Hitachi CG 24EBSS, CG 24EBSPS, CG 24EBDP, CG 24EBS, CG 24EBDPSL Service Manual

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International Sales Division

TROUBLESHOOTING GUIDE ---------------------------------------------------------------------------------------------- 1

1. Troubleshooting and correction ------------------------------------------------------------------------------- 1

REPAIR GUIDE ----------------------------------------------------------------------------------------------------------------- 2

1. Precautions on maintenance, inspection and repair ----------------------------------------------------- 2

2. Inspection standards and spark plug replacement/adjustment --------------------------------------- 2

CONTENTS

Page

CG 24EBSP(S)/CG 24EBS (S) CG 27EBSP(S)/CG 27EBS (S)

CG 24EBSP(SL)/CG 24EBS(SL) CG 27EBSP(SL)/CG 27EBS(SL)

CG 24EBDP(SL)/CG 24EBD (SL) CG 27EBDP(SL)/CG 27EBD (SL)

LIST Nos. CG 24EBSP: F056 CG 27EBSP: F060 CG 24EBS: F055 CG 27EBS: F059 CG 24EBDP: F054 CG 27EBDP: F058 CG 24EBD: F053 CG 27EBD: F057 Apr. 2014

PRODUCT NAME

Hitachi Engine Brush Cutter/Grass Trimmer

Models

CG 24EBSP(SL)/(S) CG 24EBS(SL)/(S)

CG 24EBDP(SL)/(SLN) CG 24EBD(SL)/(SLN) CG 27EBSP(SL)/(S) CG 27EBS(SL)/(S) CG 27EBDP(SL)/(SLN) CG 27EBD(SL)/(SLN)

-1-

1. Troubleshooting and correction

Problem Cause Action

Starter grip cannot be pulled.

Crank shaft does not turn.

Seized piston ring

Disassemble and replace.

Seized connecting rod bearing

Crank shaft turns. Defective starter

Engine does not start.

Dry spark plug

Empty fuel tank Replenish with fuel. Clogged fuel filter ass’y Clean or replace. Folded or improperly connected or

damaged fuel pipe

Check or replace.

Defective air vent valve of tank cap ass’y

Replace.

Clogged carburetor ass’y Clean. Defective carburetor ass’y Check or replace.

No spark

Stained or defective spark plug Clean or replace. Improperly connected high tension

cable and terminal

Check.

Damaged high tension cable Replace. Improper air gap Adjust. Defective coil Replace. Defective stop switch Replace. Improperly connected or damaged

internal wires

Check or replace.

No compression

Defective piston ring

Replace. Worn piston

Defective oil seal of crank chamber

Engine starts but cannot continue idling.

Weak sparking

Stained or defective spark plug Clean or replace. Improper air gap Adjust. Defective coil Replace.

Weak compression

Defective piston ring

Replace.

Defective oil seal of crank chamber

Proper sparking and compression

Clogged carburetor ass’y Clean. Defective carburetor ass’y Check or replace. Clogged fuel filter ass’y Clean or replace. Folded or improperly connected or

damaged fuel pipe

Check or replace.

Too low idling speed Adjust.

Engine starts and accelerates but ...

Engine stops.

Clogged carburetor ass’y Clean. Defective carburetor ass’y Check or replace. Clogged fuel filter ass’y Clean or replace.

Accelerates improperly. (Engine does not rev up.)

Defective carburetor ass’y Check or replace. Muffler clogged with carbon Clean. Clogged element of air cleaner ass’y Clean.

Engine starts but ...

Engine speed fluctuates.

Clogged carburetor ass’y Clean. Defective carburetor ass’y Check or replace.

Consumes excessive fuel.

Defective carburetor ass’y Check or replace. Clogged element of air cleaner ass’y Clean.

Cutting attachment rotates at idling speed.

Improper idling adjustment Adjust. Worn clutch section Replace.

TROUBLESHOOTING GUIDE

-2-

This section describes the troubleshooting and repair procedures for common phenomena that may occur during engine brush cutter/grass trimmer operation. The procedures described here and in the TROUBLESHOOTING GUIDE should be studied and referenced as needed to ensure efficient diagnosis and the prompt repair of problems.

1. Precautions on maintenance, inspection and repair

• As the fuel used in the engine brush cutter/grass trimmer is highly flammable, carefully keep sources of fire out of the area. Start the engine as described below, and when confirming operation, be sure to use mixed fuel of gasoline and two-cycle oil at a ratio of 25 to 50: 1.

• In case the engine section is disassembled, always be sure to replace gaskets and oil seals with new

ones prior to reassembly.

• Before starting disassembly and repair, thoroughly drain all fuel from the unit into a suitable container.

• Before disassembly, be sure to remove the cutting attachment to prevent damage to its cutting edge or

personal injury due to the cutting attachment.

• Always ensure that the engine has fully cooled down before attempting di sassembly.

• When starting, operating or performing maintenance on the unit, always avoid touching hot portions of

the muffler and other hot components, as well as the high tension cable or spark plug; otherwise, you run the risk of a serious burn injury or electric shock.

• When a cutting attachment is mounted on the unit, carefully confirm that no one else is in the immediate

area before starting the engine.

• When repairing the unit indoors or in other protected areas, carefully ensure there is adequate

ventilation.

• Upon completing repair, carefully confirm that all screws, nuts and bolts are properly tightened, the

throttle trigger returns properly to the idling position when released, and the engine stops when you set the stop switch to the STOP position.

2. Inspection standards and spark plug replacement/adjustment

Use the table below as a handy guide during and after repair to meet inspection standards, and when replacing or adjusting the spark plug.

Item Standard value

Inspection standards

Idling rotation speed 2,500 to 3,500 min

-1

No-load max. rotation speed (after warming up)

CG 24EBSP(S) CG 27EBSP(S) [with cutter blade]

8,500 to 12,500 min

-1

CG 24EBSP/EBS CG 24EBDP/EBD CG 27EBSP/EBS CG 27EBDP/EBD [with nylon head]

8,200 min

-1

Clutch engagement 3,800 to 4,800 min

-1

Engine acceleration Smooth acceleration Clearance between external circumference of

the flywheel and ignition coil

0.2 to 0.4 mm

Consumable

parts

Spark plug

Europe, Russia, Australia NGK BMR7A Other regions CHAMPION CJ6

Gap between electrodes of the spark plug 0.6 to 0.7 mm

REPAIR GUIDE

-3-

Pull the starter handle to perform startup operation according to page 5 and check whether the spark plug is wet or dry. Is fuel being properly supplied?

Is there compression?

Does the engine start?

Remove the spark plug and check the spark according to page 5. Is there a proper spark?

Fouled or defective spark plug Cleaning or replacement Snapped or improper

connection of high tension cable or internal wires

Inspection, repair or replacement as necessary.

Improper high tension cable or internal wires

Repair or replacement

Defective coil Replacement Excessive clearance between

circumference of rotor fan and coil

Readjustment

Clogged air vent valve of tank cap ass’y

Replacement

Clogged carburetor Clea ning Clogged fuel filter ass’y Cleaning or replacement

Defective primer pump of air cleaner ass'y

Replacement or readjustment

Defective piston rings Cleaning or replacement Worn piston rings Replacement Worn piston Replacement Worn or broken oil seals Replacement

Stop switch at “OFF” position

Set to “ON” position.

