GCV530- ・

GCV530 GXV530 Engine Assembly

GXV530 AssemblyInformation
Information

PISTON CYLINDER/PISTON ASSEMBLY

TOP RING MAKER MARK PISTON RINGS THRUST WASHER TIMING BELT (2) Identification of AL cylinder type and FC sleeve
REASSEMBLY: ["N" mark] REASSEMBLY: Specified belts: cylinder type:
UP
Chrome plated. ・Install with the mark facing upward 93HU8 G-200 <Cylinder>
Do not interchange as shown. INSTALLATION: AL cylinder:
CRANKSHAFT IDENTIFICATION MARK
with second ring. ・Do not interchange the top ring and Check that the belt is not worn or cracked ・"Z0A0" is stamped at the
the second ring. INSTALLATION: and do not bend or twist the belt.
・Be careful not to damage the illustrated position of the
MAKER MARK ・After assembly, check for smooth cylinder for identification.
["T" mark] movement of the piston ring. oil seal.
・Stagger the piston ring end gaps ・After installation, clean the No. 1 CYLINDER
SECOND RING crankshaft tapered surface. FC sleeve cylinder:
120° apart. Do not align with the ASSEMBLY
6 x 30 mm (2) ・"Z0A8" is stamped at the
OIL RING piston pin. 12 N·m (1.2 kgf·m, illustrated position of the
TOP RING
REASSEMBLY: (CHROME 6207 9 lbf·ft) cylinder for identification.
Space the side rail PLATED) RADIAL BALL
20 mm (0.8 in)
end gaps at least 20 mm (0.8 in) BEARING <Piston>
SECOND RING
20 mm (0.8 in) apart. AL cylinder:
PISTON
Coat the oil ring with CONNECTING ROD 8 mm FLANGE ・There is not ID mark
PIN SIDE
oil after assembly. OIL BOLT (4) NUT (8) stamped on the piston
RAIL
RING 12 N·m (1.2 kgf·m, 32 N·m (3.3 kgf·m, head.
SPACER
9 lbf·ft) 24 lbf·ft)
" FW" MARK FC sleeve cylinder:
No. 1 PISTON ・"Z0A80" is stamped on IDENTIFICATION MARK
PISTON PIN CLIP (2)
ASSEMBLY the piston head for
REASSEMBLY:
CONNECTING ROD CAP (2) No. 2 CYLINDER identification.
Set one end of the clip into the
PISTON ASSEMBLY
groove in the piston and work the INSTALLATION:

Printed In Belgium  -  Published by: Honda Motor Europe Logistics NV -  Specifications can be changed without notice  -  Edition: 8309 Sept. 2017
Identification of No. 1 cylinder side and No. 2
other end around in the groove Do not interchange with the
CONNECTING ROD cylinder side:
using a pair of needle nosed pliers. other connecting rod cap.
Install so that the end gap does not No. 1 CYLINDER No. 2 CYLINDER
CONNECTING ROD face the notch in the piston.
CRANKCASE SIDE SIDE
CAP
END GAP 8 x 14 mm
52 x 35 x 8 mm DOWEL PIN (4)
OIL SEAL
CONNECTING ROD BOLT (2) NOTCH
12 N·m (1.2 kgf·m, 9 lbf·ft) No. 2 PISTON CRANKSHAFT
(Apply grease to the lips) ASSEMBLY

CYLINDER/PISTON ASSEMBLY
Assembly of No. 1 piston assembly and cylinder: Assembly of No. 2 piston assembly and cylinder: Installation of No. 1 (No. 2) cylinder/piston assembly:
No. 1 AND No. 2 CYLINDER: No. 1 PISTON ASSEMBLY:
No. 1 CYLINDER CONNECTING No. 2 CYLINDER ・Clean the mating surfaces of the crankcase and No. 1 (No. 2)
ROD LONG END cylinder using a degreasing cleaning agent or a clean shop Liquid gasket application CONNECTING CONNECTING
area ROD CAP ROD LONG END
See the shop manual for additional information. © Honda Motor Co., Ltd. 2009

