Makita Brush Cutter EM4350LH User Manual

ECHNICAL INFORMATION  
PRODUCT  
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P 1/ 22  
H
EM4350UH, EM4350LH  
Models No.  
Description  
EM4351UH  
W
Petrol Brushcutter  
W
CONCEPT AND MAIN APPLICATIONS  
L
These models are 43.0cm³ 4-stroke petrol brushcutters developed  
in compliance with well-known exhaust emission regulations.  
Their main features are:  
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L
• Powerful 4-stroke engine for working in larger open area, and  
for easily cutting through thick weeds and longer grass  
• Newly designed throttle assembly with wide-grip throttle trigger  
• Universal guard for both metal blade and nylon cutting head  
• Toolless quick fastening handle holder for easy handling and  
angle adjustment of handle (for EM4350UH, EM4351UH only)  
• Floating structure with four rubber buffers absorbs vibration  
transmitted from engine to bike handle. (for EM4351UH only)  
The drawing  
above is  
EM4350UH.  
EM4350LH  
EM4350UH  
EM4351UH  
Dimensions: mm (")  
EM4350UH EM4350LH EM4351UH  
1,812 (71-1/2)  
1,812 (71-1/2)  
Length (L)  
Width (W)  
Height (H)  
635 (25)  
339 (13-3/8) 618 (24-1/4)  
250 (9-7/8) 528 (20-3/4)  
460 (18-1/8)  
Specification  
Specifications  
Model  
EM4350UH  
EM4350LH  
4-stroke  
EM4351UH  
Type  
Displacement: cm³ (cu.in.)  
Engine Fuel  
Max. output: kW (PS)  
Max. torque: N.m  
43.0 (2.6)  
Straight unleaded gasoline  
1.50 (2.1) at 7,500 rpm  
2.1 at 5,500 rpm  
7,200  
Max. spindle speed at no load: min.ˉ¹ = rpm  
SAE10W-30 oil  
in the Class SF or higher of API Classification  
(Automotive 4-stroke engine oil)  
Engine oil  
Carburetor  
Diaphragm  
Yes  
Engine start assist  
(by automatic mechanical decompression valve)  
Primer pump  
Clutch  
Yes  
Yes  
Fuel tank capacity: L (US oz)  
Spindle thread size  
Handle style  
0.62 (21.0)  
M10x1.25, Left-handed  
Bike handle  
Loop handle  
Bike handle  
Anti-vibration system  
Net weight*1: kg (lbs)  
Conventional low-vibration structure  
Floating structure  
8.6 (18.9)  
8.3 (18.2)  
7.9 (17.3)  
*1 Dry weight, without universal guard, cutting tool and shoulder harness  
Standard equipment  
Blade or Nylon cutting head ..................... 1  
Tool set (Hex wrench 4, Hex wrench 5,  
Socket wrench 16-17,  
Universal guard (=Protector) .................... 1  
Blade cover ............................................... 1 (for the model with blade)  
Double shoulder straps with waist pad ..... 1 (for EM4350UH)  
Double shoulder straps with waist pad  
Socket driver 16-10) .................. 1  
Accessory bag ............................................ 1  
Oil bottle without oil or  
for Loop handle model...... 1 (for EM4350LH)  
Oil bottle containing 100mL engine oil ..... 1  
Double shoulder straps with waist belt ..... 1 (for EM4351UH)  
Note: The standard equipment for the tool shown above may vary by country.  
Optional accessories  
255mm Triple blade, 300mmTriple blade, 255mm Star blade, 200mm Chisel blade, 225mm Chisel blade,  
Nylon cutting heads (UltraAuto 6), Protector, Protector extension, Protector 200 set, Protector 225 set,  
Double shoulder straps, Oil bottle  
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P 2/ 22  
Repair  
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.  
[1] NECESSARY REPAIRING TOOLS  
Code No.  
Description  
Use for  
1R004 Retaining ring pliers ST-2 for External ring removing/ installing Retaining rings  
1R005 Retaining ring pliers RT-2N for Internal ring removing/ installing Cotter by using 1R389  
1R006 Retaining ring pliers RT-2E for Internal ring removing/ installing Retaining rings  
1R028 Bearing setting pipe 20-12.2  
press-fitting Cutter shaft set into Ball bearing 6000DDU  
removing Spiral bevel gear 14 from Ball bearing 609ZZ  
press-fitting Clutch drum into Ball bearing 6004LLU/6003LLU  
removing Ball bearing 6000DDU from Cutter shaft complete  
1R031 Bearing setting pipe 28-20.2  
1R033 Bearing setting plate 10.2  
1R045 Gear extractor (Large)  
1R127 Air density tester  
removing Ball bearings  
diagnosing Carburetor  
1R247 Round bar for arbor 20-100  
removing Clutch drum complete from Clutch case  
removing Spiral bevel gear 14 from Ball bearing 6000ZZ and  
6000  
1R282 Round bar for arbor 8-50  
removing Piston pin  
1R286 Round bar for arbor 12-50  
1R291 Retaining ring S and R pliers  
press-fitting Clutch drum complete into Clutch case  
removing/ installing Retaining rings  
1R364 Flywheel puller  
removing Flywheel  
1R366 Feeler gauge set  
adjusting Ignition coil, Spark plug  
removing/ installing Cotter by using 1R005  
1R389 Cotter removal attachment  
---  
---  
---  
10mm Hex socket bit  
14mm Hex socket bit  
Wire brush  
removing/ installing Flywheel  
removing/ installing Clutch  
cleaning Spark plug  
1R219 Torque wrench shaft 7-23N.m  
1R254 Torque wrench shaft 2-6N.m  
tightening Bolts to specified torque  
[2] HANDLING OF 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.  
[3] LUBRICANT / ADHESIVE APPLICATION  
(1) Apply a little amount of Makita grease N No. 2 to Spiral spring in Recoil starter and the spline ends of Shaft in  
Shaft pipe complete.  
(2) When the inside of Gear case is cleaned, supply 11g of Makita grease N No. 2 from the grease inlet.  
(3) Apply 4g of Makita grease N No. 1 to the entire portion of Shaft in Shaft pipe complete.  
(4) Once Engine is disassembled, remove oil/grease from the mating surface of Cylinder and Crankcase complete,  
then apply ThreeBond 1215/1216 to the mating surface for the reassembly.  
[4] DISASSEMBLY/ASSEMBLY  
[4]-1. Warning  
Follow the instructions described below in advance before repairing:  
• Wear gloves.  