Empty primer pump

Push primer pump several times.

Choke lever in closed position Turn to open position.

Repair flowchart

Yes

No Yes

-4-

Weak spark

Fouled or defective spark plug

Cleaning or replacement

Improper fuel-air mixture

Clogged fuel filter ass'y

Cleaning

Clogged carburetor

Cleaning

Defective carburetor ass'y

Inspection or replacement

No compression

Worn piston rings

Replacement

Worn oil seals

Replacement

Broken magneto rotor ass'y key

Replacement

Improper fuel-air mixture

Clogged fuel filter ass'y

Cleaning

Clogged carburetor

Cleaning

Defective carburetor ass'y

Inspection or replacement

Improper fuel-air mixture

Clogged fuel filter ass'y Cleaning Clogged carburetor Cleaning

Defective carburetor ass'y

Inspection or

replacement Clogged element of air cleaner ass'y Cleaning Carbon clogged in muffler, cylinder or

exhaust vents

Cleaning Defective ignition coil ass'y Replacement

Defective gasket or packing seal Replacement

Improper carburetor adjustment Readjustment Defective carburetor ass'y

Inspection or

replacement

Defective carburetor ass'y

Inspection or replacement

Idling adjustment of carburetor too high

Readjustment

Worn clutch section

Replacement

Yes

Does the engine accelerate when throttle trigger is triggered?

Yes

Does the engine stop when the choke lever is o

en?

Does the engine stop at idling?

Is fuel consumption excessive?

Does the cutting attachment rotate at idling speed?

Engine starts. Does combustion continue?

Yes

-5-

[Bold] numbers in the description below correspond to item numbers in the Parts List and exploded assembly diagram for the Model CG 24EBSP, (Bold) numbers co rrespond to those for the Model CG 24EBDP, {Bold} numbers correspond to those for the Model CG 27EBSP, and <Bold> numbers correspond to those for the Model CG 27EBDP as represe ntative models. For other models, refer to the parts list of each model.

1. Starting the engine

(1) When the engine is cold:

(a) Set the stop switch to the ON position. (b) Push the Priming Pump Comp. [43](43){44}<44> several times so that fuel flows through the Fuel

Pipe (Pink) [126](126){126}<126>.

”. (d) Pull the recoil starter briskly, while being careful to grip the handle and not allowing it to snap back. (e) When you hear the engine beginning to start, return the choke lever to the RUN position “

”.

(f) Pull the recoil starter briskly again.

NOTE: The marks “

”

and “” are indicated on Air Cleaner (A) Ass'y [46](46){47}<47>.

(2) When the engine is warm:

(a) Set the choke lever to the RUN position “

”. (b) Set the stop switch to the ON position. (c) Pull the recoil starter briskly, while being careful to grip the handle and not allowing it to snap back.

2. Checking for sparks of the spark plug

(1) Remove the Spark Plug Ass'y BMR7A [13](13){13}<13>

from the Cylinder [19](19){19}<19>. Use a wire brush to thoroughly clean off any carbon on the electrodes of the Spark Plug Ass'y BMR7A [13](13){13}<13>. If the gap between the electrodes is improper, readjust it as shown in the figure. If the electrodes are wet with fuel, use a clean, soft cloth to thoroughly wipe the fuel off. Then remove any residual fuel in the Cylinder [19](19){19}<19> by following the procedure below.

(a) Hold the Spark Plug Ass'y BMR7A [13](13){13}<13>

away from the Cylinder [19](19){19}<19>.

(b) Face it down toward the spark plug mounting hole on

the Cylinder [19](19){19}<19>.

(2) Insert the Spark Plug Ass'y BMR7A [13](13){13}<13> into

the Plug Cap [120] (120){120}<120>. While keeping the electrode portion of the Spark Plug Ass'y BMR7A [13](13){13}<13> in contact with the metal part of the engine but avoiding contact near the Spark Plug Ass'y BMR7A [13](13){13}<13> mounting hole on the Cylinder [19](19){19}<19>, pull the starter grip.

(3) When the Spark Plug Ass'y BMR7A [13](13){13}<13> is

functioning properly, there should be sparks from the electrode portion, along with a crackling sound.

• Spark plug

Gap between electrodes (0.6 to 0.7 mm)

Remove carbon here.

High tension cable

Plug Cap

[120](120){120 }<120>

Spark Plug Ass'y BMR7A

[13](13){13}<13>

Ignition sparks

Metal part of engine (Avoid contact near the spark plug mounting hole on the cylinder.)

* Wearing thick cotton gloves is recommended.

• Checking for sparks

Inspection and repairprocedures

-6-

WARNING:

• When performing the procedure outlined above, touching an y metallic portions of the Spark Plu g Ass'y BMR7A [13](13){13}<13> when pulling the starter grip will give you electric shock. Therefore, be very careful in handling Spark Plug Ass'y BMR7A [13](13){13}<13>.

• Thoroughly wipe up any fuel around the Spark Plug Ass'y BMR7A [13](13){13}<13>, and confirm that there is no danger of fire before checking the spark.

3. Adjusting the air gap (clearance) between the magneto rotor comp. perimeter

and ignition coil ass’y

(1) Remove the Muffler Cover [2](2){2}<2>, Cylinder Cover [9](9){8}<8> and Fan Case (A) [107](107)

{107}<107>.

(2) Loosen the two Hex. Socket Hd. Bolts (W/Washers) M4 x 18 [118](1 18){118}<118> so as to

temporarily secure the Ignition Coil Ass'y [119](119){119}<119>.

(3) Insert a thickness gauge between the magnetic steel portion around the perimeter of the Magneto

Rotor Ass'y [124](124)/Magneto Rotor Comp. {124}<124> and Ignition Coil Ass'y [119](119){ 119} <119>, and then adjust the position of the Ignition Coil Ass'y [119](119){119}<119> to achieve a clearance of 0.2 to 0.4 mm.

(4) Tighten the two Hex. Socket Hd. Bolts (W/Washers) M4 x 18 [118](118){118}<118> and remove the

thickness gauge.

(5) After securely tightening the Hex. Socket Hd. Bolts (W/Washers) M4 x 18 [118](118){118}<118>,

confirm that the clearance is between 0.2 mm and 0.4 mm.

4. Wiring diagram

Wiring should be done as shown in the diagram below. The Cord [122](122){122}<122> is connected to the connector on the Ignition Coil Ass'y [119](119){119} <119>. The Earth Cord [123](123){123}<123> is fastened to the Ignition Coil Ass'y [119](119){119}<119> with the Hex. Socket Hd. Bolts (W/Washers) M4 x 18 [118](118){118}<118>. The Cord [122](122){122}

<122> and the Earth Cord [123](123){123}<123> are connected to the terminal of Throttle Lever (B) [151]{151} or Throttle Lever (A) Ass’y [99](99){99}<99>. Engage the needle tip of the Metal Fitting of Plug

Cap [120](120){120}<120> into the core wire of the high tension cable. Apply two-cycle oil to the cord mounting hole of the Plug Cap [120](120){120}<120>, and then insert the high tension cable and the Metal Fitting of Plug Cap [121](121){121}<121> into the hole. After mounting the parts, check for sparking of the Spark Plug Ass'y BMR7A [13](13){13}<13> and continuity of the Metal Fitting of Plug Cap [121] (121){121}<121>.

