Subaru EX35 User Manual

CONTENTS

Section Title Page

1. SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3. FEATURES (EX35, 40 series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS . . . . . . . . . . . . . . . . 6

5. DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5-1 PREPARATIONS AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5-2 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5-3 DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5-4 REASSEMBLY PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6. ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8. IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

10. ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

11. OIL SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

12. AUTOMATIC DECOMPRESSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . 53

13. CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

14. RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

15. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

16.TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

17. STANDARD REPAIR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

17-1 STANDARD DIMENSIONS AND LIMITS OF USE . . . . . . . . . . . . . . . . . . 72

17-2 SERVICE DATA (The following are only for your reference.). . . . . . . . . . . 77

17-3 TIGHTENING TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

17-4 AIR GAP AND CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

18.MAINTENANCE AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1. SPECIFICATIONS

Model EX35D EX40D

Type

Bore & Stroke mm (in.)

Piston Displacement ml (cu.in.)

Compression Ratio

Continuous Output kW(HP)/r.p.m.

Maximum Output kW(HP)/r.p.m.

Maximum Torque

Direction of Rotation Counterclockwise as viewed from the P.T.O. shaft side

Valve Arrangement Overhead cam system

Cooling System Forced air cooling system

Lubrication System Splash lubrication system

Lubricant

N・m / r.p.m. (kgf・m / r.p.m.) (ft・lb. / r.p.m.)

Automobile engine oil ; Grade SE or higher (SG,SH or SJ in recomended) SAE 10W-30-----Under ordinary atmospheric temperatures SAE 5W-30-------In cold areas

Air-Cooled, 4-Cycle, Slant Single-Cylinder,

Horizontal P.T.O. Shaft, OHC Gasoline Engine

89 × 65 (3.50 × 2.56)

404 (24.65)

8.3

5.5(7.5)/3000

6.3(8.5)/3600

7.4(10.0)/3600 8.8(12.0)/3600

26/2400

(2.6/2400)

(19.18/2400)

6.3(8.5)/3000

7.0(9.5)/3600

27/2400

(2.7/2400)

(19.91/2400)

Capacity of Lubricant L

Carburetor

Fuel

Fuel Consumption Rate g/kW・h (g/HP・h)

Fuel Supply System

Fuel Tank Capacity L

Ignition System

Spark Plug

Charging Capacity (Option)

Starting System

Governor System

Dry Weight kg (lb.)

V-A

Dimensions (L x W x H) mm (in.)

Specifications are subject to change without notice.

1.2

Horizontal draft, Float type

Automobile unleaded gasoline

381 (280)

Gravity type

7.0

Transistorized magneto

NGK BR-6HS

12-1A, 3A, 16.7A (Option)

Recoil starter / Electric starter (Option)

Centrifugal ﬂ yweight system

33 (72.75)

389 x 450 x 443 (15.31 x 17.72 x 17.44)

- 1 -

2. PERFORMANCE

2-1 MAXIMUM OUTPUT

The Maximum output is the output of an engine with its throttle valve fully opened and considering that all the

moving parts are properly broken in.

A new engine may not produce full maximum output while its moving parts are still not broken-in.

NOTE :

Power curves shown in the following charts are made in conformity with SAE internal combustion engine

standard test code J1349.

2-2 CONTINUOUS RATED OUTPUT

The continuous rated output is the output of an engine at optimum governed speed which is most favorable

from the view point of engin’s life and fuel consumption.

When the engine is installed on a certain equipment, it is recommended that the continuous output required

from the equipment to be kept below this continuous rated output.

2-3 MAXIMUM TORQUE

The maximum torque is the torque at the output shaft when the engine is producing maximum output at a

specific r.p.m..

- 2 -

2-4 PERFORMANCE CURVES

=MIH࡮O?

      



TORQUE



=*2?





0࡮O











EX35D

MAXIMUM TORQUE











OUTPUT



























MAXIMUM HORSEPOWER

CONTINUOUS RATED HP

RECOMMENDED HORSEPOWER RANGE

    

r.p.m.REVOLUTION

- 3 -

EX40D

=MIH࡮O?













TORQUE

=25?













