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R

epair

P  1

1

/ 1

7

[4] DISASSEMBLY/ ASSEMBLY

[4]-9. Flywheel

Fig. 38

Fig. 39

Fig. 40

DISASSEMBLING

ASSEMBLING

Note: • 

Flywheel can be easily removed with Impact driver without holding the piston.

Do not remove Spark plug as compressed air resistance in Cylinder has to be used for the disassembling.

Plug cap with Plug cap spring has to be removed from Spark plug to prevent Engine from running.

M6x16 Hex socket head bolt

1R364

Screwdriver

M6 bolt of

1R364

(2 pcs.)

Thread holes to screw

M6 bolts of 1R364

(Refer to 

Fig. 39

.)

(1) Turn M6x16 Hex socket head bolt on the center of Flywheel counterclockwise using Cordless impact driver. 

(Fig. 38)

(2) Install 1R364 on Flywheel then screw two M6 bolts of 1R364 into Flywheel as drawn in 

Fig. 39.

      

Flywheel is removed from Engine

.

Important: 

Screw two M6 bolts evenly.

(1) Wipe off the grease and oil from Crank shaft. (

Fig. 40

)

(2) Put Woodruff key 3 into Crank shaft, then align the key

      groove of Flywheel to Crank shaft with the key. (

Fig. 40

)

(3) Screw M6x16 Hex socket head bolt (with Spring washer)

      and Flat washer 7 to Crank shaft by turning them clockwise

      by hand.

(4) Tighten M6x16 Hex socket head bolt about two seconds 

      using Cordless impact driver.

Wipe off the grease and

oil from Crank shaft.  

Woodruff key 3

Crankshaft 

(in Crank case assembly)

Key groove of Flywheel’s hole

Содержание RBC414U

Страница 1: ... Nylon head 1 Wrench 17 19 1 Hex wrench 4 1 Hex wrench 5 1 Double blade 305mm 12 Triple blade 255mm 10 Triple blade 305mm 12 Star blade 230mm 9 Star blade 255mm 10 8 tooth blade 230mm 9 8 tooth blade 255mm 10 Nylon cutting head Bump Feed Z5L Nylon cutting head Ultra Auto 6L Protector for cutting blade only Universal guard Protector Universal guard extension Safety googles Fuel mixture 650 25 5 8 D...

Страница 2: ...of electrical parts Hex wrench 4 standard equipment 783223 2 782235 2 removing Clutch drum complete removing Spark plug Wire brush making Spark plug clean CAUTION Repair the machine in accordance with Instruction manual or Safety instructions removing assembling Retaining rings Tachometer 1R070 checking rpm of Engine Repair P 2 17 Follow the instructions described below in advance before repairing...

Страница 3: ...ft pipe complete Fig 5 Bike handle section can be disassembled For RBC414U and RBC414UG only Loosen Knob 57 to remove Handle holder from Shaft pipe complete Bike handle section can be disassembled Remove Pipe clamp from Shaft pipe complete by unscrewing two M6x25 Hex socket head bolts Fig 6 Assemble by reversing the disassembly procedure ASSEMBLING Assemble by reversing the disassembly procedure A...

Страница 4: ...ain Spiral bevel gear 13 and Cutter shaft complete cannot be supplied individually Order Cutter shaft set from us 7 Disassemble their assembled parts by using 1R269 and Arbor press Fig 7 Fig 10 Fig 11 Fig 8 Fig 9 M8x10 Hex bolt Grease inlet Spiral bevel gear 13 The component of Cutter shaft set Cutter shaft complete The component of Cutter shaft set Ball bearing 6000ZZ Ball bearing 6000 Ball beari...

Страница 5: ...e the spring to the bottom of Lever case L between Boss of Lever case L and the curve rib installation position Fig 15 2 While retaining Leaf spring in between the curve rib and Boss turn Lever case R counterclockwise carefully to mate it with Lever case L without pinching Fig 16 Fig 13 Torsion spring 11 Control cable Lock off lever Cable holder Throttle lever Lever case L Torsion spring 7 Fig 15 ...

Страница 6: ...prings two Wave washers 10 and two Flat washers 8 on Holder tighten them with two M8 shoulder hex bolts Fig 19 Note Face the marking of to the outside as drawn in Fig 19A 2 Put the assembled part Flat washer 6 Spring washer 6 and M6x14 Hex head bolt on the crank shaft of Engine then tighten the bolt to 12 N m with 1R219 1R220 while inserting 1R155 into Spark plug hole to lock Piston to prevent the...