• Remove the cutting tool from the unit, and if it is a saw blade, attach the blade cover to the blade.  
• 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 an impact driver.  
• Tighten the bolts and the screws to the specified torque as shown in "[4]-15. 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.  
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P 3/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-2. Engine and Shaft  
(1) Press down the tab of Cleaner plate assembly gently and separate Cleaner cover assembly from Cleaner plate assembly  
by loosening M5x20 Hex socket head bolt. (Fig. 1)  
(2) Loosen 5x16 Tapping screw and loosen Clamp that holds Bullet terminals near Cleaner plate assembly. (Fig. 2)  
(3) Disconnect Bullet terminals of Earth wire and Primary wire of Ignition coil from the wires of Stop switch. (Fig. 2)  
(4) Remove Control cable from Swivel of Carburetor; loosen the three nuts on Control cable to release the tension  
between Swivel and Cable bracket of Insulator, then remove the stopper on Inner cable end from Swivel. (Fig. 3)  
(5) For EM4351UH: Remove M5x8 Hex socket head bolt and M6x30 Hex socket head bolt in the holes of Pipe housing.  
(Fig. 4)  
For EM4350UH and EM4350LH: Remove M5x8 Hex socket head bolt and M6x30 Hex socket head bolt from  
the threaded holes of Clutch case. (Fig. 5)  
(6) Grab Shaft pipe complete by hand, then pull it off from Clutch case.  
If Shaft sticks in Clutch case, use water pump pliers or the like to pull it off.  
Note: Be sure to wrap Shaft with a rag or the like to protect it from water pump pliers. (Fig. 6)  
Fig. 1  
Fig. 2  
Swivel of Carburetor  
Cleaner plate assembly  
M5x20 Hex socket  
head bolt  
Inner cable  
Clamp  
Bullet terminals  
Control cable  
5x16  
Tapping  
screw  
Tab of  
Cleaner plate assembly  
Cleaner cover  
assembly  
Fig. 3  
Fig. 4  
Holes of  
Swivel of Carburetor  
Stopper on Inner cable end  
Cable bracket of Insulator  
Pipe housing  
M5x8  
Hex socket  
head bolt  
M6x20  
Hex socket  
head bolt  
Nut on Control cable end  
(3 pcs.)  
Fig. 5  
Fig. 6  
Threaded holes  
of Clutch case  
Rag  
Shaft  
Shaft pipe complete  
Water pump  
pliers  
M5x8 Hex socket  
head bolt  
M6x20 Hex  
socket head bolt  
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P 4/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-2. Engine and Shaft (cont.)  
ASSEMBLING  
Assemble by reversing the disassembly procedure.  
(1) Put Cable bracket between Flat washer 6 and middle Nut, and tighten them by turning lower nut, upper nut and  
the middle nut. (Fig. 7)  
(2) Put Stopper on Inner cable end into Swivel, then adjust the above nuts so that 3mm to 4mm of play is left inside of  
Swivel under condition that Throttle lever is not pulled. (Fig. 7)  
Note: Adjust the tension of Inner cable to prevent the stopper from being removed . (Fig. 7)  
Fig. 7  
Nut (upper)  
Stopper on Inner cable end  
Cable bracket of Insulator  
complete  
Nut (middle)  
Play: 3mm to 4mm  
Flat washer 6  
Nut (lower)  
Swivel  
[4]-3. Shaft pipe complete  
DISASSEMBLING  
(1) Loosen two M6x30 Hex. socket head bolt (2pcs.) and remove Protector with Protector extension attached. (Fig. 8)  
(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. 9)  
(3) Remove two M5x14 Hex socket head bolts then remove Protector clamp.  
(4) Loosen M6x30 Hex socket head bolt then remove Gear case assembly. (Fig. 10)  
Fig. 8  
Fig. 9  
M5x14 Hex socket head bolt (2 pcs.)  
M6x30 Hex. socket  
head bolt (2 pcs.)  
Shaft pipe  
complete  
Protector  
Gear case  
assembly  
The side wall of  
Protector cover  
Protector extension  
Fig. 10  
Gear case assembly  
M5x14 Hex socket  
head bolt (2 pcs.)  
M6x30 Hex  
socket head bolt  
Protector clamp  
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P 5/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-3. Shaft pipe complete (cont.)  
DISASSEMBLING  
For 4351UH:  
(5A) Loosen M5x18 Hex socket head bolt and remove Shaft pipe complete from Pipe housing. (Fig. 11)  
(6A) Pull out Shaft from Shaft pipe complete.  
For 4350UH:  
(5B) Remove two M6x25 Hex socket head bolts and Pipe clamp, then separate Bike handle section from Shaft pipe  
complete. (Fig. 12)  
(6B) Remove the following parts from Shaft pipe complete.  
• Wire clamp (2 pcs.) • Hanger set • Shaft (Fig. 13)  
For 4350LH:  
(5C) Remove four M5x30 Hex socket head screws, then remove Handle clamp 28 and then remove Loop handle 28.  
(Fig. 14)  
(6C) Loosen two M5x14 Hex socket head bolts, then separate Lever case set from Pipe shaft complete. (Fig. 15)  
(7C) Remove the following parts from Pipe shaft complete.  
• Hanger set • Spacer • Shaft  
Fig. 11  
Fig. 12  
Bike handle section  
Shaft pipe complete  
Pipe housing  
M5x18 Hex socket head bolt  
Pipe clamp  
M6x25 Hex  
socket head bolt  
Shaft pipe  
Fig. 13  
Fig. 14  
Fig. 15  
M5x30 Hex socket  
head screw (4 pcs.)  
Shaft  
Control lever assembly  
Wire clamp (2 pcs.)  
Loop handle 28  
Shaft pipe  
Shaft pipe  
complete  
Hanger set  
M5x14 Hex socket  
head bolt (2 pcs.)  
complete  
Handle clamp 28  
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P 6/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-3. Shaft pipe complete (cont.)  
ASSEMBLING  
For 4351UH:  
(1A) Insert Buffer rubber into Pipe housing so as to align the two grooves  
with the two ribs (Fig. 16) Set the four Buffer rubbers in place of  
Pipe housing. (Fig. 17)  
Fig. 16  
(2A) Insert two projections of Clutch case into Buffer rubbers.  
Insert two projections of Housing holder into the other Buffer rubbers,  
then tighten M5x18 Hex socket head bolt while holding Housing  
holder by hand. (Fig. 17)  
Ribs of Pipe housing  
Grooves of  
Buffer rubber  
Note: Make sure that Corrugate tube is put in the groove of Pipe housing.  
