Atom 102 Operator Owner's Manual

Page 1
ATOM
LAWN
EDGER
PRO
GASOLINE MODEL
102
OPERATOR/OWNER
MANUAL
Granted in Australia
& USA
Design
Registrations
Granted in Australia,
USA,
Japan, Great
Britain
Assembling
0
Safety Precautions
o Operating
Instructions
t Maintenance
IMPROPER
USE CAN CAUSE SERIOUS
INJURY
MAKE
SURE THIS
MANUAL
IS
READ AND
CAREFULLY UNDERSTOOD BEFORE
STARTING
OR
OPERATING
THIS
EQUIPMENT
1ST
EDITION
IMPORTANT MANUAL
-
DO NOT
THROW AWAY
Manual
always
to be available
for reference
or instructing
new
operators.
SUPERVISORS THIS
IS YOUR
RESPONSBILIW
I
Page 2
CONTENTS Parts
and Controls
....
..3
Safety Precautions ..........
......
...........
4
Assembling the Lawn
Ed9er..............
8
Fuel Mix and Fuelling
............ ...........9
Starting and Stopping......
...........
10
Operating 1nstructions
.....................
12
Maintenance Instructions.. ...............
I 4
Air filter maintenance .....................
1 4
Carburettor adjustment...
................
1 5
Cutter
Blade Replacement......... .....'16
Lubrication of Gears...... ................. 17
Checking
the spark
plugs
......,......... 1 7
Checking muff|er......... ...... ............
17
Trouble Shooting.......... .... .............
1 8
Parts List......
..........18/19
INTRODUCTION
This Manual contains
operating, as-
sembling,
safety, and maintenance,
instructions for the Atom
Lawn
Edger. Pay special attention to the safety
precautions
outlined on
pages
4
to
7. Allow only
persons
who under­stand this Manual to operate the Lawn Edger. This lawn edger
is not
to
be
used for
any
purpose
other
than
for edging lawns.
To receive
maximum
performance
and
satisfaction
from
this
Lawn
Edger, rt is
important
that
you
read
and
under-
stand
the maintenance
and
safety
pre-
cautions
before
using
the
edger
Contact
your
Atom
dealer
or the
Atom
distributor
for
your
area if
you
do
not
understand
or cannot
carry out
any of
the instructions
in this Manual.
ATOM'S
philosophy
is to continu-
ally improve all ol its
products.
As a
resull,
engineoring changes and
im-
provoments
are fnade from
time-to-
time. lf the operaling
characteristics
or lhe
app€arance of
your
lawn
edger differs lrorn lhose
described
in this Manual,
ploase
contact
your
ATOM dealor for irrformation
and
assistance. ATOM ressrvos lhr: right to
make
changes al
any
lirnc
wilhnul nolice.
1,2
The handles of the Lawn Edger held by
both
hands.
3. The
throttle trigger which in­creases speed of engine for automatic safety clutch to en­gage
and thus rotate
blade.
4. Starter
grip
the
grip
of the
pull
starter
which is the device to
start the engine.
5. ON/OFF
switch.
6. Handle nut for
holding handles
onto
housing
(and
adjusting
anti-vibration
of handle).
7.
Height adjustment
for adjust-
ing
depth of cutting blade.
Blade cover reduces
the risk
of flying
debris and direct con-
tact
with the feet or hands. Cutter blade rotates when en­gine
speed is increased
above
idle.
10.
/
Wheel for moving and
guiding edger. Grass shield reduces flyback of stones and foreign material. Fuel cap for sealing the fuel
tank filler.
13. Choke lever for cold engine starting.
14. Filter housing
covers the air
filter
element.
15. Fuel
pump pramer provides
additional fuel for a cold start.
16. Spark
Plug
terminal connects
the spark
plug
to the ignition
wire.
17. Muffler reduces exhaust noises and diverts exhaust gases
away from operator.
I
12.
PARTS AND CONTROLS
10 1't.
12.
8.
9.
A
WARNING
As
with any
power
lool some
spe-
cial
safely
precautions
must
be ob-
served to reduce
the risk of
per-
sonal injury. Careless
or improper
use may
cause serious or
even
fatal injury.
SAFETY WARNINGS
HE PURPOSE OF SAFETY
WARNINGS AND
NOTES IN TIlIS MANTJAL IS
T
TTRACT YOUR
ATTENTION TO POSSIBLE
DANGEIIS AND
THE
XPLANATIONS
WITH THEM DESERVE YOUR CAREFUL
ATTENTION AN
UNDERSTANDING THE
SAFETY WARNINGS IN
THIS MANUAL AND ON
THE
LAWN EDGER DO NOT, BY THEMSELVES,
ELIMINATE ANY
DANGER. THE
INSTRUCTIONS OR WARNINGS THEY
GIVE ARE NOT
SUBSTITUTES FOR
PROPER
ACCIDENT PREVENTION MEASURES
WARNING: Failure
to obey a safety
warning
can result
in
injury to
yourself
and
others.
NOTE:
Advises
you
of information
or instructions
vital to the
!
operation or
maintenance
of the equipment.
-11. FIG 2
Page 3
SAFETY
PRECAUTIONS
Like any
power
tool the use of any
lawn edger may be
dangerous. lt is
important
that
you
read, fully under-
stand,
and observe the following
safety
precautions
and warnings.
Re-read this operator's
manual and
the safety instructions
periodically.
THE
OPERATOR
Physical
Condition
Operator must be in
good
physical
condition and mental health
and
not
under the influence of any sub-
stance
(drugs,
alcohol, etc.) which
might impair vision,
dexterity or
judgement
[Fig.
3a].
Do not operate a lawn edger when fatigued. Be alert - if
you get
tired
while operating the machine,
take a
break. Tiredness may result
in loss
of
control. Working with
any
power
tool can
be strenuous. lf
you
have
any
condition that
might be aggra-
vated by strenuous
work, check
with
your
doctor
before operating
the machine. The Atom
Lawn Edger is equipped
with
vibration reducing
hand
grips
and
main handle
anti-vibration
mountings. These
are designed to
reduce
the transmission
of engine
vibrations to
the operator's hands.
Replace
hand
grips
and mountings
when
worn or damaged.
The rubber handles
do not
guaran-
tee that
you
will not sustain
whitefinger
disease or carpal
tunnel
syndrome. Therefore,
continual and
regular
users should
monitor
closely
the conditions of
their hands
and
fingers. lf any of
the above
symptoms
appear,
seek medical
advice
immediately.
Proper
Clothing
Clothing
must be sturdy
and snug-
fitting,
but allow complete
freedom
of
movement
/see
Fig. 41. Avoid
loose-fitting
jackets,
flared or
cuffed
pants,
or
anything
that could trip the
operator.
Wear
overalls or
long
pants
to
protect
your
legs.
Do not
wear shorts.
Use of
gloves
when
working
with the
lawn edger is
rec-
ommended.
Good
footing is
most
important.
Wear
sturdy shoes
with
nonslip soles.
Do not
wear san-
dals or operate
with
bare feet. In
hot or
sunny conditions
always
wear
a hat and long sleeve
shirt
for
protection
against
skin cancers.
Use of a
good
brand of
sunscreen
cream is
also recommended
on
exposed
skin surfaces.
Replace
immediately
broken
or
cracked
blade covers
and
grass
debris deflector.
Never
operate a lawn edger
unless
wearing
goggles
or
properly
fitted
safety
glasses
with adequate
top
and
side
protection
which
comply
with ANZI 287.1
(or your
applicable
national
standard).
Engine
noise may damage
your
hearing.
Wear sound barriers
(ear
plugs
or ear
mufflers) to
protect
your
hearing.
Continual and regular
users
should have their
hearing
checked
regularly.
SAFETY
PRECAUTIONS
(cont'd
rt
Uf
tl
&
FIG
'f
-n-
O
A
WARNING
Careless or improper use
of the
machine
may cause serious injury.
Have
your
Dealer show
you
how to
operate
your
lawn edger.
Safe use of
a Lawn Edger in-
volves
1. the
operator
2. the
lawn edger
3. the
use of the lawn edger
A
WARNING
The lawn
edger must not be oper-
ated by minors. Bystanders,
espe-
cially children
and animals, should
not be allowed in the
area where a
machine is in use
(at
least
15
me-
tres
away).
Never let the unit run
unattended
[Fig.
3b].
FIG 3a
FIG 3b
A
WARNING
Proper
eye
protection
is
a must.
The blade cover
may not
protect
the operator from
all fast moving
foreign objects
even though
the
discharge
is directed away
from the
operator,
as ricochets
and bounce-
backs may occur
during lawn edg-
ing operations.
A
WARNING
Do not lend,
rent or sell this
machine without
this operator's
manual.
