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9. PRECAUTIONS IN DISASSEMBLY AND REASSEMBLY
The [Bold] numbers in the descriptions below correspond to the item numbers in the Parts List and exploded
assembly diagram.
9-1. Disassembly
(1) Piston and striker
Remove the four Nylock Bolts (W/Flange) M5 x 16 [31] at the Crank Case Cover Ass'y [33] and remove the
latter. Remove the four Nylock Bolts (W/Flange) M6 x 35 [59] at the Cylinder Case [58] and pull the Cylinder
Case out of the Crank Case [35]. Pull out the Piston Pin [78] and remove the Piston [75]. Remove the
Connecting Rod Ass'y [76] from the Crank Shaft [40] by removing the Retaining Ring for D12 Shaft [39]. Pull
out the Striker [72] by hammering on the Cylinder Case with a plastic hammer. If it is difficult to pull out the
Striker, push the removed Piston together with the Connecting Rod Ass'y into the Cylinder [67] and quickly pull
them out, and the Striker will jump out together with the Piston.
(3) Disassembly of the tool holder
Slide the Grip [2] fully in direction indicated by the
arrow as shown in Fig. 18 and remove the Front
Cap [1] (since the Front Cap is made of rubber,
grasp its outer face and strongly pull it to remove).
This allows the Grip, Stopper Ring [3], Needle
Holder [4], Retainer Spring [5], Needle Rollers
(2 pcs.) [51] and Spring Holder [6] to be separated
from the Retainer Sleeve [52].
(2) Removing gears from the crank case
Remove the Retaining Ring for D17 Shaft [47] and the Thrust
Washer [46] from the Crank Shaft [40]. Pull out the First
Gear [45] with a bearing puller. Remove the Feather Key
5 x 5 x 15 [29]. Remove the Slip Clutch Ass'y [27] by
hammering the Crank Case [35] from the Gear Cover [50]
side with a plastic hammer. Remove the two Nylock Hex.
Socket Hd. Bolts M5 x 16 [38] from the Bearing Cover [43]
and pull out the Crank Shaft from the Gear Cover side.
The Slip Clutch Ass'y can be removed with the following
procedure. First, pull out the Ball Bearing 629VV [26] with a
bearing puller. Support Washer (A) [20] on a sleeve as
shown in Fig. 17 and release the press-fitted Bevel Pinion
[16] by pushing it from the Spacer [25] side using a hand
press. When removing the Gear Holder [21] from the
Second Gear [24], it is recommended to keep them inside a
vinyl bag during disassembly to prevent
Springs (C) [22] and Needle Pins D6 x 6 [23] from
scattering.
Fig. 17
Fig. 18
Front Cap [1]
Grip [2]
Washer (A) [20]
Sleeve
Spacer [25 ]
Bevel pinion [16]
