Arbortech As200x User manual

ALLSAW AS200X

SERVICE MANUAL

ALL.FG.200240.00

ALL.FG.200240.40

ALL.FG.200240.60

ALL.FG.200110.20

ALL.FG.200110.40

The contents of this manual are confidential and should not be distributed without written approval from

Arbortech Pty Ltd.

 
Contents 
1INTRODUCTION ..............................................................................................................................................1 
2SERVICING INFORMATION..............................................................................................................................1 
1 Diagnosis and Troubleshooting.............................................................................................................1 
2 Service Time Estimates .........................................................................................................................1 
3 Torque Settings and Driver Types .........................................................................................................1 
4 Exploded Diagram and Parts List...........................................................................................................2 
4.1 Mechanism and Ancillaries ...............................................................................................................2 
4.2 Motor and Electrical .........................................................................................................................4 
3SERVICE PROCEDURES ....................................................................................................................................6 
1 Head Shells and Ancillaries....................................................................................................................6 
1.1 Right Hand Head Shell ......................................................................................................................6 
1.2 Handle Locking Button......................................................................................................................6 
1.3 Left Hand Head Shell.........................................................................................................................6 
1.4 Top Handle........................................................................................................................................6 
1.5 Dust Extraction Bracket ....................................................................................................................7 
1.6 Wire Guard and Nose Hook ..............................................................................................................7 
1.7 Retractor...........................................................................................................................................7 
2 Belt and Pulleys.....................................................................................................................................8 
2.1 Belt Tensioning .................................................................................................................................8 
2.2 Belt Inspection and Replacement .....................................................................................................8 
2.3 Pulleys...............................................................................................................................................8 
3 Motor ....................................................................................................................................................9 
3.1 Brushes Inspection & Replacement..................................................................................................9 
3.2 Mounting Screws Inspection ............................................................................................................9 
3.3 Motor Separation ...........................................................................................................................10 
4 Castings and Mechanism.....................................................................................................................11 
4.1 Top Springs .....................................................................................................................................11 
4.2 Left Hand Casting............................................................................................................................12 
4.3 Gearbox inspection.........................................................................................................................13 
4.4 Conrods Assembly........................................................................................................................... 13 
4.5 Right Hand Casting..........................................................................................................................13 
 
 
 

1INTRODUCTION

This manual details the common procedures for maintenance and repair work for the Arbortech AS200X. These procedures may

be required following tool wear or failure from use. The most common maintenance items are drive belt and motor brush

replacement, which will occur from extended use. If the tool is damaged beyond these items, replacement of internal bearings,

mechanism components, castings, head shells or motor components may be necessary.

At all times when performing maintenance or repair tasks, the following safety guidelines must be observed:

•Only properly trained and qualified technicians should complete repairs involving potential hazards

•Use appropriate PPE including, but not limited to, suitable eye and ear protection

•Never attempt any service or repair work with the tool connected to any power source

•Handle electrical components with care and take all necessary precautions to avoid electrical hazards

•Beware of mechanical hazards, such as pinch points between moving parts, and components which may be hot

Procedures are described with accompanying images. Tools are listed (in brackets), for example, the size of hex key required. Refer

to the owner’s manual for operation procedures and general specifications.

2SERVICING INFORMATION

2.1 Diagnosis and Troubleshooting

The most common symptoms of a mechanical or electrical failure are listed below, with the appropriate steps to diagnose and

remedy the fault.

