Powerfist 208cc Disassembly Instructions

Transportation Technology: TTJ1O
Module: PowerFist Engine (Honda Clone GF168)
Student Name:
Student Number:
6.5HP OHV PowerFist Engine

Disassembly
Model:
Type:
Number:
Information Sheet:
Use this diagram below for reference during the disassembly of the bottom
end of your engine.
1. Mount the engine securely on the test board.
2. Drain the crankcase into a suitable container.

Once the oil is drained, secure the oil filler cap.
3. Confirm the fuel tank is empty and has no gasoline in it.
Leave the fuel strainer (8) in the tank to prevent any debris from getting in the
tank.
4. Remove the air filter assembly. Remove

the 2 wing nuts. If there is only 1 wing
nut, remove it and the air filter.
2 wing nuts M6x1.0mm
STOP!
Have your teacher inspect your work
Teachers Initials:
5. Remove the 2x Philips screws holding down the lower air filter assembly
6. There should be a clamp (11) on the fuel line pinch the clamp and shimmy it
down the fuel line. Remove the 2 nuts (9) and 1 bolt (7) that hold down the fuel
tank.
7. Remove the fuel line strap.1x 8mm bolt. Remove
the fuel tank on top of the engine (3). Disconnect
the fuel line (10) from the carburetor to the fuel tank.
A pair of needle nose pliers will make disconnecting
the fuel line to the tank easier.
2 nuts M6x10mm
1 bolt M6x10x30mm
1 clamp
8. Remove the muffler shield.
4x 8mm bolts
Then remove the two nuts that hold the

exhaust pipe onto the engine.
There should be a gasket between the

muffler and the engine. If the gasket is
damaged it should be replaced.
2 nuts M8x1.25mm
1 gasket
STOP!
Teachers Initials:
9. Remove the 2x 10mm nuts holding the intake plenum on.
Be cautious as the 2 10mm nuts hold the carburetor as

well, when pulling the shield off the carburetor will want to
come off with it.
10. Remove the governor control lever unit (6),

the governor control rod (7), the governor
control spring (5) and the governor control arm (4).
Note where the spring and rod are located on the 6
governor control arm.
Note do not take apart (20), (28) and (4).
1
2
11. Remove the carburetor (4) and carburetor gasket (3). Check the orientation
of the insulator (2) with respect to the fuel hose and the spark plug wire then
remove it. Remove the insulator gasket (1) and set everything aside.
Note: use the image above for the orientation of the carburetor.
12. Disconnect the ignition lead from the armature to the spark plug set ignition
wiring to the side it will be removed with the armature later.
13. Remove the spark plug from the cylinder head with a 13/16” spark plug
socket.
Remove any carbon or other deposits with a stiff wire brush.
STOP!
Teachers Initials:
14. Remove the 3 bolts holding the recoil starter.
Do not take apart the recoil starter.
3x 8mm bolts
15. Disconnect the On/Off switch and crank position

sensor wiring located on the side of the fan shroud
and engine block.
Take a Picture of the connections and wire
orientation.
Remove the ground strap as well at this point.

1x8mm bolt
16. Remove the flywheel/fan cover on the engine.

Take note that the longer bolt has been removed
from the lower right-hand side of the cover.
3 bolts 8mm M6x1.0x12mm

1 bolt 8mm M6x1.0x20mm
STOP!
Teachers Initials:
17. Remove the two smaller shrouds from the bottom side of the engine.
3x 8mm bolts
18. Remove the ignition coil and lead.
2 bolts M6x1.0x20mm
19. Remove the flywheel (3), cooling

fan (2), and starter pulley (4) from
the crankshaft. Note the location
of the woodruff key (1). Note the
alignment of the 4 lugs on the rear
side of the cooling fan with the
small holes on the flywheel and
the alignment of the lug on the
starter pulley with the small hole at
the center of the flywheel.
3
1 nut 21mm
Note if the flywheel does not

come off by pulling on it by
hand consult the teacher for
further instructions.
STOP!
Teachers Initials:
20. Remove the valve cover and gasket.
4x 8mm bolts
21. Using a piece of cardboard or paper (cardboard works best) draw the
cylinder head and its parts exactly how you see it from a birds eye view with
the cover off, this will help you in the assembly phase to put each part back
where it came from.
22. Measure Valve clearance at the rocker arms with a feeler gauge
23. Remove the nuts (16) holding the

rocker arms down, pull the
spacers (6) off and remove the
rocker arms (4).
Remove the rocker arm pivot bolts (15).