Страница 7: ...f Clutch case complete with 1R006 through the hole of Clutch drum complete Fig 22 3 Tap the corners of Clutch case complete carefully with Plastic hammer to remove Clutch drum complete Fig 23 4 Separate Damper and Shaft complete from Clutch drum complete Fig 24 5 Remove Retaining ring S 17 from Clutch drum complete with 1R004 Fig 25 6 Remove Ball bearing 6003LLU from Clutch drum complete with 1R02...

Страница 8: ...nd Clutch drum complete in Damper Fig 28 Assemble the assembled part to Clutch case complete by tapping the center of Clutch drum complete carefully with Plastic hammer Fig 29 3 Fit Retaining ring R 35 into the groove of Clutch case complete with 1R006 through the hole of Clutch drum complete then set M6x14 Hex bolt and Flat washer 6 on Clutch drum complete while inserting Hex wrench into Gear cas...

Страница 9: ...w 2 Clean carbonized materials on Insulated part for sparking with a wire brush 3 Do fine adjustment of Spark plug as drawn in Fig 32 Insert 0 7mm thickness gauge of 1R366 to the clearance and adjust the leg of Spark plug carefully then set Spark plug in place of Engine 4 Connect 1R181 between Spark plug and Plug cap spring and pull Starter rope gently and check that sparks appear in the spark win...

Страница 10: ...embly See Fig 35 for the appearance viewed from Cylinder cover M5x50 Hex socket head bolt Blower housing Muffler cover Cylinder cover Muffler cover M5x14 Pan head screw M5x14 Pan head screw with spring washer and flat washer 2 pcs M5x20 Pan head screw with spring washer and flat washer Fig 36 Fig 37 ASSEMBLING OF IGNITION COIL See Fig 37 1 While attaching 0 45mm thickness gauge of 1R366 to the mag...

Страница 11: ... on the center of Flywheel counterclockwise using Cordless impact driver Fig 38 2 Install 1R364 on Flywheel then screw two M6 bolts of 1R364 into Flywheel as drawn in Fig 39 Flywheel is removed from Engine Important Screw two M6 bolts evenly 1 Wipe off the grease and oil from Crank shaft Fig 40 2 Put Woodruff key 3 into Crank shaft then align the key groove of Flywheel to Crank shaft with the key ...

Страница 12: ...y then connect the other end to Starter knob Fig 44 Refer to Fig 45 how to make a knot of the rope 4 Wind the rope around Reel two or three turns 5 While turning Reel counterclockwise fit it into the base of Starter case assembly and set Spiral spring end into the hook on inside of the base Figs 44 Note This should be fixed without force 6 Secure Reel with M6x20 set screw Fig 42 Swing arm has to b...

Страница 13: ... new ones 4 Clean the routes in Carburetor with a commercial carburetor cleaner After minutes from the step blow away the liquid on the routes with a air gun Carburetor assembly Fig 48 Fig 49 Fig 47 REPLACING OF AIR CLEANER ASSEMBLY AND CARBURETOR M3x10 Pan head screw Cable bracket Swivel Washer Throttle valve Stop ring E 3 Packing ring Cleaner cover clip Air cleaner cover Carburetor Metering diap...

Страница 14: ...or Inner cable is adequate and throttle can be fully pulled After completing the repair turn the idle adjustment screw counterclockwise to adjust the engine idling speed to 2 800rpm with 1 R070 Fig 51 Face the projection of Carburetor gasket to the bottom side of Engine Stopper on Inner cable end Cable bracket Idle adjustment cable TIPS OF ASSEMBLING Repair P 14 17 4 DISASSEMBLY ASSEMBLY 4 11 Air ...

Страница 15: ...e other parts by reversing the disassembly procedure M mark on Piston Piston Flywheel Boss on groove of Piston Gap of Piton ring The gap of this piston ring is at the farthest side from here Crank case assembly Fig 53 Cylinder Crank case assembly Crankshaft assembly 1 It is highly recommended to drain the oil system of Engine block before starting disassembling because the oil remaining there will...

Страница 16: ...x14 Pan head screw with flat washer and spring washer 3 5 Cylinder cover and Crank case assembly M5x20 Pan head screw with flat washer and spring washer M5x14 Pan head screw with flat washer and spring washer 3 5 Muffler cover and Cylinder cover 3 5 Spark plug and Cylinder M14 Spark plug 15 0 Flywheel and Crankshaft assembly M6x16 Hex socket head bolt with spring washer 12 5 Clutch assembly Clutch...

Страница 17: ... M5x14 Pan head screw with flat washer and spring washer 3 5 Cylinder cover and Crank case assembly M5x20 Pan head screw with flat washer and spring washer M5x14 Pan head screw with flat washer and spring washer 3 5 Muffler cover and Cylinder cover 3 5 Spark plug and Cylinder M14 Spark plug 15 0 Flywheel and Crankshaft assembly M6x16 Hex socket head bolt with spring washer 12 5 Clutch assembly Clu...

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