Symptom

Cause

Check/Remedy

Section

Blades frequently jam

and stop during cutting

Insufficient belt tension

Check belt tension

3.2.1

Excessive belt wear

Replace belt if required

3.2.2

Motor runs but blades

do not move

Belt failure

Check tension, replace belt

3.2.2

Gearbox failure

If no pulleys move, inspect gearbox

3.4.3

Motor does not run

when switch is activated

Brush failure

Inspect/replace brushes

3.3.1

Motor failure

Replace motor

3.3.3

Conrod pitching freely

Top spring failure

Replace top spring

3.4.1

Blade does not attach or

stay attached

Incorrectly attaching blades

Refer user manual for correct method

Conrod blade mount damaged

Replace conrod assembly

3.4.4

Motor overheating

and/or running slowly

Blades jammed with debris

Clear any debris

Cooling vents blocked

Clear cooling vents

Brushes worn

Inspect brushes, replace

3.3.1

Motor casing loose

Check motor mount screws

3.3.2

Mechanism failure or jam

Inspect mechanism

Bearing or gearbox failure

Inspect bearings and/or gearbox

3.4.2 - 3.4.4

Motor failure

Replace motor

3.3.3

Excessive gearbox or

bearing noise

Bearing failure

Inspect bearings

3.4.2, 3.4.4

Crown wheel/pinion damage

Inspect gearbox

3.4.3

2.2 Service Time Estimates

Process

Time (mins)

Belt inspection and replacement, brush inspection and replacement, handle washers replacement

Crown wheel and pinion inspection or replacement, motor change

Camshaft assembly replacement, full bearing inspection and replacement

2.3 Torque Settings and Driver Types

Fastener

Torque (Nm)

Driver Type

Motor mount screws

1.5 - 2

Torx T20

Idler screw

5 mm hex

Casting screws

4 mm hex

Top spring screws (conrods and casting)

5 mm hex

Left head shell screws

Torx T25

Right head shell screws

5 mm hex

Bridging screw

5 mm hex

Dust extraction bracket screw

3 mm hex

2.4 Exploded Diagram and Parts List

2.4.1 Mechanism and Ancillaries

This diagram provides an overview of the AS200X components. Detailed diagrams of assembly positions and alignments are shown

in the Service Procedures section.

Description

Part No.

Details

Model

Qty.