Ignition Coil Ass'y [119](119){119}<119>

Hex. Socket Hd. Bolt (W/Washers) M4 x 18 [118](118){118}<118>

Magneto Rotor Ass’y [124](124) Magneto Rotor Comp. {124}<124>

Clearance between

0.2 mm and 0.4 mm

• Adjusting the clearance between the magneto rotor and ignition coil

-7-

• Wiring diagram

Core wire

High tension cable

Engage the two tips of the Metal Fitting of Plug Cap [121](121){121}<121> into the core wire.

Metal Fitting of Plug Cap

[121](121){121}<121>

• Metal fitting of plug cap

CG 24EBSP(S), CG 24EBS(S) CG 27EBSP(S), CG 27EBS(S)

CG 24EBSP(SL), CG 24EBS(SL), CG 24EBDP(SL)/(SLN), CG 24EBD(SL)/(SLN), CG 27EBSP(SL), CG 27EBS(SL), CG 27EBDP(SL)/(SLN), CG 27EBD(SL)/(SLN)

Cord [122](122){122}<122>

Earth Cord

[123](123){123}<123>

Hex. Socket Hd. Bolts (W/Washers) M4 x 18 [118](118){118}<118>

Ignition Coil Ass’y

[119](119){119}<119>

Throttle Lever (B) [151]{151}

Throttle Lever (A) Ass’y [99](99){99}<99>

Handle (Right) [156]{156}

-8-

5. Checking the fuel filter

Use a piece of wire to remove the Pump Filter Body Comp. [134](134){133}<133> from the fuel inlet of Tank (B) [133](133){132}<132>. If the Pump Filter Body Comp. [134](134){133}<133> is stained, clean it with gasoline. Remove the Pump Filter Body Comp. [134](134){133}<133> from the Fuel Pipe [125](125) {125}<125>. Check whether the Pump Filter Body Comp. [134](134){133}<133> is clogged by breathing through it. Replace the Pump Filter Body Comp. [134](134){133}<133> as necessary.

6. Cleaning the muffler and the cylinder

(1) Remove the Muffler Cover [2](2){2}<2>. (2) Loosen the two Hex. Socket Hd. Bolts M6 x 65 [4](4){3}<3>, and then remove Muffler (B) [6](6){5}<5>

together with the Heat Protection Panel [7](7){6}<6>.

(3) Use a flat-blade screwdriver (precision) to scrape carbon off the exhaust port of Muffler (B) [6](6){5}

<5>. Close the exhaust port of the Cylinder [19](19){19}<19> with the Piston [49](49){50}<50>, and then scrape carbon off the exhaust port.

NOTE: Do not scratch the inner wall surfaces of the Piston [49](49){50}<50> and the Cylinder

[19](19){19}<19>.

7. Cleaning the element

Open the Cleaner Cover [45](45){46}<46> of Air Cleaner (A) Ass'y [46](46){47}<47>. Remove the Cleaner Element [44](44){45}<45> and clean it with compressor air. If the Cleaner Element [44](44){45}

<45> is heavily stained, clean it with gasoline and dry it well before reassembly.

8. Replacing the fuel pipe

If a crack is found on the Fuel Pipe L70 [41](41){42}<42>, Fuel Pipe [125](125){125}<125> or Fuel Pipe (Pink) [126](126){126}<126>, replace the cracked pipe. Fit the Fuel Pipe [125](125){125}<125> equipped with the Pump Filter Body Comp. [134](134){133}<133> into the socket at the bottom of the Carburetor Ass'y WYC-36 [24](24)/WYC-37 {25}<25>/WYC-30*. Fit one end of the Fuel Pipe L70 [41](41){42}<42> into the socket on the side of the Carburetor Ass’y WYC-36 [24](24)/WYC-37 {25}<25>/WYC-30, and fit the other end of the Fuel Pipe L70 [41](41){42}<42> into the shorter socket on the Priming Pump Comp.

[43](43){44}<44> in Air Cleaner (A) Ass’y [46](46){47}<47>. Fit the Fuel Pipe (Pink) [126](126){126} <126> into the longer socket on the Priming Pump Comp. [43](43){44}<44> in Air Cleaner (A) Ass’y [46] (46){47}<47>.

*: Refer to the parts list of each model.

-9-

• Replacing the fuel pipe

Tank (B)

[133](133){132}<132>

Return Grommet

[127](127){127}<127>

Fuel Pipe (Pink)

[126](126){126}<126>

Fuel Grommet

[130](130){130}<130>

Fuel Pipe

[125](125){125}<125>

Fuel Pipe L70

[41](41){42}<42>

Carburetor Ass'y WYC-36 [24](24)/ WYC-37 {25}<25>/ WYC-30* *: Refer to the parts

list of each model.

ir Cleaner (A) Ass'y

[46](46){47}<47>

Cleaner Cover

[45](45){46}<46>

Cleaner Element

[44](44){45}<45>

Priming Pump Comp.

[43](43){44}<44>

ir Cleaner Housing

[42](42){43}<43>

Pump Filter Body Comp.

[134](134){133}<133>

-10-

• Idle adjust screw Idle adjust screw

9. Checking and adjusting the carburetor ass’y

(1) Checking the Carburetor Ass'y WYC-36 [24](24)/WYC-37 {25}<25>/WYC-30

While disassembling the Carb ur e to r A s s' y W Y C -3 6 [24](24)/WYC-37 {25}<25>/WYC-30 , check its parts for wear, deformation, and clogged holes. If dirt or dust is found on a part, clean it off or remove dust by using an air blower. If a deformed or worn part is found, replace the part or entire Carburetor Ass'y WYC-36 [24](24)/WYC-37 {25}<25>/WYC-30.

(2) Adjusting the Ca rburetor Ass'y WYC-36 [24](24)/WYC-37{25}<25>/WYC-30

Adjust the opening of the throttle valve during idling. Turning the idle adjust screw clockwise increases engine speed; turning it counterclockwise reduces engine speed. If the cutting attachment rotates during idling, reduce the speed so that the cutting attachment does not rotate. Note that excessively low speed may cause the engine to stop during idling. In such case, increase the speed but do not allow the cutting attachment to rotate.

10. Cleaning the spindle lock

(1) Disassembly

(a) Loosen the U-Nut (Left Hand) M10 [170](180){170}<180> of the Gear Case Ass’y (4BB) [160](170)

{160}<170>, and then remove the Nut Cover [169](179){169}<179>, Cutter Holder (B) [168](178) {168}<178>, and Cutter Holder (A) [167](177){167}<177>.

(b) Remove the press-fitted Cap [163](173){163}<173>, and then remove the Spring [164](174){164}

<174> and Lock Pin [166](176){166}<176>.

