T

ECHNICAL INFORMATION

Models No.

Description

EX2650LH

Multi Function Power Head H

PRODUCT

P 1/ 14

W

C

ONCEPT AND MAIN APPLICATIONS

Model EX2650LH loaded with 25.4mL Makita 4-stroke engine is a power head designed for versatile garden and agricultural applications.

L

The following advantages make this product ideal for a wide range of garden and agricultural applications:

• Split system of Power head and Attachment provides easier mobility.

• Clean 4-stroke engine equipped with our unique multi-position

engine lubrication system that enables the engine to be inclined

to any angle with no emission of white smoke and smell of

burning engine oil even during continuous operation

• Multi-tool system consisting of the power head and versatile

optional attachments

Dimensions: mm (")

Length (L)

Width (W)

Height (H)

975 (38-3/8)

242 (9-1/2)

323 (12-3/4)* 1

241 (9-1/2)

*1: for the countries where Barrier bar

is required by the standards of

brushcutter.

S

pecification

Engine

Engine oil

Type

Displacement: cm³ (cu.in.)

Fuel

Max. output: kW

Max. torque: N.m

Carburetor

Starting system

Fuel tank capacity: mL (US oz)

Primer pump

Clutch

Handle style

Rapid start

Net weight* 4 : kg (lbs)

4-stroke

25.4 (1.55)

Straight unleaded gasoline* 2

0.77 (at 7,000 min.

ˉ ¹)

1.1 (at 5,500 min.

ˉ ¹)

SAE10W-30 oil in the class SF or higher of API Classification

Diaphragm

Recoil starter, with mechanical decompression

600 (20.3)

Yes

Yes

Loop handle

No* 3

4.6 (10)

*2: Brazil: 25E gasoline

*3: However, equipped with mechanical decompression

*4: Dry weight

S

tandard equipment

Shoulder harness with single shoulder strap .............................................. 1

Socket wrench 16-17 ................................................................................. 1

Hex wrench 4 .............................................................................................. 1

Accessory bag ............................................................................................ 1

Oil set (oil bottle containing 80mL engine oil) ......................................... 1

Note: The standard equipment for the tool shown above may vary by country.

O

ptional accessories

Brush cutter attachment

String trimmer attachment

Pole saw attachment

Pole hedge trimmer attachment

Cultivator attachment

Coffee harvester attachment

Carrying bag

P 2/ 14

R

epair

CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.

[1] NECESSARY REPAIRING TOOLS

Code No.

Description Use for

1R004

1R006

Retaining ring pliers ST-2 for External ring removing/ assembling Retaining ring S-12

Retaining ring pliers RT-2E for Internal ring removing/ assembling Retaining ring R-24

1R028

1R031

1R033

1R045

1R127

1R171

1R247

1R282

1R286

1R291

1R364

1R366

Bearing setting pipe 20-12.2

Bearing setting pipe 28-20.2

Bearing setting plate 10.2

Gear extractor (large)

Air density tester

T-type hex. wrench 4-130

Round bar for arbor 20-100

Round bar for arbor 8-50

Round bar for arbor 12-50

Retaining ring S and R pliers

Flywheel puller

Feeler gauge set

Hex socket bit 13

Wire brush

M10-17 Hex. nut pressfitting Spiral bevel gear 14 (the component of Cutter shaft set) removing Spiral bevel gear 14 (the component of Cutter shaft set) removing Cutter shaft set removing Ball bearing 6001LLU diagnosing Carburetor removing / assembling M5 Hex socket head bolt removing Clutch drum removing Spiral bevel gear 14 (the component of Cutter shaft set) pressfitting Clutch drum removing / assembling Retaining rings removing Flywheel

Adjusting Ignition coil, Spark plug and Rocker arm assembly removing / assembling Flywheel making Spark plug clean removing Cutter shaft set

[2] HANDLING OF GASKET

When Gasket is removed:

(1) clear something that is sticking on the matching portions with Gasket.

(2) replace Gasket with the new one.

[3] LUBRICANT / ADHESIVE APPLICATION

Apply a little amount of Makita grease N No.2 to Spiral spring in Recoil starter and the spline ends of Shaft.

Apply 8g Makita grease N No.2 into Gear case after cleaning the inside.

Once the engine is diassembled, put ThreeBond 1216 to the matching surface of Crank case and Cylinder block for the reassembly. (Fig. 64)

[4] DISASSEMBLY/ASSEMBLY

[4]-1. Warning

Obey the following instructions in advance before repairing.

