Hitachi CS 33ED User manual

PRODUCT NAME

Hitachi Engine Chain Saw

Models CS 33EDP

CS 33ED

International Sales Division

TROUBLESHOOTING GUIDE ----------------------------------------------------------------------------------------------- 1

1. Troubleshooting and correction ------------------------------------------------------------------------------- 1

REPAIR GUIDE ------------------------------------------------------------------------------------------------------------------ 3

1. Precautions on maintenance, inspection and repair ----------------------------------------------------- 3

2. Inspection criteria for each section and consumable parts --------------------------------------------- 3

CONTENTS

Page

LIST Nos.

CS 33EDP: F050

CS 33ED: F049

Mar. 2014

C

-1-

1. Troubleshooting and correction

Trouble Cause Corrective action

Starter

handle

cannot be

pulled.

The crank shaft does

not rotate.

Faulty piston ring

Disassemble and

replace.

Seized piston and cylinder

Faulty crank shaft bearings

Magneto rotor contact with ignition coil

The recoil starter

does not rotate.

Broken recoil starter

Inspect and replace.

Faulty starter pawl

Clogging of dirt in starter pawl Clean.

Startup is

impossible.

No compression

Faulty piston ring

Replace.

Worn piston

Worn cylinder

Short-circuited due to foreign matter between the spark plug

electrodes.

Remove foreign matter:

In case of frequent

occurrence, disassemble

and clean the engine.

No spark

Stop switch not at startup position Adjust to startup position.

Dirty or faulty spark plug

Clean or replace.

Improperly connected plug cap

Inspect and replace.

Disconnected or improperly connected

high voltage cord

Repair or replace.

Ground connection of high voltage

cord

Repair.

Disconnected or faulty ignition coil

ass’y

Replace.

Large gap between the magneto rotor

circumference and ignition coil ass’y

Adjust.

The spark plug does

not become wet with

fuel after repeated

starting operation.

No fuel in the fuel tank

Add properly mixed fuel

(25:1 to 50:1).

Clogged fuel filter Clean or replace.

Faulty fuel pipe

Adjust, replace or

connect.

Faulty vent hole (inner cap) on the fuel

tank

Replace.

Faulty carburetor ass’y Adjust, clean or replace.

The spark plug is wet

due to excessive fuel

supplied.

Pulling the starter handle several

times while the choke lever is at the

“startup” position.

Dry the spark plug.

Remove excessive fuel.

Idling stops

although

startup is

possible.

Weak spark

Dirty or faulty spark plug Clean or replace.

Improper air gap Adjust.

Low compression

Worn piston ring

Replace. Worn piston

Worn cylinder

Good spark and

compression

Revolutions too low for idling

Adjust.

Poorly adjusted carburetor ass’y

Defective sealing of the packing

Replace.

TROUBLESHOOTING GUIDE

-2-

Trouble Cause Corrective action

Starts, but

when

accelerating

…

The engine stalls.

Clogged fuel filter Clean or replace.

Insufficient warm-up Warm up.

Poorly adjusted carburetor ass’y

Adjust.

Poor acceleration;

no increase in

revolutions

Clogged cylinder vent passage,

exhaust port and/or carbon-clogged

muffler

Clean.

Clogged air cleaner

Chain brake set on Release.

Poorly adjusted carburetor ass’y Adjust, clean or replace.

Starts, but

…

Fluctuating

revolutions at high

speed

Dirt-clogged high-speed fuel line Clean.

Defective sealing of the packing Replace.

Faulty carburetor ass’y Adjust, clean or replace.

Excessive fuel

consumption

Clogged air cleaner Clean.

Poorly adjusted carburetor ass’y Adjust.

Chain oil is not discharged.

Insufficient amount of chain oil in the

oil tank

Replenish chain oil in the

oil tank.

Clogged chain oil discharge port

Clean.

Clogged oil filler port on the guide bar

Clogged oil filter

Poor adjustment of chain oil discharge

amount

Properly adjust the chain

oil discharge amount.

Faulty oil pump Replace.

Use of high-viscosity chain oil (in cold

weather)

Use genuine or

low-viscosity chain oil

(for winter use).

Engine does not stop.

Disconnection of cord Replace.

Faulty stop switch Replace.

-3-

This section describes repair, focusing on portions requiring frequent repair. See the TROUBLESHOOTING

GUIDE in the previous section as the context for the following descriptions.

