P 2/ 19
Repair
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
Warning: Follow the instructions described below in advance before repairing:
•Wear gloves.
•Remove the cutting tool from the unit.
•When the engine is hot from use, cool down the engine enough or you can get burned.
•Remove remaining fuel from Fuel tank and Carburetor completely. [FLAMMABLE MATERIAL KEEP FIRE AWAY]
•Remove Spark plug cap from Spark plug.
•Repair the engine on a stable workbench and in a clean workplace kept as free of dust and debris as possible.
•In order to avoid wrong reassembly, draw or write down where and how the parts are assembled, and what are the parts. It is also recommended to have boxes ready to keep disassembled parts by group.
•Handle the disassembled parts carefully. Clean and wash them properly.
•If some bolts and screws are too tight, use Impact driver.
•Tighten the bolts and the screws to the specified torque as shown in "[5] Tightening torque specifications".
•Each time after you mounted a main part of the engine such as the piston, check if it moves smoothly
without abnormal noise by manually turning the crankshaft.
•After completion of reassembly, check for loose parts or abnormal noise and vibration by manually turning the crankshaft.
[1] NECESSARY REPAIRING TOOLS
| Code No. | Description | Use for |
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| 1R003 | Retaining ring pliers | removing Lock off lever |
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| 1R005 | Retaining ring pliers | removing Cotter |
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| 1R030 | Bearing setting pipe |
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| 1R223 | Torque wrench shaft | assembling Clutch complete to Crankshaft |
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| 1R224 | Ratchet head 12.7 (for 1R223) |
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| 1R288 | Screwdriver magnetizer | removing/ assembling Cotter |
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| 1R290 | Hexalobular bit | removing/ assembling Hexalobular bolt |
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| 1R291 | Retaining ring S and R pliers | removing/ installing Retaining ring |
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| 1R308 | Spring pin extractor 4.0 | removing Pin 5 from Rocker arm assembly |
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| 1R311 | Retaining ring pliers | removing Tubes |
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| 1R364 | Flywheel puller | removing Flywheel |
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| 1R366 | Feeler gauge set | adjusting the gap between Ignition coil and Flywheel, |
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| Rocker arm assembly and Valve section, Spark plug |
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| 1R372 | Crank shaft lock bolt M10 | holding the position of Piston/ preventing Crankshaft from |
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| 1R389 | Cotter removal attachment | removing Exhaust / Intake valve system |
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| Socket/ Socket bit 17 | removing/ installing Clutch |
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| Socket/ Socket bit 24 | removing/ installing Clutch |
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| Wire brush | cleaning Spark plug |
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| Hex wrench 2.5 | assembling/ removing / adjusting M5 Hex socket head bolt |
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| Wrench 8 | holding M5x9 Hex nut |
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[2] GASKET
Once Gasket is removed:
(1)Clean up the mating surface where the gasket was installed to maintain its sealing performance.
(2)Replace it with a new one.