Be sure that
anyone us-
ing this unit
understands the in-
formation contained
in this man-
ual before
use.
A
WARNING
Prolonged use of any hand held powered
machine exposing the op-
erator to vibrations
may
produce
whitefinger disease
(Raynaud's
phenomenon)
or carpal tunnel
syn-
drome. These conditions reduce
the hand's
ability to feel and
regu-
late temperature,
produce
numb-
ness and burning
sensations and
may cause nerve
and circulation
amage and tissue
necrosis.
Page 4
SAFEW
PRECAUTIONS
(cont'd
Fueling
This
Atom unit uses an oil-gasoline mixture for fuel
(see
the chapter on
"Fuel").
@
FIG 5
SAFETY PRECAUTIONS
(cont'd)
Fueling instructions Refuel outdoors only. Always
switch off the engine and allow it to cool before refueling. Relieve
fuel
tank
pressure
by loosening fuel cap
slowly. Never remove fuel filler cap
while
engine is running.
Select bare
ground
for fueling and
move at least 10 feet
(3m)
from
the
fueling
spot before starting the en-
gine.
Wipe off any spilled fuel be-
fore starting
your
lawn edger and
check for leakage.
Always tighten fuel filler cap se-
curely after fueling.
Starting You should
always inspect
your
unit
before
starting
it. Make sure
the
controls
and safety devices
are
working
properly.
As the throttle trigger is
fitted with a
% throttle lock to
assist in starting
the engine, never
leave lz throttle
lock
on other
than for starting.
For
specific starting instructions,
see the appropriate section of
this
operators manual.
Place the ma-
chine on
firm
ground
or other solid surface in an open area. Maintain good
balance and secure footing.
Failure to follow this
procedure
may
result
in
injury
to hand or fingers or
may damage the starter mecha-
nism.
Working instructions
and impor-
tant adjustments
Never
operate
your
machine if it is
damaged, improperly
adjusted or
not completely
and securely as-
sembled.
At correct idle
speed the
blade
should not
turn. Do not use
lawn
edger with
incorrect idle speed
adjustment.
Adjust the speed
your-
self
(Page
75)
setting Carburettor
ldle Speed
Adjustment,
or by a
service
dealer.
MAINTENANCE,
REPAIR
AND
STORING
Use
only original
Atom replace-
ment
parts
for maintenance
and
repair. Use
of
parts
manufactured
by others
will void
warranty, and/or
may
cause
serious or fatal injury.
Follow the
maintenance instruc-
tions in the
appropriate section of
this
manual. Any repairs should
be
carried out by
an authorised service
dealer. Check
fuel filler cap for leaks
at
regular intervals. Use the
specified
spark
plug
and
make sure it and the
ignition lead
are always in
good
condition. Remember that the risk of forest
or
grass
fires is
greater
in
hot weather.
A
WARNING
Never touch a hot muffler or burn will result.
Keep
spark
plug
and wire connec-
tion tight
and
clean.
Spark
plug
electrode
gap
should be checked
with a feeler
gauge
at least every
50 operating
hours and reset if nec-
essary. Fit
a new spark
plug
if elec-
trodes
are badly
pitted
or fouled
with carbon build up. Store lawn
edger in a dry, high or
locked
location
place
and out of
reach
of children.
A
WARNING
Start and
operate
your
unit
out-
doors in a ventilated
area.
A
WARNING
Gasoline
(petrol)
is an extremely
flammable
and explosive fuel. Use extreme caution when handling gasoline
or fuel mix. Do not smoke
or bring any
fire or flame near the
fuel.
WARNING
The lawn edger is
a one-person
machine. To reduce the risk of
eye
or other injury
from thrown objects,
ensure that
bystanders are at
least
15 feet
(5m)
away
during use. Re-
place
immediately
any worn or bro­ken debris deflector shield or blade cover. lf approached, release
throt-
tle trigger to immediately
de-
accelerate the engine.
A
WARNING
Always stop
the motor and
make
sure that
the blade
is stopped be-
fore
adjusting
blade height, doing
any maintenance
or repair
work,
cleaning
the unit or
removing
grass
or debris
from the blade.
WARNING
Always allow engine to cool before
refuelling. Accidental
spillage of
gasoline
over hot engine could
cause fire or explosion
to occur with
consequent
possible
disfigurement
or fatal injury. Wash and clean
hands after fueling.
A
WARNING
When
you pull
starter
grip,
do not
p
starter rope around
your
hand.
Do
not allow
grip
to snap back, but
guide
starter rope slowly back to
permit
rope to rewind
properly.
l\
wARNTNG
A worn or
damaged
muffler is a fire
hazard
and may cause
loss of hear-
ing. Check
to see
that the
muffler is
in
good
condition.
The lawn edger
must not be
operated if the
muffler
is not functioning
properly,
is
dam-
aged,
or has
been removed. In
order
to reduce
the risk of fire, do
not
modify or
remove any
part
of
the
muffler.
7
A
WARNING
Never store
the machine with
gaso-
line inside
a building where fumes
may reach
an open flame or spark,
e.g.
gas
or oil fired heater appli-
ance.
electric
motor
etc.
Page 5
I
SAFETY
PRECAUTIONS
(cont'd)
Before storing
for a longer
period,
always empty
the fueltank.
Keep the
space behind
and beside
the engine
clear at all times to allow
for the escape
of hot and toxic
exhaust fumes. Operate
your
machine
under
good
visibility
and daylight conditions
only. Work carefully.
Working Conditions
When
working with the lawn
edger
always
wrap
your
fingers tightly
around each
handle. Keep
your
hands in this
position
to have
your
machine under
control at all times.
never
attempt to operate lawn
edger with
one hand as loss of
control may result
in serious or fatal
injury. Make sure
the handle
grips
are in
good
condition and free of
mois-
ture,
pitch,
oil or
grease.Use
both
hands,
one on each handle, to op-
erate
and control the lawn edger.
Do not overreach.
Keep
proper
footing
& balance at alltimes.
A
WARNING
Do not touch hot motor during and immediately after use as
you
may
burn
yourself.
Fuel Mix Prepare
the mixture of
a brand-
name
unleaded
gasoline
and
qual-
ity two-stroke
(2
cycle) engine
oil in
an
approved safety-type
canister.
Pour in
the oil first
(eg.
Castrol 2T
two stroke
oil or equivalent)
and
then add
gasoline.
Do not
use BIA
or
TCW
(two
cycle
water cooled)
mix oils.
Well
known brands of
2 stroke
(2
cycle) engine
oil are recommended.
They are formulated
specially
for 2
cycle engines
and
guarantees
a
long
engine life.
For
the
sake
of
your
health
and the
environment
unleaded
gasoline
is
recommended.
A
WARNING
Pressure
may build
up in
the canis-
ter. Remove
fuel
cap slowly
to
avoid
injury from
fuel
spray.
Re-
place
fuel cap securely.
Clean
the fuel
tank and
can
from time to time.
Take
care when handling
gasoline.
Avoid direct
contact
with the
skin
and avoid
inhaling
fuelvaPor.
Change
fuel
pickup
filter
at least
once
every
year
or more
frequently
depending
on use.
Before fueling,
clean
the filler
cap
and the
area around
it to
ensure
that no dirt
falls into
the tank. Never
mix
the
gasoline
and
oil in the
fuel
tank
of the engine.
Always
allow engine
to cool
before
refuelling.
Accidental
spillage
of
gasoline
over a hot
engine
could
cause fire
or explosion
to occur.See
Page 6 Safety
Precautions
Fu-
elling. Fill or
add fuel to
the tank
only
when the
edger is
in a horizontal
position
as shown
(Fig.
7). ALLOW
engine to
cool down
for at least 5
minutes
before adding
fuel.
FIG 6
FUEL
MIX
AND FUELING
ASSEMBLING THE LAWN EDGER
Fit cross
brace to handles with brace to touch
ground.
Use 4 screws
and 4
locknuts
provided
in
packet
[see
A].
Fit handle assembly
to edger. Insert
150mm
(6")
bolt
(B).
Screw large 3 wing nut
(C)
so
that bolt end is
approximately flush
(level)
with face of centre boss of large
wing nut. This
allows handle
"platform"
to
"float"
without vibration. DO
NOT OVER-
TIGHTEN
BOLT.
Fit throttle to right
hand handle
[see
D]. Clip
in
throttle cable/ignition
switch
wire with 2 cable clamps attached to handle
[see
El
A
WARNING
Electrical
shock. Never touch
electrical
wires or components
while
the engine is running. They
are sources of high
voltage & can
give you
an electrical shock. Re-
place
immediately any faulty high
tension lead or spark
plug
cap.