1. Precautions on maintenance, inspection and repair

• The fuel used readily ignites; therefore, never bring the product near a flame.

• Use new gaskets at reassembly.

• Prior to disassembly for repair, remove the fuel and chain oil into separate containers, and allow the tool to

cool down.

• During repair, startup or running, use adequate care for portions posing the risk of burn injury or electric

shock, such as hot areas including the muffler, high voltage cord, and spark plug.

• Before running the tool with the guide bar and saw chain attached, make sure that there are no other

people nearby.

• Ensure proper ventilation when performing repair in a small room or other poorly ventilated space.

• After repair, confirm that the throttle lever returns to the idling state and the engine stops when the stop

switch is turned to the stop position.

2. Inspection criteria for each section and consumable parts

Model

Item

CS 33EDP/CS 33ED

Idling revolutions 2,800 to 3,200 min

-1

No-load maximum revolutions

(with guide bar and saw chain)

12,500 to 13,500 min

-1

Clutch engagement 4,000 to 4,800 min

-1

Accelerating performance Smooth acceleration

Gap between magneto rotor and

ignition coil ass’y

0.2 to 0.4 mm

Spark plug NGK BPMR7A

Gap between spark plug electrodes 0.6 to 0.7 mm

Saw chain type OREGON 91PX

Saw chain pitch x gauge 3/8” (9.53 mm) x 0.05” (1.27 mm)

No. of saw chain drive links 52 or 57

REPAIR GUIDE

-4-

Seized or broken piston ring Replace.

Seized piston or cylinder Replace.

Seized or broken needle bearing of the crank

shaft

Replace.

Seized ball bearing Replace.

Magneto rotor contact with ignition coil Adjust.

Broken recoil starter Inspect/replace.

Faulty starter pawl Inspect/replace.

Clogging of dirt in starter pawl Clean.

Faulty piston ring Clean/replace.

Worn piston ring Replace.

Worn piston Replace.

Worn cylinder Replace.

Remove foreign matter. Disassemble/clean.

Stop switch not at startup position

Set to startup

position.

Dirty or faulty spark plug Clean/inspect.

Improperly connected plug cap Inspect/replace.

Disconnected or improperly connected high

voltage cord and other wiring

Inspect/replace.

Ground connection of high voltage cord and

other wiring

Inspect.

Disconnected or faulty ignition coil

Replace.

Excessive gap between magneto rotor

circumference and ignition coil

Adjust.

No fuel in fuel tank or improper mixing ratio

Add properly mixed

fuel (25:1 to 50:1).

Clogged fuel filter Clean/replace.

Bent fuel pipe Adjust.

Cracked fuel pipe Replace.

Fallen fuel pipe Connect.

Faulty tank vent hole (inner cap) Replace.

Faulty pump diaphragm of carburetor ass’y Replace.

Dirt-clogged carburetor ass’y Clean.

Poorly adjusted carburetor ass’y Adjust.

Pulling the starter handle several times while

the choke lever is at the “startup” position.

Dry the spark plug.

Remove excessive

fuel.

Re

p

air flowchart

Pull the starter handle.

Is pulling possible?

Remove the spark plug to

check for sparks.

Are sparks generated?

No

Is there compression?

Return the spark plug

and plug cap to the

original positions, and

then perform proper

startup operation.

Is the tip of the spark plug

wet with fuel?

Is the spark plug wet due

to excessive supply of

fuel?

No

Yes

No

Yes

No

Yes

No

Yes

Is the spark plug

contaminated with foreign

matter?

-5-

Dirty or faulty spark plug Clean/replace.

Defective air gap

Adjust.

Worn piston ring

Replace.

Worn piston

Replace.

Worn cylinder

Replace.

Expired oil seal service life

Replace.

Revolutions low for idling

Adjust.

Poorly adjusted carburetor ass’y Adjust.

Defective sealing of the packing Replace.

Revolutions low for idling Adjust.

Poorly adjusted carburetor ass’y Adjust.

Defective sealing of the packing Replace.

Revolutions too high for idling Adjust.

Worn or faulty clutch Inspect/replace.

Poorly adjusted carburetor ass’y Adjust.

Clogged fuel filter

Clean/replace.

Inadequate warm-up, especially in cold

weather

Warm up.

Poorly adjusted carburetor ass’y

Adjust.

Defective sealing of the packing Replace.

Clogged cylinder vent passage, exhaust port

or carbon-clogged muffler

Clean.