towel.
" FW" " FW"
・Apply a bead [Ø 1.2 mm (0.05 in)] of liquid gasket (ThreeBond
MARK ALIGNMENT MARK
#1207B, Honda Bond #4 or equivalent) to the No. 1 (No. 2)
MARKS (On cylinder; specifically, to the mating surface with the crankcase.
the back side) ・Take care not to put the liquid gasket on the sleeve of the No. 1
(No. 2) cylinder. Do not apply excessive amount of the liquid
gasket to the threaded hole for the 6 x 30 mm flange blot.
・Assemble within 10 minutes after applying the liquid gasket.
PISTON RING No. 2 PISTON
PISTON RING NOTICE:
COMPRESSOR ASSEMBLY
COMPRESSOR Take care not to damage the inner wall of the cylinder and crank 6 x 30
(Commercially
(Commercially CONNECTING pin with the connecting rod big end. CONNECTING
available)
available) ROD CAP ・Apply oil to the threaded part and seat of the 8 mm flange nuts No. 1 CYLINDER/ ROD BOLT (2)
and 6 x 30 mm flange bolt. Loosely tighten the nuts and flange PISTON 12 N·m (1.2 kgf·m,
" FW"
bolt against the cylinder. ASSEMBLY 9 lbf·ft)
MARK ALIGNMENT MARKS
CONNECTING ・Apply oil to the threaded part and seat of the connecting rod (On the back side)
No. 1 PISTON ROD LONG END bolts. Tighten the connecting rod bolts to the specified torque.
ASSEMBLY
・After tightening the connecting rod bolts, tighten the four 8 mm
Set the piston so that the piston ALIGNMENT MARKS flange nuts and the 6 x 30 mm flange bolt in several steps to
CONNECTING ROD CAP 8 mm FLANGE
end is out from the sleeve end by (On your side) the specified torque. NUT (4)
approximately 10 mm (0.4 in) as CONNECTING 8 x 14 mm 32 N·m (3.3 kgf·m,
CONNECTING ROD BOLT (2) 10 mm (0.4 in)
shown. DOWEL PIN (2)
ROD BOLT (2) 24 lbf·ft)

See the shop manual for additional information. © Honda Motor Co., Ltd. 2011
www.honda-engines-eu.com
 GCV530- ・
GCV530 GXV530 Engine
GXV530 Engine Assembly
AssemblyInformation
Information

CYLINDER/PISTON ASSEMBLY CYLINDER/VALVES CAM PULLEY

Installation of No. 1 (No. 2) cylinder/piston assembly: INTAKE VALVE
8 x 14 mm DOWEL PIN (2) 6 x 12 (8)
・Set the two timing belts on the timing belt drive pulley so that the REASSEMBLY:
HEAD COVER (2)
6 x 30 "HONDA" logo on each timing belt is upside down as shown. Do not interchange with the exhaust valve. ROCKER ARM SHAFT (4)
・Pass the lower belt on the timing belt drive pulley in the No. 1 VALVE HEAD DIAMETER
cylinder, and pass the upper belt on the pulley in the No. 2 IN: 30 mm (1.2 in) EX: 26 mm (1.0 in)
cylinder. EXHAUST
・Set the thrust washer on the crankshaft as shown. CYLINDER ROCKER
・After installing the No. 1/No. 2 piston/cylinder, install the ARM (2)
respective cam pulleys.
VALVE STEM SEAL
8 mm FLANGE NUT (4) No. 2 CYLINDER/ [Intake valve only] EXHAUST VALVE
No. 1 CYLINDER (Not used for VALVE
32 N·m (3.3 kgf·m, PISTON THRUST REASSEMBLY:
24 lbf·ft) ASSEMBLY GCV530U/R) Before installation, ADJUSTING
WASHER LOCK NUT (4)
remove carbon
TIMING No. 2 CYLINDER 7.5 N·m
deposits and inspect
No. 2 PISTON ASSEMBLY: BELTS (0.75 kgf·m,
the valve.
ALIGNMENT MARKS (On your side) 5.4 lbf·ft)
CONNECTING VALVE VALVE GUIDE
ROD CAP SPRING (2)
SPARK PLUG
Standard spark plug: 6.8 x 1.9 mm
VALVE
BPR5ES (NGK) O-RING (2)
ADJUSTING
VALVE SPRING RETAINER (2) W16EPR-U (DENSO) SCREW (4) Do not reuse.
THRUST DISASSEMBLY:
No. 2 SIDE
WASHER Push down and slide the retainer to the side, so the valve CAM PULLEY (2)
TIMING BELT CAM PULLEY

