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11. Disassembly and reassembly of the ignition coil and magneto rotor

[Tools required]

• J-363 jig (No. 6694822) (8 x 120 handle)

• J-357 (No. 6695737) (center bolt)

• J-356 jig (No. 6695736) (complete rotor extraction tool)

• J-358 jig (No.

6695738) (stepped bolt 6 mm)

• Box-end wrench 10 x 19 mm

• Socket wrench (12 mm)

• Hex. bar wrench (3 mm)

• Hook wrench (for

85-92)

(1) Disassembly

Remove the recoil starter, cleaner, muffler, clutch, pump ass’y, intake, and engine case before

disassembling the ignition coil and magneto rotor.

• Remove Cord (A)

[83]

from the Ignition Coil

[82]

• Use a hex. bar wrench (3 mm) to remove the two Hex. Socket Hd. Bolts (W/Flange) M4 x 18

[79]

, and

then remove the Ignition Coil

[82]

, Cord

[78]

, and two Glass Washers

[81]

• Use a socket wrench (12 mm) to loosen the Flywheel Nut M7

[103]

and then align the tip of the screw

portion of the Crank Worm Ass’y

[89]

with the upper face of Flywheel Nut M7

[103]

• Attach the J-356 jig (No. 6695736) (complete rotor

extraction tool), J-357 (No. 6695737) (center bolt),

J-358 jig (No.

6695738) (stepped bolt 6 mm) (2

pcs.), and J-363 jig (No. 6694822) (8 x 120 handle)

as shown in the right figure, rotate the J-363 jig (No.

6694822) (8 x 120 handle) in the arrow direction,

and then tighten J-357 (No. 6695737) (center bolt)

to disassemble the magneto rotor.

CAUTION: Before tightening J-357 (No. 6695737)

(center bolt), attach Flywheel Nut M7

[103] at the tip of the screw portion of

the Crank Worm Ass’y [89]; otherwise,

the screw portion may be damaged.

• Remove the two Retaining Rings D4

[98]

of the

Magneto Sub Ass’y

[97]

, and then remove the two

Starter Pawls

[101]

and two Starter Pawl Springs

[100]

• Ignition coil and magneto rotor

• Removing the magneto rotor

Ignition Coil

[82]

Cord (A)

[83]

Cord

[78]

Hex. Socket Hd. Bolts
(W/Flange) M4 x 18

[79]

Glass Washers

[81]

Flywheel Nut M7

[103]

Bolt Washer D7

[102]

Starter Pawl

[101]

Starter Pawl Spring

[100]

Retaining
Ring D4

[98]

Engine ass’y

Woodruff Key 3 x 13 x 4.5

[94]

Magneto Sub Ass’y

[97]

Magneto Rotor Comp.

[99]

Crank Shaft

[93]

(Crank Worm Ass’y

[89]

)

Cord Insulation
Tube L60

[76]

J-363 jig (8 x 120 handle)

J-357 (center bolt)

Magneto Sub Ass’y

[97]

J-356 jig
(complete rotor
extraction tool)

J-358 jig
(stepped bolt 6 mm)

Содержание CS 33ED

Страница 1: ...tional Sales Division TROUBLESHOOTING GUIDE 1 1 Troubleshooting and correction 1 REPAIR GUIDE 3 1 Precautions on maintenance inspection and repair 3 2 Inspection criteria for each section and consumable parts 3 CONTENTS Page LIST Nos CS 33EDP F050 CS 33ED F049 Mar 2014 C ...

Страница 2: ... voltage cord Repair or replace Ground connection of high voltage cord Repair Disconnected or faulty ignition coil ass y Replace Large gap between the magneto rotor circumference and ignition coil ass y Adjust The spark plug does not become wet with fuel after repeated starting operation No fuel in the fuel tank Add properly mixed fuel 25 1 to 50 1 Clogged fuel filter Clean or replace Faulty fuel ...

Страница 3: ...e Clean Defective sealing of the packing Replace Faulty carburetor ass y Adjust clean or replace Excessive fuel consumption Clogged air cleaner Clean Poorly adjusted carburetor ass y Adjust Chain oil is not discharged Insufficient amount of chain oil in the oil tank Replenish chain oil in the oil tank Clogged chain oil discharge port Clean Clogged oil filler port on the guide bar Clogged oil filte...