• Wear gloves.

• Keep the cover on the blade other than a trial of engine running.

• Cool down engine enough, as the engine just after used may cause you to get burned.

• Remove the remaining fuel in Tank and Carburetor completely.

• Repair the engine on the stable workbench and in the clean workplace to prevent dust and debris from entering.

• Record where and how the parts are assembled, and what are the parts. Do not reassemble them wrongly.

It is recommended to prepare the several kind of boxes to keep parts group by group.

• Treat the disassembled parts carefully. Clean and wash them certainly.

• When some bolts and screws are difficult to loosen, use Impact driver.

• Tighten the bolts and the screws to the specific torque as shown in Fig. 68.

• Once the main parts are assembled, check every move and sound by manually turning each part.

• Check the assembled parts by turning them manually if there is any unusual gap or sound around.

P 3/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-2. Engine and Shaft

DISASSEMBLING Fig. 1

(1) Disconnect lead wire and grounding wire by removing each connector

after removal of Air cleaner cover. (Fig. 1)

(2) Remove Control cable from Insulator as follows:

• Loosen the nuts of Control cable so as to relax the holding to the hook of

Insulator. (Fig. 2)

• Disconnect Inner cable from Swivel of Carburetor.

(3) Loosen two M5x18 Hex socket head bolts on Pipe holder and remove M5x12

Hex socket head bolt. (Fig. 3)

Fig. 2 (4) Pull Shaft pipe B complete and Shaft B complete out of Engine. (Fig. 4)

Note: Shaft B complete in the Shaft B pipe complete may get stuck

at the spline engagement. If yes, use Waterpump pliers to pull out

the shaft. (Fig. 5)

Swivel

Inner cable of

Control cable

Connector (4pcs.)

Nut of Control cable

(2 pcs.)

Fig. 3 Fig. 4

Engine

Shaft pipe B complete

M5x12 Hex socket head bolt

M5x18 Hex socket head bolt (2pcs.)

Pipe holder

Shaft B complete

ASSEMBLING

Assemble by reversing the disassembly procedure.

• Set Control cable in place. (Figs. 2 and 6)

- Secure it on the hook of Insulator with two Nuts of Control cable.

- Fit Inner cable end into the groove of Swivel of Carburetor.

Note: Adjust the tension of the cable to allow the play 1mm up to 2mm.

Fig. 6

Hook of Insulator for Control cable

Fig. 5

Waterpump pliers

Shaft B complete

Inner cable end

Nuts to fix on the hook of Insulator

Control cable

Hook of Insulator for Control cable

P 4/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-3. Brushcutter attachment

Fig. 7

DISASSEMBLING

(1) Loosen two M6x30 Hex. socket head bolts and remove Protector with Protector

extension attached. (Fig. 7)

(2) While pulling the side walls of Protector cover toward outside, remove Protector cover

from Shaft pipe A complete. (Fig. 8)

(3) Remove two M5x14 Hex socket head bolts and Protector clamp. (Fig. 9)

(4) Loosen M5x25 Hex socket head bolt and remove Gear case assembly from Shaft pipe

A complete. (Fig. 9)

(5) Pull Shaft A from Gear case installation side and then remove Retaining ring S-7 from

Protector

M6x30 Hex socket head bolt (2pcs.)

Shaft A. (Fig. 10)

(6) Push the projection of Leaf spring complete deeply and remove it from the hole of

Shaft pipe A complete. Slip the projection along the inside of Shaft pipe A complete

toward the shaft end. (Fig. 11) Leaf spring complete is removed from Shaft pipe A

Protector extension

complete.

Note: Pushing the projection hard causes the deformation of Leaf spring complete. Be careful of the handling.

Fig. 8

Shaft pipe A complete

Fig. 9

Shaft pipe A complete

Fig. 10

Shaft pipe A complete viewed from Gear case installation side

M5x14 Hex socket head bolt

M5x25 Hex socket head bolt

Retaining ring S-7

Protector cover

Side wall of Protector cover M5x14 Hex socket head bolt (2 pcs.)

Gear case assembly

Protector clamp

Shaft A

Fig. 11

Projection of Leaf spring complete

Spring portion of

Leaf spring complete

ASSEMBLING

Assemble by reversing the disassembly procedure.