(2) Cleaning

(a) Thoroughly wipe off grease from the Lock Pin [166](176){166}<176> hole on the gear case and its

vicinity .

(b) Thoroughly wipe off grease from the Spring [164](174){164}<174> and Lock Pin [166](176){166}

<176>.

[167](177){167}<177>.

(3) Reassembly

(a) Apply grease to the Lock Pin [166](176){166}<176> and insert the pin into the gear case hole. (b) Mount the Spring [164](174){164}<17 4> and press-fit the Cap [163](173){163 }<173 > tothe Lock Pin

[166](176){166}<176>. Be sure to use a new Cap [163](173){163}<173>.

-11-

• Cleaning the spindle lock

U-Nut (Left Hand) M10

[170](180){170}<180>

Nut Cover

[169](179){169}<179>

Cutter Holder (B)

[168](178){168}<178>

Cutter Holder (A)

[167](177){167}<177>

Cap

[163](173){163}<173>

Spring

[164](174){164}<174>

Lock Pin

[166](176){166}<176>

Hex. Socket Hd. Bolt M5 x 30

[161](171){161}<171>

Screw 5 x 12/W.S

[162](172){162}<172>

Bolt (W/Plus) M6 x 8

[165](175){165}<175>

Gear Case Ass'y (4BB)

[160](170){160}<170>

Gear shaft D24

-12-

1. Disassembly of the engine unit

(1) Separating the engine from the main pipe

Loosen the Hex. Socket Hd. Bolt (W/Sp. Washer) M5 x 12 [100](100){100}<100> and two Hex. Hole Bolts 5 x 22/S [101](101){101}<101>, and then sep arate the engine from the shaft ass’y.

(2) Disassembly of the outer parts

(a) Disassembly of the muffler cover

Loosen the screws below to remove the Muffler Cover [2](2){2}<2>. CG 24EBSP/CG 24EBDP: Seal Lock Hex. Socket Hd. Bolt M5 x 30 [1](1)

Hex. Socket Hd. Bolt (W/Flange) M4 x 18 [3](3)

CG 27EBSP/CG 27EBDP: Two Screws (W/Washers) M5 x 16 (Black) {1}<1>

(b) Disassembly of the cylinder cover

Loosen the screws below to remove the Cylinder Cover [9](9){8}<8>. CG 24EBSP/CG 24EBDP: Seal Lock Hex. Socket Bolt (W/Washers) M5 [12](12)

Two Hex. Socket Hd. Bolts (W/Flange) M4 x 18 [3](3)

CG 27EBSP/CG 27EBDP: Two Seal Lock Hex. Socket Hd. Bolts M5 x 30 {12}<12>

Two Hex. Socket Hd. Bolts (W/Flange) M4 x 18 {10}<10>

NOTE: Be careful not to lose Collar (B) [10 ](10){9}<9>.

Loosen the screws below to remove Fan Case (A) [107](107){107}<107>. CG 24EBSP/CG 24EBDP: Seal Lock Hex. Socket Bolt (W/Washers) M5 [12](12) CG 27EBSP/CG 27EBDP: Seal Lock Hex. Socket Hd. Bolt M5 x 30 {12}<12>

(d) Disassembly of the tank

To remove Tank (B) [133](133){132}<132>, pull out the Fuel Pipe [125](125){125}<125> and Fuel Pipe (Pink) [126](126){126}<126> from the Carburetor Ass'y WYC-36 [24](24)/WYC-37 {25}<25> and Air Cleaner (A) Ass’y [46](46){47}<47>, and then loosen the screws below. CG 24EBSP/CG 24EBDP: Three Bolts (W/Flange) L27.8 [137](137) CG 27EBSP/CG 27EBDP: Two Flange Bolts {136}<136>

Bolt (W/Flange) L27.8 {137}<137>

(e) Disassembly of the recoil starter

To remove the Recoil Starter Body Ass'y [64](64){66}<66>, remove the Cylinder Cover [9](9){8}<8> as described in (b) above, and then loosen the screws below. CG 24EBSP/CG 24EBDP: Hex. Socket Hd. Bolts (W/Flange) M4 x 18 [3](3) CG 27EBSP/CG 27EBDP: Two Hex. Socket Hd. Bolt s (W/Flange) M4 x 18 {10}<10>

Disassembly and reassembl

-13-

• Disassembly of the outer parts (1)

Models CG 24EBSP, CG 24EBS, CG 24EBDP, and CG 24EBD

Tank (B) [133](133)

Muffler Cover [2](2)

Cylinder Cover [9](9)

Fan Case (A) [107](107)

Stand [136](136)

Recoil Starter Body Ass'y

[64](64)

Cleaner Cover [45](45)

Spacer [131](131)

Collar (B) [10](10)

Hex. Socket Hd. Bolts (W/Flange) M4 x 18 [3](3)

Seal Lock Hex. Socket Hd. Bolt M5 x 30 [1](1)

Hex. Socket Hd. Bolt (W/Flange) M4 x 18 [3](3)

Seal Lock Hex. Socket Bolt (W/Washers) M5 [12](12)

Bolts (W/Flange) L27.8 [137](137)

Hex. Socket Hd. Bolt (W/Flange) M4 x 18 [3](3)

Seal Lock Hex. Socket Bolt (W/Washers) M5 [12](12)

Muffler Heat Cover [75](75)

Tapping Screw D4 x 10 [76](76)

For CG 24EBSP and CG 24EBDP only

-14-

• Disassembly of the outer parts (2) Models CG 27EBSP, CG 27EBS, CG 27EBDP, and CG 27EBD

Tank (B) {132}<132>

Muffler Cover {2}<2>

Cylinder Cover {8}<8>

Fan Case (A) {107}<107>

Stand {135}<135>

Recoil Starter Body Ass'y

{66}<66>

Cleaner Cover {46}<46>

Spacer {131}<131>

Collar (B) {9}<9>

Hex. Socket Hd. Bolts (W/Flange) M4 x 18 {10}<10>

Seal Lock Hex. Socket Hd. Bolts M5 x 30 {12}<12>

Bolt (W/Flange) L27.8 {137}<137>

Flange Bolts {136}<136>

Screws (W/Washers) M5 x 16 (Black) {1}<1>

Hex. Socket Hd. Bolts (W/Flange) M4 x 18 {10}<10>

Seal Lock Hex. Socket Hd. Bolt M5 x 30 {12}<12>

Muffler Heat Cover {77}<77> Tapping Screw D4 x 10 {78}<78>

For CG 27EBSP and CG 27EBDP only

-15-

(3) Removing the muffler

Loosen the two Hex. Socket Hd. Bolts M6 x 65**[4](4){3}<3>, and then remove Muffler (B) [6](6){5} <5> and the Heat Protection Panel [7](7){6}<6> together.

**: For the Models CG 24EBS, CG 24EBD, CG 27EBS and CG 27EBD, loosen the hex. socket hd.

bolts M6 x 55.

(4) Removing the spark plug

Remove the Plug Cap [120](120){120}<120> from the Spark Plug Ass’y BMR7A [13](13){13}<13>, and then remove the Spark Plug Ass'y BMR7A [13](13){13}<13>.