Страница 4: ...guide bar and saw chain attached make sure that there are no other people nearby Ensure proper ventilation when performing repair in a small room or other poorly ventilated space After repair confirm that the throttle lever returns to the idling state and the engine stops when the stop switch is turned to the stop position 2 Inspection criteria for each section and consumable parts Model Item CS 3...

Страница 5: ...ace Excessive gap between magneto rotor circumference and ignition coil Adjust No fuel in fuel tank or improper mixing ratio Add properly mixed fuel 25 1 to 50 1 Clogged fuel filter Clean replace Bent fuel pipe Adjust Cracked fuel pipe Replace Fallen fuel pipe Connect Faulty tank vent hole inner cap Replace Faulty pump diaphragm of carburetor ass y Replace Dirt clogged carburetor ass y Clean Poorl...

Страница 6: ...lean Chain brake set on Release Poorly adjusted carburetor ass y Adjust Faulty carburetor ass y pump diaphragm Replace Dirt clogged carburetor ass y Clean Dirt clogged high speed fuel line of the carburetor ass y Clean Air intake from the packing section Inspect Faulty carburetor ass y pump diaphragm Replace Poorly adjusted carburetor ass y Adjust Revolutions low for idling Adjust Poorly adjusted ...

Страница 7: ...e port Clean Clogged guide bar oil feed port Clean Clogged oil filter Clean Poorly adjusted chain oil discharge amount Adjust Defective oil pump Replace Use of high viscosity chain oil in cold weather Use genuine or low viscosity chain oil for winter use Is chain oil discharged No ...

Страница 8: ...Lever 156 d Pull the starter handle several times 2 Insert Spark Plug Ass y BPMR7A 73 into the Spark Plug Cap 77 and then place the electrodes in contact with the metallic portion of the engine Under these conditions set the Stop Switch 147 to the startup position and pull the starter handle 3 When all the above steps are completed normally the electrodes of Spark Plug Ass y BPMR7A 73 should make ...

Страница 9: ...bly can be conducted by reversing the disassembly procedure However special attention should be given to the following items Do not bend the Fuel Pipes FKM 71 163 and Fuel Pipe 2 5 x 4 x 90 168 See 9 Connecting the fuel pipes for details Turn the Choke Lever 153 to Close and confirm that the Choke Lever 153 automatically returns to Open and the choke valve of the Carburetor Ass y 9 opens to the in...

Страница 10: ...andle 195 See the figure Tightening the Flange Nut M6 165 on the next page Use a 10 mm wide box wrench socket type to remove the Antivibration Spring 161 2 Reassembly Reassembly can be conducted by reversing the disassembly procedure However special attention should be given to the following items Reassemble the anti vibration mechanism of the Front Handle 195 by following the procedure below Fron...

Страница 11: ...by using a flat blade screwdriver and then tighten Flange Nut M6 165 by using a box end wrench 10 x 19 mm so that the Spring Holder 159 does not co rotate d Hold Flange Nut M6 165 by using a box end wrench 10 x 19 mm and then tighten the bolt of the Spring Holder 159 to 4 5 0 5 N m by using a torque wrench with a minus bit Antivibration Spring 161 1 mm or less Antivibration Spring 161 must not pro...

Страница 12: ...S 186 from the Reel NS 191 with the Starter Rope NS 186 loosened Loosen the Set Screw NS 189 to remove the Cam Plate NS 190 Reel NS 191 and Spiral Spring NS 192 CAUTION Removing the Reel NS 191 without releasing the windings of the Spiral Spring NS 192 may cause the Spiral Spring NS 192 to jump out possibly resulting in injury Fan Case NS 187 Air Deflector Ass y 188 Set Screw NS 189 Cam Plate NS 1...

