.8 N·m (1.0 kgf·m, 7 lbf·ft) INSPECTION: page 14-6
INSTALLATION: [1]
GX200T2: (7 x 34 mm) Be careful not to damage the oil seal lips. [2]
12 N·m (1.2 kgf·m, 9 lbf·ft)

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CRANKCASE
PISTON DISASSEMBLY/ASSEMBLY
Remove the piston (page 14-4).

MAKER MARK
PISTON RING SET (Entire surface)
INSPECTION: (base shop manual : page 14-7) TOP RING
INSTALLATION:
To install the oil ring, install the spacer [1] first,
and then install the side rails [2].
Be sure that the top ring [3] and second ring [4]
are not interchanged.
Install the top ring and second ring on the piston
with the maker mark side facing up.
Check that the piston rings rotate smoothly after 120° SECOND RING
installing them. 120°
Space the piston ring end gaps 120° apart, and 120°
do not align the ring end gaps with the piston pin
bore. SIDE RAIL

[3]

OIL RING
[4] 10 mm (0.4 in)
(COMBINATION RING)

[2]

10 mm (0.4 in) SPACER

[1]

[2] MARK
SIDE RAIL
PISTON PIN
(Outer surface)
INSPECTION:
(base shop manual : page 14-7)

PISTON
(Ring groove and piston pin hole)
INSPECTION:
(base shop manual : page 14-7)

PISTON PIN CLIP (2)

INSTALLATION:
Install by setting one end of the piston pin
clip in the groove of the piston pin bore,
holding the other end with long needle pliers,
and rotating the clip in.
Do not align the end gap [1] of the piston pin
clip with the cutout [2] of the piston pin bore.

[1] CONNECTING ROD UPPER

(Small end bearing)
INSPECTION:
(base shop manual : page 14-7)
LONG END INSTALLATION:
Set the connecting rod upper with
the long end toward away from the
mark on the piston head.

[2]

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CRANKCASE
CYLINDER BARREL/CRANKSHAFT/
CAMSHAFT INSPECTION
CYLINDER BARREL
CAMSHAFT JOURNAL I.D.
Measure the camshaft journal I.D. of the cylinder barrel
assembly.
STANDARD: 14.000 – 14.018 mm (0.5512 – 0.5519 in)

SERVICE LIMIT: 14.048 mm (0.5531 in)

If the measurement is more than the service limit,
replace the cylinder barrel.
Inspect the camshaft O.D. (page 14-6).

CAMSHAFT
CAMSHAFT O.D. [1]
Measure the O.D. of the camshaft.

STANDARD: 13.966 – 13.984 mm (0.5498 – 0.5506 in)

SERVICE LIMIT: 13.916 mm (0.5479 in)

If the measurement is less than the service limit,
replace the camshaft.
CAM HEIGHT [2] [1]
Measure the cam height of the camshaft.
GX160T2:
STANDARD:
IN: 27.500 – 27.900 mm (1.0827 – 1.0984 in)
EX: 27.546 – 27.946 mm (1.0845 – 1.1002 in)
SERVICE LIMIT:
IN: 27.450 mm (1.0807 in)
EX: 27.500 mm (1.0827 in)

GX200T2:
STANDARD:
IN: 27.500 – 27.900 mm (1.0827 – 1.0984 in)
EX: 27.547 – 27.947 mm (1.0845 – 1.1003 in) [2]
SERVICE LIMIT:
IN: 27.450 mm (1.0807 in)
EX: 27.500 mm (1.0827 in)
If the measurement is less than the service limit,
replace the camshaft.

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CRANKCASE
CRANKSHAFT
RUNOUT [1]
Set the crankshaft on V-blocks and measure the runout
[1]
using a dial indicator.
[2]
SERVICE LIMIT: 0.10 mm (0.004 in)
If the measured runout is more than the service limit,
replace the crankshaft.
CRANKPIN O.D. [2]
Measure the crankpin O.D. of the crankshaft.
STANDARD: 29.970 – 29.980 mm (1.1799 – 1.1803 in)

SERVICE LIMIT: 29.92 mm (1.178 in)

If the measurement is less than the service limit, A B C D
replace the crankshaft.
A: 14.8 mm (0.58 in)
B: 14.0 mm (0.55 in)
C: 25.0 mm (0.98 in)
D: 20.0 mm (0.79 in)

CAMSHAFT BEARING/OIL SEAL

REPLACEMENT
CAMSHAFT BEARING (6205)
Remove the oil seal and drive out the camshaft bearing.
[4]
Drive a new camshaft bearing [1] until it is fully seated
on the end using the special tools.
TOOLS:
Bearing driver attachment,
52 x 55 mm [2] 07746-0010400 [1]
Pilot, 25 mm [3] 07746-0040600
Driver handle [4] 07749-0010000 [2]

[3]

CAMSHAFT OIL SEAL

Remove the oil seal.
[4]
Drive a new oil seal [1] in the position as shown using
the special tools.
INSTALLATION HEIGHT [2]: 1.3– 1.8 mm
(0.05 – 0.07 in) [1]
[3]
TOOLS:
Bearing driver attachment,
40 x 42 mm [3] 07746-0010900 [2]
Driver handle [4] 07749-0010000

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CRANKCASE
CRANKSHAFT BEARING
REPLACEMENT
CRANKSHAFT BEARING (6205)
Pull out the crankshaft bearing [1] using special tools.

TOOLS:
[3]
Bearing remover shaft set,
25 mm [2] 07936-ZV10100
Sliding hammer weight [3] 07741-0010201
Drive a new crankshaft bearing [4] until it is fully seated
on the end using the special tools. [2]

TOOLS:
Bearing driver attachment,
52 x 55 mm [5] 07746-0010400 [1]
Pilot, 25 mm [6] 07746-0040600
Driver handle [7] 07749-0010000

[7]

[4]
[5]

[6]

14-8
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INDEX
CAMSHAFT BEARING/OIL SEAL REPLACEMENT ····14-7 P.T.O. DIMENSIONAL DRAWINGS······························· 1-8
C P

CRANKCASE COVER REMOVAL/INSTALLATION·····14-3 PERFORMANCE CURVES············································ 1-5

CRANKSHAFT BEARING REPLACEMENT·················14-8 PISTON DISASSEMBLY/ASSEMBLY·························· 14-5
CRANKSHAFT/CAMSHAFT/PISTON REMOVAL/ RECOIL STARTER DISASSEMBLY/ASSEMBLY········ 10-3
R

INSTALLATION·····························································14-4 RECOIL STARTER REMOVAL/INSTALLATION ········· 10-2

CYLINDER BARREL/CRANKSHAFT/CAMSHAFT TOOL
T

INSPECTION ································································14-6 CRANKCASE··························································· 14-2

DIMENSIONAL DRAWINGS···········································1-7 SERVICE INFORMATION ········································· 2-3
D

DIMENSIONS AND WEIGHTS SPECIFICATIONS ········1-2 TORQUE VALUES ························································· 2-2

ENGINE SPECIFICATIONS ···········································1-3 VALVE CLEARANCE CHECK/ADJUSTMENT ·············· 3-2
E V

MAINTENANCE STANDARDS·······································2-2
M

15

15-1