25:lMixChart
Gasoline L 1
z
3
4
2-cvcle
oil ML 4 80
120 160 200
Recommended Mixing
Ratio
Term
Gasoline
:Oil
Up
to 20 hours use
20 .1
After 20 hours use
25 .1
Page 6
STARTING & STOPPING
INSTRUCTIONS
STARTING & STOPPING
INSTRUCTIONS
(cont'd
Inferior
quality gasolines
or oils
may
damage
the engine, sealing
rings,
fuel
lines or fuel tank, and
6sgulsttor.
Also causes rough and
irregular
running and starting.
Only
mix
sufficient fuel for a few
weeks
work - store in approved
safety-lype
canisters.
Pour
oil in
first. Screw
fhe
fuel can cap on tightlY
and
thdroughly
shake the mixture
before
fueling
your
machine.
FIG 7
1. Pla6e
lawn edger on
ground
in
horizontal
position
lsee
Fig. 91.
gs
sure the ignition switch is
'g$".
Pull switch toward opera-
1s1
to
turn
ON.
Switch located
on
fight
side of trigger
fsee
Fig.
81.
2.
Set trigger throttle to 112
THROTTLE LOCK by
placing
hand
on handle
grip
and
push-
ing down safety interlock
with
thumb,
and
pulling
up and hold-
ing trigger
with finger. Then
move thumb to hold in 112
throttle button, release
trigger,
then release
1/2 throttle button.
Trigger
throttle is then engaged
at
half speed for starting
(only).
'l'
It
I
FIG 9a
3. COLD START:
Move choke
lever up to start
position.
Press
and release
primer
3 or 4 times
untilthe fuelflows
into the clear
tube. Place
one foot on the
cross
brace.
FIG 9b
Make sure
you
have a firm footing. Hold down motor with left hand and with right hand
pull
the starter
grip
slowly until
you
feel
it
engage - and then
give
it a fast
pull
[Fig.
9]. Do not
pull
out starler rope more than
26"
(65cm)
-
it might break.
Stand between handles to start. Do not let starter
grip
snap
back.
Guide it back slowly so that the starter rope can rewind slowly.
PULL THE STARTER ROPE BRISKLY
until
you
hear the
engine
sound like it wants to
run or runs then stops
(normally
1-5
pulls).
Open choke
gradually
to allow
motor to run. lf it stops,
re-start and allow the
engine
to run for a few more seconds on lz lhrollle lock (engine
runs fast). Pull throttle
trigger
(releases
%
throttle lock), & allow throttle trigger to slowly
pull
back to engine idle.
Note: ln warm temperature or hot motor fhis sfep may not be necessary.
HOT OR WARM START: (Engine
has already been started and warmed up). Switch ignition "ON". Set 1/2
THROT-
TLE
LOCK
[Fig.
8]. Pullstarter
until
motor runs and let it run for a few seconds before releasing % THROTTLE LOCK. This
aI. lows cooler fuel to enter the carburettor.
Allow throttle trig-
ger
to slowly
pull
back to idle.
Note: A built-in automatic cen­trifugal clutch disengages the blade
from rotating at engine
idle speed.
The clutch engages
the blade
when the engine
speed is increased.
Throttle
trigger
(engine
accel-
erator control)
is operated by
pushing
down interlock with
thumb
and
pulling
on trigger
[Fis
8].
FLOODED ENGINE:
(Engine
will not staft).
lf smoke or fuel
comes from
exhaust and en-
gine
will not start.
i. Check
that ignition switch is
"ON',
CHOKE LEVER is on
RUN
position,
throttle is set
on HALF THROTTLE
LOCK
position.
ii. Pull
starter rope up to
10
times to
clear engine of fuel
so it can start.
iii. lf
engine has excessive
fuel
that cannot be cleared
by i &
ii
above,
remove spark
plug
from
engine and from spark
plug
terminal,
crank engine
to clear excess
fuel, wipe
and
dry spark
plug
of all
fuel, re-install
spark
plug
and terminal, and restart
as
above.
IMPORTANT:
After t hours
use tighten
all screws
(especially
9 screws
around
gear
case), check
every 20
hours use.
10.
To stop motor
push
switch slide
on throttle trigger
side forward.
8.
il
I
il
I
4.
5.
1.
7.
A
WARNING
The blade
will rotate when engine
is
idling
fast
(eg.
on
starting
(1/2
throt-
tle lock]
or when motor is cold).
TO
STOP MOTOR move
ignition
switch
up into the
"OFF"
position
fpage
10 Fig.
8].
lqxtrtoN
,r
swr'cH.{
I
l0
ll
Page 7
Anti-Vibration
(AV)
Adjustment
Handle nut
can
be
tightened
to mark on knob to obtain best AV affect to reduce handle vibrations.
During
break-in
period
A factory new machine should not be run at high revs
(full
throttle) without any load. This avoids un­necessary wear during the break-in period.
As all
moving
parts
have to
bed in during break-in
period,
fric­tional resistances in the engine are greater
during this
period.
Engine
develops its maximum
power
after
about 5 to 15 tank fillings. When using, increase engine revs
as load is increased on lawn edger. When lawn edger is under
full load,
full throttle is to be
used.
After finishing work Storing for short
period
-
keep
the unit in a dry
place
until
you
need it again. Do not
store where
naked flame or electrical
machinery
is operating. Storing for a long
period
-
drain
the
fuel tank, run engine until car-
burettor is
dry.
EDGING
OF
LAWN
The edger is very easy and simple to use, and most opera­tors can immediately
adapt to
its unique
use.
For some
people
it may take a few edgings to become accus­tomed to its operation.
Thoroughly inspect
the area where the edger is to be used and remove all stones, sticks, wires and other foreign objects.
1.
2.
OPERATING
INSTRUCTIONS
3. Adjust blade
height. With a new
blade try second hole closest to
oPerator'
HETcHTADJUsTMENT
FIG
10
With both arms fully extended downwards
(see
illustration
on
front cover)
hold both handle
grips
firmly.
With the engine
running
pull
the throttle trigger
to increase
engine speed.
lf blade is not deep enough,
or
is digging too
deep, adjust
blade height or
slightly raise or
lower
handles to suit depth
re-
quired
[Fig.
11]. However
it is
always more comfortable
and
relaxed to have arms
fully ex-
tended
downwards.
As
cutting
action begins,
push
the lawn edger forward so
that
the blade can cut the edge
as
you
move forward.
OPERATING
INSTRUCTIONS
(cont'd)
7.
Continue at a moderate
pace
10. Clutch.
The lawn edger
is
equipped
with a centrifugal
clutch. DO
NOT run edger at
low
speeds or if blade
jammed
at high speeds
as clutch
shoes will
prematurely
wear
out and cause damage.
FIG 12
l\
wARNTNG
Only operate unit when moving for­ward. DO NOT operate
walking
backwards as
you
may trip, fall and
injure
yourself.
A
WARNING
To avoid
personal
injury, never
carry the
edger while the engine is running. Stay clear of the rotating blade.
Stop the engine
prior
to mak-
ing adjustments
and
cleaning.
l3
8.
until
you
are familiar with the
controls
and the handling of the
lawn edger. lf blade
jams
or stops in
ground,
lower handles,
or
pull back unit and recommence. Control engine and cutting speed to suit work
being done.
When cutting efficiently,
engine
speed
should be full throttle
under load. SidewaysTilting
: Lower either
left
or right
hand to achieve
9.
4.
5.
6.
angle
cutting.
To
edge
deePer
lift
handles
FIG
11
t2
Page 8
MAINTENANCE
the filter to spread
the oil and
to
remove
excess oil
[Fig.
16].
Reinstall the
filter air filter
cover.
Note: lf
the unit is
operated
with
a dry or dirty
filter or with-
out
the air filter
and/or carburet-
tor/air filter cover,
you
will void
wananty.
Note: Fuel
Filter. When
the mo-
tor runs
short of fuel
supply
and
the tank has
gasoline
in
it,
check the
fuel filter for
block-
age.
CARBURETTOR
ADJUST-
MENT
This unit
is equipped
with a
diaphragm-type
slide
carburetor
that
has been carefully
calibrated
at
the factory.
In most cases
no fur-
ther
adjustment will
be required.
The condition
of the
air filter is
important to
the operation
of the
edger.
A dirty air
filter will restrict
the air flow, which
upsets the
fuel-
air mixture in
the carburettor.
The
resulting
symptoms are
often
mis-
taken
for
an
out-of-adjustment
car-
burettor.
Therefore. check
the con-
dition of
the air filter
before adjust-
ing
the carburettor.
lf the following
conditions
are expe-
rienced,
it may
be necessary
to
adjust the carburettor: o
The motor
will not idle.
.