Страница 13: ... 191 side by using a single knot and tie the end of the rope on the Starter Knob 185 side by using a slide knot Mount the Reel NS 191 and Spiral Spring NS 192 so that the pawl of the reel interlocks with the hook at the end of the spring Turn the Reel NS 191 clockwise and confirm that the Reel NS 191 is rewound by spring force Mounting the Spiral Spring NS 192 Matching Apply about 0 5 gram of Shel...

Страница 14: ...1 and wind the Starter Rope NS 186 If the Starter Rope NS 186 cannot be fully wound wind it again as per the procedure above Confirm that the Reel NS 191 rotates three or four times until the Starter Rope NS 186 is fully pulled If the Reel NS 191 rotates less than three times replace the Starter Rope NS 186 Also confirm that the Reel NS 191 rotates clockwise a half turn more when the Starter Rope ...

Страница 15: ... and Trigger Lockout 144 in the Rear Handle 166 Pull out the Spring Pin 5 x 25 146 and remove the Throttle Lever 156 and Throttle Lever Spring 145 Remove Cord A 83 and the Cord 78 from the Stop Switch 147 Push the Stop Switch 147 from inside to outside and remove it from the Rear Handle 166 If the switch proves difficult to remove push it out while pushing the retaining pin on the upper surface of...

Страница 16: ...he Clutch 30 and then remove the Clutch Housing Comp 31 Needle Bearing D 32 Clutch Washer 33 and Crank Shaft Collar 34 2 Reassembly Reassembly can be conducted by reversing the disassembly procedure However special attention should be given to the following items Insert Needle Bearing D 32 into the Crank Worm Ass y 89 and apply 0 3 to 0 5 gram of Albania RL3 around the periphery Perform reassembly...

Страница 17: ... given to the following items If the Oil Pipe 49 or Air Vent Valve B 172 becomes worn or has flaws replace it with a new one If the Pump Gear ED 44 becomes worn replace it with a new one Remove any dust inside the Pump Case 46 or Pump Gear ED 44 Remove any dust inside the Oil Pump Cover 35 Apply 0 5 to 1 0 gram of Shell Albania RL3 to the Pump Gear ED 44 and then insert the gear into the Pump Case...

Страница 18: ...ge 48 Air Vent Valve B 172 Oil Pipe 49 Pipe Joint 50 Tapping Screw W Flange D4 x 20 Black 36 Needle Roller 2 5 x 19 8 37 Pump Case 46 Pump Gear Spring ED 45 Pump Gear ED 44 Needle Roller 43 Adjuster Cap 42 Bolt Washer M4 Black 41 Adjuster Spring 40 Oil Pump Adjuster ED 39 Pump Ass y 47 Engine Case Ass y 51 A Tapping Screw W Flange D4 x 16 Black 140 Engine Case Cover 157 ...

Страница 19: ...new one If the Muffler Special Packing 56 or Muffler Special Packing S 54 has any breakage or cracks replace it with a new one Perform reassembly from the muffler side in the following order Muffler Gauze 58 Gauze Fixing Plate 57 Muffler Special Packing 56 Exhaust Pipe 55 Muffler Special Packing S 54 and Packing Plate 53 Attention must be paid to the mounting direction of the Gauze Fixing Plate 57...

Страница 20: ...into the Rear Handle 166 2 See pages 20 and 22 for wiring of the high tension cord Pass the high tension cord of the Ignition Coil 82 through the Engine Case Ass y 51 Apply a small quantity of oil onto the tip of the high tension cord and then insert it into the Spark Plug Cap 77 Mount Metal Fitting of Plug Cap A 80 so that it penetrates the core wire of the high tension cord Pull the high tension...

Страница 21: ...iming Pump Comp 169 Engine Case Ass y 51 Fuel Grommet 162 Pump Ass y 47 Pipe Joint 50 Fuel Grommet A 171 Clip 178 Pump Filter Body 177 Oil Filter Body 179 Oil Filter 180 Bolt Washer D5 181 Clip 72 Idle Sponge 167 Engine ass y Idle Sponge 38 Fuel Pipe FKM 71 Clip 178 Cord A 83 Cord 78 Spark Plug Cap 77 Rear Handle 166 Stop Switch 147 Grommet 155 Engine Case Cover 157 Air Deflector Ass y 188 ...

