T

ECHNICAL INFORMATION

Models No.

EM2650UH/ EM2650LH,

EM2651UH/ EM2651LH

Description

Petrol Brushcutter

C

ONCEPT AND MAIN APPLICATIONS

These four 25.4mL Petrol Brushcutters have been developed as the successor models of EBH252U/EBH252L and EBH253U/EBH253L equipped with 24.5mL 4-stroke engine.

Their main feature is the multi-position engine lubrication system.

This unique system enables the engine to be inclined to any angle even during continuous operation with no emission of white smoke and smell of burning engine oil for wider application range of the brushcutters.

EM2651UH and EM2651LH additionally feature rapid start.

EM2650UH and EM2651UH are Bike handle models.

EM2650LH and EM2651LH are Loop handle models.

H

W

L

W

PRODUCT

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L

H

EM2650UH

EM2651UH

EM2650LH

EM2651LH

Model No.

Length (L)

Width (W)

Dimensions: mm (")

EM2650UH

EM2651UH

EM2650LH

EM2651LH

1,765 (69-1/2)

620 (24-3/8) 330 (13)

Height (H) 474 (18-5/8) 264 (10-3/8)

S

pecification

Specifications

Type

Model

Engine

Displacement: mL (cu.in.)

Fuel

Max. output: kW

Max. torque: N.m

No load speed *2 : min.

-1 = rpm

Engine oil

Carburetor

Starting system

Fuel tank capacity: L (oz)

Spindle thread size

Primer pump

Clutch

Handle style

Rapid start

Waist cushion

Net weight *4 : kg (lbs)

EM2650UH EM2650LH EM2651UH

4-stroke

25.4 (1.5)

Straight unleaded gasoline *1

0.77 [at 7,000 min1 ]

1.1 [at 5,500 min1 ]

7370

Bike handle *3

6,630

SAE10W-30 oil

7370 in the Class SF or higher of API Classification

Diaphragm

Recoil starter, with mechanical decompression

0.6 (20.3)

M10, Left-handed

Yes

Yes

Loop handle Bike handle *3

No

No

5.5 (12.1)

No

No

5.1 (11.2)

Yes

Yes

5.6 (12.3)

EM2651LH

*1 Brazil: 25E gasoline

*2 No load speed of the cutting tool

*3 Of asymmetrical design

*4 Dry weight, without universal guard, cutting tool and shoulder harness

S

tandard equipment

Cutting tool ......................................................................................... 1

Universal guard (=Protector) ............................................................. 1

Shoulder harness with double shoulder straps ................................... 1 (for EM2650UH, EM2651UH)

Shoulder harness with single shoulder strap ...................................... 1 (for EM2650LH, EM2651LH)

Socket wrench .................................................................................... 1

Hex wrench (for M4) ......................................................................... 1

Hex wrench (for M5) ......................................................................... 1

Wire clamp (for tying cables) ............................................................. 2 (for EM2650UH)

Oil bottle without oil or Oil bottle containing 80mL engine oil ......... 1

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

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

O

ptional accessories

Metal blades [230mm (9") 3-tooth, 4-tooth, 8-tooth], Nylon cutting heads [Ultra auto 4, Bump & feed 4,

Bump & feed Z5], Gardening attachments (for EM2650LH, EM2651LH)

6,630

Loop handle

Yes

No

5.2 (11.4)

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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

Retaining ring pliers ST-2 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 Makita grease N No.2 to Spiral spring in Recoil starter and the spline ends of Shaft.

When cleaning the inside of Gear case, apply 40g Makita grease N No.2 into Gear case.

When disassembling the engine, put ThreeBond 1216 to the matching surface of Crank case and Cylinder block. (Fig. 61)

[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. 65.

• 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.

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[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 by loosening the adjust screw (Fig. 2)

then by the disconnecting 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)

(4) Pull Shaft pipe complete out of Engine (Pipe holder).

Note:: Shaft in the Shaft pipe may get stuck at the spline engagement.

Use Waterpump pliers to pull out the shaft. (Fig. 4) Fig. 2

ASSEMBLING

Inner cable of Control cable

Take the disassembling step in reverse.

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

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

- Fit the hook of 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.

Projection of Insulator

Fig. 3 Fig. 4

M5x13 Hex. socket head bolt

M5x18 Hex. socket head bolt (2pcs.)