The
motor hesitates or stalls on
acceleration.
.
The loss of motor
power
that is
not corrected
by cleaning the
air filter
and muffler.
AIR FILTER
MAINTENANCE
Note: Clean and re-oil the
air filter
Every 5 hours of operation
or daily.
The air filter is
one of the most
important areas
to maintain. lf it is
not maintained,
you
will void
the
warranty.
Before cleaning,
make
sure
the unit is turned off.
FIG 16
Wash the
filter in detergent
and
waler
[Fig.
75l. Rinse
the filter
thoroughly
and allow
it to dry.
Apply enough
clean two-stroke
oil or SAE
30 oil to saturate
the
filter when
squeezed.
Squeeze
1.
2.
l4
MAINTENANCE
(cont'd)
.
The
motor
operates in an er-
ratic
or
fuel-rich condition
(indicated
by
excessive ex-
haust
smoke from
the muffler).
Note: Careless adjustments
can seriously
damage
the car-
bureftor
and/or motor.
ADJUSTING THE CARBU­RETTOR
1.
Clean air and fuel filter
if
it is dirty. Refer to Air Filter Mainte­nance
(Page
74). Throttle trig-
ger
to be in idle
position.
Fuel Filter: When the motor runs short
of fuel supply and
the tank has
gasoline
in it,
clean the fuel filter for blockage
[Fis.
17]
2. Throttle Cable: The
normal
play
is 1-2mm
when measured
at the carburetor
side. Re-
adjust with
the
cable
adjustor
as required.
3. Engine ldling
Setting: To in­crease motor idle speed, turn clockwise ldle screw
(
) [Fig.
191 lo decrease
motor idle speed, turn counter(anti)­clockwise.
Note:
Edger
blade not to rotate
when motor is idling.
Note: Throttle cable wire is not
to be
pulled
tight
(against
trig-
ger
throttle). Trigger.to have small initial movement before it pulls
cable and carby throttle
lever.
Note: Forcing the high speed
mixture screw
(B) (with
screw­driver) will damage the screw tip and the seat in the carburet­tor body.
Close high speed
jet and open 2.5 turns ! 1/2 turn [Fis
1e].
Set 1/2 throttle lock
[Fig.
I
page
70l. Start the motor and let it
run for
a few
seconds-
Release 1/2 throttle lock and let the
motor idle.
lf the
motor
stops, turn the idle screw
(A) clockwise 1/8 turn at a time (as
required) until the motor idles. lf idle speed it too high turn
idle screw
(A)
counter
(anti)-clockwise.
3.
4.
FIG 17
Page 9
MAINTENANCE
(cont'd)
5. High Speed Screw Mixture Adjustment:
The factory
presets
the high
speed mixture screw
(B)
at
2.112 t 1/2 turns out from the closed
position.
Your unit
should
perform
well at this set-
ting. lf additional adjustment
of
the high speed mixture is
re-
quired,
contact
your
local au-
thorized service dealer.
Note: The edger blade
should
not
rotate when the motor idles.
Note: lf the carburettor adjust­ments
do not help the unit to
run
properly,
contact
your
au-
thorized service dealer.
Recom­mended idle speed is 3000 to 3200 RPM.
BLADE REPLACEMENT
1. Stop motor. Clean area around dust cover and
pry
out with
screwdriver
[Fig.20].
2. Through dust cover hole
place 14mm single socket spanner. On blade end
of shaft
place 17mm spanner on blade nut [Fig.
21].
3.
Unscrew nut counter(anti)­clockwise
(normal
right
hand thread).
4. Remove one smallwasher,
one
large washer and blade.
Before
fitting blade and
washers, clean
all
grit
and
grease.
Assemble
these
parts
clean and dry.
Fit
large washer, new blade
with
flat blade on inside,
large
washer, one small
washer, and
nul
[Fig.23l.
Tighten nut.
A
WARNING
Use only
Atom blades
(P/N
43105).
Other
blades have larger
size holes
(1/2)
which will cause
out-of-
balance
vibrations
which will dam-
age
unit and
MUST NOT BE
FIT-
TED.
-
-
scnewDavea LEVER3
OFF
DUST
COVER
ETPOSINO
lilllt| HEX
HEAD
FOR
U}|SCRE!4NO
BLAOE
IIUT
FIG 21
A
WARNING
Do not run
motor without
blade
tightened to
blade shaft
as
gear
damage
will occur.
l6
l7
MAINTENANCE
(cont'd)
5. Clean
plastic
dust cap and
housing,
press
back
by
gently
tapping into
place.
Clean
inside
blade cover of any
built up dirt.
CHECK
THE SPARK
PLUG
lf motor is down
on
power,
difficult
to start
or runs
poorly
at
idling
speed, check
the spark
plug.
.
Allow motor
to
cool down.
.
Remove
spark
plug.
o
Clean
dirty
spark
plug.
.
Check electrode
gap
-
it should
be 0.02"
(0.5mm).
.
Rectify
faults which
have
caused
fouling
of spark
plug.
Possible faults
include:
a
a
a a
I ncorrect
carburettor
setting
Too much
oil or wrong
tyPe
of
oil in fuel
mix
Old
fuel mix
Dirty air
filter.
o
Unfavourable
running
condi-
tions
(eg.
operating
at
Part
load).
Do not
clean the
spark
plug
in an
abrasive
grit
spark
plug
cleaner,
as
expensive
damage to
the mo-
tor
could occur
through
loose
grit
damaging
chrome
in
cylinder
bore. Fit a new spark
plug
after
approxi-
mately 100
operating hours
or ear-
lier
if electrodes
are badly
eroded
(recommended
type
Champion
RCJ-]Y). CHECKING EXHAUST
MUFFLER
Tighten exhaust
screws.
lf exhaust
gasket
is leaking,
replace
gasket.
if
the motor
is down
on
power
check
the muffler.
Allow
motor
to
cool
down.
Remove
and scrape
out
ex-
cess
carbon on
both inlet
and
exit
exhaust
or have
this
done by
a
service
dealer.
FIG22
LOOSE BLADE
As in 1 and 2 of Blade
Replacement
and tighten
nut clockwise.
LUBRICATION
OF GEARS
The oil in the
gear
case should
be
topped up according
to use
by
adding light free flowing
lithium-
based
grease
(Castrol
EPO)
through fill hole
in casing
[Fig.
20].
Use a suitable
filling
gun
or
squeeze oil
pack
(P/N
43227).
Re-
move bleed screw
to allow
grease
to eject indicating
gear
box is 3/4
full. Refit bleed screw and
push
in
3-4 more
pumps.
Refit fill bolt
(tighten
gently).
A
WARNING
Over
tightening will cause
plastic
thread
to strip.
Page 10
TROUBLE
SHOOTING
PROBLEM
CAUSE
ACTION
Motor will
not
run.
lgnition switch
is
"OFF"............,..... Turn
switch
"ON".
Push down.
Fill fuel
tank.
Press
primer
bulb
fully & slowly 5
times.
I lse slartina nrocedrrre wilhout
Primer bulb
was not
pushed
enough
times
using
choke. See
page
1 1
Motor
will not
idle.
Carburettor
misadjusted.....
Adiust throftle idle soeed adiust-
ing screw. Adjust carburettor.
See
page
15.
Motor
will not
accelerate.
Carburettor
misadiusted......
Arliusi carblrre,ttor See oaoe 15
Motor runs rough or
hard
to start.
Carburettor/crankcase/
cylinder
gaskets/
crankshaft seal
leaking......
Damaged
motor
parts......
Tighten
screws
Replace
gaskets
with a sealant
and
tighten screws.
Replace
crankshaft
seal, damaged
parts.
Motor lacks power
or stalls
when cutting.
Diriv air filter
Clean or replace
air filter.
See
page
14. Readjust carburettor. See
page
15.
Wrong carburettor
adjustment
...
Cutting
blade does nottum when
operating.
Blade cover
filled with
dirt/grass
(1lr
rlah elinnina
Clean. Cul less deoth Check clutch.
hlada
Tighten
nut.
See
page
17.
Gear
case leak-
ing.
Tighten.
Replace.
EtrnLan
"f.\"
rina
Noisy
gears.
No heavy oil in
gear
case
Loose blade
nut or
gear
adjustment
Refill. See
page
15.
Reassemble
parts
correctly.
l8
Page 11
Atom Industries
(ATOM)
watrants each
new ATOM
Lawn Edger
for TWELVE
(12)
months
for domestic
use to
the lollowino
terms
This wirranty
extends to the
original
retail
purchaser
only
and commences
on the
date of original
retail
puc
chase.