Clogged air cleaner

Clean.

Chain brake set on

Release.

Poorly adjusted carburetor ass’y

Adjust.

Faulty carburetor ass’y pump diaphragm

Replace.

Dirt-clogged carburetor ass’y

Clean.

Dirt-clogged high-speed fuel line of the

carburetor ass’y

Clean.

Air intake from the packing section Inspect.

Faulty carburetor ass’y pump diaphragm Replace.

Poorly adjusted carburetor ass’y Adjust.

Revolutions low for idling Adjust.

Poorly adjusted carburetor ass’y Adjust.

Defective sealing of the packing Replace.

Clogged air cleaner Clean.

Poorly adjusted carburetor ass’y Adjust.

Does the engine stop when

the speed rapidly decelerates

from high speed?

Yes

No

Yes

Does the engine stop by

pulling the throttle lever?

No

Does the speed increase

by pulling the throttle lever?

Are revolutions fluctuated

during acceleration?

Tilt the tool during idling.

Does the engine stop?

No

Yes

Does the saw chain rotate

during idling?

Yes

No

Yes

Start the tool and set to

idling mode.

Does the engine stop?

Is fuel consumption

excessive?

Yes

No

Yes

-6-

Insufficient chain oil in the oil tank Supply oil.

Clogged chain oil discharge port Clean.

Clogged guide bar oil feed port Clean.

Clogged oil filter Clean.

Poorly adjusted chain oil discharge amount Adjust.

Defective oil pump Replace.

Use of high-viscosity chain oil

(in cold weather)

Use genuine or

low-viscosity chain

oil (for winter use).

Is chain oil discharged?

No

-7-

• Spark plug

• Checking for sparks

High voltage cord

Ignited sparks

Spark Plug Ass’y

BPMR7A [73]

Plug cap

Metallic portion of the engine

[Bold] numbers in the description below correspond to item numbers in the Parts List and exploded

assembly diagram for the Model CS 33EDP.

WARNING: Always stop the engine prior to disassembly or when replacing the saw chain.

1. Checking for sparks of the spark plug

CAUTION:

• Be careful not to touch the metallic portion of Spark

Plug Ass’y BPMR7A [73] when pulling the starter

handle; otherwise, you run the risk of electric shock.

Wear gloves to prevent electric shock.

• Carefully wipe off any fuel around the plug to avoid a

sudden flash of fire.

(1) Remove Spark Plug Ass’y BPMR7A [73] from the Cylinder

[74]. Use a wire brush to clean off carbon deposits on the

electrodes of Spark Plug Ass’y BPMR7A [73], as needed.

Adjust the gap between the electrodes if necessary. Use a

cloth to wipe off any fuel on the electrodes. Remove fuel left

in the Crank Case [96] by following the procedure below.

(a) Remove the Spark Plug Ass’y BPMR7A [73] from the

Cylinder [74].

(b) Open the Choke Lever [153], and then set the Stop

Switch [147] to the stop position.

(c) Open the throttle (by pulling the Throttle Lever [156]).

(d) Pull the starter handle several times.

(2) Insert Spark Plug Ass’y BPMR7A [73] into the Spark Plug

Cap [77], and then place the electrodes in contact with

the metallic portion of the engine. Under these conditions,

set the Stop Switch [147] to the startup position and pull

the starter handle.

(3) When all the above steps are completed normally, the electrodes of Spark Plug Ass’y BPMR7A [73]

should make a snapping sound to generate sparks.

2. Adjustment of the carburetor

(1) Use the Idle Adjust Screw [12] to adjust the carburetor.

• Use this screw to adjust revolutions at idling. Turning the

screw clockwise increases engine revolutions; turning it

counterclockwise decreases engine revolutions.

(2) Standard setting of the carburetor

• 2,800 to 3,200 min

-1

(Confirm that the saw chain does not rotate.)

(3) Fine adjustment

• Idling adjustment

(a) Adjust the idling revolutions after the engine is fully

warmed up.

(Tip on warm-up: Let the engine idle for one minute with the engine in half-throttled status.)

(b) Use the Idle Adjust Screw [12] to set revolutions so that the Saw Chain [132] does not start

rotating while the engine runs stably.

(c) Set idling revolutions to 2,800 to 3,200 min

-1

by using the Idle Adjust Screw [12].

(Adjust to approx. 3,000 min

-1

.)