Страница 22: ...ump Comp 169 Engine Case Ass y 51 Engine Case Ass y 51 A A A A B B B B 152 to 162 mm 191 to 201 mm 4 mm Idle Sponge 167 Fuel Pipe L220 164 Fuel Pipe FKM 163 Fuel Grommet 162 Fuel Pipe FKM 163 Fuel Grommet A 171 Fuel Pipe 182 Fuel Pipe L220 164 ...

Страница 23: ...2 Reassembly Reassembly can be conducted by reversing the disassembly procedure However special attention should be given to the following items Do not reuse the Hex Socket Bolt M4 26 and Seal Lock Hex Socket Bolts W Washers M5 29 Insert the high tension cord into the Spark Plug Cap 77 and then attach the Metal Fitting of Plug Cap A 80 to the high tension cord Pass the high tension cord through th...

Страница 24: ...737 center bolt J 358 jig No 6695738 stepped bolt 6 mm 2 pcs and J 363 jig No 6694822 8 x 120 handle as shown in the right figure rotate the J 363 jig No 6694822 8 x 120 handle in the arrow direction and then tighten J 357 No 6695737 center bolt to disassemble the magneto rotor CAUTION Before tightening J 357 No 6695737 center bolt attach Flywheel Nut M7 103 at the tip of the screw portion of the ...

Страница 25: ... the Crank Worm Ass y 89 from the Cylinder 74 If it is difficult to remove remove liquid packing ThreeBond 1207C applied onto the two Oil Seals 91 and Cylinder 74 move the two Oil Seals 91 until they become loose and then pull out the Crank Worm Ass y 89 Remove the Hex Socket Hd Bolts M4 x 10 69 3 pcs x 2 and remove Scavenging Cover A 84 and Scavenging Cover B 70 If the covers are difficult to rem...

Страница 26: ...nd reassembly of the piston and piston ring Tools required Long nose pliers J 359 jig No 6695741 piston pin extraction tool ass y 1 Disassembly Remove the Crank Worm Ass y 89 from the Cylinder 74 before disassembly Use long nose pliers to remove the two Circlips 85 Insert a hex socket hd bolt M5 x 12 into the pushing side of the Piston Pin 88 and then turn the pin pullout bolt of the J 359 jig pis...

Страница 27: ...screwdriver Long nose pliers 1 Disassembly Remove the Side Case 121 from Engine Case Ass y 51 and perform disassembly with the brake being applied Remove the Tapping Screw D4 x 10 134 and Tapping Screw D3 135 and then remove Guide Plate B 131 and the Chain Puller 130 Remove the Brake Spring 136 while pinching the end of the spring with long nose pliers Remove the three Tapping Screws W Flange D4 x...

Страница 28: ... Brake Lever Spring 123 Brake Link 137 Brake Band 138 Brake Handle 124 Brake Link Cover 126 Tapping Screw W Flange D4 x 16 Black 140 Chain Puller 130 Guide Plate B 131 Tapping Screw D3 135 Tapping Screw D4 x 10 134 Needle Roller D3 139 Brake Spring 136 ...

Страница 29: ...ers M4 Black 52 2 0 to 3 0 21 to 31 Other Engine Case Ass y 51 5 Seal Lock Hex Socket Bolt W Washers M5 29 4 9 to 6 9 50 to 70 Damper A 150 2 Damper Set Bolt 152 2 4 to 3 4 25 to 35 Antivibration Spring 161 1 Damper Set Bolt A 160 3 5 to 4 5 35 to 45 1 Damper Set Bolt 197 3 5 to 4 5 35 to 45 Spring Holder 159 2 Flange Nut M6 165 4 0 to 5 0 41 to 51 Front Handle 195 2 Tapping Screw W Flange D5 x 25...

Страница 30: ...the starter handle to start the engine As a guide pull 2 or 3 times at ordinary temperature 20 C 8 Lightly pull the throttle lever and confirm that half throttle status is canceled and the engine returns to idling Do not run the engine in half throttled status with the chain brake on 9 Release the chain brake Make sure that the respective moving and rotating parts work smoothly without any abnorma...