Fig. 5

Pipe holder

Shaft

Water pump pliers

Shaft pipe Shaft

Shaft pipe complete

Pipe holder

Fig. 6

Hook to fit into Swivel

Adjust screw

Inner cable

Control cable

Nuts to fix on the projection of Insulator

Insulator

Connector (4pcs.)

Swivel

Adjust screw of

Control cable

Nuts of Control cable

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[4] DISASSEMBLY/ASSEMBLY

[4]-3. Shaft pipe complete

DISASSEMBLING

(1) Loosen two M6x30 Hex. socket head bolt (2pcs.) and remove Protector with Protector extension attached. (Fig. 7)

(2) Enlarge the space between the side wall of Protector cover and M5x14 Hex socket head bolt, and remove Protector cover

from Shaft pipe complete. (Fig. 8)

(3) Remove M5x14 Hex socket head bolt with Flat washer and spring washer then remove Protector clamp.

(4) Loosen M5x25 Hex socket head bolt then remove Gear case assembly. (Fig. 9)

(5) Remove four M5x30 Pan head screws then remove Loop handle and Handle clamp 24 from Shaft pipe complete. (Fig. 10)

(6) Remove four 4x18 Tapping screws and two M5x14 Hex socket head bolts then separate Lever case R and L. (Fig. 11)

(7) According to the clause of [4]-2, Remove Shaft pipe complete.

(8) Remove Hanger and Shaft from Shaft pipe complete. (Fig. 12)

Fig. 7 Fig. 8

M6x30 Hex. socket head bolt (2pcs.)

M5x14 Hex socket head bolt with Flat washer and

Spring washer

Shaft pipe complete

Protector

The side wall of

Protector cover

Gear case assembly

Protector extension

Fig. 9

M5x25 Hex socket head bolt

Protector clamp

Fig. 11

Lever case set

Gear case assembly

Fig. 10

M5x30 Pan head screw (4pcs.)

M5x14 Hex socket head bolt with Flat washer and spring washer (2 pcs.)

Handle clamp 24

Fig. 12

Note: Hanger has to be assembled to Shaft pipe complete

in direction of the following arrow.

Shaft pipe complete

Loop handle

M5x14 Hex socket head bolt

4x18 Tapping screw

The distance between a hole and one pipe end is long.

Shaft

ASSEMBLING

Assemble in the reverse order of disassembly.

• Slip Hanger on Shaft pipe complete as drawn in Fig. 12.

Hanger

The distance is short.

Shaft pipe complete

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[4] DISASSEMBLY/ASSEMBLY

[4]-4. Gear case assembly

DISASSEMBLING

(1) According to the clause of [4]-3, Remove Gear case assembly.

(2) Remove M8x10 + Hex bolt that is the stopper of Grease inlet on Gear case set. (Fig. 13)

(3) Remove Retaining ring R-24 with 1R006. (Fig. 14)

(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. 15.

(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. 16) Refer to Fig. 17 for the components.

(7) Remove Retaining ring R-28 with 1R291. (Fig. 18)

(8) Pretighten Receive washer and 1R033 with M10-17 Hex. nut to Cutter shaft as drawn in Fig. 19, and give

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

Refer to Fig. 20 for the components.

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

Fig. 13 Fig. 15 Fig. 16

Fig. 14

M8x10 + Hex bolt

Ball bearing 609ZZ

1R282

1R031

Retaining ring R-24

Fig. 17

Spiral bevel gear 14

(The component of Cutter shaft set)

Ball bearing 609ZZ

Retaining ring S-9

Retaining ring R-24

Fig. 19

Receive washer

Gear case

1R033

M10-17 Hex. nut

Workbench

Fig. 20

M8x10 + Hex bolt

Fig. 18

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

Take the disassembling step in reverse.

• 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. 21

Ball bearing 6001LLU 1R028

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[4] DISASSEMBLY/ASSEMBLY

[4]-5. Clutch

DISASSEMBLING

Note: (1) Clutch can be easily removed with Impact driver

without holding the piston.

(2) Do not remove Spark plug as compressed air resistance

has to be used for the disassembling.

(3) Plug cap with Plug cap spring has to be removed from

Spark plug.

• Loosen two M6x25 shoulder hex bolts by turning each bolt

counterclockwise using Cordless impact driver with 13mm Socket bit.