(Fig. 18)  
(3A) Assemble by reversing the disassembly procedure.  
For 4350UH and 4350LH:  
Assemble by reversing the disassembly procedure.  
Fig. 17  
Pipe housing  
Projections of Clutch case  
Buffer rubber (4 pcs.)  
Housing holder  
Fig. 18  
Groove of Pipe housing Corrugate tube  
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P 7/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-4. Gear case assembly  
DISASSEMBLING  
(1) According to the clause of [4]-3, Remove Gear case assembly. (Refer to Figs. 8, 9 and 10)  
(2) Remove M8x10 + Hex bolt from the grease inlet of Gear case assembly. (Fig. 19)  
(3) Remove Retaining ring R-26 with 1R006. (Fig. 20)  
(4) Remove an assembled part of Spiral bevel gear 13*, Ball bearing 6000ZZ, Ball bearing 6000 and Retaining ring S-10  
by tapping Gear case assembly with Plastic hammer. (Fig. 21)  
Note: If the assembled part cannot be removed, use a heat gun or hair dryer to warm Gear case assembly.  
(5) Remove Retaining ring S-10 with 1R291. (Fig. 21)  
(6) Receive Ball bearing 6000 with 1R031, then press down the shaft end of Spiral bevel gear 13 using 1R282 with  
Arbor press. (Fig. 22) Refer to Fig. 23 for the components.  
(7) Remove Retaining ring R-32 with 1R291. (Fig. 24)  
(8) Preset Receive washer and 1R033 with M10-17 Hex nut to Cutter shaft complete* as drawn in Fig. 25, and give  
the impacts using the plastic hammer. An assembled part of Cutter shaft complete* and Ball bearing 6201LLU is  
removed. Refer to Fig. 26 for the components.  
(9) Remove Ball bearing 6201LLU with 1R045.  
*Neither Spiral bevel gear 13 or Cutter shaft set is supplied individually. It is supplied as a set “Cutter shaft set”.  
Fig. 19  
Fig. 21  
Fig. 22  
Arbor press  
1R282  
M8x10  
+ Hex bolt  
Ball bearing  
6000ZZ  
Fig. 20  
Assembled part  
Ball bearing  
6000  
1R031  
Spiral bevel  
gear 13*  
Retaining ring S-10  
Retaining ring R-26  
Fig. 23  
Fig. 24  
M8x10  
+ Hex bolt  
Ball bearing 6000  
Ball bearing 6000ZZ  
Retaining ring S-10  
Spiral bevel gear 13*  
Retaining  
ring R-32  
Retaining ring R-26  
It was removed by the previous step (3).  
Fig. 25  
Fig. 26  
Receive  
washer  
1R033  
O ring 32  
Cutter shaft complete*  
M10-17  
Hex nut  
Ball bearing 629ZZ  
Ball bearing 6201LLU  
Retaining ring R-32  
It was removed by the previous step (7).  
Gear case  
assembly  
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P 8/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-4. Gear case assembly (cont.)  
Fig. 27  
ASSEMBLING  
1R028  
Assemble by reversing the disassembly procedure.  
Note:  
• Make sure that O ring 32 is put into the inner groove of  
Gear case assembly in advance.  
Ball bearing  
6000DDU  
The components of  
Cutter shaft complete  
• When mounting Cutter shaft complete into Gear case  
assembly, press-fit them together using arbor press and  
1R028 as shown in Fig. 27.  
Gear case assembly  
[4]-5. Clutch shoe  
DISASSEMBLING  
Warning: Remove Spark plug cap from Spark plug to prevent accidental engine starting.  
Note: Clutch can be easily removed with a cordless impact driver without locking Piston, because it is locked in a position  
due to the compressed air resistance in Cylinder.  
Therefore, do not remove Spark plug, or the air in Cylinder cannot be compressed.  
(1) Remove two Clutch shoes and Tension springs 5 by loosening each M8 Shoulder hex bolt counterclockwise. (Fig. 28)  
(2) Remove Clutch base by turning the hex portion counterclockwise. (Fig. 29)  
Fig. 28  
Fig. 29  
Clutch shoe (2 pcs.)  
Hex portion of  
Clutch base  
M8 Shoulder hex bolt  
(2 pcs.)  
Tension spring 5 (2 pcs.)  
ASSEMBLING  
(1) Set Clutch base in place by turning the hex portion clockwise.  
(2) Set two Clutch shoes and Tension springs 5 in place by tightening each M8 Shoulder hex bolt clockwise; first by hand,  
then with a cordless impact driver*  
*This is because the M8 Shoulder hex bolt is a shoulder bolt. Therefore, tighten by hand until the shoulder of the shaft portion contacts the upper end  
surface of Clutch shoe, then tighten fully with a cordless impact driver. (Fig. 30)  
Note:  
• Face the arrow marks on Clutch shoes toward the upper side. (Fig. 31)  
• Put Clutch shoe between Wave washer 10 and Flat washer 8, then tighten M8 Shoulder hex bolt.  
Refer to Figs. 30 and 31.  
Fig. 30  
Fig. 31  
Arrow marks on  
Clutch shoes  
(2 pcs.)  
M8 Shoulder hex bolt  
Wave washer 10  
Clutch base  
Flat washer 8  
(2 pcs.)  
shaft portion  
shoulder  
Clutch shoe  
Wave washer 10 (2 pcs.)  
M8 Shoulder hex bolt (2 pcs.)  
Flat washer 8  
Clutch base  
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P 9/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-6. Clutch drum  
DISASSEMBLING  
For 4351UH: Refer to Parts breakdown in Fig. 35.  
(1A) Remove four M6x20 Hex socket head bolts, then separate Clutch case from Engine. (Fig. 33)  
(2A) Remove Retaining ring (INT) R-42 in Clutch case with 1R006. (Fig. 33)  
(3A) Put 1R247 on Clutch drum in Clutch case, press down Clutch drum using Arbor press. (Fig. 34)  
Note: If it is difficult to remove Clutch drum from Clutch case, warm Clutch case with a heat gun.  
(4A) Remove Retaining ring (EXT) WR-20 from Clutch drum with 1R004.  
(5A) Remove Ball bearing 6004LLU from Clutch drum with 1R045.  
Fig. 32  
Clutch case  
M6x20 Hex  
Fig. 34  
Fig. 35  
Engine  
Arbor  
press  
Clutch case  
socket head screw  
(4 pcs.)  