0࡮O

















MAXIMUM TORQUE

MAXIMUM HORSEPOWER





OUTPUT



















CONTINUOUS RATED HP

RECOMMENDED HORSEPOWER RANGE

    

r.p.m.REVOLUTION

- 4 -

3. FEATURES (EX35, 40 series)

3-1 HIGH OUTPUT

Thanks to the adoption of a cam profile exclusively for intake and exhaust and the optimization of the shape

of the intake/exhaust port and the shape of the combustion chamber, the top-of-the-class-level maximum

output is achieved.

3-2 EXTREMELY SILENT - SOFT TONE QUALITY

EX engines are 2dBA quieter and softer in tone than other engines in the same class. This quiet and soft tone is achieved by:

- Resin blower housing reduce noise leakage of mechanical noise.

- Employment of an optimized capacity Rigid Muffler.

3-3 EXTREMELY EASY START

Reliable Starting and Less Pulling Force are achieved by: Sophisticated Mechanical Compression Release System as well as newly designed Combustion Chamber.

3-4 EXTREMELY EASY MAINTENANCE

Extreme ease of maintenance is realized by:

- High Parts Commonality simplifies maintenance & lowers repair cost due to fewer parts for service.

- Only with ordinary tools, routine maintenance, assembly and disassembly can be performed.

3-5 EXTREMELY ADVANCED TECHNOLOGY

Extreme reliability and durability are achieved by:

- Heavy Duty Chain Driven OHC System Oval type case-hardened steel links enhance performance and resist stretching, which result in extended maintenance free operation.

- Completely New Main Bearing Cover’s Design Flush-mounted main bearing cover with lower moment of deformation significantly increases reliability and engine life.

- Superior Cooling and Lubrication System Heat reduction is achieved by more efficient, larger and more numerous cooling fins on crankcase, cylinder and mounting base, as well as by outstanding oil delivery system.

- Large Ball Bearings on both ends of crankshaft for maximum stability under demanding loads.

- Cast Iron Cylinder Liner resists wear

3-6 EXTREME POWER AND PERFORMANCE

Extremely Higher Power and Lower Fuel Consumption are realized by:

- High speed and homogeneous combustion achieved by sophisticated Pentroof Combustion Chamber which includes Intake and Exhaust Valves located at optimum angle.

- Straight Intake Port with minimal air flow resistance.

Environmentally friendly

EX engines comply with EPA Phase 2 and CARB Tier III Emission Regulations in the USA.

Extreme application compatibility

With four versatile models, existing slant-cylinder engines can be easily replaced.

- 5 -

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS

4-1 CYLINDER AND CRANKCASE

The cylinder and crankcase are aluminum die-casting

as a single piece. A special cast iron cylinder liner is

molded into the aluminum die-casting.

The crankcase has a mounting surface on the output

shaft side to which the main bearing cover is attached.

The cylinder is inclined to the right at an angle of 25

degrees from the horizontal as viewed from the output

shaft side.

4-2 MAIN BEARING COVER

The main bearing cover is an aluminum die-casting,

which is mounted on the output shaft side of the

crankcase. By removing the main bearing cover,

inside of the engine can be inspected with ease.

Pilots and bosses are machined into the cover

to facilitate the direct coupling of the engine with

machines such as generators and pumps.

Oil gauges (fillers) are on both sides of the cover for

easy maintenance.

the

4-3 CRANKSHAFT

The crankshaft is forged carbon steel, and the crank

pin is high-frequency inductionhardened.

The crank sprocket used to drive the chain and the

gear used to drive the governor gear are pressed into

the output end of the shaft.

25°

Fig.4-1

Fig.4-2

4-4 CONNECTING ROD AND PISTON

The connecting rod is a specially heat-treated

aluminum alloy die-casting. Its large and small ends

function as bearings. A splasher built into the

connecting rod lubricates by splashing engine oil.

The piston is an aluminum alloy casting with grooves

for mounting one compression ring and one oil ring.

Fig.4-3

Fig.4-4

- 6 -

EXHAUST VALVE

INTAKE VALVE

4-5 PISTON RINGS

The piston rings are made of special cast iron. The profile of the top ring is a tapered face.

The oil ring is designed for better sealing and less oil consumption, in combination with 3 pieces.

TOP

RING

Fig.4-5

OIL

RING

TAPER

THREE-PIECE CONSTRUCTION

4-6 CAMSHAFT

The camshaft and the sprocket are made of special

sintered alloy. They are constructed as a single

piece. The camshaft is provided with intake and

exhaust cam, and the decompression release lever is

mounted on the sprocket shaft end side.