[4]-4. String trimmer attachment

DISASSEMBLING

(1) Remove two M6x20 Hex. socket head bolts and Protector

from Clamp complete. (Fig. 12)

(2) Remove M5x10 Hex socket head bolt and Clamp complete

from Head case. (Fig. 12)

(3) Loosen M5x25 Hex socket head bolt and remove Head case

from Bent pipe assembly. (Fig. 12)

(4) Remove Bearing washer from Head case installation side of

Bent pipe assembly. (Fig. 13)

Remove Flexible shaft from Bent pipe assembly by pulling it

off from shaft joint side.

(5) Remove two M5x14 Screws. Cutter is removed from Safety

cover as drawn in Fig. 14.

Fig. 12

Bent pipe assembly

M5x25 Hex socket head bolt

Fig. 14

M5x14 Screw (2 pcs.)

Fig. 13

M5 Washer

(2 pcs.)

Bent pipe assembly viewed from Head case side

M6x20 Hex socket head bolt (2 pcs.)

Clamp complete

Head case complete

Protector

M5x10 Hex socket head bolt

M5 Spring washer

(2 pcs.)

Flexible shaft Bearing washer Safety cover Cutter

M5 Nut

(2 pcs.)

P 5/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-5. Gear case assembly

DISASSEMBLING

(1) According to the clause of [4]-3, Remove Gear case assembly. (Refer to Figs. 7, 8 and 9)

(2) Remove M8x10 + Hex bolt that is the stopper of Grease inlet on Gear case set. (Fig. 15)

(3) Remove Retaining ring R-24 with 1R006. (Fig. 16)

(4) Remove an assembled part of Spiral bevel gear 14, Ball bearing 609ZZ and Retaining ring S-9 by striking Gear case

assembly against workbench as drawn in Fig. 17.

(5) Remove Retaining ring S-9 with 1R291.

(6) Receive Ball bearing 609ZZ with 1R031, then press down the top of Spiral bevel gear 14 using 1R282 with Arbor press

(Fig. 18) Refer to Fig. 19 for the components.

(7) Remove Retaining ring R-28 with 1R291. (Fig. 20)

(8) Preset Receive washer and 1R033 with M10-17 Hex. nut to Cutter shaft as drawn in Fig. 21, and give the impacts

using the plastic hammer. An assembled part of Cutter shaft complete, Ball bearing 6001LLU is removed.

Refer to Fig. 22 for the components.

(9) Remove Ball bearing 6001LLU with 1R045.

Fig. 15 Fig. 17 Fig. 18

Fig. 16

M8x10 + Hex bolt

Ball bearing 609ZZ

1R282

1R031

Retaining ring R-24

Fig. 19

Spiral bevel gear 14

(The component of Cutter shaft set)

Ball bearing 609ZZ

Retaining ring S-9

Retaining ring R-24

Fig. 21

Receive washer

Gear case

1R033

M10-17 Hex. nut

Workbench

Fig. 22

M8x10 + Hex bolt

Fig. 20

Cutter shaft set

Retaining ring

S-28

(Note: Spiral bevel bear 14 shown in Fig. 17 is also

the component.)

Ball bearing 6001LLU

Retaining ring R-28

ASSEMBLING

Assemble by reversing the disassembly procedure.

• Receive Gear case assembly with the U-shape table of Arbor press,

then press down Ball bearing 6001LLU using 1R028 with Arbor

press to insert Cutter shaft set in place. (Fig. 23)

Fig. 23

Ball bearing 6001LLU 1R028

P 6/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-6. Shaft pipe B complete

DISASSEMBLING

(1) Remove two M5x25 Hex socket head bolts and Pipe clamp 24 from Shaft pipe B complete.

Clamp cover A, Pipe clamp 33 and Loop handle are removed. (Fig. 24)

(2) Remove four 4x18 Tapping screws and two M5x14 Hex socket head bolts from Control lever assembly.

Control lever assembly is now separated to L and R. (Fig. 25)

(3) Loosen M5x12 Hex socket head bolt and M6x25 Hex socket head bolt, and remove Joint 24 from Shaft pipe B complete.

(Fig. 26)

(4) Loosen M5x20 Pan head screw of Hanger set, and remove Hanger set itself and Spacer 24 from Shaft pipe B complete.

(Fig. 27)

(5) Pull out Shaft B complete from the pipe joint side of Shaft pipe B complete. (Fig. 28)

Remove Retaining ring S-12.