1R247  
Clutch  
case  
Retaining ring  
(EXT) WR-20  
Fig. 33  
Inside view of  
Clutch case  
Clutch drum  
Ball bearing  
6004LLU  
Holes for  
access to  
Retaining ring  
(INT) WR-42  
Clutch drum  
Retaining ring  
(INT) WR-42  
Clutch drum  
Clutch case  
For 4350UH and 4350LH: Refer to Parts breakdown in Fig. 39.  
(1B) Remove four M6x20 Hex socket head bolts, then separate Clutch case from Engine. (Fig. 36)  
(2B) Remove three M5x20 Hex socket head bolts, then separate Pipe retainer from Clutch case. (Fig. 36)  
(3B) Remove Retaining ring R-35 in Clutch case with 1R006. (Fig. 37)  
(3B) Put 1R247 on Clutch drum in Clutch case, press down Clutch drum using Arbor press. (Fig. 38)  
Note: If it is difficult to remove Clutch drum from Clutch case, warm Clutch case with a heat gun.  
(4B) Remove Retaining ring S-17 from Clutch drum with 1R004.  
(5B) Remove Ball bearing 6003LLU from Clutch drum with 1R045.  
Fig. 36  
Fig. 38  
Fig. 39  
M6x20 Hex socket head  
screw (4 pcs.)  
Arbor  
press  
Clutch case  
M5x20 Hex  
socket head  
screw (3 pcs.)  
Clutch  
case  
1R247  
Spacer  
Retaining ring  
S-17  
Pipe retainer  
Clutch case  
Clutch drum  
Fig. 37  
Inside view of  
Ball bearing  
6003LLU  
Clutch case  
Clutch drum  
Retaining ring  
R-35  
Holes for  
access to  
Retaining ring R-35  
Clutch drum  
Clutch case  
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P 10/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-6. Clutch drum (cont.)  
ASSEMBLING  
For 4351UH:  
(1) Press-fit Ball bearing 6004LLU to Clutch drum with 1R031 in Fig. 40.  
Note: Put Retaining ring (INT) R-42 between Ball bearing 6004LLU and Clutch drum in advance.  
(2) Set Retaining ring (EXT) WR-20 in the groove on Clutch drum.  
(3) Put Clutch case on the table of Arbor press horizontally without tilt, and press-fit Clutch drum into Clutch case with  
1R286. (Fig. 41)  
(4) Set Retaining ring (INT) R-42 to the inner groove of Clutch case.  
(5) Assemble by reversing the disassembly procedure.  
Fig. 40  
Fig. 41  
Arbor press  
1R286  
Clutch drum  
Retaining ring (INT)  
R-42  
Clutch case  
Ball bearing 6004LLU  
1R031  
For 4350LH and 4350UH:  
(1) Press-fit Ball bearing 6003LLU to Clutch drum with 1R031 in Fig. 42.  
Note: Put Retaining ring R-35 between Ball bearing 6003LLU and Clutch drum in advance.  
(2) Set Retaining ring S-17 in the groove on Clutch drum.  
(3) Put Clutch case on the table of Arbor press horizontally without tilt, and press-fit Spacer and Clutch drum into  
Clutch case with 1R286. (Fig. 43)  
(4) Set Retaining ring R-35 to the inner groove of Clutch case.  
(5) Assemble by reversing the disassembly procedure.  
Fig. 42  
Arbor press  
Fig. 43  
Clutch drum  
1R286  
Retaining ring R-35  
Clutch case  
Ball bearing 6003LLU  
1R031  
Spacer  
(Refer to Fig. 39 of  
the previous page.)  
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P 11/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-7. Ignition system  
CHECKING PLUG CAP  
(1) Remove Plug cap from Spark plug, then check the continuity between Plug cap spring and the ground (earth) terminal  
of Ignition coil with a circuit tester. If there is normal continuity, the resistance value will be 2.0kΩ±0.5kΩ. (Fig. 44)  
(2) If there is no or intermittent continuity, check the continuity between Ignition cable and Plug cap spring by following  
the procedure described below.  
1. Apply spray lubricant in Plug cap, then pull out Plug cap spring together with Ignition cable from Plug cap using  
small pliers. (Fig. 45)  
2. Check if Plug cap spring is properly connected to Ignition cable. If not, connect them properly.  
Also check Plug cap for any crack. If Plug cap is cracked, replace it with a new one.  
3. Insert Plug cap spring in the center of Ignition cable. Then using small pliers, put them back into Plug cap while  
taking care not to disconnect Plug cap spring from Ignition cable.  
4. Make sure that Plug cap spring is firmly connected to Ignition cable by doing the same as you did in step (1) with  
a circuit tester.  
Note: Poor continuity between Plug spring cap and Ignition cable will result in no or weak spark.  
Fig. 44  
Fig. 45  
Plug cap  
Small pliers  
Plug cap spring  
Plug cap spring  
Ignition coil  
Circuit tester  
Primary wire of  
Ignition coil  
CHECKING SPARK PLUG  
WARNING !!  
• When a spark is produced, high-voltage current is delivered from Ignition coil to Spark plug.  
It is, therefore, very dangerous to pull Recoil starter knob with your hand on Ignition cable.  
Be sure to keep your hands off from Ignition cable when checking for spark.  
• Fuel is extremely flammable and fuel vapors are explosive.  
Therefore, clean up spilled fuel before starting to check for spark.  
Also, be careful not to do the check near Carburetor.  
(1) Remove Plug cap from Spark plug, then Spark plug from Cylinder with the supplied socket wrench.  
Note: If the electrodes of Spark plug are wet, wipe them with a rag then dry them with an air blower.  
(2) Using a wire brush, carefully clean up carbon deposits (if any) from the electrodes and the ceramic insulator  
around the center electrode.  
(3) Adjust the electrode gap to 0.7 to 0.8mm by carefully bending the side electrode.  
Use Feeler gauge set (1R366) to check the gap width:  
between the center electrode and the side electrode, insert 0.8mm leaf  
Fig. 46  
of Feeler gauge set. (Fig. 45)  
(4) Install another Spark plug into spark plug hole to prevent air/fuel  
side electrode  
Electrode gap  
mixture from leaking outside of engine.  
(5) Connect the removed Spark plug with Plug cap, then ground the threads  
of Spark plug to a proper metal part of the engine.  
must be  
0.7 to 0.8mm.  