Inspection and repair procedures

Gap between

electrodes

(0.6 to 0.7 mm)

Remove carbon here.

• Idle adjust screw

Idle Adjust Screw [12]

Revolutions

decrease.

Revolutions

increase.

-8-

• Cleaner and carburetor

1. Disassembly and reassembly of the cleaner and carburetor

[Tools required]

• Phillips screwdriver

• Hex. bar wrench (4 mm)

(1) Disassembly

• Loosen the Cleaner Knob [142] and remove the Cleaner Cover [141].

• Remove the Choke Lever [153].

• Pull out Cleaner Element (A) [5] and Cleaner Element (B) [4].

• Pull out the Fuel Pipes FKM [71] [163] from the Carburetor Ass’y [9], remove the Hex. Socket Hd.

Bolts M5 x 45 [6] by using a hex. bar wrench (4 mm), and then remove the Cleaner Support [8] and

Carburetor Ass’y [9].

• Remove the Fuel Pipe 2.5 x 4 x 90 [168] from the Carburetor Ass’y [9].

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

• Do not bend the Fuel Pipes FKM [71] [163] and Fuel Pipe 2.5 x 4 x 90 [168]. (See “9. Connecting the

fuel pipes” for details.)

• Turn the Choke Lever [153] to “Close” and confirm that the Choke Lever [153] automatically returns to

“Open” and the choke valve of the Carburetor Ass’y [9] opens to the initial position when the Throttle

Lever [156] is operated.

• Confirm that the four Grommets [155] are securely mounted.

Disassembly and reassembly

Cleaner Knob [142]

Cleaner Cover [141]

Cleaner Element (B) [4]

Cleaner Element (A) [5]

Cleaner Support [8]

Hex. Socket Hd. Bolt M5 x 45 [6]

Carburetor Ass’y [9]

Choke Lever [153]

Fuel Pipe 2.5 x 4 x 90 [168]

Fuel Pipe FKM [163]

Fuel Pipe FKM [71]

Grommets [155]

Washer 5 [7]

-9-

2. Disassembly and reassembly of the front handle

[Tools required]

• Phillips screwdriver

• Flat-blade screwdriver

• Box-end wrench 10 x 19 mm

• Socket wrench (10 mm)

(1) Disassembly

• Use a Phillips screwdriver to remove the two Tapping Screws (W/Flange) D5 x 25 (Black) [193]. Use

a flat-blade screwdriver to remove the Flange Nut M6 [165], and then use a box-end wrench 10 x 19

mm to remove the Front Handle [195]. (See the figure “Tightening the Flange Nut M6 [165]” on the

next page.)

• Use a 1

0-mm wide box wrench (socket type) to remove the Antivibration Spring [161].

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

• Reassemble the anti-vibration mechanism of the Front Handle [195] by following the procedure

below.

• Front handle

Front Handle [195]

Flange Nut M6 [165]

Spring Holder [159]

Damper Set Bolt [197]

Bolt Washer M6 [62]

A

ntivibration Spring [161]

S

p

rin

g

Cover

[

196

]

Tapping Screw (W/Flange)

D5 x 25 (Black) [193]

-10-

• Reassembly of the antivibration structure of the coil spring

(a) Insert the Spring Holder [159] so that the first winding of the Antivibration Spring [161] does not

protrude into the first winding of the Spring Holder [159].

(b) Apply 0.1 to 0.3 gram of CHEMITEC’s Chemiseal L-391 to the bolt of the Spring Holder [159] or the

female screw of Flange Nut M6 [165].

(c) As shown in the right photo, secure the

minus groove portion of the bolt of the

Spring Holder [159] by using a flat-blade

screwdriver, and then tighten Flange Nut

M6 [165] by using a box-end wrench 10 x

19 mm so that the Spring Holder [159]

does not co-rotate.

(d) Hold Flange Nut M6 [165] by using a

box-end wrench 10 x 19 mm, and then

tighten the bolt of the Spring Holder [159]

to 4.5±0.5 N•m by using a torque wrench

with a minus bit.

Antivibration Spring [161]

1 mm or less

Antivibration Spring [161] must not protrude

into this face of the Spring Holder [159].