Fig. 24 Fig. 25

*Loop handle *M5x25 Hex socket head bolt (2 pcs.)

Control lever assembly

*Clamp cover A

*Pipe clamp 24

*Pipe clamp 33

*mark: The components of

Loop handle set

Fig. 26

Shaft B complete on Pipe joint side

4x18 Tapping screw (4 pcs.)

M5x14 Hex socket head bolt (2 pcs.)

Fig. 27

Shaft B complete on Engine side

Spacer 24

Joint 24

M5x12 Hex socket head bolt

M6x25 Hex socket head bolt

Fig. 28

Pipe joint side of Shaft pipe B complete

Retaining ring S-12

Hanger set

(Hanger and M5x20 Pan head screw)

Joint end of Shaft B complete for installing the tool head

ASSEMBLING

Assemble by reversing the disassembly procedure.

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-6. Clutch drum

DISASSEMBLING

(1) Remove Clutch case section from the engine.

(2) Remove Retaining ring S-12 with 1R004 from clutch case section.

(3) Remove Clutch drum from Clutch case section by pressing 1R247 with

Arbor press. (Fig. 29)

ASSEMBLING

(1) Put Clutch case on the table of Arbor press vertically, then press-fit

the shaft of Clutch drum into the hole of Ball bearing 6201LLU with

1R286 and Arbor press as drawn in Fig. 30.

(2) Set Retaining ring S-12 in place with 1R004.

Fig. 29

Fig. 30

Clutch drum

P 7/ 14

Arbor press

1R247

Clutch case

1R286

Clutch case

[4] DISASSEMBLY/ASSEMBLY

[4]-7. Ignition

CHECK OF PLUG CAP

(1) Remove Plug cap from Spark plug, then detect the continuity between

Plug cap spring in Plug cap and Earth terminal of Ignition coil.

It is the normal condition when Tester shows 2.0kΩ±0.5kΩ. (Fig. 31)

(2) In case of no continuity or unstable continuity, check the connection

between Plug cap spring and Ignition coil as follows:

(A) Spray the lubricant in Plug cap, then pull out Plug cap spring

together with Ignition cable using Long-nose pliers. (Fig. 32)

(B) In case no connection or inconsistent connection, then check

the condition of Plug cap and spring. Reassemble them or replace

them if they are disorder.

(C) Insert the end of Plug cap spring into Ignition cable then return

them back to the inside of Plug cap carefully so as not to be

disconnected.

(D) Check Plug cap and spring again according to the step of (1)

to avoid poor connection causing the poor sparks of Spark plug.

Fig. 31

Fig. 32

Plug cap spring in Plug cap

Long-nose pliers

Tester

Earth terminal of Ignition coil

Flywheel

(inside of Clutch case)

Plug cap spring

Plug cap

CHECK OF SPARK PLUG

(1) Remove Plug cap with Plug cap spring, then remove Spark plug with Socket wrench

16-17 (standard equipment).

Note: When the spark area is wet with Fuel, wipe it away with a cloth and dry it by

air blow.

Fig. 33

0.6 up to 0.7mm

(2) Clean carbonized materials on Insulated part for sparking with a wire brush.

(3) Do fine adjustment of Spark plug as drawn in Fig. 33.

Leg

Insert 0.7mm thickness gauge of 1R366 to the clearance and adjust the leg of Spark plug carefully.

(4) Install Plug cap with Plug cap spring on Plug and connect the plug screw part to a metal part of Engine, then pull Starter

rope slowly. The sparks can be seen when starter rope is pulled.

(5) When the sparks can not be seen, try [CHECK OF PLUG CAP] to detect the continuity.

If required, replace Plug and recheck the sparks through the above process.

Fig. 34

P 8/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-7. Ignition (cont.)

DISASSEMBLING OF IGNITION COIL Spacer

(2pcs.)

See Fig. 34.

(1) Remove Cylinder cover and cable from Ignition coil terminal.

(2) Loosen two M4x20 Hex socket head bolts and remove Ignition

coil from Engine.

Note: Do not lose two spacers on the bolts as the heat protection.

ASSEMBLING OF IGNITION COIL

See Fig. 35.

(1) While attaching 0.3mm thickness gauge of 1R366 to the magnet

portion of Flywheel, set Ignition coil in place.

Note: Two M4x20 Hex socket head bolts (Fig. 34) are with

threadlocker.

Therefore, when re-using them,

apply ThreeBond 1342 or Loctite 242 to the threads.