(5) Removing the air cleaner ass’y, carburetor ass’y, and carburetor insulator

Open the Cleaner Cover [45](45){46}<46> of Air Cleaner (A) Ass’y [46](46){47}<47>, loosen the two Machine Screws (W/Washers) M5 x 60 (Black) [40](40){41}<41>, and then remove Air Cleaner (A) Ass’y [46](46){47}<47>, Carburetor Ass’y WYC-36 [24](24)/WYC-37 {25}<25>/WYC-30, and Carburetor Packing [22](22){23}<23> together. Loosen the two Seal Lock Hex. Socket Bolts (W/Washer) M5 [12](12){22}<22>, and then remove the Carburetor Insulator [21](21){21}<21> and Intake Packing [20](20){20}<20> together.

(6) Removing the fan case and clutch shaft

Place Fan Case (A) [107](107){107}<107> so that its surface facing the crank case is positioned downward, and then remove the Retaining Ring for D12 Shaft [106](106){106}<106>. Use a hand press or other tool to slowly push the shaft of the Clutch Shaft [110](110){110}<110> and remove it without damaging the ball bearing of Fan Case (A) [107](107){107}<107>. Next, remove the Retaining Ring 37 mm [109](109){109}<109> and slowly push the Ball Bearing 6301ZZC3 [108](108){108}<108> out from the front end of Fan Case (A) [107](107){107}<107>.

(7) Removing the ignition coil and spark plug cap

Loosen the two Hex. Socket Hd. Bolts (W/Washers) M4 x 18 [118](118){118}<118>, and then remove the Ignition Coil Ass’y [119](119){119}<119>. Add a drop of oil into the hole on the Spark Plug Ass’y BMR7A [13](13){13}<13> side, move the high-voltage wire back and forth to spread oil inside the hole, and then slowly pull out the Plug Cap [120](120){120}<120>, while being careful not to extend the Metal Fitting of Plug Cap [121](121){121}<121>.

(8) Removing the clutch ass’y and starter pulley

In order to lock the Crank Shaft Comp. [58](58)/Crank Shaft {59}<59>, first insert the rope of the recoil starter or other rope into the Spark Plug Ass’y BMR7A [13](13){13}<13> mounting hole on the Cylinder

[19](19){19}<19>, and then turn the Magneto Rotor Ass’y

[124](124) and Magneto Rotor Comp.

{124}<124> counterclockwise until the Piston [49](49){50}<50> is locked at top dead center. Next,

loosen the two Step Bolts [111](111){111}<111> and remove the Clutch [114](114){114}<114>. To remove the Starter Pulley Ass’y [60](60){62}<62>, lock the Crank Shaft Comp. [58](58)/Crank Shaft {59}<59>, and then use a plastic hammer to lightly strike the Starter Pulley Ass’y [60](60){62}<62> to turn it counterclockwise.

NOTE: Use a clean rope to lock the crank shaft. Also be careful not to leave cut pieces of rope

inside the Cylinder [19](19){19}<19>.

-16-

Magneto Rotor Ass’y [124](124)/ Magneto Rotor Comp. {124}<124>

J-357 (center bolt)

Hex. socket hd. bolt M4

Pin pullout bolt

J-359 jig (piston pin extraction tool ass’y)

(9) Removing the magneto rotor

• Use a 13-mm socket wrench to remove the Flywheel Nut [116](116){116}<116>.

• With the screw end face of the Crank Shaft Comp. [58](58)/Crank Shaft {59}<59> made flush with the upper face of a commercially available M8 nut, rotate the J-363 jig (8 x 120 handle) in the arrow direction and tighten the J-357 jig (center bolt) as shown in the illustration on the right. Then remove the Magneto Rotor Ass’y [124](124)/ Magneto Rotor Comp. {124}<124>.

(10) Removing the cylinder

Loosen the four Hex. Socket Hd. Bolts (W/Sp. Washer) M5 x 18 [8](8)/Hex. Socket Bolts M5 x 20 {7}<7>, and then slowly pull out the Cylinder [19](19){19}<19>.

(11) Removing the piston and piston ring

• Remove the Piston Rings [48](48){49}<49> while expanding the closed gap of the rings. As the Piston Rings [48](48){49}<49> are cast-iron parts, do not forcibly expand them. Doing so may break the rings.

• Remove the two Cir Clips [50](50){51}<51> with long-nose pliers.

• Insert a hex. socket hd. bolt M4 into the pushing side of the Piston Pin [52](52){52} <52>, and then turn the pin pullout bolt of the J-359 jig (piston pin extraction tool ass’y) clockwise to pull out the Piston Pin

[52](52){52}<52>. CAUTION: Do not scratch the Piston [49]

(49){50}<50>.

(12) Removing the crank case ass’y

Loosen the four Hex. Socket Hd. Bolts (W/Sp. Washer) M5 x 18 [8](8){53}<53>, remove the Crank Case Ass’y [53](53), Crank Case (A) Ass’y {60}<60> and Crank Case (B) Ass’y {54}<54> by using a wooden hammer to lightly strike the Crank Shaft Comp. [58](58)/Crank Shaft {59}<59>, and then remove the Crank Shaft Comp. [58](58)/Crank Shaft {59}<59>.

(13) Removing the muffler heat cover

Loosen the Tapping Screw D4 x 10 [76](76){78}<78> and then remove the Muffler Heat Cover [75] (75){77}<77>.

• Removing the magneto rotor J-363 jig (8 x 120 handle)

J-356 jig (complete rotor extraction tool

)

J-365 jig (stepped bolt 5 mm)

• Removing the piston

-17-

• Mounting the piston Piston [49](49){50}<50>

Pin pullout bolt

Piston Pin [52](52){52}<52>

Hex. socket hd. bolt M4

Round bar 7.8 mm in diameter (e.g., borer 8 mm in diameter)

Needle bearing (A) (Crank Shaft Comp. [58](58)/Crank Shaft {59}<59>)

Cir clip mounting groove

Connecting rod small end

2. Reassembly of the engine unit

(1) Removing carbon

Before reassembling the engine, remove carbon from the head of the Piston [49](49){50}<50>, the exhaust port of the Cylinder [19](19){19}<19>, and inside the combustion chamber. If the Piston Rings [48](48){49}<49> fitted in the ring groove on the Piston [49](49){50}<50> cannot move smoothly, carefully wipe off carbon from the ring groove and side surface of the Piston Rings [48](48){49}<49>. During cleaning, be careful not to damage the surfaces of the Cylinder [19](19){19}<19> and Piston [49](49){50}<50>. Also remove carbon from the intake and exhaust ports of Muffler (B) [6](6){5}<5>.

(2) Cleaning the parts

Be sure to thoroughly clean the Crank Shaft Comp. [58](58)/Crank Shaft {59}<59>, Piston [49](49) {50}<50>, and Cylinder [19](19){19}<19> with gasoline.

(3) Mounting the piston and piston ring

• Insert the Piston Pin [52](52){52}<52> by following the procedure below. (See the figure below.) (a) Insert the Piston Pin [52](52){52}<52> into the Piston [49](49){50}<50> by about 7 mm.