Страница 31: ...99 100 101 102 103 88 85 87 86 84 69 71 74 81 82 83 77 78 79 80 69 70 10 19 20 21 22 23 24 25 11 12 13 14 15 16 17 18 9 29 2 1 61 62 54 55 56 57 58 59 60 3 52 53 30 31 32 33 34 35 36 37 45 48 49 50 29 51 29 46 44 38 6 26 27 47 28 75 72 76 67 66 68 67 85 97 94 89 65 1 38 39 40 42 43 41 73 63 64 104 105 ...

Страница 32: ...154 156 144 145 146 147 148 150 151 152 153 155 165 133 132 159 160 161 157 140 158 162 163 164 172 171 175 176 173 174 501 502 3 140 149 177 178 179 180 181 178 182 188 187 36 195 196 62 197 161 159 165 193 194 183 184 185 186 189 190 192 198 183 187 189 192 150 151 152 166 191 167 168 170 169 ...

Страница 33: ...ET SCREEN 1 23 6685215 NEEDLE VALVE 1 24 6685216 VALVE SPRING 1 25 6685217 CONTROL LEVER 1 26 6698792 HEX SOCKET BOLT M4 2 27 6699951 INTAKE 1 28 6699952 INTAKE PACKING 1 29 6699044 SEAL LOCK HEX SOCKET BOLT W WASHERS M5 5 30 6600316 CLUTCH 1 31 6685144 CLUTCH HOUSING COMP 1 32 6685361 NEEDLE BEARING D 1 33 6685414 CLUTCH WASHER 1 34 6685360 CRANK SHAFT COLLAR 1 35 6699610 OIL POMP COVER 1 36 3020...

Страница 34: ... 6696766 SCAVENGING COVER B 1 71 6698907 FUEL PIPE FKM 1 72 6685311 CLIP 1 73 6699320 SPARK PLUG ASS Y BPMR7A 1 74 6600083 CYLINDER 1 75 6600051 CORD INSULATION TUBE L100 1 76 6699175 CORD INSULATION TUBE L60 1 77 6696771 SPARK PLUG CAP 1 78 6600052 CORD 1 79 6696326 HEX SOCKET HD BOLT W FLANGE M4 X 18 2 80 6696772 METAL FITTING OF PLUG CAP A 1 81 6698700 GLASS WASHER 2 82 6699977 IGNITION COIL 1 ...

Страница 35: ...92 CHAIN BAR 16 INCH 3 8 SPROCKET PRC 1 134 958715 TAPPING SCREW D4 X 10 1 135 696352 TAPPING SCREW D3 1 136 6600054 BRAKE SPRING 1 137 6685388 BRAKE LINK 1 138 6685140 BRAKE BAND 1 139 6685391 NEEDLE ROLLER D3 1 140 305812 TAPPING SCREW W FLANGE D4 X 16 BLACK 6 141 6699970 CLEANER COVER 1 142 6699971 CLEANER KNOB 1 143 6699965 REAR HANDLE GRIP 1 144 6685350 TRIGGER LOCKOUT VERMILION 1 FOR EUROPE ...

Страница 36: ... 6685199 PUMP FILTER BODY 1 178 6685311 CLIP 2 179 6685310 OIL FILTER BODY 1 180 6696804 OIL FILTER 1 181 6685407 BOLT WASHER D5 1 182 6698715 FUEL PIPE 1 183 6600061 STARTER HANDLE ASS Y 1 INCLUD 184 186 184 6699465 ROPE STOPPER 1 185 6699467 STARTER KNOB 1 186 6600060 STARTER ROPE NS 1 187 6600066 FAN CASE NS 1 187 6600067 FAN CASE NS 1 FOR USA 188 6600089 AIR DEFLECTOR ASS Y 1 INCLUD 170 189 66...

Страница 37: ...CCESSORIES CS 33EDP DESCRIPTION REMARKS 501 6685439 CHAIN COVER 14 1 501 6685440 CHAIN COVER 16 1 502 6685402 COMBI BOX SPANNER 10 19MM 1 3 14 Printed in Japan 7 140317N ALTERNATIVE PARTS NO USED CODE NO ITEM NO ...