(2) After setting Ignition coil, remove the thickness gauge then turn

Flywheel by hand to check if it turns smoothly

without being stuck.

Note: Be sure to insert Spacer on M4x20 Hex socket head bolt

when fastening Ignition coil to Engine. (Fig. 34)

(3) Assemble Cylinder cover to Engine.

[4]-8. Flywheel

Earth terminal of Ignition

M4x20 Hex socket head bolt (2pcs.) coil to connect with Cable Connector of Cable

Fig. 35

Ignition coil

Flywheel

Clearance between

Flywheel and

Ignition coil: 0.3mm

DISASSEMBLING

Note: • Flywheel can be easily removed without holding the piston.

• Do not remove Spark plug as compressed air resistance has to be used for the disassembling.

• Plug cap with Plug cap spring has to be removed from Spark plug to prevent Engine from running. (Fig. 31)

(1) Turn M8 Flange nut in the center of Flywheel counterclockwise using Cordless impact driver with 13mm Socket bit.

(Fig. 36)

(2) Install 1R364 on Flywheel then screw two M6 bolts into Flywheel as drawn in Fig. 37 instead of

M6x25 shoulder hex bolts. Flywheel is removed from Engine.

Important: Screw two M6 bolts evenly.

Fig. 36 Fig. 37

1R364

Flange nut

(M8)

M6 bolts

(the components of 1R364)

ASSEMBLING

(1) Wipe off the grease and oil from Crank shaft.

(Fig. 38)

(2) Put Woodruff key 3 into Crank shaft, then align the key groove of Flywheel to the crank shaft with the key. (Fig. 38)

(3) Screw M8 Flange nut to the thread of Crank shaft by turning the nut clockwise by hand.

(4) Tighten M8 flange nut about two seconds using Cordless impact driver with 13mm socket bit.

Fig. 38

Key groove of

Flywheel’s hole

Wipe off the grease and oil from Crank shaft in advance.

Woodruff key 3

Crankshaft in cylinder block assembly)

P 9/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-9. Recoil starter

DISASSEMBLING

(1) Remove Starter case from Engine.

(2) Pull out and cut the rope when it is still connected.

If it is impossible to cut Starter rope;

First, pull the rope one turn of Reel, then, Hook the rope with

the notch of Reel and turn the hooked rope

clockwise until Spiral spring loses the tension. (Fig. 39)

Note: Be careful. Reel is revolved by the recoil force of Spiral spring.

(3) Loosen M5x12 Tapping screw and remove Swing arm and Reel from

Starter case. (Fig. 40)

Note: Be careful when removing this screw as there is a possibility

that Spiral spring pops out.

(4) Untie the knot of the rope in Reel and remove the rope from Reel.

Fig. 39

M5x12 Tapping screw

(Set screw)

Fig. 40

Reel notch of Reel

Swing arm

M5x12

Tapping screw

(Set screw)

ASSEMBLING

(1) When Spiral spring pops out of Reel:

- Set the one end of Spiral spring in the slot outer side in the Reel.

- Rewind the spring counterclockwise toward the center of circle and

fit the spring end in the slot inside of Reel. (Fig. 41)

(2) Apply a little amount of Makita grease N No.2 to the spring.

(3) Make a knot on the new rope end and pass it through Reel and

Starter case, then, connect the other end to Starter knob. (Fig. 42)

Refer to Fig. 43 how to make a knot of the rope.

(4) Wind the rope two or three turns.

(5) While turning Reel counterclockwise, fit it into Starter case and hook

Spiral spring end on the rib inside of Starter case. (Fig. 44)

Note: This should be fixed without force.

(6) Set Collar and Swing arm in place, then secure them with M5x12

Tapping screw. (Fig. 45)

Swing arm has to be passed through the groove of Reel.

Important: In case Reel turning is not smooth after tightening M5x12

Tapping screw, Reel is not properly fixed to Starter case.

Repeat the step (5) so that Reel can revolves smoothly

even after M5x12 Tapping screw is completely tightened.

(7) Hook the rope in the notch of Reel while straining the rope, then,

turn reel counterclockwise. (Fig. 46) When the rope is removed

from the notch, the Reel winds the rope with spring recoil force.

Repeat the step until the rope slacks are cleared.