CAUTION: Do not tilt the Piston Pin [52](52){52}<52>.

(b) Set the J-359 jig (piston pin extraction tool ass’y) to the Piston [49](49){50}<50>, and then set a

hex. socket hd. bolt M4 into the pushing side of the Piston Pin [52](52){52}<52>.

{50}<50>. (Align the triangular arrow on top of the Piston [49](49){50}<50> with the direction of the exhaust port of the Cylinder [19](19){19}<19>.) Insert a round bar about 7.8 mm in diameter (e.g., borer 8 mm in diameter) into the Piston [49](49){50}<50> opposite the side where the Piston Pin [52](52){52}<52> is inserted, in order to prevent needle bearing misalignment.

(d) With the round bar 7.8 mm in diameter inserted, turn the pin pullout bolt of the J-359 jig (piston pin

extraction tool ass’y) clockwise, and then push in the Piston Pin [52](52){52}<52> just before the cir clip mounting groove of the Piston [49](49){50}<50>.

• Use long-nose pliers to fit the tip of the two Cir Clips [50](50){51}<51> into the groove on the Piston

[49](49){50}<50>, and then turn it until the Cir Clips [50](50){51}<51> are completely mounted.

• Align the opening of the two Piston Rings [48](48){49}<49> with the knock pin of the Piston [49](49)

{50}<50>.

• After mounting the Piston [49](49){50}<50>, apply a few drops of 2-cycle oil to the needle bearing.

-18-

Arrow

Piston [49](49){50}<50>

(4) Reassembling the crank case ass’y, piston, and cylinder

When press-fitting Oil Seal TB 12227 [55](55){56}<56> into the Crank Case Ass’y [53](53), Crank Case (A) Ass’y {60}<60> and Crank Case (B) Ass’y {54}<54>, position the pressurizing spring inside, and then fill the gap between the lips with Multemp PS No. 2 (product of Kyodo Yushi Co., Ltd.). Dispose of the oil seal removed at disassembly, and always use a new oil seal. Before mounting the Cylinder [19](19){19}<19>, be sure to apply two-cycle engine oil to the Ball Bearing 6001 C3 [56](56)

{57}<57>, the large and small bearings at the ends of the connecting rod, the Piston Rings [48](48) {49}<49>, and the inner surface of the Cylinder [19](19){19}<19>. When mounting the Piston [49](49) {50}<50>, position it so that the exhaust mark (arrow) on top of the piston points to the muffler. When mounting the Cylinder [19](19){19}<19>, correctly align the closed gap of the Piston Rings [48](48) {49}<49> with the lock pin at the groove on the Piston [49](49){50}<50>, and the Cylinder [19](19){19} <19> with the Piston [49](49){50}<50>. Otherwise, the Piston Rings [48](48){49}<49> may be easily

damaged.

(5) Mounting the magneto rotor

• Models CG 24EBSP, CG 24EBS, CG 24EBDP, and CG 24EBD Insert the Woodruff Key 3 x 13 x 4.5 [51](51) in the key groove on the Crank Shaft Comp. [58](58), and mount it into the key groove at the center hole of the Magneto Rotor Ass'y [124](124).

• Models CG 27EBSP, CG 27EBS, CG 27EBDP, and CG 27EBD Mount the Magneto Rotor Comp. {124}<124> with the integral key at the center hole of the Magneto Rotor Comp. {124}<124> aligned with the key groove on the Crank Shaft {59}<59>.

(6) Reassembling the carburetor ass’y

When reassembling Carburetor Ass'y WYC-36 [24](24)/WYC-37 {25}<25>/WYC-30, align the pulsed holes on the Carburetor Packing [22](22){23}<23> and Intake Packing [20](20){20}<20> with those on the Cylinder [19](19){19}<19> and Carburetor Ass’y WYC-36 [24](24)/WYC-37 {25}<25>/WYC-30.

(7) Mounting the fan case

Insert a press-fitting jig fit for the pipe insertion hole of Fan Case (A) [107](107){107}<107> and push the outer ring of the Ball Bearing 6301ZZC3 [108] (108){108}<108> with the press-fitting jig from the engine side. Then mount the Retaining Ring 37 mm [109](109){109}<109>. While holding the inner ring of the ball bearing in Fan Case (A) [107](107){107}<107>, press-fit the Clutch Shaft [110](110){110}<110> and then attach the Retaining Ring for D12 Shaft [106](106){106}

<106>.

• Mounting the ball bearing

• Orientation of the piston

Fan Case (A)

[107](107){107}<107>

Ball Bearing 6301ZZC3

[108](108){108}<108>

BB press-fitting jig

D36

-19-

(8) Mounting the muffler heat cover

Put the Muffler Heat Cover [75](75){77}<77> in the Muffler Cover [2](2){2}<2>. Align the screw holes and tighten the Tapping Screw D4 x 10 [76](76){78}<78>. Check that the Muffler Heat Cover [75](75)

{77}<77> contacts the inner wall of the Muffler Cover [2](2){2}<2> and there is no rattling.

3. Disassembly of the shaft unit

• Models CG 24EBSP, CG 24EBS, CG 27EBSP, and CG 27EBS (1) Pull out the Drive Shaft [186]{186} from the Main Pipe [185]{185}. (2) Loosen the Screw 5 x 12/W.S [162]{162} and Hex. Socket Hd. Bolt M5 x 30 [161]{161}, and then

detach the Gear Case Ass’y (4BB) [160]{160} from the Main Pipe [185]{185}.

• Models CG 24EBDP, CG 24EBD, CG 27EBDP, and CG 27EBD (1) Loosen the Handle Knob (152)<152>, pull the

lock pin, and then pull out the attachment ass’y.

(2) Loosen the Hex. Socket Hd. Bolt M5 x 12

(154)<154> and Hex. Socket Hd. Bolt (W/Button) M6 (156)<156>, and then remove the Joint Case (169)<169> from Main Pipe (A)

(163)<163>. Pull out Drive Shaft (A) (165) <165>.

(3) Loosen the Screw 5 x 12/W.S (172)<172> and

Hex. Socket Hd. Bolt M5 x 30 (171)<171>,and then remove the Gear Case Ass’y (4BB) (170) <170> of the attachment ass’y from Main Pipe (A) (195)<195>. Pull out the Drive Shaft B 783L (196)<196> from the Gear Case Ass’y (4BB) (170)<170> side.

4. Reassembly of the shaft unit

• Models CG 24EBSP, CG 24EBS, CG 27EBSP, and CG 27EBS (1) Mounting the drive shaft

Wipe off dirty grease from the Drive Shaft [186]{186} and apply a thin coat of “Molub-Alloy 777” grease to the shaft. Then insert the drive shaft into the Main Pipe [185]{185}.