Handle washer

ALL.FG.WASH030

200

Handle Pin

ALL.FG.PIN005

10 x 35 mm dowel

200

Top handle

ALL.FG.HANDLE003

200

Idler nut

ALL.FG.NUT006

M6 Nyloc

170/175/200

Idler washer

ALL.FG.WASH024

170/175/200

Tension idler

ALL.FG.TENSION002

Includes ALL.FG.BEARING003

175/200

Tension idler bearing

ALL.FG.BEARING003

170/175/200

Idler screw

ALL.FG.SCREW013A

M6 x 20 grade 12.9

200

Right hand head shell

ALL.FG.HEADSHELLRH

Includes button ALL.FG.BUTTON001

200

Handle locking button

ALL.FG.BUTTON001

200

Right head shell screw

ALL.FG.SCREW025

M6 x 10 grade 12.9

200

Drive belt

ALL.FG.BELT003

OPTIBELT 3PJ280

175/200

Power pulley

ALL.FG.PULLEY008

175/200

Driven pulley

ALL.FG.PULLEY007

175/200

Nose hook

ALL.FG.HOOK001

200

Wire guard

ALL.FG.GUARD005

200

Motor screw

ALL.FG.SCREW028

Includes spring washers

200

Retractor homing spring

ALL.FG.SPRING005

200

Retractor

ALL.FG.RETRACTOR001

200

Dust Boot

ALL.FG.BOOT003

200

Conrods assembly

ALL.FG.CONROD004

200

Top spring washer

ALL.FG.WASH027

170/175/200

Conrod clamp washer

ALL.FG.WASH022

170/175/200

Top spring conrod screw

ALL.FG.SCREW013

M6 x 20 grade 12.9

170/175/200

Top springs kit

ALL.FG.SPRINGASS003

200

Double clamping washer

ALL.FG.WASH025

170/175/200

Nord-lock washer

ALL.FG.WASH019

170/175/200

Top spring casting screw

ALL.FG.SCREW026

M6 x 16 grade 12.9

200

Casting screw, long

ALL.FG.SCREW023

M6 x 35 grade 12.9

200

Casting screw, short

ALL.FG.SCREW022

M6 x 16 grade 12.9

200

Left hand head shell

ALL.FG.HEADSHELLLH

200

Left head shell screw

ALL.FG.SCREW018

M5 x 10 self-tapping

200

Bridging screw

ALL.FG.SCREW019

M6 x 30 plastic tapping

200

Handle locking pin e-clip

ALL.FG.CLIP006

6 mm

200

Handle button spring

ALL.FG.SPRING007

200

Handle locking pin

ALL.FG.PIN003

200

Left hand casting

ALL.FG.HOUSE200LH

Includes bearings

200

Camshaft bearing

ALL.FG.BEARING002

170/175/200

LH crown shaft bearing

ALL.FG.BEARING011

200

Crown shaft assembly

ALL.FG.CROWN200

200

Gearbox O-ring

ALL.FG.SEAL003

54 x 2 mm

200

RH crown bearing circlip

ALL.FG.CLIP008

200

RH crown shaft bearing

ALL.FG.BEARING002A

200

Right hand casting

ALL.FG.HOUSE200RH

Includes bearings, circlips, o-ring

200

Dust extraction bracket screw

ALL.FG.SCREW024

M4 x 10 grade 12.9

200

Dust extraction bracket

ALL.FG.BRACKET005

200

Motor

Australia

ALL.FG.MOTOR175.00

230V

175/200

ALL.FG.MOTOR175.40

230V

175/200

UK Industrial

ALL.FG.MOTOR175.41

120V

175/200

Europe

ALL.FG.MOTOR175.60

230V

175/200

USA

ALL.FG.MOTOR175.20

120V

175/200

Armature circlip

ALL.FG.CLIP005

22 x 1.2 increased abutment

175/200

Armature bearing

ALL.FG.BEARING007

175/200

Spindle O-ring

ALL.FG.SEAL175

BS020

175/200

Pinion gear

ALL.FG.PINION002

175/200

Pinion nut

ALL.FG.NUT002

175/200

2.4.2 Motor and Electrical

Description

Part No.

Qty.

Bearing Cup

See item 102

Rear armature bearing

See item 102

Magnet

See item 102

Armature

See item 102

Baffle fan

N399419

Plug, rubber

949638-02

Field

230V

N474622

120V

N474963

Field case

N548995

Brush box

See item 107

Spring

See item 107

Brush cap

N462741

Brush cap screw, M3

648777-00

Brush box screw, M3 x 8

593478-00

Separator

N458066

Insert

N451017

Switch

N451612

Switch screw, M4 x 6

330065-07

Cord

Australia

562226-85

562226-86

UK Industrial

562226-87

Europe

562226-84

USA/CAN

330081-18

Protector

N542553

Cord clamp

N174601

Cord clamp screw, M3.5 x 16

30019-03

Field case screw, M4 x 40

N389438

End handle screw, M4 x 18

330065-08

Capacitor

Omitted in USA/CAN region

N482574

102

Armature assembly

230V

N490496

UK Industrial

N474960

USA/CAN

N490499

107

Brush box

N413349

108

Brush (pair)

230V

N489059

UK Industrial

N421361

USA/CAN

N257540

109

End handle assembly

N548991

3SERVICE PROCEDURES

3.1 Head Shells and Ancillaries

3.1.1 Right Hand Head Shell

To disassemble:

1. Unscrew the bridging screw (5 mm hex)

2. Unscrew the three right hand head shell screws (5

mm hex)

3. Remove the shell. Most resistance will be around

the base of the top handle.

Assembly is the reverse procedure, taking care to align the

handle pivot pin, handle locking pin and retractor pivot into

their corresponding holes. Torque the right head shell

screws to 6 Nm and the bridging screw to 8 Nm.

3.1.2 Handle Locking Button

Warning: detaching the button from the right hand head

shell permanently damages the button. It should only be

removed if it requires replacement.

1. Remove the right hand head shell as per 3.1.1. From

the inside of the shell, use a sharp probe to bend or

snap the button retaining hooks until the button

can be removed. Take care not to damage the

surrounding hole surface.

2. Align the new button with the head shell hole and

press firmly to engage the hooks through the hole.