Spring Holder [159]

Front Handle

[

195

]

Flan

g

e Nut M6

[

165

]

Dam

p

er Set Bolt

[

197

]

Bolt Washer M6 [62]

S

p

rin

g

Cover

[

196

]

• Tightening the Flange Nut M6 [165]

Flange Nut M6 [165]

Flat-blade screwdriver

Box-end wrench 10 x 19 mm

-11-

• Recoil starter ass’y

3. Disassembly and reassembly of the recoil starter ass’y

[Tool required]

• Phillips screwdriver

(1) Disassembly

• Use a Phillips screwdriver to loosen the four Tapping Screws (W/Flange) D4 x 20 (Black) [36], and

then remove the Recoil Starter Ass’y (NS) [198] and Air Deflector Ass’y [188].

NOTE: During disassembly, the spiral spring may come off and jump out. To prevent injury or

other accidents, wear protective goggles and work gloves.

• Turn the Reel (NS) [191] about one-fourth clockwise by hand and remove the Starter Rope (NS) [186]

from the Reel (NS) [191] with the Starter Rope (NS) [186] loosened.

• Loosen the Set Screw (NS) [189] to remove the Cam Plate (NS) [190], Reel (NS) [191] and Spiral

Spring (NS) [192].

CAUTION: Removing the Reel (NS) [191] without releasing the windings of the Spiral Spring

(NS) [192] may cause the Spiral Spring (NS) [192] to jump out, possibly resulting in

injury.

Fan Case (NS) [187]

Air Deflector Ass’y [188]

Set Screw (NS) [189]

Cam Plate (NS) [190]

Reel (NS) [191]

Spiral Spring

(NS) [192]

Starter Handle Ass’y [183] Starter Knob [185]

Starter Rope (NS) [186]

Rope Stopper [184]

Tapping Screw (W/Flange)

D4 x 20 (Black) [36]

Recoil Starter Ass’y (NS) [198]

• Disassembly of the recoil starter ass’y

Reel

(

NS

)

[

191

]

Starter Rope (NS) [186]

Starter Knob [185]

Set Screw (NS) [189]

Cam Plate

(

NS

)

[

190

]

Starter Rope (NS) [186]

-12-

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

• Mount the Spiral Spring (NS) [192] by

matching the end hook of the spring

to the groove of the Fan Case (NS)

[187].

• Apply about 1 g of Shell Albania RL3

to the entire Spiral Spring (NS) [192].

• Apply about 0.5 g of Shell Albania

RL3 to the sliding portions of the

Reel (NS) [191] and Fan Case (NS)

[187].

• Tie the end of the Starter Rope (NS) [186] on the Reel (NS) [191] side by using a single knot, and tie

the end of the rope on the Starter Knob [185] side by using a slide knot.

• Mount the Reel (NS) [191] and Spiral Spring (NS) [192] so that the pawl of the reel interlocks with the

hook at the end of the spring. Turn the Reel (NS) [191] clockwise and confirm that the Reel (NS) [191]

is rewound by spring force.

• Mounting the Spiral Spring (NS) [192]

Matching

Apply about 0.5 gram of

Shell Albania RL3 here.

Apply about 1 gram of Shell

Albania RL3 to the entire

Spiral Spring (NS) [192].

• How to tie the Starter Rope (NS) [186] (Starter handle side)

• How to tie the Starter Rope (NS) [186] (Reel side)

• Mounting the Starter Rope (NS) [186] and Reel (NS) [191]

Pawl

Hook

S

p

iral S

p

rin

g

(

NS

)

[

192

]

Reel

(

NS

)

[

191

]

-13-

• Mount the Cam Plate (NS) [190] so that the pawl of the plate interlocks with the hook at the end of

spiral spring (B). Turn the Cam Plate (NS) [190] clockwise while holding the Reel (NS) [191] by hand,

and confirm that the Cam Plate (NS) [190] is rewound by spring force.

• Wind the Starter Rope (NS) [186] five times around the Reel (NS) [191] by following procedure below

and referring to the photos.

(a) Rotate the Reel (NS) [191] counterclockwise and wind the Starter Rope (NS) [186] three times.

(b) Hook the Starter Rope (NS) [186] in the groove of the Reel (NS) [191]. While preventing the rope

from coming off, hold the Starter Rope (NS) [186] by hand and wind the Reel (NS) [191] clockwise

two times. Then release your hand from the Reel (NS) [191] and wind the Starter Rope (NS) [186].

If the Starter Rope (NS) [186] cannot be fully wound, wind it again as per the procedure above.