(2) Mounting the gear case

Fully insert the Main Pipe [185]{185} into the main pipe insertion hole on the Gear Case Ass’y (4BB) [160]{160} until it contacts the end. Align the hole on the side of the Main Pipe [185]{185} with the M5 screw hole on the side of the Gear Case Ass’y (4BB) [160]{160}. Firmly tighten the Screw 5 x 12/W.S [162]{162} while confirming that it does not touch the Main Pipe [185]{185}. Tighten the Hex. Socket Hd. Bolt M5 x 30 [161]{161}. Finally, make sure the Drive Shaft [186]{186} is completely put in the pinion. When the drive shaft is completely put in the pinion, the gear shaft D24 of the Gear Case Ass’y (4BB) [160]{160} rotates when rotating the Drive Shaft [186]{186} projected from the side edge of the engine of the Main Pipe [185]{185}.

• Models CG 24EBDP, CG 24EBD, CG 27EBDP, and CG 27EBD (1) Reassembling the attachment ass’y

When press-fitting the Bushing (192)<192> to the Drive Shaft B 783L (196)<196>, press-fit it to 50 mm from the spline end of the Drive Shaft B 783L (196)<196>. Wipe off dirty grease from the Drive Shaft B 783L (196)<196> after press-fitting the Bushing (192) <192> and apply a thin coat of “Molub-Alloy 777” grease to the shaft. Then insert the drive shaft into Main Pipe (A) (195)<195>. Fully insert Main Pipe (A) (195)<195> into the main pipe (A) insertion hole on the Gear Case Ass’y

• Disassembly of the shaft Models CG 24EBDP, CG 24EBD,

CG 27EBDP, and CG 27EBD

Lock pin

Handle Knob (152)<152>

Joint Case

(169)<169>

ttachment ass’y

(Main Pipe (A) (195)<195>)

Location hole

Engine side

Main Pipe (A)

(163)<163>

Drive Shaft B 783L (196)<196>

-20-

(4BB) (170)<170> until it contacts the end. Align the hole on the side of Main Pipe (A) (195)<195> with the M5 screw hole on the side of the Gear Case Ass’y (4BB) (170)<170>. Firmly tighten Screw 5 x 12/W.S (172)<172> while confirming that it does not touch Main Pipe (A) (195)<195>. Tighten the Hex. Socket Hd. Bolt M5 x 30 (171)<171>. Finally, make sure the Drive Shaft B 783L (196)<196> is completely put in the pinion. When the drive shaft is completely put in the pinion, the gear shaft D24 of the Gear Case Ass’y (4BB) (170)<170> rotates when rotating the Drive Shaft B 783L (196)<196> projected from the side edge of the engine of Main Pipe (A) (195)<195>.

(2) Reassembling the shaft unit on the engine side

Wipe off dirty grease from Drive Shaft (A) (165)<165> after mounting the Retaining Ring for D10 Shaft (162)<162> and apply a thin coat of “Molub-Alloy 777” grease to the shaft. Then insert the drive shaft into Main Pipe (A) (163)<163>. Mount the Pulley Washer (161)<161>, Spacer (160)<160> and Spacer 1.6 (159)<159> to Main Pipe (A) (163)<163> and insert Main Pipe (A) (163)<163> into the Joint Case (169)<169>. At this time, align the hole on the side of Main Pipe (A) (163)<163> with the M5 screw hole on the side of the Joint Case (169)<169>. Firmly tighten the Hex. Socket Hd. Bolt M5 x 12 (154)<154> while confirming that it does not touch Main Pipe (A) (163)<163>. Tighten the Hex. Socket Hd. Bolt (W/Button) M6 (156)<156>.

(3) Reassembling the attachment ass’y

Insert Main Pipe (A) (195)<195> into the Joint Case (169)<169> while pulling up the lock pin. Align the lock pin with the hole on the upper surface of Main Pipe (A) (195)<195> and release the lock pin. Make sure the lock pin is completely in the hole on the upper surface of Main Pipe (A) (195)<195>. Then firmly tighten the Handle Knob (152)<152>.

-21-

Main Pipe [185]{185}/ Main Pipe (A) (163)<163>

Level Mark [183](164){183}<164>

Loop Handle (W/Barrier) [152](167){152}<167> or loop handle without a barrier For details, see the parts list of the relevant model.

Barrier

Main Pipe [185]{185}

Handle (Right) [156]{156}

Handle (Left) [155]{155}

Handle Holder (A) [154]{154}

Hex. Hole Bolt M5 x 25/S [153]{153}

Handle Holder (B) [157]{157}

5. Mounting the handle

• Models CG 24EBSP(S), CG 24EBS(S), CG 27EBSP(S), and CG 27EBS(S) Place the Handle (Right) [156]{156} and Handle (Left) [155]{155} on Handle Holder (B) [157]{157} attached to the Main Pipe [185]{185}, and then place Handle Holder (A) [154]{154} over these components. While holding Handle Holder (A) [154]{154}, secure these components in place by tightening the four Hex. Hole Bolts M5 x 25/S [153]{153}.

• Models CG 24EBSP(SL), CG 24EBS(SL), CG 24EBDP(SL)/(SLN), CG 24EBD(SL)/(SLN),

CG 27EBSP(SL), CG 27EBS(SL), CG 27EBDP(SL)/(SLN), and CG 27EBD(SL)/(SLN) Position the Loop Handle (W/Barrier) [152](167){152}<167> as indicated by the Level Mark [183](164){183}<164> on the Main Pipe [185]{185}/Main Pipe (A) (163)<163>, and then fasten it by evenly tightening the four bolts (black) M5 x 30.

Models CG 24EBSP(S), CG 24EBS(S), CG 27EBSP(S), and CG 27EBS(S)

Models CG 24EBSP(SL), CG 24EBS(SL), CG 24EBDP(SL)/(SLN), CG 24EBD(SL)/(SLN),

CG 27EBSP(SL), CG 27EBS(SL), CG 27EBDP(SL)/(SLN), and CG 27EBD(SL)/(SLN)

• Mounting the handle

-22-

Tightening torque

Location

Q’ty Part name Tightening torque

Recoil starter

Recoil Starter Body Ass'y

[64](64){66}<66>

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

[3](3){10}<10>

1.5 to 2.5 N•m {15 to 25 kgf•cm}

Starter Pulley Ass’y [60](60){62}<62>

1M8

9.0 to 12 N•m {92 to 122 kgf•cm}

Electrical system

Ignition Coil Ass’y

[119](119){119}<119>

Hex. Socket Hd. Bolt (W/Washers) M4 x 18

[118](118){118}<118>

2.5 to 4.5 N•m {26 to 46 kgf•cm}

Magneto Rotor Ass’y [124](124) Magneto Rotor Comp. {124}<124>

Flywheel Nut

[116](116){116}<116>

15 to 20 N•m {153 to 204 kgf•cm}

Spark Plug Ass'y BMR7A

[13](13){13}<13>

1M14

10 to 15 N•m {102 to 153 kgf•cm}

Carburetor

Air Cleaner Housing [42](42){43}<43>

Machine Screw (W/Washers) M5 x 60 (Black)

[40](40){41}<41>

4.0 to 6.0 N•m {41 to 61 kgf•cm}

Carburetor Insulator [21](21){21}<21>

Seal Lock Hex. Socket Bolt (W/Washer) M5

[12](12){22}<22>

3.0 to 4.0 N•m {31 to 41 kgf•cm}

Engine

Crank Case Ass’y [53](53)