3.1.3 Left Hand Head Shell

To disassemble:

1. Remove the right hand head shell as per 3.1.1

2. Unscrew the three left head shell screws (Torx T25)

3. Rotate the head shell around the retractor as

shown until the shell is inverted then unhook the

retractor from the conrods and the wire guard.

Rotating either forwards or rearwards may be

easier depending on the conrods position.

Assembly is the reverse process, taking care to correctly

hook the retractor through the conrods and the wire guard.

When starting the three screws take care to correctly find

the hole threads since they are easily damaged. Torque the

left head shell screws to 6 Nm.

3.1.4 Top Handle

To service the top handle and handle adjustment

mechanism, first remove the right hand head shell as per

3.1.1.

The top handle, handle washers and pivot pin can then be

inspected and replaced if necessary. A small amount of

movement between the handle and the pivot pin is

acceptable and is part of the vibration isolation system.

When installing a new top handle ensure it is facing forwards

with one handle washer on each side.

To remove the handle locking pin, pry off the e-clip with a

small flat blade screwdriver. The pin will be partly ejected by

the spring. When assembling the locking pin do not apply oil

or grease to the mechanism as they may attract dust.

3.1.5 Dust Extraction Bracket

To remove the bracket, unscrew the dust extraction bracket

screw (3 mm hex). The bracket can then be pivoted

downwards and unhooked from the right hand casting. Note

the wire guard may spring out of place by several mm.

When assembling the dust extraction bracket, hook it into

the casting then pivot upwards to trap the wire guard.

Ensure the bracket is seated squarely then tighten the screw

carefully to the required torque (2 Nm).

3.1.6 Wire Guard and Nose Hook

To disassemble:

1. Remove the head shells as per 3.1.1 & 3.1.3 and the

dust extraction bracket as per 3.1.5

2. Unwind the three casting screws by 4 turns each (4

mm hex)

3. Using a soft-face hammer, separate the left hand

casting from the right hand casting until it reaches

the limit of the casting screws or the nose hook is

released.

4. Remove the nose hook

5. To also remove the wire guard, pinch together the

front ends until they are released from the castings.

Assembly is the reverse procedure, with the following notes:

•Use a soft-face hammer to tap the left hand casting

back to its original position. Do not use the casting

screws to pull the castings together.

•As the left hand casting is assembled check the

gearbox o-ring is still correctly seated inside the

gearbox.

•Once the left hand casting is assembled, tighten the

three casting screws to hand tight, then torque to

10 Nm.

3.1.7 Retractor

Shallow marking or grooving of the retractor can occur as

part of normal operation. Severe grooving may indicate a

malfunction in one or both conrods. If the retractor is

damaged or no longer allows blades to be installed or

removed, it must be replaced. If the retractor does not

return to the home position after use, the retractor homing

spring should be inspected and may need replacing.

To disassemble:

1. Remove the head shells as per 3.1.1 & 3.1.3. The

retractor should rotate smoothly in the left hand

head shell and the homing spring should force the

retractor to its home position.

2. Unhook the retractor homing spring from the left

hand head shell post.

3. Slide the retractor out of the head shell hole.

4. If replacing the homing spring, unhook it from the

retractor.

Assembly is the reverse process, taking care to ensure the

homing spring is oriented correctly and is hooked onto the

left hand head shell post.

3.2 Belt and Pulleys

3.2.1 Belt Tensioning

To tension the belt without disassembly:

1. Loosen the idler screw (5 mm hex) until the screw

can be moved along the slot (approximately 1 turn).

Do not loosen further.

2. Using the hex key, push the screw upwards towards

the handle to tension the belt. While the screw is

being pushed, tighten it to hand tight.

3. Torque the idler screw to 8 Nm.

4. Check belt tension is sufficient to prevent slipping

during use.

If belt tension cannot be achieved remove the right hand

head shell as per 3.1.1 and inspect the belt as per 3.2.2

3.2.2 Belt Inspection and Replacement

Remove the right hand head shell as per 3.1.1.

The belt can be tensioned as per 3.2.1 if required.

