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(1) Remove Clutch drum section and Clutch section. Refer to 

      [2]-2 “Clutch drum section” and [2]-5 “Clutch section”

(2) Remove Tension spring 10. Refer to 

[2]-3 “Chain brake section”

.

(3) Remove Pump drive from Crank shaft while sliding Pump drive 

      back and forth slowly to disengage with Gear teeth of Oil pump 

      adjustment set.

(4) Remove Oil suction line complete from Oil pump complete.

(5) Remove Oil pump complete from Engine housing complete 

      by unscrewing 4.7x16 Hexalobular tapping screw. 

(6) Oil suction line complete is in Engine housing complete

      with Oil pump complete and Chain oil tank connected. And 

      therefore, pull Oil suction line complete carefully out of 

      Engine housing complete, then remove Oil suction line 

      complete from Oil pump complete as drawn in 

Fig. 15

.

Note

: Even if some of Oil pump complete are out of order, 

          replace all the Oil pump complete with new one.

While pushing Adjusting screw against its compression spring 

reaction force, turn the screw counterclockwise until the pin ends

are fit into two slits of Oil pump body. If this way is difficult, 

push Piston slightly in the direction of Body.

Note

: When set Oil pump complete in place, turn Adjusting 

          screw counterclockwise to the full.   

Refer to 

Figs. 15 and 16

 for the mechanism of Oil pump section. 

Oil pump to supply Chain oil runs by Pump drive on Crank shaft.

The gear teeth of Pump drive are engaged with those of Oil pump,

and therefore, Chain oil is supplied to Chain when Engine runs.

The fluid amount of Chain oil can be adjusted by turning Adjusting

screw as follows:

clockwise = increase

counterclockwise = decrease

Fig. 15

R

epair

DISASSEMBLING

ASSEMBLING

[2] DISASSEMBLY/ ASSEMBLY

[2]-6. Oil pump section

Fig. 16

Pump drive

4.7x16 

Hexalobular

tapping screw

4.7x16 Hexalobular tapping screw

Gear teeth of

Oil pump 

adjustment set

Adjusting screw

for oil fluid

Oil pressure line

complete

Oil pressure

line complete

Oil suction line complete

Pump drive

Oil pump complete

Oil pump adjustment set

Adjusting screw with 

compression spring

Pin ends

Pass Pin ends through

Slits to remove

Adjusting screw.

Piston

Body

Slits

Summary of Contents for EA3500S

Page 1: ...Mixed gasoline Mixture ratio of 50 1 JASO FC or ISO EGD Specifications Model Type Dry weight kg lbs Speed at no load min 1 rpm Starting system Yes Rapid start Spring assisted recoil starter Decompres...

Page 2: ...g with 1R223 1R254 when removing assembling Hexalobular tapping screw socket head bolt Torque wrench shaft 20 90N m 1R223 Torque wrench shaft 2 6N m 1R254 adjusting a proper gap between Flywheel and I...

Page 3: ...h drum assembly if chain brake works Fig 5 5 Remove Clutch drum assembly Fig 6 1 Check that the following portions of Clutch drum assembly do not have damage wear Fig 5 Inside Chain sprocket portion N...

Page 4: ...l starter section 9 Remove 4 7x16 Hexalobular tapping screw and Flat washer 5 from Starter complete installation side on Hand guard Fig 8 10 Remove Stop ring E 4 from Pin A of Engine housing complete...

Page 5: ...areful to each direction Note Wear gloves for safety Be careful that Muffler stays very hot for a while after running the engine Fig 10 Repair DISASSEMBLING 2 DISASSEMBLY ASSEMBLY 2 4 Muffler section...

Page 6: ...5 to two Clutch shoes Be careful to the hooking direction of Tension springs 5 When one of Tension spring 5 has a damage replace two Tension springs 5 with the new at the same time Do not replace the...

Page 7: ...ce turn the screw counterclockwise until the pin ends are fit into two slits of Oil pump body If this way is difficult push Piston slightly in the direction of Body Note When set Oil pump complete in...

Page 8: ...ng as follows After making the slack of rope between Starter grip and Reel put the slack into the groove of Reel and pull the starter grip lightly Note Be sure to loosen the spring force before the st...

Page 9: ...washers into two seated holes of Cylinder 2 Pretighten Ignition coil in place by tightening two M5x20 Hexalobular socket head bolts through Isolating washers 3 Insert 1R366 between Ignition coil and...

Page 10: ...ke lever 5 5x16 Hexalobular tapping screw 2 pcs Tube 2 5 112 to Fuel nipple Contact spring 3x10 Tapping screw Grounding wire of Cable harness Tube 2 5 72 removed from Carburetor Guide pin of Engine ho...

Page 11: ...ck Diaphragm assembly metering Refer to Figs 31 and 32 Check that the tip of Valve inlet needle is not worn Replace it the new one if it looks worn Check that Lever metering is not worn and it is asse...

Page 12: ...n of Tank assembly 2 Set Catch lever to the hinge position of Tank assembly Fig 36 Note Torsion spring 10 has to be hooked with Throttle lever as drawn in Fig 37 See Fig 34 and the explanation Assembl...

Page 13: ...ant Supply Soap liquid onto the suspicious surface of Fuel leakage during the pressure test After the above steps reverse the disassembling procedure of DISASSEMBLY of 2 11 Tank assembly Pick up Gasol...

Page 14: ...ide Be sure to use New Gasket Fig 11 and New Crank case sealing When replacing Ball bearing 6201 press fit the inner ring portion to Crank shaft using the same size pipe and a block for placing the co...

Page 15: ...be 0 5 mm Is the gap between Flywheel and Ignition coil 0 25 0 3 mm Is the gap even without any contact wear Is there damage to Insulation of High voltage cable or Ignition cable or coils of Igniton...

Page 16: ...onent of Muffler complete and Cooling plate 266605 8 2 M5x16 Hexalobular socket head bolt 8 1 266606 6 1 M5x40 Hexalobular socket head bolt 8 1 Carburetor 266604 0 2 M4x40 Hexalobular socket head bolt...

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