Fig. 41

Curved end of

Spiral spring

(Outer side)

Fig. 42

Fig. 43

Reel

Curved end of Spiral spring (Inside)

Approx. 10mm

Approx. 10mm

Fig. 44

Inside curved end of Spiral spring

Inside rib of

Starter case

Fig. 45

Groove of Reel to hook

Swing arm

Swing arm Collar

Fig. 46

M5x12

Tapping screw

(Set screw)

Swing arm notch of Reel

P 10/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-10. Carburetor

DISASSEMBLING

(1) Remove Cleaner cover assembly by unscrewing M4 Thumb screw. (Fig. 47)

(2) Remove two Air cleaner elements. (Fig. 48)

(3) Remove two M5x60 Hex. socket head bolts for fastening Carburetor and Cleaner plate assembly to Insulator. (Fig. 48)

Note: Carburetor can not be removed without removing the bolts completely.

(4) Disconnect two tubes from Carburetor, then remove Carburetor.

Fig. 47 Fig. 48

M4 Thumb screw

M5x60 Hex. socket head bolts

Air cleaner elements: Be careful of

each shape and

direction.

Cleaner cover assembly

CLEANING / MAINTENANCE

Refer to Fig. 49.

(1) Remove four 3x24 Tapping screws, then separate Metering diaphragm and Metering diaphragm gasket.

Note: In case Metering diaphragm remains attached to the others in disassembling of Carburetor, be careful to remove

Metering diaphragm and gasket. It is fragile.

(2) Replace Metering diaphragm when the following problems happen:

• slackened • hardened • worn / debased

(3) Loosen M3x4 screw in Pump body to remove Inlet needle and Control lever etc.

(Refer to Fig. 50) from Carburetor.

Fig. 50

Control lever Spring

(4) Before assembling Pump body, check that the top of Inlet needle is not

deformed/ worn out. (Fig. 51).

(5) When Control lever is set in place, make sure that Spring is put properly. (Fig. 52)

(6) Regarding three M3x8 Pan head screws with washers, loosen Idling screw fully

first, and then remove them.

(7) After checking if Inlet screen is clogged with dust, fit it into Pump body.

(8) Spray carburetor cleaner each route in Carburetor and then clean it with gasoline

after a few minutes.

Fig. 49

M3x4 + screw

Fig. 51

Pin

Note:

Inlet needle

These items can not be supplied solely.

Order Pump body to replace them.

Pump body

(M3x4 screw

is included.)

Metering diaphragm gasket

Inlet

Carburetor screen

M3x8 Pan head screw with washer

(2pcs.)

(Throttle valve assembly)

Swivel

Washer

Stop ring

E-3

(Idling screw)

Normal

Fig. 52

Out of order

Metering diaphragm

Normal

Air purge body

Primer pump

Conical compression spring 5-9

O ring 2

Jet

Out of order

Pump gasket

Pump diaphragm

Primer pump cover

3x24 Tapping screw (4pcs.)

Dust in Pump body causes the leakage of pressure.

Fig. 53

P 11/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-10. Carburetor (cont.)

ASSEMBLING

Carefully assemble each part in right direction and order.

(Nipple to connect

yellow tube of Tank)

TEST OF AIRTIGHT STRUCTURE

Connect 1R127 to the nipple of Carburetor as drawn in Fig. 53.

Give air pressure from 1R127 and check if the pressure gauge indicates

0.05Mpa for around 10 seconds, then, there is no problem with Carburetor.

ASSEMBLING TO ENGINE

Nipple of Carburetor to connect black tube of Tank

Fig. 54

(1) Assemble Cleaner plate assembly, Carburetor and Gasket to Insulator

with two M5x60 Hex socket head bolts.

(2) Connect black tube of Fuel tank to the nipple of Carburetor.

Connect yellow tube of Fuel tank to the other nipple of Carburetor.

(Figs. 53 and 54)

Connect Tube from Cylinder and Breather pipe to the Cleaner plate

assembly.

Note: Make sure that fuel tubes do not touch on Cylinder cover.

(3) Set Air cleaner elements in place. The felt element is put on the bottom,

and the sponge element is on the front.

(4) Hook the tabs of Cleaner plate assembly with the holes of Cleaner cover

assembly. (Fig. 55)

Tank

Fig. 55

Black tube

Yellow tube

1R127

Tabs of

Cleaner plate assembly

[4]-11. Stop switch

Check the continuity of two Lead wires’ ends routed from Control lever with Tester. (Fig. 56)

Fig. 56

Stop switch is in order if it works as followings:

* Circuit tester shows no connectivity

when Engine turns on.

