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6

(1) Remove Sprocket guard, Guide bar and Saw chain from the machine.

(2) Remove “Recoil starter section”. See 

[2]-7.

(3) Remove Spark plug and set 1R372 into the hole for Spark plug to prevent Crank shaft from being turned together with 

      M8x1 Hex nut in the next step.

(4) Remove M8x1 Hex nut by turning it counterclockwise with Socket wrench, and then remove Spring washer 8. (

Fig. 19

)

(5) While holding the machine by hand or securing it on workbench with soft cloths seated on, tap Crank shaft end with 1R090.

      Flywheel is removed from the taper portion of Crank shaft by the shock. (

Fig. 20

Fig. 19

Fig. 20

R

epair

DISASSEMBLING

[2] DISASSEMBLY/ ASSEMBLY

[2]-7. Recoil starter section

Socket wrench

Flywheel complete

M8x1 Hex nut

Spring washer 8

(between M8x1

  Hex nut and 

  Flywheel complete)

1R090

Hold the machine.

Refer to 

Figs. 17 and 18

 for the mechanism of Recoil starter section. 

(1) Remove three 5.5x16 Hexalobular tapping screws and Housing of 

      Starter complete. (

Fig. 17

)

(2) Remove Air guide plate. and then loosen the force of Rewind spring

      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 step (3).

(3) Remove 5x12 Tapping screw, and then separate Cam plate and Torsion 

      spring 20 from the center pin of Housing.

(4) Remove Reel from the center pin of Housing.

(5) Remove Rewind spring set from Housing by rotating Housing carefully.

Note

: Rewind spring may pop out of Housing, and therefore, wear goggles 

          for eye protection and gloves.

          If Rewind spring has popped out, reset it in Spring cassette.

          Refer to “Rewind spring set” in 

Fig. 18

.  

DISASSEMBLING

Fig. 18 

(The components of Starter complete)

Fig. 17

Air guide plate

5x12 Tapping screw 

Cam plate

Reel

Rewind

spring

Rewind spring set 

(factory-assembled)

(Housing of Starter

complete)

Housing of 

Starter complete

Square washer 4

Starter rope

Center pin of 

Housing

Starter grip

Spring

cassette

Torsion spring 20

5.5x16 Hexalobular tapping screw (4 pcs.)

[2]-8. Flywheel

Set Flywheel to the taper of Crank shaft, and place Spring washer 8. Then, tighten M8x1 Hex nut to fastening torque

20 ± 5 N·m.

Note

: The taper portion of Crankshaft must always be degreased before assembly.

ASSEMBLING

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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