If sufficient tension to prevent slipping during use cannot be

achieved within the travel of the idler, the belt is worn and

should be replaced:

1. Loosen the idler screw (5 mm hex) until the idler can

be moved along the slot (approximately 1 turn). Do

not loosen further.

2. Move the idler down the slot away from the handle.

3. Remove the belt.

4. Install the new belt. Avoid rolling the belt during

installation. Check to ensure it is correctly seated on

all three pulleys.

5. Tension as per 3.2.1

3.2.3 Pulleys

Before servicing the pulleys, both head shells must be

removed as per 3.1.1 and 3.1.3 and the belt must be

removed as per 3.2.2.

Remove the power pulley by locking the opposite end of the

shaft with a flat blade screwdriver and unwinding the pulley

with a pin spanner. Note it is a left-hand (reversed) thread.

Warning: never activate the motor when the power pulley is

disassembled. Doing so may cause permanent damage to

the gears.

Remove the driven pulley by locking the near end of the

shaft with a flat blade screwdriver and unwinding the pulley

with a pin spanner. It uses a right-hand (standard) thread.

When installing the driven pulley apply a drop of Loctite 243

to the camshaft thread. Tighten both pulleys thoroughly.

Before removing the tension idler, move it to its highest

position and hold the idler nut in place so it does not fall into

the mechanism. Fully unwind the screw to remove the

pulley. During assembly ensure:

•The idler washer’s largest face is towards the casting

•The tension idler’s open side is away from the casting

Reassemble the belt and tension as per 3.2.2.

3.3 Motor

3.3.1 Brushes Inspection & Replacement

The AS200 motor uses two brushes (top and bottom), one of

which is fitted with an auto cut-off system. If the brush fitted

with the system has reached the auto cut-off, or if either

brush has worn to limit, replace both.

To disassemble:

1. Unscrew the two screws retaining the brush covers

(flat blade screwdriver or Torx T10)

2. Remove both brush covers (see diagram for pry

point)

3. Lift both brush springs to the side

4. The brushes can be lifted from their holders for

inspection without disconnecting

5. If replacing the brushes, disconnect the connector

at the end of the brush wire and remove the old

brush

Assembly is the reverse process, taking care to:

•fit the brush wire into the slot in the brush holder

•seat the brush spring in the slot in the brush holder

and in the groove on top of the brush.

Warning: confirm the brush springs have been

seated. Failure to do so can cause rapid damage to

brushes and commutator.

3.3.2 Mounting Screws Inspection

The motor is attached to the right hand casting with four

dedicated plastic tapping screws with spring washers. If the

motor is loose on the casting, remove the head shells as per

3.1.1 & 3.1.3 and tighten the screws (Torx T20) to 2 Nm. If

they cannot be tightened to the specified torque, the plastic

motor housing has stripped and should be replaced as per

3.3.3. Do not substitute alternate screws. Take care when

removing and installing screws to avoid stripping the thread.

3.3.3 Motor Separation

If the armature requires replacement, the LH casting and

crown shaft should be disassembled first as per 3.4.2 and

3.4.3 before separating the motor. Most other tasks

requiring motor separation (such as replacing the field,

replacing the field case, or inspecting the armature) can be

performed with the LH casting in place.

To disassemble:

1. Remove the head shells as per 3.1.1 & 3.1.3

2. Lift the brushes as per 3.3.1

3. Unscrew the four motor mount screws (Torx T20)

4. Pull the motor away from the casting. There should

be a slight resistance as the armature separates

from the motor. Pull straight without bending or

twisting. Take care not to damage the armature,

which will remain attached to the right hand

casting.

If the left hand casting and crown shaft have already

been disassembled, the armature can be separated

from the right hand casting:

5. Hold the armature using a soft-jaw vice at the

location indicated

6. Undo the pinion nut (10 mm)

7. Pull the armature out of the armature bearing

8. If the bearing requires replacement, remove the

circlip, bearing and o-ring.

Inspection points:

Check the motor commutator, armature and field for visible

damage or significant wear.