(Fig. 22)

Fig. 22

13mm Socket bit M6x25 shoulder hex bolt (2pcs.)

ASSEMBLING

• Because M6x25 shoulder hex bolt (2pcs.) has the stepped shape. First tighten it by hand (Fig. 23),

next use cordless impact driver. (Fig. 24)

Note: Face the marking of L to the outside as drawn in Fig. 25.

Turn two M6x25 shoulder hex bolts clockwise using Cordless impact driver with 13mm Socket bit. (Fig. 25)

Fig. 23 Fig. 24 Fig. 25

L

[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 with Arbor press. (Fig. 26)

ASSEMBLING

(1) Put Clutch case on the table of Arbor press vertically, then pressfit Clutch drum into

Ball bearing 6201LLU with 1R286 and Arbor press as drawn in Fig. 27..

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

Fig. 26

Fig. 27

Clutch drum

Arbor press

1R247

Clutch case

1R286

Clutch case

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[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. 28)

(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 Pliers. (Fig. 29)

(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 dis-

order.

(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. 28

Plug cap

Ignition coil

Fig. 29

Earth terminal

Flywheel

Plug cap

Plug cap spring

CHECK OF SPARK PLUG

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

driver 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.

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

(3) Do fine adjustment of Spark plug as drawn in Fig. 30.

Insert 0.7mm thickness gauge of 1R366 to the clearance and adjust the leg of

Spark plug carefully.

Fig. 30

0.6 up to 0.7mm

Leg

(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.

DISASSEMBLING OF IGNITION COIL

See Fig. 31.

(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.

Fig. 31

Spacer (2pcs.)

M4x20 Hex socket

head bolt (2pcs.)

ASSEMBLING OF IGNITION COIL

See Fig. 32.

(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. 31) 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. 31)

(3) Assemble Cylinder cover to Engine.

Tab of Ignition coil to connect with Cable

Connector of Cable

Fig. 32

Clearance between Flywheel and Ignition coil: 0.3mm

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[4] DISASSEMBLY/ASSEMBLY

[4]-8. Flywheel

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. 29)

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

(Fig. 33)

(2) Install 1R364 on Flywheel then screw two M6 bolts into Flywheel as drawn in Fig. 34

instead of M6x25 shoulder hex bolts. Flywheel is removed from Engine.

Important: Screw two M6 bolts evenly

Fig. 33 Fig. 34

1R364

M8 bolts

(the components of 1R364)

Flange nut

(M8)

ASSEMBLING

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

(Fig. 35)

(2) Put Woodruff key 3 into Crank shaft, then align the key groove of Flywheel to the crank shaft with the key. (Fig. 35)

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

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

Fig. 35

Key groove of

Flywheel’s hole

Woodruff key 3

Wipe off the grease and oil from Crank shaft.

Crankshaft (in cylinder block assembly)

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[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. 36)

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. 37)

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. 36

M5x12 Tapping screw

(Set screw)

Fig. 37

Reel Swing arm

P 9/ 14 notch of Reel

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. 38)

(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. 39) Refer to Fig. 40 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. 41)

Note: This should be fixed without force.

(6) Set Collar and Swing arm in place, then secure them with M5x12 Tapping screw. (Fig. 42)

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. 43) 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. 39

Fig. 38

Curved end of Spiral spring

(Outer side)

Reel

Curved end of Spiral spring (Inside)

Fig. 40

Approx. 10mm

Fig. 41

Approx. 10mm

Fig. 42

Inside curved end of Spiral spring

Groove of Reel to hook

Swing arm

Swing arm Collar

Inside rib of

Starter case

Fig. 43

M5x12

Tapping screw

(Set screw)

Swing arm notch of Reel

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[4] DISASSEMBLY/ASSEMBLY

[4]-10. Carburetor

DISASSEMBLING

(1) Remove Cleaner cover assembly. (Fig. 44)

(2) Remove Air cleaner element. (Fig. 45)

(3) Remove two M5x60 Hex. socket head bolts for fastening

Carburetor and Cleaner plate assembly to Insulator.

Note: Carburetor can not removed before the bolts are removed

completely.

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

Fig. 44

Air cleaner element

P 10/ 14

Fig. 45

M5x60 Hex. socket button head bolts are completely removed.

CLEANING / MAINTENANCE

Refer to Fig. 46.

(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. 47) from Carburetor.