(6) With Stop switch on, pull Recoil starter knob gently and check for spark.  
Note: • It is hard to see the spark in a bright location. Therefore, be sure to  
do the check in a shady but well-ventilated place.  
center electrode  
• Sparks do not happen at without exceeding 500 rpm.  
(7) If spark is not produced, replace Spark plug with a new one,  
then check for spark by following the procedure (1) to (6) once again.  
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P 12/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-7. Ignition system (cont.)  
Fig. 47  
Female terminal of  
REMOVING IGNITION COIL  
M4x20 Hex socket  
head bolt (2 pcs.)  
Primary wire  
(1) Before removing Ignition coil, separate Cylinder cover  
from Engine, and pull out Primary wire from Ignition coil  
in advance. (Fig. 47)  
(2) Remove two M4x20 Hex socket head bolts and Ignition coil  
from Engine. (Fig. 47)  
Ignition coil  
Note: Be careful to the torque to loosen the bolts because  
adhesive is applied on the threads under our quality  
control.  
Once removing their bolts, do not fail to apply adhesive  
to the threads.  
Spacer (2 pcs.)  
MOUNTING IGNITION COIL  
Fig. 48  
(1) Insert 0.3mm leaf of 1R366 between Ignition coil and  
the magnet of Flywheel. (Fig. 48)  
Ignition coil will be attracted to the magnet through 1R366.  
Then, without removing 1R366, fasten Ignition coil to  
Engine with two M4x20 Socket head bolts. (Fig. 47)  
(2) Remove 1R366. Then make sure that Flywheel does not  
touch Ignition coil by turning it by hand.  
Ignition coil  
0.3mm thick leaf  
of 1R366  
Flywheel  
[4]-8. Flywheel  
Fig. 49  
Warning: Remove Spark plug cap from Spark plug to prevent accidental  
engine starting.  
M8 Collared  
Hex nut  
Note: Flywheel can be easily removed with a cordless impact driver without  
using any locking tool, because Piston is locked in a position due to  
the compressed air resistance in Cylinder.  
Therefore, do not remove Spark plug, or the air in Cylinder cannot be  
compressed.  
DISASSEMBLING  
(1) Turn M8 Collared Hex nut in the center of Flywheel counterclockwise  
using a cordless impact driver. (Fig. 49)  
(2) Mount 1R364 on Flywheel, then screw two M5 bolts of 1R364 into  
Flywheel as drawn in Fig. 50.  
Fig. 50  
Flywheel can now be removed from Crankshaft complete by turning  
the center bolt of 1R364 clockwise using a screwdriver or the like.  
Important: Screw two M5 bolts evenly.  
ASSEMBLING  
1R364  
(1) Wipe off grease and oil from Crankshaft complete.  
(2) Aligning the key way of Crankshaft complete with Woodruff key 3 on  
Flywheel, install Flywheel onto Crankshaft complete. (Fig. 51)  
(3) Screw M8 Collared Hex nut to Crankshaft complete by turning it clockwise  
by hand.  
M5 bolt  
of 1R364  
(2 pcs.)  
(4) Tighten M8 Collared Hex nut firmly using an impact driver.  
Fig. 51  
Keyway in  
the hole of  
Flywheel  
Woodruff key 3 on  
Crankshaft complete  
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P 13/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-9. Recoil starter  
DISASSEMBLING  
Fig. 52  
Starter cover assembly  
Fig. 53  
(1) Remove Starter cover assembly by loosening  
four M5x20 Hex socket head bolts. (Fig. 52)  
(2) Pull Starter rope out of Starter cover assembly  
approximately one winding long.  
Reverse side of  
Starter cover assembly  
Then hook Starter rope on the U-shaped notch of  
Reel, and then turn Reel clockwise until Spiral  
spring is unwound. (Fig. 53)  
Note: Be careful with Reel because it will turn very  
fast.  
(3) Remove Reel from Starter cover by loosening  
5x10 Tapping screw.  
Note: Be careful with Spiral spring that can suddenly  
pop out of Starter cover.  
(4) Unite the knot of Starter rope to remove the rope  
from Reel.  
Starter rope  
M5x20 Hex socket  
head bolt  
(4 pcs.)  
U-shaped  
notch of Reel  
ASSEMBLING  
(1) If Spiral spring has popped out of Reel, put it back in place; hook the outer end of Spiral spring onto the spring hook  
of Reel first, then by winding Spiral spring counterclockwise towards the center of Reel. (Fig. 54)  
(2) Apply a little amount of Makita grease N No.2 to the whole surface of Spiral spring.  
(3) Put a new Starter rope through Starter cover.  
Then tie one end to Starter knob and the other to Reel by making  
a knot. (Fig. 55)  
Fig. 54  
Reel viewed from Starter cover side  
(4) Make sure that the inner end of Spiral spring is positioned close to  
the shaft portion of Starter cover for the step (6). Then put Reel in  
Starter cover.  
Inner end of  
Spiral spring  
(5) Wind Starter rope around Reel two or three times.  
(6) While turning Reel counterclockwise, mount it in Starter cover.  
The inner end of Spiral spring will be engaged with the spring hook  
of Shaft portion in Starter cover by the counterclockwise rotation of  
Reel. (Figs. 54 and 55)  
Outer end of  
Spiral spring  
Spring hook  
of Reel  
Note: You do not need force to mount Reel in place.  
(7) Fasten Reel to the shaft portion of Starter cover with  
Fig. 55  
M6x20 Set screw. (Fig. 56)  
Note: Reel is not properly set in place if the rotation of  
Reel is slow after the screw is fastened.  
Spring hook of Shaft portion  
in Starter cover  
Starter rope  
In this case, repeat steps (5) and (6) until normal  
rotation of Reel is obtained.  
(7) Hook Starter rope on the U-shaped notch of Reel.  
Then, while pulling Starter rope, turn Reel counter-  
clockwise. (Fig. 57)  
Starter rope  
Release Starter rope from the U-shaped notch and  
Starter rope will be wound around Reel due to the  
rotational force of Spiral spring. Repeat this operation  
until the slack is completely removed from Starter rope.  
about  
10mm  
about  
10mm  
Reel  
Fig. 56  
Fig. 57  
M6x20 Set screw  
Reel  
Starter rope  
Starter cover  
U-shaped notch of Reel  
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P 14/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-10. Carburetor section  
DISASSEMBLING  
Fig. 58  
Fig. 59  
(1) Press down the tab of Cleaner plate assembly gently and separate  
Air cleaner cover from Cleaner plate assembly by loosening  
M5x20 Hex socket button head screw. (Fig. 1 of [4]-2.)  