* Circuit tester shows a connectivity

when Engine turns off.

[4]-12. Fuel tube

Assemble Tube complete (Black tube, Yellow tube and

Grommet) to Fuel tank as drawn in Fig. 57.

Assemble Gasoline filter and Hose clamp to the black tube, then put them into Fuel tank. (Fig. 58)

Fig. 57

Black tube Yellow tube

Fig. 58

Grommet

Gasoline filter

Black tube

Hose clamp

P 12/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-13. Spark arrester (Only for some countries, i.e., having dry atmospheres at high temperature)

MAINTENANCE

(1) Remove Cylinder cover.

(2) Remove Exhaust Muffler.

(3) Remove Spark arrester from Exhaust muffler (Fig. 59).

Sweep it off if dirt or soot is on Spark arrester.

Replace it with a new one if spark arrester has a breakage or fray.

(4) Assemble Spark arrester to Exhaust muffler.

(5) Set Exhaust muffler in place.

Note: • Refer to Parts breakdown, and do not forget muffler gasket.

• Two M5x40 Hex socket head bolts on Exhaust muffler are threadlocker type.

Once removing them for repair, apply ThreeBond 1342 / Loctite 242 to

the threads to screw them.

(6) Set Cylinder cover in place.

Fig. 59

Exhaust muffler

[4]-14. Engine block

DISASSEMBLING Fig. 60

(1) Drain the oil from Engine as much as possible so that the remaining oil

is not spilled out when disassembling.

(2) Remove the following parts from Engine.

• Cylinder cover • Tank guard • Fuel tank • Clutch case

• Recoil starter assembly • Clutch • Ignition coil • Flywheel

• Rocker cover inner • Rocker cover gasket • Rocker arm assembly

• Rod 2.5 • Cam lifter • Cam gear • Insulator • Air cleaner • Carburetor

• Spark plug • Muffler

(3) Open Cylinder block by removing six M5x16 Hex socket head bolts. (Fig. 60)

(4) Remove Clips from both ends of Piston pin hole with the awl. (Fig. 61)

Note: • Be careful as the clip pops out.

• Do not reuse the removed Piston clip.

(5) Remove Piston pin by pushing it with 1R171. (Fig. 62)

(6) Piston can be now removed from Crankshaft.

Fig. 61

Piston Awl

Spark arrester

Cylinder block

Fig. 62

Piston pin hole

Clip

1R171

Piston pin

P 13/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-14. Engine block (cont.)

ASSEMBLING

(1) Piston can be assembled in either direction.

Apply Makita grease N No. 2 to the needle bearing of Crank shaft assembly in advance.

(2) Insert Piston pin through Piston and Crank shaft, and fix it with Clips by using the awl (Clip has no direction).

(3) Piston rings have their directions and each different shapes as drawn in Fig. 63.

First, install Piston ring 34, and next, install Piston ring (second) 34, then finally install Piston ring (top) 34.

The piston ring 34 for the lowest groove on Piston consists of three part; top ring, middle ring and bottom ring.

Top ring and bottom ring have a clearance and the distance of each clearance point must have 120° angle.

Piston ring (top) 34 and Piston ring (second) 34 consist of single part and the distance between their clearances

must have 180° angle when they fixed into the grooves on the piston.

Note: Piston rings are easy to break. Do not enlarge them too much when fixed.

(4) Assemble Cylinder block assembly.

After removing grease from the matching surface of Cylinder block and Crank case (Refer to Fig. 64), apply ThreeBond

1216 on the Crank case side.

Note: The layer of ThreeBond 1216 has to be thin so as not to enter into the oil route in Engine and get clogged.

Apply 4-stroke oil to the contact surface of Piston and Cylinder.

While holding Piston rings, install the assembled part of Piston into Cylinder block.

(5) Fasten Cylinder block assembly by tighten the screws in crisscross pattern.

Fig. 63

Piston ring (top) 34

The position between two clearances must be at 180° opposite point.

Piston ring (second) 34

Piston top end

Difference of the clearance should be 120°.

Piston ring 34

Top layer

Middle layer

Piston ring (top) 34

The center is expanded.

Piston ring (second) 34

The bottom is wider than the top.

Bottom layer

Cross section of Piston

Piston ring 34 for the lowest groove on Piston consists of three layers.

The top layer and the bottom layer have a clearance as drawn above. Clearances should not be overlapped each other.