Check the armature bearing (in right hand casting). Replace

if it does not rotate smoothly or is visibly damaged. Replace

the o-ring if it is damaged.

To assemble

1. Fit the replacement o-ring and bearing if required,

and fit the circlip with rounded face away from the

bearing (tabs pressing towards the bearing)

2. Check the armature spindle is clean then align and

push the spindle into the bearing

3. Fit the pinion onto the armature spindle inside the

gearbox

4. Apply a small drop of Loctite 243 to the thread for

the pinion nut then thread the nut on with the small

serrations towards the pinion.

5. Hold the armature and tighten the pinion nut to

firm hand tight

6. Check the brushes are outside the motor body then

carefully feed the armature into the motor.

7. Once the motor seats against the casting, check the

motor and casting are oriented correctly (trigger

opposite to top springs).

8. Carefully thread in the four motor screws, locating

the existing threads if possible. Tighten the screws

to 2 Nm, taking care not to strip the threads.

9. Re-fit the brushes as per 3.3.1

3.4 Castings and Mechanism

The aluminium castings (left hand and right hand) form the

gearbox and provide mounting points for the mechanism,

head shells and ancillaries. The left hand casting must be

disassembled to access the gearbox, remove the armature

or to remove the mechanism. The left hand casting must be

assembled when removing or installing the top springs.

3.4.1 Top Springs

If a top spring has failed, both springs should be replaced

using the top springs kit. Warning: a top spring failure can

damage other components such as the head shells, which

should be inspected thoroughly. Replace all existing washers

and screws with the new washers and screws supplied in the

kit. Note: the conrods assembly kit and top springs kit

include several duplicate washers and screws.

To disassemble:

1. Remove the head shells as per 3.1.1 & 3.1.3

2. Unscrew the four top spring screws (5 mm hex)

(two at the casting and two at the conrods).

Inspect the casting spring seat and the tops of the conrods

for any damage caused by a broken spring. If any damage is

visible, replacement is required.

Note the left hand casting must be in place before

assembling new top springs.

To assemble:

1. Check the spring seat, the tops of the conrods,

the threaded holes in the casting, the springs and

all washers are clean.

2. Do not scrape or abrade the springs to remove

residue or debris. If a spring is scratched it must

be replaced.

3. Assemble the screws and washers as shown,

taking care to orient each washer correctly

(top/bottom and front/back).

4. Include a small drop of Loctite 243 on the last

thread of each screw and wind them into the

casting and conrods. Note the shorter (16 mm)

screws fasten into the casting and the longer (20

mm) screws fasten into the conrods. Do not

tighten any screws until all four are in place.

5. Gradually tighten the four screws, ensuring the

washers at the conrods remain square to the top

springs. Tighten all four screws to 18 Nm. Pay

special attention to the conrod screws which

may give a false tight feeling while the screws

and washers settle (approx 1 turn before fully

tightening).

Do not allow the tool to sit for more than 10 mins

with Loctite applied before tightening fully.

3.4.2 Left Hand Casting

To disassemble:

1. Remove the head shells as per 3.1.1 & 3.1.3 and the

drive belt as per 3.2.2. Remove the dust extraction

bracket as per 3.1.5 can improve access but is not

essential.

2. Remove the top spring conrod screws (5 mm hex)

and washers

3. Remove the three casting screws (4 mm hex)

4. Use a soft-face hammer to gently tap the left hand

casting away from the right hand casting. A rod-

type punch with a soft end (e.g. plastic) can be used

with care at the locations indicated.

Inspection points:

Check both the bearings which mount in the left hand casting

(they may remain attached to their shafts after disassembly).

Replace if they do not rotate smoothly or are visibly

damaged. Check the o-ring for cracks or tears and replace if

any defects are found. If possible, replace the o-ring each

time the left hand casting is disassembled.

To assemble:

1. Seat the o-ring into the right hand casting, flush

with the opening face of the gearbox.