Printed In Belgium  -  Published by: Honda Motor Europe Logistics NV -  Specifications can be changed without notice  -  Edition: 8309 Sept. 2017
stem slips through the hole at the side of the retainer.
No. 1 SIDE INSTALLATION: SHAFT (2)
CONNECTING CONNECTING NOTICE: INTAKE ROCKER
TIMING BELT Take care not to drop the can pulley.
ROD BOLT (2) ROD LONG END "HONDA" Do not remove the valve spring retainer while the piston is ARM (2)
12 N·m (1.2 kgf·m, 9 lbf·ft) LOGOS installed, or the valves will drop into the cylinder.

OIL PUMP [Equipped type only]

CAM PULLEY : Type without oil pump only GOVERNOR
[*1]: SHAFT ASSEMBLY
Installation of cam pulley/rocker arm shaft: [*1]: Oil pump equipped type [*1]: 7.7 x 2.5 mm INSTALLATION:
OIL PUMP O-RING (2)
<No. 1 cylinder> No. 1 [*1]: OIL PUMP BODY ASSEMBLY Install the governor
PIPE
1) Set the engine upright (i.e. with the carburetor toward up). 3 IGNITION 7 INSTALLATION: Do not reuse. shaft assembly by
2) Remove the spark plugs. COIL STUD CAM PULLEY 1) Apply oil to the inside of the oil pump aligning the two
3) Rotate the flywheel clockwise until the "T" mark on the cooling fan aligns with BOLT SHAFT body and inner rotor and outer rotor. [*1]: 6 x 14 (2) alignment pins on the
center of the stud bolt of the No. 1 ignition coil. (This alignment point is the 2) Install the outer rotor on the body. reverse side of the
CENTER 6 x 28 (2)
top dead center of the No. 1 cylinder.) 3) Install the oil pump plate on the oil governor shaft
4) Set the timing belt on the cam pulley from the flange side of the cam pulley. 6.8 x 1.9 mm pump body. assembly with
O-RING alignment holes in
See the shop manual for additional information. © Honda Motor Co., Ltd. 2009

5) Align the alignment marks on the cam pulley so that they are in line with the 4) Install the oil pump body assembly
head cover mating surface. The top dead center of the compression stroke "T" MARK by aligning the two alignment pins the oil pan.
6 mm
is in the position where the head cover mating surface is in line with the cam on the reverse side of the pump
<No. 2 cylinder top "T" MARK WASHER GOVERNOR
pulley alignment marks. Be careful to avoid turning the crankshaft when 4 cover with the alignment holes in
GOVERNOR HOLDER CLIP
installing. dead center position the oil pan.
6) Apply oil to the 6.8 x 1.9 mm O-ring and install it on the cam pulley shaft. of the compression 5) After installation, check for smooth WEIGHT HOLDER INSTALLATION:
7) Install the cam pulley shaft in the cylinder. TIMING stroke> PINS
BELT
rotation of the oil pump. 6 x 16 WASHER Insert firmly into
8) Holding the cam pulley alignment marks in line with the head cover mating the shaft groove.
surface, check again where the piston is at top dead center of the No. 2 IGNITION [*1]: OUTER ROTOR
GOVERNOR
compression stroke. FLANGE COIL STUD INSTALLATION: Clean GOVERNOR
[*1]: SLIDER
9) If the alignment marks and the head cover mating surface are out of BOLT CENTER 270° the rotor thoroughly. ARM A
alignment or if the piston is not at top dead center of the compression
CAM PULLEY 6 x 20
GOVERNOR FORK
stroke, repeat the procedure from the step 3. ALIGNMENT MARKS ROCKER ARM SHAFTS [*1]: OIL PUMP PLATE
<No. 2 cylinder> 5 5 x 8 mm SCREW (2)
Rotate the crankshaft 270° to put the No. 2 cylinder at top dead center of its TIMING 31 x 50 x 8 mm OIL SEAL 5.5 N·m (0.55 kgf·m, 4.0 lbf·ft)
compression stroke. BELT INSTALLATION: 10 x 16 x 4.5 mm OIL SEAL
Be sure that the No. 2 cylinder is at top dead center of the compression stroke. ・Do not reuse. INSTALLATION:
Repeat the operation of the step 4 through step 9 explained above at the ・Apply oil to the outer surface ・Do not reuse.
No. 2 cylinder, and install the cam pulley. VIEW FROM and install the oil seal. After ・Apply oil to the outer surface and
<Rocker arm shaft> PTO SIDE: CAM installation, apply grease to install the oil seal. After installation,
OIL PAN
Install the rocker arm shaft from the opposite side of the cam pulley as shown. HEAD COVER MATING SURFACE PULLEY the lip. apply grease to the lip.