• Confirm that the Reel (NS) [191] rotates three or four times until the Starter Rope (NS) [186] is fully

pulled. If the Reel (NS) [191] rotates less than three times, replace the Starter Rope (NS) [186]. Also

confirm that the Reel (NS) [191] rotates clockwise a half turn more when the Starter Rope (NS) [186]

is fully pulled. If the reel does not rotate, release the Starter Rope (NS) [186] by one turn from the Reel

(NS) [191].

• Avoid getting Cord (A) [83] and the Cord [78] caught by the Air Deflector Ass’y [188].

• Reassembly of the Recoil Starter Ass’y (NS) [198] is made easier by first pulling the starter handle,

and then returning it a little.

• Mounting the spiral spring (B) and Cam Plate (NS) [190]

Hook

Pawl

Spiral spring (B)

Cam Plate (NS) [190] Reel (NS) [191]

• How to wind the Starter Rope (NS) [186]

Groove

Reel (NS) [191]

-14-

4. Disassembly and reassembly of the rear handle

[Tools required]

• Phillips screwdriver

• Flat-blade screwdriver

• Box-end wrench 10 x 19 mm

(1) Disassembly

• Remove the two Damper Set Bolts [152] and Flange Nut M6 [165] that connect the Rear Handle

[166] and Engine Case Ass’y [51] by using a flat-blade screwdriver and a box-end wrench 10 x 19

mm. (See the figure “Tightening the Flange Nut M6 [165]” on page 10.) Remove the Intake [27] from

the Rear Handle [166], and then remove the Rear Handle [166].

• Remove the Tapping Screws (W/Flange) D4 x 16 (Black) [140] that connect the Rear Handle Grip

[143] and Rear Handle [166].

• Take out the Throttle Rod (ED) [154] and Trigger Lockout [144] in the Rear Handle [166]. Pull out the

Spring Pin 5 x 25 [146], and remove the Throttle Lever [156] and Throttle Lever Spring [145].

• Remove Cord (A) [83] and the Cord [78] from the Stop Switch [147].

• Push the Stop Switch [147] from inside to outside and remove it from the Rear Handle [166].

If the switch proves difficult to remove, push it out while pushing the retaining pin on the upper surface

of the Stop Switch [147].

• Rear handle

Cord [78]

Cord (A) [83]

Rear Handle [166]

Damper (A) [150]

Distance Piece (B) [151]

Damper Set Bolt [152]

Flange Nut M6 [165]

Spring Holder [159]

A

ntivibration Spring [161]

Damper Set Bolt (A) [160]

Rear Handle Grip [143]

Tapping Screw

(W/Flange) D4 x 16

(Black) [140]

Throttle Rod (ED) [154]

Trigger Lockout [144]

Throttle Lever [156]

Throttle Lever Spring [145]

Spring Pin 5 x 25 [146]

Stop Switch [147]

Engine Case Ass’y [51]

Intake [27]

-15-

• Detaching the clutch

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

• When removing Cord (A) [83] and the Cord [78] from the Stop Switch [147], be sure to use new Cord

(A) [83] and Cord [78] because their grip force of the terminals will be decreased.

• Mount the Spring Holder [159] and Antivibration Spring [161] in the same way as described in “2.

Disassembly and reassembly of the front handle.”

NOTE: Prevent Cord (A) [83] and the Cord [78] from getting caught on any other parts.

5. Disassembly and reassembly of the clutch

[Tool required]

• Jig J-372 (clutch detaching tool)

(1) Disassembly

• As shown in the right figure, insert the claws of Jig

J-372 (clutch detaching tool) into the double slit of the

Clutch [30], rotate the tool in the arrow direction,

remove the Clutch [30], and then remove the Clutch

Housing Comp. [31], Needle Bearing (D) [32], Clutch

Washer [33], and Crank Shaft Collar [34].

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

• Insert Needle Bearing (D) [32] into the Crank Worm Ass’y [89], and apply 0.3 to 0.5 gram of Albania

RL3 around the periphery.

• Perform reassembly from the Engine Case Ass’y [51] side in the following order: Crank Shaft Collar

[34], Clutch Washer [33], Needle Bearing (D) [32], Clutch Housing Comp. [31], and Clutch [30].

• Before mounting the Clutch [30], degrease the female screw of the Clutch [30] and the screw of the

Crank Worm Ass’y [89].

• Tighten the Clutch [30] by using our 14.4-V impact driver for about one second to obtain the specified

torque.