Any
part
of
the ATOM Lawn
Edger
manufactured
or
supplied by
ATOM and found
in the reasonable
judgement
of ATOM to
be detective in
material or
workmanship
will be
repaired or
replaced by
an authorised
ATOM seryice
dealer
without
charge for
parts
and labour
The ATOM Lawn
Edger, including
any
defective
part,
must be returned
to an authorised
seryice dealer
within
the
warranty
period.
The expense
of delivering
the ATOM Lawn
Edger to
the dealer
for warranty
work and
the expense of
returnino it
back to the owner
after
repair or replacement
will
be
-paid for
by the owner.
ATOM'S
responsibility
in
respect
to claims is
limited to making
the required
repalrs
or
replacements and
no claim
ot breach of
warranty shall
be
cause tor cancellation
or rescission
of the
Conkact ot
Sale ot
any ATOM Lawn
Edger.
Proof of
purchase
will be
requrred
by the dealer
to substantiate
any mrranty
claim.
All rerranw
work must
be
performed
bv an authorised
AToM seryice
dealer
or bv At6m
Industries
This warranty is
limited to
NINEry
(90) days from the
date of
original retail
purchase
for any ATOM Lawn
Edger
that is
used for commercial
purposes
and ONE
(1)
month
lor rental ourooses.
This
watranty does
not cover
any ATOM Lawn Edger
that
has been subject
to misuse,
neglect,
negligence or
accident, or
that has been
operated
in any way
contrary to
the operating instructions
as
specified
in the ATOM Opera-
tor's Manual.
This warranty
does not apply
to any damage
to the
ATOM Lawn Edger
that
is the result
of improper
maintenance
or to any
ATOM Lawn Edger
that
has been
altered
or modified
so as to
adversely
atfect the
products
operation,
performance
or durability
or that
has been al-
tered
or modified
so as to
change its
intended use
The
warranty
does not extend
to
repalF made
necessary by
normal
wear or by the
use of
parts
or accessoties
which
are either incompatible
with the ATOM
Lawn Edger
or
adversely
affect its operation,
performance
or
durability
PLEASE
FILL IN INFORMATION
BELOW ON
PURCHASE
AS THIS
WILL ALSO BE
REOUIRED
FOR ANY
WAR-
RANTY
DATE OF
PURCHASE:
PURCHASED
BY:
Address:
State
I
Post/Zip
Code: SOLD BY: Addressr
State:
lPostZip
Code:
Operator
Manual
Part No.
43580 Printed
in Australia
Copyrighl
@ 1997 ATOM
INDUSTRIES.
ALL RIGHTS
RESERVED
A separale Lawn
Edger Workshop
Manual is available
Part No.
43564 also
Engine
Manual Part
No 43572
ATOM INDUSTRIES,
9
FRED STREET,
LILYFIELD,
NSW. 2040,
AUSTRALIA
PO
Box 513,
Rozelle, NSW,2039,
AUSTRALIA
Phone
within Auslralia:
(02)
9810 6691
-
International:.
+61
2
9810 0194
Fax
within Australia:
(02)
9810
6691
-
International:
+61
2 9E10
6691
ATOM INDUSTRIES
is a division
of Solo Industries
Pty Lld
(ACN
000583924)
ATOM
reserues the right
to change or
improve the
design of
any ATOM Lawn Edger
without assuming any
obligation
to modify any
product previously
manufactured.
ALL IMPLIED WARRANTIES
ARE
LIMITED
IN OURA-
TION
TO THE TWELVE
(12)
MONTH
WARRANry PE-
RIOD OR NINEW
(90)
DAYS FOR
PRODUCTS USED
FOR ANY COMMERCIAL
PURPOSE
ACCOROINGLY
ANY SUCH
IMPLIED WARRANTIES
INCLUDING
MER-
CHANTABILITY.
FITNESS
FOR
A PARTICULAR PUR-
POSE
OR OTHERWISE.
ARE DISCLAIMED
IN THEIR
ENTIRETY
AFTER
THE EXPIRATION
OF THE APPROPRI.
ATE TWELVE
(12)
MONTHS
OR NINEry
(90)
DAY
WAR-
RANTY PERIOD
ATOM'S OBLIGATION
UNDER
THIS
WARRANry
IS STRICTLY
AND EXCLUSIVELY
LIMITED
TO THE REPAIR
OR REPLACENiIENT
OF
DEFECTIVE
PARTS,
AND ATOM DOES
NOT
ASSUME OR
AUTHO-
RISE
ANYONE TO
ASSUME FOR
THEM
ANY OTHER
OBLIGATION.
SOME STATES
DO
NOT ALLOW LIMITA-
TIONS ON
HOW LONG
AN IMPLIED
WARRANTY LASTS,
SO THE ABOVE LIMITATION
MAY NOT
APPLY TO YOU,
ATOM
ASSUMES NO
RESPONSIBILITY
FOR INCI.
DENTAL.
CONSEQUENTIAL
OR OTHER
DAMAGES IN.
CLUDING,
BUT NOT LIMITED
TO EXPENSE
OF
RE-
TURNING
THE ATOM
PRODUCT TO
AN AUTHORISED
SERVICE
DEALER
AND EXPENSE
OF DELIVERING
IT
BACK TO
THE OWNER.
MECHANIC'S
TRAVEL TIME,
TELEPHONE
OR
TELEGRAM
CHARGES, RENTAL
OF A
LIKE PRODUCT
DURING
THE TIME
WARRANTY SER-
VICE
IS BEING PERFORMED.
TRAVEL. LOSS
OR DAM-
AGE TO
PERSONAL
PROPERry,
LOSS OF REVENUE,
LOSS OF USE
OF THE
PROOUCT, LOSS
OF TIiTE,
OR
INCONVENIENCE,
SOME STATES
DO NOT
ALLOW THE
EXCLUSION
OR LIMITATION
OF
INCIDENTAL OR
CON-
SEOUENTIAL
DAMAGES,
SO
THE ABOVE LIMITATION
OR EXCLUSION
MAY
NOT APPLY
TO YOU.
This
warranty
gives you
specitic
legal rights, and
you
may also have
other rights
which
vary
from
state to s-tate.
Thrs warranty applies
to all
ATOM Lawn EdEers
manuiactured
by ATOM
G
:
o
o
=
U'
o E
f
E
62
tlJ
s
56
s=
Jo
:* ;*
a-
5(! FO
20
Page 12
2
v
v
ATOM
LA\ryN
E,DGE,R
GK3-f)
PRO-ENGINE
SERVICE
MANUAL
CONTENTS Specifications
& Standards
Special Tools
Dissassembly
of Engine
Fuel
Supply
System
Carburettor
Fuel
Feed
Line
Ignition
System
Recoil
Starter Clutch Parts
List
Exploded
View
Page
No
WARNING:
FUEL
IS A HIGHLY
COMBUSTIBLE
SUBSTANCE.
DRAIN
ALL
FUEL FROM
TANK
AND
KEEP AWAY
FROM
WORKPLACE
IN A
SEALED
CONTAINER
BEFORE
COMMENCING
REPAIRS.
MAKE
SURE
ALL PARTS
ARE
CLEAN BEFORE
ASSEMBLY.
2-3
3
4-8
9 10 lt t2 13 t4 l5 t6
ATOM INDUSTRTES P.O. Box 513,
Rozelle
NSW
2039
9 Fred
Street Lilvfield
NSW
2040
Tel:
(02)
9810
0194
Fax:
(02)
9810
6691
E-mail:
atom@loom.com.au
Page 13
ECIFICATIONS
G3K.D
Piston displacement
Air
cooled
2-stroke
gasoline
engine
cc
33.6
mm
36x33 Nikki Flywheel
magneto,
transistor control
Champion
RCJ-8Y
Rewind
starter
Primary
coil short-circuiting
Mixture
of alcohol-free
gasoline
and 2-cycle
oil
(ratio
25:1)
L
0.65
TECHNICAL
DATA
G3K-D
Maximum output
kW 1.10
at 7000 rpm
Maximium torque
N-m 1.77
at 5500 rpm
ldling
range
rpm
2100 - 2300
utch engaging
range
rpm 2750
-
3250
stall range
rpm
4250 - 4750
fuel consump-
g/kW-h
620
FUEL
/
OIL
RATIO
Gasoline
: Oil
Up to
20 hours use
20 : 1
20 hours use
25 1
MAINTENANCE
STANDARDS
ITEM
.