See the shop manual for additional information. © Honda Motor Co., Ltd. 2011
www.honda-engines-eu.com
 GCV530- ・
GCV530 GXV530 Engine Assembly
GXV530 AssemblyInformation
Information

GOVERNOR OIL PAN ASSEMBLY

Installation of governor weght holder/clip/ 8 x 40 (7) 20 mm DRAIN BOLT WASHER Installation of oil pan:
governor slider: GOVERNOR 24 N·m (2.4 kgf·m, OIL PAN [Equipped type only] Check that the thrust washer is set on the crankshaft properly.
1) Apply oil to the governor holder shaft and install HOLDER SHAFT 17 lbf·ft) ASSEMBLY 1) Install the cam pulley on the timing belt of the No. 1/No. 2 cylinder.
20 mm OIL DRAIN BOLT
the 6 mm washer and governor weight holder 2) Clean the mating surfaces of the crankcase and oil pan using a degreasing cleaning
[Equipped type only]
shaft. agent or a clean shop towel.
44 N·m (4.5 kgf·m, 33 lbf·ft)
2) Set the clip at the end of the governor holder 3) Set the two 8 x 14 mm dowel pins on the crankcase.
shaft. 4) Apply a bead [Ø 1.2 mm (0.05 in)] of liquid gasket (ThreeBond #1207B, Honda
OIL FILTER [Equipped type only]
3) Raise the governor weight holder toward the GOVERNOR Bond #4 or equivalent) to the oil pan; specifically, to the mating surface with the
clip. GOVERNOR WEIGHT REMOVAL/INSTALLATION: crankcase.
4) Holding the governor weight open, set the 6 x HOLDER CLIP HOLDER Remove/install the oil filter using Assemble within 10 minutes after applying the liquid gasket.
16 mm washer and governor slider on the the special tool. Before installation, 5) Apply grease to the 31 x 50 x 8 mm oil seal lip and set the oil pan on the crankshaft.
governor holder shaft. GOVERNOR 6 x 16 mm WASHER coat the rubber seal with engine 6) Apply oil to the oil pump pipe O-ring. Align the end of the oil pump pipe with the pipe
5) Check that the washer and slider are securely SLIDER oil and the threaded portion of installation hole in the crankcase (Oil pump equipped type only).
set in recesses in the governor weight. 8 x 14 mm the crankcase and oil filter. 7) Align the mating surfaces of the oil pan and crankcase securely by turning the
Push in the governor slider and set the clip DOWEL TORQUE: 12 N·m (1.2 kgf·m, crankshaft and tapping on the oil pan with the hand. Turn the crankshaft until the oil
securely in the groove in the governor holder PIN (2) 9 lbf·ft) pan and crankcase mate with each other securely.
shaft. GOVERNOR NOTICE:
OIL FILTER WRENCH Do not tighten the bolt without aligning the mating surfaces. It can damage the idle
6) After assembly, check that the governor weight GOVERNOR WEIGHT 07HAA-PJ70100 gear and/or timing belt drive pulley gear.
and governor slider operate smoothly. WEIGHT (3) HOLDER
8) Loosely tighten each 8 x 40 mm flange bolts, then tighten to the specified torque in
GOVERNOR SLIDER RECESSES GOVERNOR the numbered sequence.
WEIGHT TORQUE: 24 N·m (2.4 kgf·m, 17 lbf·ft)
9) Wait for approximately 20 minutes after assembly before filling oil and starting the
engine.