(4) Before assembling Pump body, check that the top of Inlet needle is not deformed / worn out. (Fig. 48).

(5) When Control lever is set in place, make sure that Spring is put properly as drawn in Fig. 49.

(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. 46 Fig. 47

Control lever Spring

Pump body

(M3x4 + screw

is included.)

Carburetor

Inlet screen

M3x8 Pan head screw with washer

(2pcs.)

Swivel

Washer

Stop ring

E-3

Metering diaphragm gasket

Metering diaphragm

(Throttle valve assembly)

Idling screw

Fig. 49

Inlet needle

M3x4 + screw

Pin

Note:

These items can not be supplied solely.

Order Pump body to replace them.

Air purge body

Conical compression spring 5-9

Normal

Primer pump

O ring 2

Jet

Pump gasket Out of order

Primer pump cover

3x24 Tapping screw (4pcs.)

Pump diaphragm

Dust in Pump body causes the leakage of pressure.

Fig. 48

Normal Out of order

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[4] DISASSEMBLY/ASSEMBLY

[4]-10. Carburetor (cont.)

ASSEMBLING

Carefully assemble each part in right direction and order.

TEST OF AIRTIGHT STRUCTURE

Connect 1R127 to the nipple of Carburetor as drawn in Fig. 50.

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

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

Fig. 50

P 11/ 14

(Nipple to connect

yellow tube of Tank)

1R127

Carburetor.

ASSEMBLING TO ENGINE

(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. 50 and 51)

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. 52)

Nipple of Carburetor to connect black tube of Tank

Fig. 51

Fuel tank

Fig. 52

Black tube

Yellow tube

[4]-11. Stop switch

Check the continuity of two Lead wires’ ends routed from Control lever with Tester. (Fig. 53)

Fig. 53

Tabs of Cleaner plate assembly

[4]-12. Fuel tube

Assemble Tube complete (Black tube, Yellow tube and

Grommet) to Fuel tank as drawn in Fig. 54.

Assemble Gasoline filter and Hose clamp to the black tube, then put them into Fuel tank. (Fig. 55)

Fig. 54

Black tube Yellow tube

Fig. 55

Gasoline filter

Black tube

Hose clamp

Grommet

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[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. 56).

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

Replace it wit 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. 56

Exhaust muffler

Spark arrester

[4]-14. Engine block

DISASSEMBLING Fig. 57

(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. 57)

(4) Remove Clip from Piston with needle. (Fig. 58) Fig. 58

Note: • Be careful as the clip pops out.

• Use the new clip. Do not use the used clip.

(5) Push Piston pin out with 1R171. (Fig. 59)

(6) Remove Piston.

Cylinder block

Fig. 59

1R171

Clip

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[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 an awl (Clip has no direction).

(3) Piston rings have their directions and each different shapes as drawn in Fig. 60.

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

The piston ring 34 (fast one) 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.

Degrease the matching surface of Cylinder block and Crank case (Refer to Fig. 61), 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 4stroke 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. 60

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

Bottom layer

Cross section of Piston

Fig. 61

Piston ring (top) 34

The center is expanded.

Piston ring (second) 34

The bottom is wider than the top.

Piston ring 34 consists of three layers.

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

Piston

The matching surface: emphasized by black color

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. 62)

• Align the marking on Cam gear assembly with the marking on Cylinder block. (Fig. 63)

• 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. 64)

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

Fig. 62

Marking on Ignition coil

Fig. 63 Fig. 64

P 14/ 14

1R170

Marking on

Flywheel

Marking on

Cam gear assembly

Marking on

Cylinder block

1R366

[4]-15. Fastening torque

Fig. 65

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 COMPLETE

CONTROL CABLE and INSULATOR

NUT (M5)

Screw/ Nut

HEX SOCKET HEAD BOLT (M4×10)

FLANGE NUT (M8)

HEX SOCKET HEAD BOLT (M4×20,W,SW,MEC)

CLUTCH BOLT (M6×25)

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 (M5×20)

HEX SOCKET HEAD BOLT (M5×12,SW)

NUT (M6)

Fastening torque (N ･m)

5.0

6.0

5.0

5.0

9.0

8.0

11.0

5.0

4.0

6.0

6.0

6.0

6.0

3.0

6.0

16.0

3.0

6.0

2.0

5.0

7.0

7.0

6.0