(2) Remove Air cleaner element. (Fig. 58)  
Air cleaner element  
M5x60 Hex socket  
head bolt (2 pcs.)  
(3) Remove two M5x60 Hex socket head bolts that fasten  
Carburetor assembly and Cleaner plate assembly to Insulator  
complete. (Fig. 59)  
Note: Remove the bolts completely, or Carburetor cannot be  
removed from Insulator complete.  
(4) Remove three tubes from Carburetor assembly, then separate  
Carburetor assembly from Engine.  
DISASSEMBLING/ CLEANING CARBURETOR  
(1) Remove four Pan head screws, then separate Metering cover, Metering diaphragm and Metering diaphragm gasket  
from Carburetor. (Fig. 60)  
Note: If Metering diaphragm gasket is sticking on the adjacent part, remove it with care because it is easily broken.  
(2) Check Metering diaphragm for shrinkage, hardening or breakage due to aged deterioration. If any, replace it with  
a new one.  
(3) The inner parts of Pump body assembly can be removed by separating the pan head screw designated in Fig. 61.  
(4) Before mounting the inner parts of Pump body assembly in place, make sure that the tip of Inlet needle is neither  
worn nor deformed. (Fig. 62)  
Note: The inner parts are not available individually. If you need any of the inner parts, order Pump body assembly.  
(5) When mounting Control lever, make sure that the upper end of Spring is firmly held in place under the projection of  
Control lever. (Fig. 63)  
(6) Remove the pan head screw of Pump cover. (Fig. 64)  
(7) Make sure that Inlet screen is not clogged, then set it back in place. (Fig. 65)  
(8) Spray Carburetor cleaner in all the fuel lines of Carburetor, then after several minutes, wash out dirt and debris with  
clean gasoline.  
Fig. 60  
Fig. 61  
Pan head screw (4 pcs.)  
Inner parts of Pump body assembly  
Pan head screw  
Inlet needle  
Pin  
Spring  
Control lever  
Carburetor  
Pump body assembly  
Fig. 62  
Fig. 63  
Correct assembling  
of the inner parts of  
Pump body assembly  
Wrong examples  
with good tip  
with worn tip  
Control lever is not parallel  
to Pump body assembly.  
Metering diaphragm  
Control lever  
Spring  
An Inlet needle with  
worn tip can cause  
a pressure leak.  
Debris in valve seat can The upper end of Spring  
cause a pressure leak. is out of place.  
Inlet needle  
Fig. 64  
Fig. 65  
Pump cover  
Pan head screw  
Inlet screen  
Carburetor body  
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P 15/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-10. Carburetor section (cont.)  
Fig. 66  
ASSEMBLING CARBURETOR  
Assemble by reversing the disassembly procedure.  
Carburetor  
Note: Make sure that the assembling direction of each part is correct.  
VACUUM LEAK TEST OF CARBURETOR  
1R127  
Connect 1R127 with the fuel inlet of Carburetor, then increase the testing  
pressure up to 0.05Mpa. The pressure will stay the same about 10 seconds  
if there is no vacuum leak. (Fig. 66)  
MOUNTING CARBURETOR  
(1) Fasten the following parts to Cylinder block assembly with two M5x60 Pan head screws. (Fig. 67)  
Carburetor gasket (2 pcs: small and large) , Carburetor, Cleaner plate assembly, Insulator complete  
(2) Connect three Tubes to Carburetor as drawn in Fig. 68.  
Then connect Tube 5-160 and Pipe to Cleaner plate assembly as drawn in Fig. 69.  
(3) Mount Air cleaner element onto Cleaner plate assembly.  
(4) Mount Air cleaner cover complete onto Air cleaner plate, then secure with M5x20 Hex socket head bolt. (Fig. 1 of [4]-2.)  
Note: Be sure to fit the tab of Cleaner plate assembly into the slot of Cleaner cover assembly.  
Fig. 67  
Fig. 68  
Carburetor gasket (large)  
behind Carburetor  
Tube 3-120 (blue)  
between Primer pump and Insulator complete  
and Carburetor  
Tube 3-35 between Carburetor Tube 3-250 (black)*  
between Carburetor  
and Fuel tank  
Carburetor  
*The component of  
Tube complete  
Carburetor  
gasket (small)  
Carburetor  
gasket (large)  
Carburetor  
gasket (small)  
Cleaner plate  
assembly  
Primer pump  
Fuel tank  
M5x70 Pan head  
screw (2 pcs.)  
(Spiral tube 6-100 to  
protect Tube 3-120)  
Insulator complete  
Carburetor  
Fig. 69  
Clamp on  
Rocker cover outer  
Clamp on Insulator complete  
Tube 5-160 and Pipe are connected as follows:  
Tube 5-160 (black) for Rocker cover outer  
and Cleaner plate assembly  
Cylinder  
block  
assembly  
(Corrugate tube) Cleaner plate assembly  
Cleaner plate  
assembly  
Pipe  
Tube 5-160  
(black)  
Pipe for Cleaner plate assembly and the nipple of Cylinder block assembly  
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P 16/ 22  
Repair  
[4] DISASSEMBLY/ ASSEMBLY  
[4]-11. Stop switch section  
CHECKING STOP SWITCH  
Fig. 70  
Check the continuity between the bullet terminals on the two lead wires  
extending from Control lever with a circuit tester. (Fig. 70)  
If Stop switch functions properly, there will be no continuity with  
the switch ON and there will be continuity with the switch OFF.  
[4]-12. Fuel tube section  
FUEL TUBE ROUTING  
Set Tube complete* in place as shown in Fig. 71.  
• Connect Tube 3-260 to Carburetor and Gasoline filter with Hose clamp.  
• Connect Tube 3-150 to the long pipe of Primer pump.  
• Connect Tube 3-120 to the short pipe of Primer pump.  
Also refer to Fig. 72.  
(3) Put Coil spring 8 and Clamp on Tube 3-150. (Fig. 71)  
(4) Route Tube 3-150 as drawn in Fig. 72.  
Route Tube 3-120 between Tube 3-150 and Cleaner plate assembly. (Fig. 73)  
Fig. 71  
Tube 3-260 (black)  
Breather (to intake air into Tank)  
(to Carburetor)  
Holders of  
Cleaner plate assembly  
Tube complete  
Breather  
long pipe of  
Primer pump  
Hose clamp  
Tube 3-260  
(black)  
Gasoline filter  
Clamp  
Tube  
3-150  
(blue)  
Coil  
spring 8  
Grommet  
short pipe of Primer pump  
to connect Tube 3-120  
(Refer to Figs. 68 and 69.)  