2. Align the left hand casting on the crown shaft and

cam shaft, and gently tap with a soft-face hammer

to begin fitting

3. Check the two dowel bushes are aligned with the

corresponding holes (see diagram) and the o-ring

remains seated inside the gearbox.

4. Ensure the wire guard and nose hook are fitted as

per 3.1.6. They cannot be added after the casting is

assembled.

5. Continue tapping the casting into position with a

soft-face hammer until it is fully seated (no gaps at

the contact surfaces).

6. Install the three casting screws to hand tight. Note

the short screw (16 mm) fastens at the upper hole

near the top springs, and the two longer screws (35

mm) fasten at the front and lower holes.

7. Torque the three casting screws to 10 Nm.

8. Reassemble the top spring conrod screws, washers

and Loctite 243 as per 3.4.1. Torque to 18 Nm.

 13 
3.4.3 Gearbox inspection 
To disassemble: 
1. Remove the head shells as per 3.1.1 & 3.1.3, the 
drive belt as per 3.2.2, the power pulley as per 3.2.3 
and the left hand casting as per 3.4.2. 
2. Use a soft-face hammer to tap the threaded end of 
the crown shaft until it releases from the gearbox. 
 
Inspection points: 
Check crown wheel and pinion for worn or broken teeth, and 
replace the crown shaft assembly if necessary. To replace the 
pinion, the motor must be separated as per 3.4.2. 
Check the pinion is tightly locked to the armature. If the 
pinion can rotate on the armature, separate the motor and 
tighten the pinion nut as per 3.4.2. 
Check the grease condition and replace if any debris is found. 
Check the right hand crown shaft bearing rotates smoothly. 
If not, or if it is visibly damaged, it must be replaced (first 
remove the retaining circlip which may be hidden by grease). 
To assemble: 
1. Start the crown shaft into the right hand bearing 
2. Push the shaft into place, ensuring it meshes 
correctly with the pinion and seats against the 
bearing. 
3. Assemble the left hand casting as per 3.4.2 
 
3.4.4 Conrods Assembly 
To disassemble: 
1. Remove the head shells as per 3.1.1 & 3.1.3, the 
drive belt as per 3.2.2 and the driven pulley as per 
3.2.3 
2. Remove the top spring conrod screws (5 mm hex) 
3. Disassemble the left hand casting as per 3.4.2 
4. Use a soft-face hammer to tap the threaded end of 
the camshaft until it releases from the right hand 
casting (the bearing may stay attached to the 
camshaft). Take care not to bend the casting. 
 
Inspection points: 
Check the right hand camshaft bearing and replace if it does 
not rotate smoothly or is visibly damaged. 
Replace the conrods assembly if the conrod bearings do not 
rotate freely, the conrods are cracked or the conrod blade 
attachment mechanisms are damaged or excessively worn. 
Warning: individual conrods are not serviceable and 
attempts to remove them from the camshaft or disassemble 
the conrods can cause permanent damage. If a conrod or 
component requires replacement the entire conrods 
assembly must be replaced. 
Note: the conrods assembly kit and top springs kit include 
several duplicate washers and screws. 
To assemble: 
1. Press the conrods assembly into the right hand 
camshaft bearing (threaded end first), ensuring the 
camshaft seats fully against the bearing. Avoid 
collision with the top springs and right hand casting. 
2. Assemble the left hand casting as per 3.4.2 
3. Assemble the top spring conrod screws, washers 
and Loctite 243 as per 3.4.1. Torque to 18 Nm. 
4. Assemble the driven pulley, drive belt and head 
shells. 
 
 
 
 
 
 
 
 
3.4.5 Right Hand Casting 
If the right hand casting becomes deformed, cracked or 
otherwise damaged during use it must be replaced. 
Replacing the right hand casting requires removal of the 
head shells, ancillaries, top springs, left hand casting, 
drivetrain, conrods assembly and motor including armature. 
The tension idler must also be removed as per 3.2.3. 
Notes for assembly: 
•Assemble the tension idler to the right hand casting 
first as per 3.2.3 before any other assembly steps. 
•Do not tighten any top spring screws until the 
castings are fully assembled. 
 