4-7 VALVE ARRANGEMENT

This engine has a chain-driven overhead cam and

overhead valve construction, with a single cam which

has individual profile for intake and exhaust to

perform high output.

4-8 CYLINDER HEAD

The cylinder head is on aluminum die-casting with a

dome-shaped combustion chamber. The intake and

Fig.4-6

Fig.4-7

exhaust ports are arranged in a cross direction to

improve combustion efficiency.

Fig.4-8

- 7 -

4-9 GOVERNOR SYSTEM

GOVERNOR GEAR

This engine is equipped with a centrifugal flyweight

type governor that makes it possible to operate the

engine at a constant speed, even with load

variations. (The governor flyweights are mounted on

a governor gear.)

Fig.4-9

4-10 COOLING SYSTEM

The engine uses a forced air-cooling system in which a synthetic resin cooling fan (which is separate from the

flywheel), reduce noise and forces cooling air into the cylinder and cylinder head.

Baffles are provided to guide the flow of cooling air. (As for with starting motor, baffle 1 is not mounted.)

4-11 LUBRICATION SYSTEM

The rotating parts, sliding parts and valves of the engine are lubricated with oil in the crankcase.

The oil is splashed onto the parts by the oil splasher on the connecting rod.

4-12 TIMING CHAIN

Timing chain system is adopted and designed for

lubricating for the upper portion of cylinder head.

The timing chain is engaged between the sprocket

portion of integrated camshaft in the cylinder head and

the crankshaft gear sprocket.

The sprocket teeth in particular shape are adopted to

enhance the durability and to realize low noise level.

4-13 IGNITION SYSTEM

The ignition system is a transistor controlled magneto

system with the ignition timing set at 24 degrees

before the top dead center. The magneto consists of

a flywheel and ignition coil. The flywheel (cooling fan

is separete from the flywheel) is directly mounted on

the crankshaft and the ignition coil is directly

mounted on the crankcase.

TIMING CHAIN

OIL SPLASHER

Fig.4-10

FLYWHEEL

* Model EX35 and 40 has a smooth advanced

ignition timing system to improve starting

performance. (For further details, refer to page

46, section “7. MAGNETO”.)

IGNITION COIL

FAN

Fig.4-11

- 8 -

4-14 CARBURETOR

RETURN SPRING

ROCKER ARM (EXHAUST VALVE SIDE)

EXHAUST VALVE

CAMSHAFT

The engine is equipped with a horizontal draft

carburetor. The carburetor setting is calibrated after

careful testing for optimum all-round performance

(including starting, acceleration, fuel consumption,

output power characteristics). Special attention is

also paid to the general-purpose use of the engine.

(For further information, refer to page 54, section “13.

Fig.4-12

CARBURETOR”.)

4-15 AIR CLEANER

The engine uses an air cleaner that is quieter than

conventional ones. A semi-wet urethane foam

element is used in the STD air cleaner.

Dual element air cleaner (with a primary element of

dry type sponge and secondary element of dry type

paper) and other types are also provided as special

options.

4-16 BALANCER

Unbalanced inertia force is cancelled by the balancer

which rotates at the same speed as the crankshaft to

effectively reduce vibration.

Urethane Element Type

AIR CLEANER COVER

Dual Element Type

AIR CLEANER COVER

URETHANE FOAM

PEPER ELEMENT

Fig.4-13

AIR CLEANER BASE

4-17 DECOMPRESSION SYSTEM

The automatic decompression system is mounted on

the camshaft. It opens the exhaust valve before the

compression top, thereby alleviating the compression

pressure and reducing the force required to pull the

recoil starter.

During engine operation, the decompression system

is overpowered by centrifugal force and compression

is fully utilized to produce power.

- 9 -

Fig.4-14

Fig.4-15

4-18 SECTIONAL VIEW OF THE ENGINE

Cross sectional view – across the shaft

BLOWER HOUSING

COOLING BLOWER

RECOIL STARTER HANDLE

STARTING PULLEY

FUEL TANK

TANK CAP

GOVERNOR LEVER

GOVERNOR GEAR

CRANKSHAFT

RECOIL STARTER

FLYWHEEL

RECOIL BRACKET

BOLT (RECOIL BRACKET)

CHARGE COIL (OPTION)

Fig.4-16

OIL SENSOR (OPTION)

CONNECTING ROD

MAIN BEARING COVER

Cross sectional view – along the shaft

FUEL TANK

GOVERNOR GEAR

MAGNETIC SWITCH

STOP SWITCH

GOVERNOR SHAFT

CHAIN GUIDE

GOVERNOR LEVER

MUFFLER COVER

PISTON PIN

EXHAUST VALVE

MUFFLER

TAIL SCREEN or DEFLECTOR (OPTION)

SPARK ARRESTER (OPTION)

ROCKER ARM

CAMSHAFT

INTAKE VALVE

STARTING MOTOR

(OPTION)

OIL GAUGE

BALANCER GEAR

OIL DRAIN PLUG

TIMING CHAIN

For without starting motor㧦Buffle 1 is mounted, instead of starting motor.