Printed In Belgium  -  Published by: Honda Motor Europe Logistics NV -  Specifications can be changed without notice  -  Edition: 8309 Sept. 2017
GROOVE
GOVERNOR HOLDER CLIP COOLING FAN/FLYWHEEL/IGNITION COILS
16 x 35 COOLING FAN SETTING PLATE Installation of cooling fan/flywheel:
OIL PAN ASSEMBLY STARTER PULLEY 157 N·m (16.0 kgf·m,
1) Clean the taper on the crankshaft
LUGS COOLING FAN
[Equipped type only] 116 lbf·ft) COOLING FAN and the tapered hole in the
NOTICE: flywheel, then install the flywheel. HOLES
4 8 When removing and installing, take NOTICE:
OIL PAN care not to damage the fan blades. The flywheel may push the key
⑥ No. 1 IGNITION COIL out of its slot; check after
STUD BOLT installation.
④ ① 12 N·m (1.2 kgf·m, 2) Attach by aligning the three lugs
9 lbf·ft) FLYWHEEL ALIGN FLYWHEEL
on the rear side of the fan with
No. 1 IGNITION
the small holes in the flywheel. PROJECTION COOLING
②
COIL [Right side]
See the shop manual for additional information. © Honda Motor Co., Ltd. 2009

No. 2 IGNITION COIL STUD BOLT 3) Align the three cutouts in the
6 x 28 12 N·m (1.2 kgf·m, 9 lbf·ft) FAN
Liquid
⑦ ⑤ ③
WIRE CLAMP cooling fan setting plate with the
gasket INSTALLATION: three projections on the cooling
application Install as shown. No. 2 IGNITION COIL [Left side] fan, and install the cooling fan
area setting plate with the projection
No. 2 SIDE ENGINE INSTALLATION:
on the cooling fan toward the
STOP DIODE WIRE Note that the No. 2 ignition coil
6 x 45 flywheel. Attach by aligning the
7 CRANKSHAF can be identified with the longer
ENGINE two lugs on the rear side of the COOLING
high tension cord, while the HOLE
STOP starter pulley with the small holes FAN SETTING
No. 1 ignition coil has the shorter
O-RING DIODE in the cooling fan cover PLATE PROJECTIONS
OIL PAN high tension cord.
HIGH SUB (Equipped type only).
4) Apply oil to the seat and the CUTOUTS
OIL PUMP PIPE TENSION WIRE
IDLE CORD HARNESS HIGH TENSION CORDS threaded part of the 16 x 35 mm
16 x 35
GEAR flange bolt.
OIL PUMP PIPE 6 x 12 INSPECTION:
INSTALLATION 5) Install the 16 x 35 mm flange bolt
WOODRUFF KEY Check for cracked or damaged
HOLE IDLE GEAR using a commercially available
INSTALLATION: insulation; replace if necessary.
TIMING BELT strap wrench.
DRIVE PULLEY After installing the flywheel, 6) Tighten to the specified torque.
GEAR check to be sure that the TORQUE: 157 N·m (16.0 kgf·m,
woodruff key is still in its slot 116 lbf·ft) STRAP WRENCH
IGNITION COLLAR (2)
CRANKCASE on the crankshaft. (Commercially available)
[No. 2 ignition coil side only]

See the shop manual for additional information. © Honda Motor Co., Ltd. 2011
www.honda-engines-eu.com