ENGINE
pression pressure
G3K-D
STANDARD
LIMIT
7.0
5.0 36 36.04 36
35.86 I
9.04
0.045 0.2
0.002T 0.05L
1.5
1.6
0.04 0.15 '1.5
1.4
0.1 - 0.3
0.7
9
898 12 12.03 12 1 1.95
0.02
0.07
0.1
-
0.3 0.4
REMARKS
Reject
if
plating
dam-
aged
inder bore
outer diameter pin
bore
rence
between
cylinder
&
pistion
Tolerance between
piston
hole &
piston pin
T=tight; L=loose
of
groove
for
piston
ring
between
groove
and
piston
ring
iston ring
width
iston
ring end
gap
iston
pin
outer
diameter
rod
small end bore
rankshaft
diameter at
bearino section
ft misalignment
rankshaft
end
play
INTENANCE
STANDARDS . IGNITION
SYSTEM
ITEM
G3K-D
ISTANDARD
ALLOWANCE
REMARKS
gap
between
core
and rotor
10.4
r 0.1
Spark
plug
air
gap
06
,0.7
Primary
coil resistance
C
67
l!
15Vo Reading
between core & switch
wire terminal
coif
resistance
::::
! 20o/o Readino
between core and o
Page 14
MAINTENANCE
STANDARDS
.
CARBURETTOR
G3K-D
ITEM
STANDARD
IALLOWANCE
REMARKS
ldle limiter
oosition
Level of metering
lever
Main
jet
# - high
speed Jetneedle#-stage Inlet valve
cracking
pressure
kg/cm2
,1
A
2.5 596
-
2/3
0.
r 0.1 r 0.5
44
-t
I
Right
turn:
lean.
Left turn:
rich.
See
page
10
See
page
9
(item
21)
Top stage:
lean.
Bottom
stage. rich.
ASTENER
SPECIFICATIONS
.
WORKING
UNIT
ITEM
THREAD
DIMENSIONS
(metric)
TIGHTENING
TORQUE
(kgcm)
Engine mounting
bolt /
E
M5 x 1.0
50-90
FASTENER
SPECIFICATIONS
.
POWER
UNIT
ITEM
Crankcase
halves
fastening
screw
Cylinder
mounting bolt
(Except
for YBC3OD)
Starter
pulley
mounting nut
(YBCSOD
only)
Rotor mounting
nut
(YBC30D
& YBC4OD
only)
utch
shoe
mounting bolt
(Except
for YBC3OD)
ffler mounting
bolt
(Except
for YBC30D)
mounttng
screw
rter case
mounting
screw
(YBC3OD
&
YBC4OD only)
park plug
THREAD
DIMENSIONS
(metric) M5 x 0.8 M5 x 0.8
M10 x
'1.0
M8
x 1.0
M8x10 M6 x 1.0 M5 x 0.8 M5 x 0.8
M14 x
1.25
TIGHTENING
TORQUE
(kg-cm)
25-40
50-80 200 - 300 120 - 180 110
-
170
80 - 120
30-45
20-35
150 - 220
CIAL
TOOLS
PART NUMBER
Puller
assembly
Set
block
Rod
assembly
Stopper
To remove
rotor and
starter
pulley
1 075-961 00 1 400-9621
0 1600-96300 1
664-9641 1
lTo
set
pole
core
gap To remove/install piston pin To
hold crankshaft
K
12
Page 15
SEftVICE GUIDE
ENGINE BLOCK
Construction
t1
13
!
NL\>.
EJY
v
\:J-ruryr
:\,
o-,
-e
i,q,
frP
@o
1.
Cylinder
2.
Gasket,
cylinder
3.
Crankcase,
rotor
slde
4.
Crankcase,
starter
slde
5: Gasket,
crankcase
6. Maln
bearing
7.
Oll seal,
slarter slde
8.
Oll seal,
rotor side
9.
Clrclip
10. Piston
11.
Piston
ring
12.
Plston
pin
13.
Circlip
14.
Thrust
washer
15.
Crankshafl
15.
17.
18.
Key
Shim
Needle bearing
v
A. Disassembly:
l.
Separate engine from
work unit Drain fuel
tank and
clean the exterior
ofthe
eneine.
2. Remove
fuel
tank. air
cleaner" carburettor.
muffler
guard.
muffler.
rylinder
cover. starter
case,
fan
cover and spark
plug.
NOTE.
When removing
carburettor and muffler.
take care not
to damage the
gasket.
Ifdarnaged.
replace
with a new
one without fail
3.
While holding
clutch shoes u'ith
:r
rod. unfas-
ten securing
bolts
with
a sockc
Page 16
4)
Unfasten
the
rotor
securing
nut
and remove
rotor
by
using
the
specialtool.
Note:
.
Do
not
attempt
to
remove
rotor
by
hitting
on
crankshaft.
That
may
disorder
the
crankshaft
di_
mensions.
.
When
litting
the
puller,
make
sure
to
thread
in
the
side
bolts
to
equal
depth
over
10mm
or
threads
on rotor
may
be
damaged.
5)
Unfasten
the
stader
pulley
securing
nut
and re_
move
starter
pulley
by
using
the
special
tool.
Note: Do
not
attempt
to
remove
the
pulley
by
hitting
on
crankshaft.
That
can
damage
the
crjnXinaft.
Extending
the
end
gap,
remove piston
ring.
Remove
circlips
from
both
sides
of
piston
pin
by
using
a
pointed
tool.
D
d4'
6) Remove
cylinder
by
pulling
it
straight.
Note: Do
not
twist
cylinder,
or
piston
ring
may
be
broken.
Note:
Take
care
not
to
damage
piston.
9)
Push
out
piston
pin
with
the
speciallool.
7) B)
v
Page 17
t-
Rod
assembly
Note:
Wnen
tapping
on special
tool, hold
piston
in hand
so as
not
to
give
shock
on connecting rod.
10)
Unfasten
four screws,
separate crankcase
halves
and
pull
out
crankshaft.
Note: .
Make sure
that
key
is removed
from
crankshaft.
.
Do
not use a
screwdriver
to
pry
open the fitting
surface
of crankcase
halves.
When
it difficult to
separate,
lightly
tap
on
the halves
with a soft
hammer.
Reference:
Removing
oilsealand
main bearing.
1) Oilsealshould
be broken
otf{rom
crankcase.
2) Main
bearing should
be
pressed
out with
jigs
ap'
plied
as
shown
in the figure.
Note: Do not re-use such an oil seal once removed.
Notes:
1.
2.
3.
The
crankshaft
is
a built-up
type. Do not attempt
to disassemble
without
due facilities.
lf
defective
be
found
in the component, replace as crankshaft
complete.
Check
the service limits as
necessary.
Gaskets once removed should
be replaced
with new ones.
PTO slde
Starler slde
B.
Inspection:
Parl Check
point Repair
Cylinder
Piston
Piston
ring
Needle
bearing
Crankcase
Crankshaft
.
Carbon
deposits on the
head and exhaust
port.
.
Scoring
or
peeling
ofl
of
plated
bore.
.
Carbon
deposits on lhe crown
and in the
ring
groove.
.
Serious
damage or
partial
wear on the surface.
.
Damage or
partial
wear.
.
Looseness,
damage
or discoloration.
.
Damage, wear
or
hardening of oil seals.
.
Rough rotation of main bearing.
.
Crack ordarnage ol case
body.
.
Damage, discoloration or excessive
wear
of connecting
rod either end.
.
Scrape
otf carefully.
.
Replace.
.
Scrape
otf carefully.
.
Replace.
.
Replace.
.
Replace.
.
Replace.
.
Replace.
.
Replace.
.
Replace.
Page 18
4) Install
bearing
and washers
lo connecting rod
small
end.
Assemble
piston
with
piston
pin
by using
the
special
tool.
Then,
secure
piston
pin
with
circlips.
Note:
.
Make
sure
to
point
the arrow mark
on
piston
toward
the
exhaust
side.
.
lf
circlip is
distorted,
use new
one
without
fall.
Cut
this
section
off.
6)
Fit
piston
ring to
piston groove.
Make
sure
that the
end
gap
is
properly
located
at the
positioning
pin.
7) lnstall cylinder to
crankcase while holding
piston
ring
in
the
groove.
Tighten
evenly
with
four screws.
Note:
.
Confirm cylinder bore
and
piston
ring are coated
with oil.
.
Use new
gasket
for cylinder
base
flange.
.
Twisting of cylinder can damage
piston
ring
and
cylinder bore.
8)
Fit key to crankshaft PTO
side.
Install
rotor
with
keyway fitted. Tighten firmly with
nut.
Note: .
Check key
and
keyway for
damage or distortion.
lf necessary,
use
new
parts
without fail.
.
Keyway
position
is indicated
by
wedge-shaped
mark
on the boss of rotor.
9)
,Tighten
starter
pulley
to crankshaft.
10) lnstall
other
parts
as
they are.
Note: .
Pay special
attention to carburetor flange
gasket.
lf defective, replace without fail.
.