CRANKCASE

CRANKSHAFT

OIL SENSOR (OPTION)

Fig.4-17

CONNECTING ROD

PISTON

PISTON RING

AIR CLEANER

TENSIONER

BAFFLE 2

5. DISASSEMBLY AND REASSEMBLY

FLYWHEEL PULLER

5-1 PREPARATIONS AND PRECAUTIONS

(1)

When disassembling the engine, memorize the location of each part so that you can reassemble the engine

correctly. If necessary, attach identification tags with the required assembly information to the parts.

(2) Store groups of parts in separate boxes. This will make reassembly easier.

(3) To prevent parts from being mislaid, keep each group provisionally assembled after removing the parts

from the engine.

(4) Handle the disassembled parts with the utmost care. Clean them with cleaning oil if necessary.

(5) Use the correct tools in the correct way when disassembling and reassembling the engine.

5-2 SPECIAL TOOLS

Tool name Use

Commercially available product Flywheel puller For pulling off the ﬂ ywheel

Commercially available product Chain wrench For locking the ﬂ ywheel

CHAIN WRENCH

Fig.5-1

5-3 DISASSEMBLY PROCEDURE

Step Parts to remove Remarks and procedures Fasteners

Drain the engine oill Remove a drain plug (M14 x 12mm) located on both

sides of the case.

Drain the fuel Shut (OFF) the fuel strainer.

OIL GAUGE

Take care not to lose the gaskets.

To discharge oil quickly, remove the oil guage(M22).

Drain fuel from the carburetor drain.

14 mm spanner

+ or - screwdriver

GASKET

STEP 2

STEP 1

GASKET

DRAIN PLUG

Fig.5-2

OFF

FUEL STRAINER

Fig.5-3

Step Parts to remove Remarks and procedures Fasteners

PAPER ELEMENT

URETHAN FOAM

URETHANE ELEMENT TYPE

DUAL ELEMENT TYPE

AIR CLEANER COVER

URETHAN FOAM

AIR CLEANER COVER

AIR CLEANER BASE

M6 FLANGE NUT : 2 pcs.

M6 x 16 FLANGE BOLT : 1 pc.

GASKET

BREATHER PIPE

Air cleaner cover Remove the air cleaner cover and element.

screwdriver

Air cleaner Remove the air cleaner while pulling the breather pipe

away from the rocker cover.

STEP 3

10 mm box spanner M6 nut : 2 pcs. M6 x 16 : 1 pc.

STEP 4

Fig.5-4

Step Parts to remove Remarks and procedures Fasteners

FUEL STRAINER

M6 x 12 BOLT : 1 pc.

Muffler and Muffler cover (1) Remove the muffler cover from the muffler.

(2) Remove the muffler from the cylinder head. Take

care not to lose the gasket.

Take care not to cut your hand with the muffler

Fuel tank (1)

gasket.

Seal the exhaust port with adhesive tape or plug

it with cloth to prevent nuts and other objects from falling inside.

Remove the fuel tank mounting nuts and bolts from the crankcase.

(2)

Disconnect fuel hose from the strainer to carburetor side. Remove the bolt for fuel strainer.

(3)Remove the fuel tank from the crankcase.

12 mm box spanner 10 mm box spanner or spanner

M6 x 8 mm : 4 pcs. M8 nut : 2 pcs. M8 x 12 mm : 1 pc.

12 mm box spanner 12 mm spanner M8 nut : 2 pcs. M8 x 25 mm : 2 pcs.

- screwdriver 10 mm box spanner M6 x 12 mm : 1 pc.

Fig.5-6

STEP 6

FUEL TANK

M8 NUT : 2 pcs.

MUFFLER COVER

M6 x 8 FLANGE BOLT : 4 pcs.

STEP 5

M8 NUT : 2 pcs.