Once the pivot bolts are removed the
push rod guide (14) and push rods (3)
will be loose remove them and push
them into your cardboard layout so they
may go back in the same locations.
24. Remove the 4 12mm bolts (13) holding the cylinder

head onto the engine block. When lifting the
cylinder head off the engine block take note of the
orientation of the head gasket (5) and both dowels
(12). Note the dowels may stick in the cylinder head
or/and the engine block remove them and set them
carefully aside.
STOP!
Teachers Initials:
25. Remove the crankcase cover and gasket (3)

by removing the 6 10mm bolts (10). Be careful
not tear or rip the gasket.
6 bolts M6x1.0x28mm
Note the gasket may be silicone, rubber, or

cork, if there is a silicone gasket present you
must clean the crankcase cover mounting
surface and use appropriate RTV silicone
when reassembling it.
Crankshaft Camshaft
26. After removing the crankcase cover you will
see 2 gears one metal (crankshaft gear) and
one plastic (camshaft gear/valve lifter). Note
the crankshaft gear is half the size of the
camshaft gear.
Look at the face of both gears to find the
timing marks indicated by 1 dot on each gear,
this will be important during the reassembly
phase.
Pull the camshaft towards you it should easily
become free.
27. Remove the valve lifters (5) from the crankcase.
STOP
Have your teacher inspect your work.
Teacher’s Initials: __________

28. Take chalk or whiteout and mark the connecting rod and connecting rod cap
with a line, this will help in the reassembly phase. Remove the connecting
rod cap from the connecting rod by removing the 2 bolts. The marks on the
connecting rod and connecting rod cap should be aligned.
29. Push up on the connecting rod and remove

the piston from the cylinder.
30. Here is an exploded view of the piston and

its components.
31. Remove the crankshaft from

the crankcase carefully to
ensure you do not damage
the bearing or the crankshaft.
STOP you have completely disassembled the engine.
Have your teacher inspect your work.
Teacher’s Initials: __________

Use this page for any drawings or notes you may require through disassembly.

Powerfist 208cc Disassembly Instructions

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Transportation Technology: TTJ1O

Module: PowerFist Engine (Honda Clone GF168)

6.5HP OHV PowerFist Engine

1. Mount the engine securely on the test board.

2. Drain the crankcase into a suitable container.

3. Confirm the fuel tank is empty and has no gasoline in it.

4. Remove the air filter assembly. Remove

8. Remove the muffler shield.

Then remove the two nuts that hold the

There should be a gasket between the

9. Remove the 2x 10mm nuts holding the intake plenum on.

Be cautious as the 2 10mm nuts hold the carburetor as

10. Remove the governor control lever unit (6),

14. Remove the 3 bolts holding the recoil starter.

Do not take apart the recoil starter.

15. Disconnect the On/Off switch and crank position

Remove the ground strap as well at this point.

16. Remove the flywheel/fan cover on the engine.

3 bolts 8mm M6x1.0x12mm

18. Remove the ignition coil and lead.

19. Remove the flywheel (3), cooling

Note if the flywheel does not

20. Remove the valve cover and gasket.

23. Remove the nuts (16) holding the

Remove the rocker arm pivot bolts (15).

24. Remove the 4 12mm bolts (13) holding the cylinder

25. Remove the crankcase cover and gasket (3)

Note the gasket may be silicone, rubber, or

27. Remove the valve lifters (5) from the crankcase.

Teacher’s Initials: __________

29. Push up on the connecting rod and remove

30. Here is an exploded view of the piston and

31. Remove the crankshaft from

STOP you have completely disassembled the engine.

Have your teacher inspect your work.

Teacher’s Initials: __________

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