NOTE: After reassembly, operate the product to confirm that the Clutch [30] is not loose.

Clutch [30]

Jig J-372 (clutch detaching tool)

• Clutch

Clutch [30]

Clutch Housing Comp. [31]

Needle Bearing (D) [32]

Clutch Washer [33]

Crank Shaft Collar [34]

Engine Case Ass’y [51]

-16-

• Pump gear (1)

6. Disassembly and reassembly of the oil pump

[Tools required]

• Phillips screwdriver

• Flat-blade screwdriver (for precision machinery)

• Long-nose pliers

(1) Disassembly

Disassemble the oil pump after disassembling the Clutch [30].

• Remove the two Tapping Screws (W/Flange)

D4 x 16 (Black) [140], and then remove the Engine

Case Cover [157].

• Remove the two Tapping Screws (W/Flange) D4 x 16 (Black) [1], and then remove the Oil Pump

Cover [35].

• Remove the Pipe Joint [50] and Oil Pipe [49].

• Remove the Oil Pipe [49] from the Engine Case Ass’y [51] by pinching its tip (on the oil discharge

side) with long-nose pliers.

• Remove the Tapping Screw (W/Flange) D4 x 20 (Black) [36] that secures the Pump Ass’y [47], pull

out the Air Vent Sponge [48], and then remove the Pump Ass’y [47].

• For the Pump Ass’y [47], remove the two Needle Rollers 2.5 x 19.8 [37] and then remove the Pump

Gear (ED) [44] and Pump Gear Spring (ED) [45] in the Pump Case [46].

• Insert a flat-blade screwdriver (for precision machinery) to remove Air Vent Valve (B) [172].

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

• If the Oil Pipe [49] or Air Vent Valve (B) [172] becomes worn or has flaws, replace it with a new one.

• If the Pump Gear (ED) [44] becomes worn, replace it with a new one.

• Remove any dust inside the Pump Case [46] or Pump Gear (ED) [44].

• Remove any dust inside the Oil Pump Cover [35].

• Apply 0.5 to 1.0 gram of Shell Albania RL3 to the Pump Gear (ED) [44], and then insert the gear into

the Pump Case [46].

• Engage the Pump Ass’y [47] with the worm on the crank shaft.

• Insert the Pump Gear Spring (ED) [45], Pump Gear (ED) [44],

and Adjuster Cap [42] into the Pump Case [46], and then insert

the two Needle Rollers 2.5 x 19.8 [37] while slightly pushing the

Pump Gear (ED) [44].

• Before assembling the Oil Pipe [49], confirm that there is no

dust on the insertion location of the Pump Case [46], and apply

0.2 to 0.4 gram of chain oil inside the Oil Pipe [49]. Then mount

the Oil Pipe [49] so that its holes match those of the Pump Case

[46].

• Note that you must not lose the Air Vent Sponge [48] and Air Vent Valve (B) [172].

Application range of

Shell Albania RL3

(0.5 to 1.0 gram)

Pump Gear (ED) [44]

Do not apply grease

to this range

.

8.8

+5

0

• Pump gear (2)

B

A

B

A - A

B - B

Sealing grease (0.2 g)

Pump Gear Spring (ED) [45]

Pump Case [46]

Needle Roller 2.5 x 19.8 [37]

Adjuster Cap [42]

Pump Gear (ED) [44]

Needle Roller 2.5 x 19.8 [37]

5.8

+4

0

0.2

-0.4

0

0.2

-0.4

0

-17-

• Air vent valve

Engine Case Ass’y [51]

Air Vent Valve (B) [172]

B

B-B

A

• Oil pump

Tapping Screw

(W/Flange) D4 x 16

(Black) [1]

Oil Pump Cover [35]

Air Vent Sponge [48]

Air Vent Valve (B) [172]

Oil Pipe [49]

Pipe Joint [50]

Tapping Screw

(W/Flange) D4 x 20

(Black) [36]

Needle Roller

2.5 x 19.8 [37]

Pump Case [46]

Pump Gear Spring (ED) [45]

Pump Gear (ED) [44]

Needle Roller [43]

Adjuster Cap [42]

Bolt Washer M4 (Black) [41]

Adjuster Spring [40]

Oil Pump Adjuster (ED) [39]

Pump Ass’y [47]

Engine Case Ass’y [51]

A

Tapping Screw (W/Flange)

D4 x 16 (Black) [140]

Engine Case Cover [157]

-18-

• Muffler

7. Disassembly and reassembly of the muffler

[Tools required]

• Phillips screwdriver

• Hex. bar wrench (5 mm)

(1) Disassembly

• Remove the two Tapping Screws (W/Flange) D4 x 16 (Black) [1] that secure the Muffler Cover [2].