Hex. Socket Hd. Bolt (W/Sp. Washer) M5 x 18

[8](8){53}<53>

4.0 to 8.0 N•m {41 to 82 kgf•cm}

Crank Case (A) Ass’y {60}<60> Crank Case (B) Ass’y {54}<54>

Scavenging Cover (A) [15](15){15}<15> Scavenging Cover (B) [18](18){18}<18>

Hex. Socket Hd. Bolt M4 x 12

[16](16){16}<16>

2.5 to 4.5 N•m {25 to 46 kgf•cm}

Muffler (B) [6](6){5}<5>

Hex. Socket Hd. Bolt M6 x 65

[4](4){3}<3>

10 to 12 N•m {102 to 122 kgf•cm}

Cylinder [19](19){19}<19>

Hex. Socket Hd. Bolt (W/Sp. Washer) M5 x 18 [8](8)

6.0 to 9.0 N•m {61 to 92 kgf•cm}

Hex. Socket Bolt M5 x 20

{7}<7>

6.0 to 9.0 N•m {61 to 92 kgf•cm}

Clutch [114](114){114}<114>

Step Bolt [111](111){111}<111>

7.0 to 12 N•m {71 to 122 kgf•cm}

Fan Case (A) [107](107){107}<107>

Seal Lock Hex. Socket Bolt (W/Washers) M5 [12](12)

3.5 to 4.5 N•m {36 to 46 kgf•cm}

Seal Lock Hex. Socket Hd. Bolt M5 x 30 [1](1)

3.5 to 4.5 N•m {36 to 46 kgf•cm}

Seal Lock Hex. Socket Hd. Bolt M5 x 30 {12}<12>

3.5 to 4.5 N•m {36 to 46 kgf•cm}

Muffler Cover {2}<2>

Screw (W/Washers) M5 x 16 (Black) {1}<1>

2.0 to 3.0 N•m {20 to 31 kgf•cm}

Tank (B) [133](133){132}<132>

Bolt (W/Flange) L27.8

[137](137)

2.5 to 3.5 N•m {26 to 36 kgf•cm}

Bolt (W/Flange) L27.8

{137}<137>

2.5 to 3.5 N•m {26 to 36 kgf•cm}

Flange Bolt {136}<136>

2.5 to 3.5 N•m {26 to 36 kgf•cm}

Shaft

Main Pipe [185]{185} Main Pipe (A) (163)<163>

Hex. Socket Hd. Bolt (W/Sp. Washer) M5 x 12

[100](100){100}<100>

3.5 to 4.5 N•m {36 to 46 kgf•cm}

Hex. Hole Bolt 5 x 22/S

[101](101){101}<101>

3.5 to 4.5 N•m {36 to 46 kgf•cm}

Gear Case Ass’y (4BB)

[160](170){160}<170>

Hex. Socket Hd. Bolt M5 x 30

[161](171){161}<171>

4.0 to 5.0 N•m {41 to 51 kgf•cm}

Screw 5 x 12/W.S

[162](172){162}<172>

3.0 to 4.0 N•m {31 to 41 kgf•cm}

Bolt (W/Plus) M6 x 8

[165](175){165}<175>

3.9 to 5.9 N•m {40 to 60 kgf•cm}

-23-

Confirmation after reassembl

Location

Q’ty Part name Tightening torque

Shaft

Joint Case (169)<169>

Hex. Socket Hd. Bolt M5 x 12

(154)<154>

4.0 to 7.0 N•m {41 to 71 kgf•cm}

Hex. Socket Hd. Bolt (W/Button) M6 (156)<156>

6.0 to 9.0 N•m {61 to 92 kgf•cm}

Hanger [187](166){187}<166>

1 M5 hex. screw

3.0 to 4.0 N•m {31 to 41 kgf•cm}

Throttle Lever (B) [151]{151}

1 M5 screw

2.0 to 3.0 N•m {20 to 31 kgf•cm}

2 P tite screw

1.3 to 1.7 N•m {13 to 17 kgf•cm}

Throttle Lever (A) Ass’y

[99](99){99}<99>

1 M5 screw

1.5 to 2.0 N•m {15 to 20 kgf•cm}

4 P tite screw

1.3 to 2.0 N•m {13 to 20 kgf•cm}

Handle Holder (C) [158]{158}

Hex. Hole Button Screw 6 x 25S [159]{159}

4.0 to 7.0 N•m {41 to 71 kgf•cm}

Other Throttle wire 1 M6 nut

1.0 to 3.0 N•m {10 to 31 kgf•cm}

1. Check the following before starting the engine.

(1) Confirm that all fastening screws, bolts and nuts are properly tightened. (2) Confirm that there is no gas leaking from any part of the engine section. (3) Confirm that the crank shaft rotates and there is compression when pulling the starter handle. (4) Perform priming ten times and then confirm that the priming pump is full of fuel.

2. Check the following after starting the engine.

(1) Confirm that the engine starts up by following the procedure b elow.

(a) Set the stop switch to the startup position. (b) Perform priming ten times. (c) Set the choke lever to the CLOSED position (

(d) Pull the starter handle and check for initial ignition. (As a guide, pull the handle 3 to 5 times at

ambient temperature of 20°C. Pull the handle more at lower temperatures.)

(e) Set the choke lever to the RUN position (

(f) Pull the starter handle to start the engine. (As a guide, pull the handle 2 or 3 times at ambient

temperature of 20°C. Pull the handle more at lower temperatures.) (2) Confirm that each moving part functions properly, and that rotating parts make no abnormal noise. (3) Check the speed as follows and adjust the carburetor according to “2. Checking and adjusting the

carburetor ass’y” on page 10.

(a) Speed at full throttle for up to 30 seconds after idling for 30 seconds

• When attaching the cutter blade: 8,500 to 12,500 min

-1

• When attaching the nylon cord: 8,200 min-1 or higher (projecting part of nylon cord: 170 mm)

(b) Idling speed (Increase the speed to 6,000 to 8,000 min

-1

prior to measurement.)

The idling speed should be stable for at least 10 seconds at 2,500 to 3,500 min

-1

. Make sure the

cutting attachment does not rotate.

-1

(4) Make sure that the engine accelerates smoothly. (5) Release the throttle lever and make sure that the engine idles. (6) Let the engine idle, and then rapidly accelerate and decelerate the engine. Make sure that the engine

does not stop.

(7) Confirm that the stop switch functions properly.

ENGINE

Model CG 24EBD

ENGINE BRUSH CUTTER

LIST NO. F053

(E1)

2014

4 25

100

101

102

103

104

105

106

107

111

112

113

114

115

116

117

119

120

121

118

122

123

124

130

125

127

128

129

133

134

135

136

110

131

137

126

108

109

132

137

CG 24EBD

- 2 -

167

168

171

178

179

180

181

173

190

182

183

184

185

186

187

188

189

501

502

503

504

172

191

192

193

194

195

193

205

202

203

206

207

208

204

209

210

211

198

199

200

201

197

196

166

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

169

170

174

175

177

176

CG 24EBD

4 - 14

- 3 -

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