MUFFLER

M8 x 12 BOLT : 1 pc.

GASKET(It has two faces)

M8 x 25 BOLT : 2 pcs.

Seal the exhaust port with adhesive tape or plug it with cloth.

Fig.5-5

Step Parts to remove Remarks and procedures Fasteners

Stop switch Disconnect the wire and remove the stop switch from

the blower housing.

Recoil starter Remove the recoil starter from the blower housing. 10 mm box spanner

Blower housing

Recoil bracket

Baffle 2

M4 x 12 SCREW and WASHER : 2 pcs.

(1)

Remove the blower housing (synthetic resin) from the crankcase.

(2) Remove the recoil bracket from the crankcase.

Remove the baffle 2 ( synthetic resin ) from the crankcase.

M6 x 14 BOLT : 4 pcs.

STEP 7

+ screwdriver M4 x 12 mm : 2 pcs.

M6 x 14 mm : 4 pcs.

10 mm box spanner M6 x 16 mm : 5 pcs. M6 nut : 4 pcs.

10 mm box spanner M6 x 12 mm : 3 pcs.

STEP 8

STOP SWITCH

M6 FLANGE NUT : 4 pcs.

M6 x 16 BOLT : 5 pcs.

M6 x 12 BOLT : 3 pcs.

STEP 10

BAFFLE 2

Fig.5-7

BLOWER HOUSING

RECOIL BRACKET

RECOIL STARTER

STEP 9

Step Parts to remove Remarks and procedures Fasteners

GOVERNOR SPRING

M6 x 12 BOLT : 1 pc. (temporary screw)

ROD SPRING

GOVERNOR ROD

SPEED CONTROL LEVER and BRACKET

GASKET

CHOKE LEVER

GASKET

CARBURETOR

GASKET

INSULATOR

GOVERNOR LEVER

GOVERNOR SHAFT

STEP 11

STEP 12

STEP 13

Speed control lever and Bracket

Governor system (1) Loosen the bolt and remove the governor lever

Carburetor, Insulator Remove the carburetor from the cylinder head.

Remove the speed control lever and bracket from the cylinder head. Release the bolt temporarily. Slide to dismount the speed control lever and bracket from the cylinder head and the choke lever of the carburetor.

from the governor shaft. There is no need to

remove the bolt. (2) Remove the governor spring. (3) Remove the governor rod and the rod spring from

the carburetor.

Remove the insulator.

10 mm box spanner M6 x 12 mm : 1 pc.

10 mm box spanner or spanner

M6 x 25 mm : 1 pc.

Fig.5-8

Step Parts to remove Remarks and procedures Fasteners

FLYWHEEL PULLER

ATTACH NUT TEMPORARILY

Ignition coil Remove the spark plug cap from the spark plug and

remove the ignition coil from the crankcase.

Starting pulley Cooling Blower

Flywheel Remove the flywheel from the crankshaft. Leave the nut

Remove the starting pulley and cooling Blower from the flywheel.Fit a box wrench or a socket wrench on the flywheel nut and loosen the nut by knocking the wrench sharply with a hammer. (See Fig. 5-10) NOTE:

1. Do not insert a screwdriver or other object between the flywheel blades which is a synthetic resin, otherwise the risk of damaging the blades might be occurred.

2. Knock the wrench with a hammer in a counter clockwise direction.

temporarily to prevent the flywheel from dropping out. Fit the flywheel puller as shown in Figure 5-11 and remove the flywheel from the crankshaft by rotating the bolt at the center in a clockwise direction. (Knock the center bolt with a hammer sometimes)

10 mm box spanner M6 x 25 mm：2 pcs.

24 mm box spanner or socket wrench M18 nut

Flywheel puller

M6 x 8 BOLT : 1 pc.

CLAMP

Fig.5-10 Fig.5-11

STEP 16

FLYWHEEL

COOLING BLOWER

Fig.5-9

STARTING PULLEY

M18 NUT : 1 pc.

WIRE : 1 pc.

IGNITION COIL

STEP 15

M6 x 25 BOLT and WASHER : 2 pcs.

STEP 14

Step Parts to remove Remarks and procedures Fasteners

[MODEL WITH ELECTRIC STARTER TYPE]

Control box, Diode rectifier, Magnetic switch Electric starter (option)

[MODEL WITHOUT ELECTRIC STARTER TYPE]

Baffle 1 (Case)

(1) Disconnect the grounding cable from battery. (2) Disconnect the wire leading from the key

switch“ST” terminal to the magnetic switch.