Tube 3-150 (blue)  
(to intake air into Tank)  
Fuel tank  
Fig. 72  
Fig. 73  
Tube 3-120  
Tube 3-260  
(black)  
Tube 3-150 (blue)  
Nipple of Carburetor  
(blue)  
Tube 3-120  
(blue)  
Tube 3-150  
(blue)  
Spiral tube  
6-100  
Fuel tank  
Breather  
Pipe  
Spiral tube 6-80  
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P 17/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-13. Engine block  
DISASSEMBLING  
(1) It is highly recommended to drain the oil system of Engine block before starting disassembling  
because the oil remaining there will drip out to delay your operation.  
(2) From the engine section, remove the following parts):  
Ignition coil, Flywheel complete, Rocker cover inner, Rocker cover outer, Rocker arm assembly (2 pcs),  
Rod 2.5 (2 pcs), Cam lifter (2 pcs), Cam gear assembly, Insulator complete, Cleaner plate assembly, Carburetor,  
Spark plug, Exhaust muffler.  
(3) Remove the assembly of Cylinder head and Cylinder block. (Fig. 74)  
(4) Remove Clip (2 pcs. in total) from each end of Piston pin with a pointed tool such as an awl as shown in Fig. 75.  
Note: Be careful with Clip because it can pop out unexpectedly during removal operation.  
Do not use removed Clip. Be sure to replace it with new one.  
(5) Remove Piston pin with 1R171 or the like as shown in Fig. 76.  
(6) Remove Piston from Crankshaft complete, then separate Top ring, Second ring and Oil ring from Piston.  
Note: Mark on one of Top or Second ring to distinguish the original position for reassembling.  
Fig. 74  
Fig. 75  
Cylinder head  
Cylinder block  
Piston  
Awl  
Clip  
Piston  
Crank shaft  
complete  
Fig. 76  
1R171  
Piston pin  
Crank case  
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P 18/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-13. Engine block (cont.)  
ASSEMBLING  
(1) Connect Piston with Crank shaft complete by inserting Piston pin into place; there is no front/back to Piston.  
Note: Be sure to apply a little amount of Makita grease N No.2 to Needle roller bearing.  
(2) Secure Piston pin by mounting Clip onto each end of Piston pin. Any setting direction is allowed.  
(3) Install Oil ring in the grooves of Piston; Side rail first, Spacer next, then the other Side rail.  
Important: Be sure to fit the three rings with the ring gaps at 120 degrees to one another as shown in the left of Fig. 77.  
(4) Install Second ring first then Top ring in the groove of Piston.  
Important 1: Be sure to fit the two rings with the ring gaps at 180 degrees to each other as shown in the right of Fig. 77.  
Important 2: Second ring has a taper face and must be installed with the large diameter facing Oil ring. (Fig. 78)  
Distinguishing between Top ring and Second ring & Discriminating the larger diameter of Second ring:  
If both of the two rings are new and unused,  
• You can distinguish from their appearances; there is a T marking on the right upper end of Second ring as shown in  
Fig. 75 while not on the upper end of Top ring.  
• You can face the large diameter of Second ring by placing Second ring with the T marking on your right and  
with the ring gap near you as shown in Fig. 79.  
If both of the two rings are used and the T marking of Second ring is rubbed off, carefully press the side face of  
the two rings to the inner wall surface of Cylinder. You will be able to distinguish the two rings or to discriminate  
the large diameter of Second ring through the differences in contact feelings that the different side faces make.  
Fig. 77  
ring gap  
Oil ring  
ring gap  
Top ring  
Side rail  
Second ring  
ring gap  
Spacer  
Side rail  
ring gap  
ring gap  
Fig. 78  
Fig. 79  
Second ring  
Note: Makita genuine second ring  
has T marking on the right  
upper end if it is not worn out.  
Face the T marking toward  
upward for assembly.  
Top ring, with barrel face  
Second ring, with taper face  
Side rail  
T
Spacer  
Oil ring  
Side rail  
T marking  
Fig. 80  
(5) Apply 4-cycle engine oil to the following portions:  
Oil ring, Needle roller bearing that holds Piston pin,  
Needle roller bearing of Crank shaft complete.  
(6) Remove oil/grease from the mating surface of  
Cylinder block and Crank case.  
Crank case viewed  
from the upper side  
Then apply ThreeBond 1215/ 1216 carefully to  
the mating surface of Crank case as shown in Fig. 80.  
Note: Do not apply the adhesive to the area  
designated by the enlarged view.  
Apply 4-cycle engine oil to the sliding surface of  
Piston section and Cylinder block assembly, and then  
while compressing Piston rings, mount Cylinder block  
onto Crank case.  
Gray colored portions:  
where the adhesive should  
be applied  
Do not apply the adhesive  
to the designated area.  
(7) Tighten eight M6x25 Hex socket head bolts in  
a crisscross pattern.  
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P 19/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-13. Engine block (cont.)  
DISASSEMBLING  
(8) Adjust Valve clearance as follows:  
1. Align the marks on the following parts:  
Fig. 83  
• Ignition coil and Flywheel complete (Fig. 81)  
• Cam gear assembly and Cylinder block (Fig. 82)  
2. Set two Cam lifters and two Rods 2.5 in place, then assemble two Rocker arm  
assemblies to them.  
Note: The ends of two Rods 2.5 have to be fit into the holes on Rocker arm assemblies  
and Cam lifters. (Fig. 83)  
3. Assemble Cam gear cover gasket and Cam gear cover to Cylinder block assembly by  
tightening four M5x16 Hex socket head bolts firmly.  
Hole on  
Rocker arm  
assembly  
4. Revolve Flywheel assembly two turns clockwise (Fig. 84) and align the marks on  
Flywheel complete and Ignition coil to move Piston to the upper dead point. (Fig. 81)  
Rod 2.5  
Fig. 81  
Mark on Ignition coil  
Mark on Flywheel  
Fig. 82  
Mark on  
Cam gear assembly  
Hole on  
Cam lifter  
Mark on  
Cylinder block  
5. Tighten Hex nuts of Rocker arm assemblies, then loosen Adjusting screws of Rocker arm assembly.  
Insert 0.08mm thick leaf of 1R366 into the clearance between Rocker arm and Valve section (Re: Fig. 85), then  
adjust the valve clearance.  