• Remove the two Hex. Socket Hd. Bolts M6 x 55 [61] that secure the Muffler [59], and then remove

Bolt Washer M6 [62] and the Muffler Packing [60].

• Remove the three Screws (W/Washers) M4 (Black) [52] and detach the Muffler Gauze [58], Gauze

Fixing Plate [57], Muffler Special Packing [56], Exhaust Pipe [55], Muffler Special Packing (S) [54],

and Packing Plate [53].

(2) Reassembly

Reassembly can be conducted by reversing the disassembly procedure. However, special attention

should be given to the following items.

• Do not reuse the Hex. Socket Hd. Bolt M6 x 55 [61].

• To maintain sealing performance, replace the Muffler Packing [60] with a new one.

• If the Muffler Special Packing [56] or Muffler Special Packing (S) [54] has any breakage or cracks,

replace it with a new one.

• Perform reassembly from the muffler side in the following order: Muffler Gauze [58], Gauze Fixing

Plate [57], Muffler Special Packing [56], Exhaust Pipe [55], Muffler Special Packing (S) [54], and

Packing Plate [53].

• Attention must be paid to the mounting direction of the Gauze Fixing Plate [57]. (The rectangular

shape of the Exhaust Pipe [55] shall match that of the plate.)

• Before attaching the Muffler [59], degrease the screw holes of the Cylinder [74].

• Tighten the Muffler [59] with the Hex. Socket Hd. Bolt M6 x 55 [61] to 5.5 to 9.0 N•m, and after

checking the operation, retighten it by 10 to 12 N•m.

Muffler Packing [60]

Muffler [59]

Muffler Gauze [58]

Gauze Fixing Plate [57]

Bolt Washer M6 [62]

Hex. Socket Hd. Bolt M6 x 55 [61]

Muffler Special Packing [56]

Exhaust Pipe [55]

Muffler Special Packing (S) [54]

Packing Plate [53]

Screw (W/Washers) M4 (Black) [52]

Muffler Cover [2]

Tapping Screw (W/Flange) D4 x 16 (Black) [1]

Engine Case Ass’y [51]

-19-

8. Wiring diagram

(1) See pages 20 and 23 for wiring of Cord (A) [83] and the Cord [78].

• Connect the terminal of the Ignition Coil [82] with the silver side of Cord (A) [83].

• Connect the round terminal side of the Cord [78] with the Ignition Coil [82] by using the Hex. Socket Hd.

Bolt (W/Flange) M4 x 18 [79].

• Pass Cord (A) [83] and the Cord [78] through the hole on the Engine Case Ass’y [51].

• Insert Cord (A) [83] and the Cord [78] into Cord Insulation Tube L60 [76], and then store Cord

Insulation Tube L60 [76] in the hole on the Engine Case Ass’y [51].

• Pass Cord (A) [83] and the Cord [78] through the hole on the Rear Handle [166] in which the Stop

Switch [147] is stored, and then connect both with the terminals of the Stop Switch [147].

• Insert the Stop Switch [147] into the Rear Handle [166].

(2) See pages 20 and 22 for wiring of the high tension cord.

• Pass the high tension cord of the Ignition Coil [82] through the Engine Case Ass’y [51].

• Apply a small quantity of oil onto the tip of the high tension cord, and then insert it into the Spark Plug

Cap [77].

• Mount Metal Fitting of Plug Cap (A) [80] so that it penetrates the core wire of the high tension cord.

• Pull the high tension cord and store Metal Fitting of Plug Cap (A) [80] in the Spark Plug Cap [77].

9. Connecting the fuel pipes

Make the connections as illustrated on pages 20 and 21.

• Fully insert the pipes down to their roots.

• Do not bend or twist the pipes.

• Be careful not to get pipes caught by other parts.

• The end faces of the Fuel Pipe (FKM) [163] and Fuel Pipe L220 [164] should protrude from the edge of

the Fuel Grommet [162] by 152 to 162 mm and 191 to 201 mm, respectively.

CAUTION: Never mix up fuel pipes inserted into the Priming Pump Comp. [169].

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