Fig. 64

Piston

The matching surface: emphasized by black color

P 14/ 14

R

epair

[4] DISASSEMBLY/ASSEMBLY

[4]-14. Engine block (cont.)

ASSEMBLING

(6) Adjust the valve clearance as follows:

• Align the marking on Flywheel with the marking on Ignition coil. (Fig. 65)

• Align the marking on Cam gear assembly with the marking on Cylinder block. (Fig. 66)

• Assemble two Cam lifters and two Rod 2.5, and then assemble two Rocker arm assembly to them.

Note: The ends of Rod 2.5 have to be put into the round depressions of Cum lifter and Rocker arm.

• Loosen the adjust screws of Rocker arm assembly, and put 0.1mm thickness gauge of 1R366 between Valves

and Rocker arms.

Then adjust the valve clearance. (Fig. 67)

• After the adjustment, tighten the nuts of Rocker arm assembly, remove 0.1mm thickness gauge of 1R366.

Fig. 65 Fig. 66 Fig. 67

Marking on Ignition coil

1R170

Marking on

Flywheel

Marking on

Cam gear assembly

Marking on

Cylinder block

1R366

[4]-15. Fastening torque

Fig. 67

Parts to fasten

CYLINDER BLOCK and CRANK CASE

CRANK CASE and RETAINER PLATE

CRANK CASE and OIL CASE

FLYWHEEL and CRANK SHAFT 1

COIL and CYLINDER BLOCK

CAM GEAR COVER and CYLINDER BLOCK

ROCKER ARM ADJUSTING SCREW and NUT

ROCKER COVER OUTER and CYLINDER BLOCK

CLUTCH and FLYWHEEL

MUFFLER and CYLINDER BLOCK

SPARK PLUG and CYLINDER BLOCK

INSULATOR and CYLINDER BLOCK

CLUTCH CASE and CYLINDER, CRANK CASE

PULLEY and CRANK SHAFT 2

RECOIL STARTER and CYLINDER, CRANK CASE

MUFFLER PLATE and CRANK CASE

OIL PIPE and OIL CASE

CASE, GEAR ASSEMBLY and PIPE SHAFT

CASE, GEAR ASSEMBLY and PIPE SHAFT

HANDLE HOLDER 2, 3 and PIPE SHAFT

CONTROL LEVER and HANDLE

BRACKET PIPE and SHAFT PIPE COMPL

BRACKET PIPE and SHAFT PIPE COMPL

CONTROL CABLE and INSULATOR

JOINT 24 and LEVER 94

JOINT 24 and PIPE SHAFT B

JOINT 24 and PIPE SHAFT B

Screw/ Nut

HEX SOCKET HEAD BOLT (M5×16)

HEX SOCKET HEAD BOLT (M4×10)

HEX SOCKET HEAD BOLT (M5×16)

FLANGE NUT (M8)

HEX SOCKET HEAD BOLT (M4×20, W, SW, MEC)

HEX SOCKET HEAD BOLT (M5×16)

NUT (M5)

HEX SOCKET HEAD BOLT (M5×16)

CLUTCH BOLT (M6×25)

HEX SOCKET HEAD BOLT (M5×40,W,MEC)

M10×P1.0

HEX SOCKET HEAD BOLT (M5×18,W,SW)

HEX SOCKET HEAD BOLT(M5×18,W,SW)

M8

HEX SOCKET HEAD BOLT (M5×16,W,SW)

HEX SOCKET HEAD BOLT (M5×14,W,SW)

HEX SOCKET HEAD BOLT (M5×14,W,SW)

HEX SOCKET HEAD BOLT (M5×25,SW)

HEX SOCKET HEAD BOLT (M5×14,SW)

HEX SOCKET HEAD BOLT (M5×30,SW)

SCREW PAN HEAD (M4x25,W,SW)

HEX SOCKET HEAD BOLT (M5×18,SW)

HEX SOCKET HEAD BOLT (M5×12,SW)

NUT (M6)

NUT (M6)

HEX SOCKET HEAD BOLT (M5×12)

HEX SOCKET HEAD BOLT (M6×25)

Fastening torque

(N·m)

6.0

8.0

11.0

5.0

5.0

6.0

5.0

5.0

5.0

3.0

6.0

16.0

4.0

6.0

6.0

6.0

9.0

5.0

5.0

2.0

7.0

7.0

7.0

6.0

2.0

4.0

4.5