6. After checking the feeler gauge can be passed through the clearance and the clearance itself is not more than  
0.12mm, tighten Hex nuts of Rocker arm assembly securely, and then remove the gauge from the clearance.  
Note: While making two Rocker arms close to the center (Fig. 86), adjust the valve clearance with Hex nuts pushing  
down by hand slightly (Fig. 87) and check the valve clearance.  
After setting Spark plug in place and turning Flywheel left and right to 45° two or tree times (Fig. 88), retry  
checking of the valve clearance.  
Fig. 84  
Fig. 85  
Fig. 86  
Rocker arm (2 pcs.)  
0.08 mm thick leaf  
of 1R366  
Hex bit  
1R170  
M5 Hex nut (2 pcs.)  
Refer to Fig. 81 for  
the cross section.  
Adjusting screw (2 pcs.)  
Fig. 87  
Rocker arm  
Fig. 88  
Push down Hex nut of  
Rocker arm  
Valve section  
Rod 2.5  
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P 20/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-13. Engine block (cont.)  
ASSEMBLING  
Assemble by reversing the disassembly procedure.  
[4]-14. Valve section  
DISASSEMBLING  
(1) Remove two Rocker arm assemblies and Pin 5 from Cylinder block assembly. (Fig. 89)  
(2) Push a rag into Cylinder block assembly from the bottom side so as not to fall off Intake valve and Exhaust valve.  
The rag works as protection of the inside of Cylinder block assembly.  
(3) Remove Cotters, Retainers and Compression springs 11 from Intake valve and Exhaust valve with 1R389 and 1R005.  
(Figs. 90 and 91)  
Fig. 89  
Fig. 91  
Rocker arm assembly  
Cotter (4 pcs.)  
(2 pcs.)  
Pin 5  
Retainer (2 pcs.)  
Compression spring 11 (2 pcs.)  
Fig. 90  
1R389  
1R005  
Exhaust  
valve  
Intake  
valve  
Cotter  
(4 pcs.)  
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P 21/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-14. Valve section (cont.)  
ASSEMBLING  
(1) Apply 0.05cc of 4-cycle engine oil to Exhaust valve and Intake valve as drawn in Fig. 92, then insert them into  
the holes in Cylinder block assembly. (Fig. 93)  
(2) Push a rag into Cylinder block assembly so as not to fall off Intake valve and Exhaust valve.  
(3) Assemble Retainers, Cotters and Compression spring 11 to Cylinder block assembly as drawn in Figs. 91 and 90,  
then while pushing Compression springs 11, pass the valve tops through the holes of Retainers, (Figs. 94 and 95)  
Then assemble Retainers, cotters and valves each other.  
Note: If it is difficult to assemble them, use 1R389 with 1R005.  
(4) Set Pin 5 and two Rocker arm assemblies in place of Cylinder block assembly. (Fig. 89)  
Fig. 92  
Fig. 93  
10mm up to  
15mm  
10mm up to  
15mm  
Holes in Cylinder  
block assembly  
4-cycle engine oil  
Fig. 94  
Fig. 95  
Cotters  
Exhaust valve  
Intake valve  
Rag to prevent Valves from falling  
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P 22/ 22  
Repair  
[4] DISASSEMBLY/ASSEMBLY  
[4]-15. Tightening torque specifications  
Application  
(for fastening A and B)  
Tightening torque  
(N.m)  
Fastener  
A
Cylinder block  
Crank case  
B
Crank case  
M6x25 Hex socket head bolt (8 pcs.)  
M5x18 Hex socket head bolt  
11.0  
6.0  
Retainer plate  
Crank case  
Flywheel  
Oil case  
M5x18 Hex socket head bolt (4 pcs.)  
M8 Collared hex nut  
6.0  
16.0  
4.0  
Crank shaft  
Ratchet  
Flywheel  
M5x12 Hex socket button head bolt (2 pcs.)  
Ignition coil  
Cam gear cover  
M4x20 Hex socket head bolt (2 pcs.)  
M5x16 Hex socket head bolt  
M5 Hex nut (2 pcs.)  
4.0  
6.0  
6.0  
Cylinder block  
Rocker arm adjusting screw M5 Hex nut  
Rocker cover outer  
Clutch base  
Cylinder block  
Crank case  
M5x18 Hex socket head bolt (4 pcs.)  
M8 Hex portion of Clutch base  
M8 Shoulder hex bolt (2 pcs.)  
6.0  
16.0  
10.0  
Clutch shoe  
Clutch base  
Muffler  
Cylinder block  
M6x20 Hex socket head bolt  
M6x20 Hex socket head bolt (4 pcs.)  
Spark plug (M10-pitch 1.0)  
11.0  
11.0  
12.0  
Engine base  
Spark plug  
Cylinder block, Crank case  
Cylinder block  
Insulator complete  
M5x20 Hex socket head bolt (2 pcs.)  
M5x20 Hex socket head bolt (4 pcs.)  
6.0  
5.0  
Cylinder block  
Crank case  
Starter cover assembly  
Muffler plate  
M5x18 Hex socket head bolt (3 pcs.)  
5.0  
Oil pipe  
Oil case  
Insulator  
M5x18 Hex socket head bolt  
M5x60 Hex socket head bolt  
5.0  
4.0  
Cleaner plate assembly  
Cleaner cover assembly  
Cylinder cover  
Cleaner plate assembly  
Engine base  
M5x20 Hex socket head bolt  
0.5  
2.5  
M5x20 Hex socket head bolt (4 pcs.)  
Cylinder cover  
Starter cover assembly  
M5x20 Hex socket head bolt  
2.5  
5.0  
M5x14 Hex socket head bolt (2 pcs.)  
Gear case assembly  
Shaft pipe complete  
M6x30 Hex socket head bolt  
M6 Nut  
13.0  
1.5  
Control cable  
Pipe bracket  
Insulator  
Shaft pipe complete  
M5x18 Hex socket head bolt  
5.0  
Cleaner plate  
M6x30 Hex socket head bolt  
M5x18 Hex socket head bolt  
9.0  
5.0  
EM4351UH  
Housing holder  
Shaft pipe complete  
EM4350UH  
Pipe clamp  
Pipe holder  
M6x25Hex socket head bolt  
M5x14 Hex socket head bolt  
6.0  
2.5  
EM4350LH  
Control lever assembly  
Shaft pipe complete  
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