When
installing clutch shoes,
face the arrow
side to outside. lf reversed, the shoes
will be
worn
rapidly accompanied
with extra vibration.
v
v
Exhaust ma;k
5) Put
crankshaft
into
crankcase
starter side
and fit
crankcase
side with
gasket
inserted. Tighten
the
halves
evenly
with four
screws.
Note: .
Use new
gasket.
.
Check the fitting
surfaee
for
chips of old
gasket.
.
Cut off
excessive
gasket
protruding
at cylinder
base
flange.
Page 19
1)
2l
Assembly:
Note: .
Clean disassembled
parts
well and keep them
free from metal
or carbon
chips.
.
Apply
grease
to
the lip of oil seals.
.
Coat moving
parts
with
2-cycle
oil.
.
Before
actual
assembly, check fit
of
parts.
Fit the circlip
in the
groove
on the shaft hole
(PTO
side only).
Press
fit the main bearing
to the
shaft
hole of
crankcase.
Note:
.
Make
sure to
press
the bearing
straight.
.
Do not
use a hammer
to
install the
bearing.
.
Make
the number
side opposite to
the oil seal.
.
Before
pressing
in,
coat the bearing
with oil.
3)
Coat
the
lip of oil
sealwith heat-proof
grease,
then
fit in
the
shaft hole
as shown in
the figure.
PTO slde
Starler side
PTO slde
Starter
side
Page 20
FUEL
SUPPLY SYSTEM. G3KD
v
v
I
.fuh
23
25
26
27 28
29 30
--o
-@,
-e
1,
Screen
3.
Cleaner
4.
Element
7.
Maln
body
8.
Rubber
cap
9.
Body
cap
10.
Throttle
sprlng
1 1. Needle
spring
12.
Recelve
13.
Jel
needle
14.
Throttle
valve
16.
Pump
cover
assembly
17.
Pump
dlaphragm
18.
Gssket
19.
Sprlng
20.
ldle
adjusting
screw
21.
Maln
adJustlng
screw
23.
Needle
valve
24.
Hlnge
sprlng
25.
Hlnge
26.
Hinge
pln
27.
Set
screw
28.
Gasket
29.
Maln
dlaphragm
30.
Maln
diaphragm
cover
-\1
,e*:")^-
^Nl
,o__M.^
./
n
@o''
"
l. Fueltank
2.
Cap
3. Inner cap
4.
Gasket
5. Filter
assembly
6.
Clip
8.
Suction
pipe
9.
Check
valve
10.
Primer
pump
ll.
Stopper
NOTE: Pipe from tank
goes
to fuel
pump
(left
hand
side).
Pipe frorn
primer goes
to
right hand
side of carburettor
near main adjusting screw,
Page 21
l.
A.
1)
2l
3)
Carburetor
Disassembly
Remove
air cleaner by loosening
two air
cleaner
securing
screws
(M4).
Remove
carburetor by loosening two
carburetor
securing
screws
(M5).
Note:
Take care
not to damage
the
gasket.
Loosen
body cap
and
pull
out throttle
cable to-
gether
with throttle valve.
Then, remove
cable end
from
throttle
valve. This enables
removal of throt-
tle
valve,
jet
needle, receive,
body
cap and rubber
cap.
4)
Loosen
four
diaphragm
cover
securing
screws
(M3)
and
remove
main
diaphragm
cover, main
dia-
phragm
and
gasket.
At this
time,
take care not
to
damage
the
gasket.
Inspection and Adjustment
Check
the
stamped
number
on
jet
needle
and
throttle
valve.
<Number location>
Jet
needle
Throtll€
vatve
f596
-
2/3
step
Insert needle valve and
clean
if
any.dirt is
at-
tached. Replace it if contact face to valve
seat is
abnormallyand roughly worn. lnspect fuel
passage
hole
of
needle
jet
and main
jet
and
inside
sensing chamber. lf dirt is
attached,
blow compressive
air and then wash with
clean
washing
oil by shaking.
Measure the level
of hinge and adjust to 1.6mm if
needed.
B.
1)
2)
3)
4l
#05
6
Bottom
vlew
o
/,6+,-
MAIN
JET
ADruSTMENT:2Y,
t
%
TURN
OPEN
+-@KD
Remove
hinge,
hinge
pin,
hinge
spring
and
needle
valve
by
loosening
a set
screw
(M3)lor
hinge
pin.
Remove
pump
cover
assembly,
pump
diaphragm
1nd
gasket
by loosening
four
securing
screws
(M3)for
pump
cover
assembly.
Note:
control lever
arm will
point
slightly
upwards
s)
6)
c.
1)
2l
3)
Assembly
Set hinge
pin
and needle
valve
to hinge
and as-
semble the hinge
together
with
hinge
spring to
carburetor body and
secure
with
set screw
(M3).
Set
gasket,
pump
diaphragm
and
pump
cover
assembly
to carburetor
body in that order
and
secure with screw
(M3).
Set
gasket,
main
diaphragm
and
main diaphragm
cover to carburetor
body
in that order and
secure
with screw
(M3).
Part Name Standard
Jel needle Throttle
valve
596
-
2/3
slep
05
l0
Page 22
4l Pass rubber
cap, body cap and
throttle
spring
through throttle
cable in that order.
Then assem-
ble cable end
to throttle valve with
jet
needle.
At
this time, be sure
to insert spring
receive
and
needle clip
between
jet
needle clip and
spring.
lf
you
lail to
do do, the
jet
needle will
go
off
during
operation ol throttle.
Align throttle
valve
guide pin
of
carburetor
body
with
groove
of throttle
valve, insert throttle
valve
into
carburetor
body and tighten body
cap.
Secure carburetor to cylinder
with screw
(M5),
putting
gasket
between
them.
Tightening
torque: 30 - 45
kg-cm
7) Secure
air cleaner
to carburetor with screws
(M4).
Tightening torque: 5
-
9
kg-cm
Fuel
feed
line
Disassembly
Disconnect fuel
hose
from
carburetor.
The tank
can be
removed by loosening three
tank securing
screws
(M5).
Remove
primer pump
and suction
hose from
fuel
tank.
Remove
Filter
Assy from
suction
hose.
Remove
the check valve from the
primer pump.
Note:
When
inspecting
filter
Assy only,
just
pull
out
suction
pipe
from
fuelfilter
port.
Inspection
Inspect
suction
hose
and
primer
pump.
Replace
if
they
are
damaged
or deterioraled.
Inspect filter and
wash
or
replace
if they
are
clogged
with
dirt.
Inspect the air vent
valve
in the
fuel
cap
and clean
or replace
if necessary.
Inspect the tank body
and
the cap
gasket
and
replace
if damaged.
Assembly
lnsert check
valve
into
grommet
and
insert
grom-
met
into
primer pump.
Be sure
to
insert in the
correct direction.
PumP
<t
)
ranr
Assemble
primer pump
and
suction
hose,
and
press
in the
hose to
fuel tank.
At
this time,
push
around
primer pump
with
wooden
spatula.
Take
care
not to scratch
the sealing
face.
fuel
pipe
into
carburetor
and
secure
the
B.
1)
2l
3)
4)
c.
1)
v
5)
6)
2)
il. A.
1)
2l
3)
4)
3)
lnsert
tank.
ll
Page 23
G3K-D
1. Rotor
2. Ignition
coil
3. High tension
lead
4. Cap
5.
Sparkplugcap
6.
Spring
7.
Sparkplug
8. Cord, primary
lffi'Lru
1
'ffi
IGNITION
SYSTEM
Construction:
A. DISASSEMBLY Proceed
to
disassembly
referring
to the
above figure
Note: Avoid removing
ignition
coil from
fan
cover
unless necesary.
B. INSPECTION
l. Rotor
:
since
the rotor
turns at high
speeds, it
is
exlremely
dangerous
ifit
shakes, is
deformed
or has
external
cracks. In
the following
cases replace
the rotor
with a new
one.
o
Cracked,
deformed
or chipped
fan
blades;
o
Loose
magnets
or counter-weights
which
are moulded
in
the
rotor:
.
Damaged
tapered
area;
.
Damaged
kelrvay;
.
Cracked
centre
bss.
2.
Ignition
coil : The
usability
ofa
coil can
be briefly
checked
by measunng
the
circuit resistance
with a radio
tester
(drv
cell type).
r
The
primary
coil resistance
(reading
between
the
steel
core
and the
primary
terminal)
0.6'/A
+
SoA.
The
secondary
coil resistance
(reading
between
the
steel
core) 44000
!20oA.
a
Others : Inspect
the high
tension
cord
and the
primary
leads.
and make
sure that
they
are securely
connected
to their
terminals.
Replace
if insulation
is
damaged.
Turn
clockwlse
lo thread
ln.