(3) Disconnect the wire that connects the positive

terminal of the battery to the magnetic switch.

(4) Remove the electric starter.

Remove the Baffle 1 from the crankcase.

12 mm box spanner M8 nuts

12 mm box spanner M8 x 12 mm : 1 pc.

MODEL WITH ELECTRIC STARTER TYPE (OPTION)

M8 x 28 BOLT : 2 pcs.

M8 NUT

ELECTRIC STARTER

STEP 17

MODEL WITHOUT ELECTRIC STARTER TYPE

BAFFLE 1 (CASE)

M8 x 12 BOLT : 1 pc.

STEP 17

Fig.5-12

Step Parts to remove Remarks and procedures Fasteners

[MODEL WITH CHARGE COIL TYPE]

Wire clamp

Disconnect the wire clamp.

NOTE: Disconnect the wire clamp in this step, also an engine which has both of the charge coil and the oil sensor. However, please make sure to not damaged (cut off) the oil sensor wire after disassembly procedure.

10 mm box spanner M6 x 10 mm : 1 pc.

Charge coil

Spark plug Remove the spark plug from the cylinder head. 21 mm plug wrench

Remove the charge coil.

WIRE CLAMP

CHARGE COIL

M6 x 10 TAPPING BOLT : 1 pc.

STEP 18

15W 40W

200W

+ screwdriver

BOLTCHARGE COI L Q’ty

M6 x 20L M6 x 25L M6 x 20L

2 2 4

STEP 19

SPARK PLUG

15W

CHARGE COIL CHARGE COIL

CHARGE COIL

200W40W

VIEW A

Fig.5-13

Step Parts to remove Remarks and procedures Fasteners

Punch marks

The position of compression top dead center

Rocker cover (1) Remove the rocker cover from the cylinder head.

(2) Remove the gasket (rocker cover).

Rocker arm Remove the pin (rocker arm) and the rocker arm from

the cylinder head at the compression top dead center. (See Fig. 5-16)

ROCKER ARM (EXHAUST VALVE SIDE)

PIN (ROCKER ARM)

ROCKER ARM (INTAKE VALVE SIDE)

10 mm box spanner M6 x 12mm : 4 pcs.

Fig.5-15

STEP 21

ROCKER ARM (INTAKE VALVE SIDE)

GASKET(ROCKER COVER)

Fig.5-16

ROCKER ARM (EXHAUST VALVE SIDE)

PIN (ROCKER ARM)

VIEW A

Fig.5-14

STEP 20

ROCKER COVER

M6 x 12 BOLT : 4 pcs.

Step Parts to remove Remarks and procedures Fasteners

Main bearing cover Remove the flange bolts of main bearing cover from

the crankcase. Remove the main bearing cover while tapping gently around the cover using a plastic hammer or similar tool. (See Fig. 5-18) Be careful not to damage the oil gauge or oil seal or not to lose the pipe knocks.

12 mm box spanner M8 x 38mm : 8 pcs.

Fig.5-18

M8 x 38 BOLT : 8 pcs.

STEP 22

PIPE KNOCK

MAIN BEARING COVER

Fig.5-17

TENSIONER

SPRING (TENSIONER)

CHAIN

PIN (TENSIONER)

PIN (CAMSHAFT)

CAMSHAFT

M6 x 12 BOLT : 1 pc. Bolt used to prevent the pin (camshaft) from coming out

CHAIN

STEP 23

Step Parts to remove Remarks and procedures Fasteners

CHAIN

CAMSHAFT

PIN (TENSIONER)

PIN (CAMSHAFT)

M6 x 12 BOLT : 1 pc. Bolt used to prevent the pin (camshaft) from coming out

Tensioner, Camshaft (1) Remove the tensioner. (See Fig. 5-20)

Do not lose the pin (tensioner).

(2) Remove the retaining bolt of pin (camshaft) from

the cylinder head. (See Fig. 5-21)

(3) Remove the pin (camshaft), taking care not to

scratch the O-ring.

(4) Remove the chain from the camshaft sprocket and

then take out the camshaft. (See Fig. 5-22)

(5) Remove the chain from the crankshaft.

Fig.5-20

Fig.5-21

M10 box spanner or spanner M6 x 12mm : 1 pc.

Pliers

Fig.5-22

Fig.5-19

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