Страница 38: ...8 99 100 101 102 103 88 85 87 86 84 69 71 74 81 82 83 77 78 79 80 69 70 10 19 20 21 22 23 24 25 11 12 13 14 15 16 17 18 9 29 2 1 61 62 54 55 56 57 58 59 60 3 52 53 30 31 32 33 34 35 36 37 45 1 48 49 50 29 51 29 46 44 38 6 26 27 47 28 75 72 76 67 66 68 67 85 97 94 89 65 38 39 40 42 43 41 63 64 104 105 ...

Страница 39: ... 138 141 140 142 152 154 143 144 145 146 147 148 149 150 151 153 163 132 131 157 158 159 155 139 156 160 161 162 167 170 169 173 174 171 172 175 176 177 178 179 176 180 186 185 36 193 194 62 195 159 157 163 501 502 139 165 191 192 166 181 182 183 184 187 188 189 190 196 181 185 187 190 168 ...

Страница 40: ...T SCREEN 1 23 6685215 NEEDLE VALVE 1 24 6685216 VALVE SPRING 1 25 6685217 CONTROL LEVER 1 26 6698792 HEX SOCKET BOLT M4 2 27 6699951 INTAKE 1 28 6699952 INTAKE PACKING 1 29 6699044 SEAL LOCK HEX SOCKET BOLT W WASHERS M5 5 30 6600316 CLUTCH 1 31 6685144 CLUTCH HOUSING COMP 1 32 6685361 NEEDLE BEARING D 1 33 6685414 CLUTCH WASHER 1 34 6685360 CRANK SHAFT COLLAR 1 35 6699610 OIL POMP COVER 1 36 30208...

Страница 41: ... SCAVENGING COVER B 1 71 6698907 FUEL PIPE FKM 1 72 6685311 CLIP 1 73 6699320 SPARK PLUG ASS Y BPMR7A 1 74 6600083 CYLINDER 1 75 6600051 CORD INSULATION TUBE L100 1 76 6699175 CORD INSULATION TUBE L60 1 77 6696771 SPARK PLUG CAP 1 78 6600052 CORD 1 79 6696326 HEX SOCKET HD BOLT W FLANGE M4 X 18 2 80 6696772 METAL FITTING OF PLUG CAP A 1 81 6698700 GLASS WASHER 2 82 6699977 IGNITION COIL 1 83 66999...

Страница 42: ...PPING SCREW D4 X 10 1 134 696352 TAPPING SCREW D3 1 135 6600054 BRAKE SPRING 1 136 6685388 BRAKE LINK 1 137 6685140 BRAKE BAND 1 138 6685391 NEEDLE ROLLER D3 1 139 305812 TAPPING SCREW W FLANGE D4 X 16 BLACK 6 140 6699970 CLEANER COVER 1 141 6699971 CLEANER KNOB 1 142 6699965 REAR HANDLE GRIP 1 143 6685350 TRIGGER LOCKOUT VERMILION 1 144 6696838 THROTTLE LEVER SPRING 1 145 6685282 SPRING PIN 5 X 2...

Страница 43: ...IL FILTER BODY 1 178 6696804 OIL FILTER 1 179 6685407 BOLT WASHER D5 1 180 6698715 FUEL PIPE 1 181 6600061 STARTER HANDLE ASS Y 1 INCLUD 182 184 182 6699465 ROPE STOPPER 1 183 6699467 STARTER KNOB 1 184 6600060 STARTER ROPE NS 1 185 6600066 FAN CASE NS 1 186 6600089 AIR DEFLECTOR ASS Y 1 INCLUD 168 187 6600062 SET SCREW NS 1 188 6600064 CAM PLATE NS 1 189 6600065 REEL NS 1 190 6600063 SPIRAL SPRIN...

Страница 44: ...ACCESSORIES CS 33ED DESCRIPTION REMARKS 501 6685439 CHAIN COVER 14 1 501 6685440 CHAIN COVER 16 1 502 6685402 COMBI BOX SPANNER 10 19MM 1 3 14 Printed in Japan 7 140317N ALTERNATIVE PARTS NO USED CODE NO ITEM NO ...

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