Turn
counler-clockwlse
to remove.
Hlgh
tenslon
cord
Prlmary
Thread
ln
over
1Smm
r
Inspect
the spark
plug
cap and
replace ifcracked.
To
disconnect
the
cap without
damage to
the high
tension
cord and the
terminal
spring, lubricate
the
cap
with
oil and
pull
it
out slowly from
the cord.
C. INSTALLATION
OF IGNITION
COIL ANI)
TRANSISTOR
UNIT
l. Put ignition
coil
on the
bosses
offan cover,
temporar-
ily
fasten it
with three
screws.
2. Fit
the
Set
Block
to fan
cover with
the
positioning
holes
and
knock
pins
mated.
While
pressing
the
coil
to the
set block, fasten
the mounting
screws firrnly.
NOTE:
When
the set
block is
not
available. install
fan
cover to
crankcase
and
remove
rylinder
to
adjust
coil
gap
by
feeler
gauge.
T2
Spark
breaking
out RPM
is
set at 600
to
700
rpm.
When testing
spark use recoil
starter.
r
Do
not
allow
the
components
to
be heated
over 80oC.
.:.
@
Page 24
12
iit'
+-1 / lo
@u
Er
I Slaner
ci"use
\6
,t I 3
iffi*
'e@d6"
10 Ratchet
I 1 Spring, return 12 E-ring
-)
:-4
RECOIL
STARTER
Construction:
A. DISASSEMBLY
I Pull
out rope
and
make a temporary
knot in the
way to
untie the knot in
the
knob.
Using the temporary knot,
allow
rope to
wind back slowly. Turn
reel clockwise until the inside hook of
spiral
spring is disengaged from the
reel.
Unfasten
the reel
securins
screw and take out reel
slowlv.
C.
ASSEMBLY
Make
a circle of wire with
about 170 mm
circumfer-
ence. Then,
wind up spiral
spring
along the inside
of
the circle.
Apply
grease
over the inside
bottom ofstarter case.
Then: fit the outside hook
of spiral to the
retaining
groove
on case.
As
holding the
spring agarnst the
case bottom.
remove
the wire circle.
Make a knot
at one end of rope
and
pass
it
through reel. Wind
rope into reel,
pass
out the remaining rope
through case
hole
and
install
knob on the rope
end.
By turning reel left.
gear
it
to the
inside hook
of spiral spring. Secure
reel
with screw.
NOTE. Apply lock
cement to the screw.
As holding
starter case, turn the
reel 3% turns left
with rope
hooked in a notch
on
reel
edge.
While
holding reel.
pull
back rope. Then
release
reel and allow
rope
to wind
in.
NOTE. When
rope is sagged in the full returned
posi-
tion,
give
one or
two more turns to reel. When
replac-
ing
rope.
check
new
one
for
proper
lenglh and diame-
ter, or the
rope may
interfere
the
inside wall of case.
re-
sulting
in malfunction of starter.
8 When
installing ratchet, assemble with
return
spring
first. then
put
them into the
pulley
hole with
"R'beside
it.
Secure
with E-ring.
B.
NOTE: Make
sure that the spiral spring does
not
bounce out
Ratchet
can be
removed by removing E-ring
behind.
INSPECTION
Replace the rope with a
new
piece
if it is
excessively
worn or
kinked.
ROPE
SIZE
(D
x L): 3.5mm x l000mm
3
Replace
the
reel ifit is distorted
or cracked.
Replace
the spiral spring
ifit is
broken
or excessively
de­formed. Replace
the
ratchet
with
a new
part
if
the engagement
area with the
reel is noticeablv worn.
l3
6rOP
Page 25
2
%
1.
Glutch shoe
2.
Clulch
bolt
3.
Clutch sprlng
4.
Washer,
plaln
5.
Washer, wave
w
pre.ffi
CLUTCH
Construction:
A.
DISASSEMBLY
-
see
page
4' ENGINE
section
B.
INSPf,CTION
I
Inspect
the clutch
shoes and
replace
with
new
parts if
they
are
worn
or damaged.
2
Any oil
which
has adhered
to
the
lining
must be
re-
moved
with
gasoline
or
thinner.
3
Inspect
the clutch
spring
and
replace
if
it is worn
or
damaged.
C.
ASSEMBLY
I Hook
up the ends
of
spnng
to clutch
shoes.
Note:
When
hooking,
do
from the
outside
surface
indi-
cated
by arrow
mark.
Arrow mark
2
Place
plain
washers
on bosses
ofrotor.
put
on
clutch
shoes
and
fasten
bolts
with
wave
washer
assembled.
Note. e
Coat
the sliding
bolt
with
grease.
.
Take
care
not to
mistake
the
installing
direction
of
wave
washer.
v
v
l4
Page 26
KEY
#
DESCRIPTION
ATOM
PART
NO.
,|
CYLINDER
46100
2
BOLT
46102
3
GASKET
46104
4
GASKET
461
06
5
GASKET
461
08
6
GASKET
46110
7 INSULATOR
46112
I SCREW
46114
I
SCREW
461 16
10
CRANKCASE
SET
46118
11
GASKET
46120
12
BEARING
46't22
13
SEAL
46124
14
SEAL
46126
15
RING
46128
16
BOLT
461 30
17
GUARD
46132
18
SCREW
46134
19
PISTON
461 36
20
RING
461
38
21 PIN
46140
22
RING
46142
23
BEARING
46144
24
WASHER
46146
25
CRANKSHAFT
COMP
46148
26
SHIM.
O.3T
461
50
27 SHIM.
O.1T
46152
28 NUT
46154
29
KEY
461 56
30
SHOE
461 58
31
SPRING
46160
32
SCREW
46162
33
WASHER
46164
34
WASHER
46166
35
ROTOR
46168
36
COIL ASSEMBLY
46170
37
CORD
46172
38
CAP
46174
39
GROMMET
46176
40
GROMMET
46178
41
CAP
461
80
42 SPRING
46182
43
SCREW
46184
44
MUFFLER
461 86
45
SCREW
46188
46
BOLT
461
90
47
COVER
46't92
48
BOLT
46194
49
BOLT
461 96
50
COVER.
fan
461 98
51
GROMMET
46200
52
BOLT
46202
53
CLAMP
46201
54 PIPE
46203
55
COVER. cvlinder
46204
56
SCREW
46206
57
SCREW
46208
58
GUARD
46210
59
GROMMET
46212
60
CORD
46214
61
CORD.
earth
46216
62
SPARK PLUG
46218
63
STARTER
ASSEMBLY Onlv
as oarts
ATOM
PROFESSTONAL
EDGER
[MODEL
201021
G3KD
ENGINE
PARTS
LIST
rc3K2sAM,
p/N
43s70
KEY
# DESCRIPTION
ATOM
PART
NO.
63A
STARTER
HOUSING
46219
64
RECOIL ASSEMBLY
Onlv as
oarts
65
REEL
46220
66 SPRING
46222
67
SCREW
46224
68
ROPE
46226
69 KNOB
46228
70 TAPE
46230
71 PULLEY
ASSEMBLY
Only
as
parts
714
STARTER PULLEY
CATCH
46231
72
RATCHET
46232
73
SPRING
46234
74
E-RING
46236
75
SCREW
46238
76
CARBURETOR
ASS'Y
46240
77
RETAINER
46242
78
NEEDLE
46246
79
VALVE
46248
80
SPRING
46250
81
SCREW
46252
82
SPRING
46254
83
PIN
46256
84 ARM
46258
85 VALVE
46260
86
SPRING
46262
87 SCREW
46268
88 GASKET
46270
89
DIAPHRAGM
ASS'Y
46272
90
COVER
46274
91 SCREW
46276
92 GASKET
46278
93
DIAPHRAGM
46280
94 COVER
ASS'Y
46282
95 SCREW
46284
96 NEEDLE
46286
97 CAP COMP
46288
98
CAP
46290
99
SEAL
46292
100
CLIP
46294
101 CLEANER
ASSEMBLY Only as
parts
1014
AIR FILTER BODY
46296
102
ELEMENT
46298
103 LABEL
46300
104 SCREEN
46302
105 SCREW
46304
106
ANK ASS'Y
46306
107
CAP ASS'Y
46308
108
VALVE COMP
4631 0
109
PACKING
46312
110 STOPPER
46314
111
PIPE COMP
46316
112 FILTER
ASSEMBLY
4631 8
113
CLIP
46320
114
PUMP COMP
46321
115
PUMP
46322 116 117
11S 119
1n
121 a4 n5
GROMMET JOINT IUBE VALVE f/ASHER SCREW CABTE COMP 3LAMP
46324
46326 46328 46330 4$n 46334 46336
Page 27
G3KD
ENGINE
PARTS
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