Atom 102 Installation instructions
ATOM
LAWN
EDGER
PRO
GASOLINEMODEL
102
OPERATOR/OWNER
MANUAL
Patents
GrantedinAustralia
&USA
Design
Registrations
GrantedinAustralia,
USA,
Japan,Great
Britain
Assembling
0
SafetyPrecautions
oOperating
Instructions
t Maintenance
IMPROPER
USE
CANCAUSE
SERIOUS
INJURY
MAKE
SURETHIS
MANUAL
IS
READ
AND
CAREFULLY
UNDERSTOOD
BEFORE
STARTING
OROPERATING
THIS
EQUIPMENT
1ST
EDITION
IMPORTANTMANUAL
-DONOT
THROWAWAY
Manual
always
to beavailable
for reference
or instructing
new
operators.
SUPERVISORSTHIS
ISYOUR
RESPONSBILIW
I
CONTENTS
Parts
andControls ....
..3
SafetyPrecautions..........
......
...........
4
AssemblingtheLawn
Ed9er..............
8
FuelMixandFuelling
.......................9
StartingandStopping......
...........
10
Operating1nstructions
.....................
12
MaintenanceInstructions.................
I4
Airfiltermaintenance.....................
14
Carburettoradjustment...
................
15
Cutter
BladeReplacement..............'16
LubricationofGears.......................17
Checking
thespark
plugs
......,.........17
Checkingmuff|er...........................
17
TroubleShooting...........................
18
PartsList...... ..........18/19
INTRODUCTION
ThisManualcontains
operating,as-
sembling,
safety,andmaintenance,
instructionsfor the Atom Lawn
Edger.
Payspecialattentiontothesafety
precautions
outlinedon
pages
4 to
7. Allowonly
persons
whounder-
standthisManualto operatethe
LawnEdger.Thislawnedger
isnot
to be usedfor anypurpose
other
than
foredginglawns.
To receive
maximum
performance
and
satisfaction
from
thisLawn
Edger,rtis
important
that you read and under-
stand
themaintenance
and
safety
pre-
cautions before using the edger
Contact
your
Atomdealer
orthe
Atom
distributor
for yourareaif you do not
understand
or cannot
carryoutany of
theinstructions
inthisManual.
ATOM'S
philosophy
is to continu-
allyimproveallolits
products.
Asa
resull,
engineoringchangesand
im-
provoments
arefnadefrom
time-to-
time.lftheoperaling
characteristics
or lhe app€aranceof your lawn
edgerdifferslrornlhose
described
inthisManual,
ploase
contact
your
ATOM dealorfor irrformation
and
assistance.
ATOMressrvoslhr:rightto make
changesalany
lirnc
wilhnulnolice.
1,2
The handles of the Lawn
Edgerheldby
both
hands.
3. The
throttletriggerwhichin-
creasesspeedof enginefor
automaticsafetyclutchto en-
gage
andthusrotate
blade.
4. Starter
grip
the
grip
ofthe
pull
starter
whichis thedeviceto
starttheengine.
5. ON/OFF
switch.
6. Handlenutfor
holdinghandles
onto housing
(andadjusting
anti-vibration
ofhandle).
7. Heightadjustment
foradjust-
ing
depthofcuttingblade.
Bladecoverreduces
therisk
offlying
debrisanddirectcon-
tact
withthefeetorhands.
Cutterbladerotateswhenen-
gine
speedisincreased
above
idle.
10.
/
Wheelformovingand
guiding
edger.
Grassshieldreducesflyback
ofstonesandforeignmaterial.
Fuelcap for sealingthe fuel
tankfiller.
13.Chokeleverfor coldengine
starting.
14.Filterhousing
coverstheair
filter
element.
15.Fuel pump pramerprovides
additionalfuelforacoldstart.
16.Spark
Plug
terminalconnects
the spark
plug
to the ignition
wire.
17.Muffler reduces exhaust
noisesand divertsexhaust
gases
awayfromoperator.
I
12.
PARTSANDCONTROLS
10
1't.
12.
8.
9.
A WARNING
Aswithany
power
loolsome
spe-
cial
safely
precautions
must
beob-
servedto reduce
theriskof per-
sonalinjury.Careless
or improper
usemay causeseriousor even
fatalinjury.
SAFETYWARNINGS
HEPURPOSEOF SAFETY
WARNINGSAND
NOTESIN TIlISMANTJALIS
T
TTRACT YOUR ATTENTION TO POSSIBLE DANGEIIS AND THE
XPLANATIONS
WITH THEM DESERVEYOURCAREFUL
ATTENTIONAN
UNDERSTANDINGTHE
SAFETYWARNINGSIN THISMANUALANDON THE
LAWNEDGERDO NOT,BY THEMSELVES,
ELIMINATEANY DANGER.THE
INSTRUCTIONSOR WARNINGSTHEY GIVEARE NOT SUBSTITUTESFOR
PROPER
ACCIDENTPREVENTIONMEASURES
WARNING:Failure
to obeya safety
warningcan result in
injuryto yourself
and
others.
NOTE:
Advises
you
ofinformation
or instructions
vitalto the
! operationor maintenance
oftheequipment. -11. FIG2
SAFETY
PRECAUTIONS
Likeany
power
tooltheuseofany
lawnedgermaybe
dangerous.ltis
important
that
you
read,fullyunder-
stand,
and observethe following
safety
precautions
andwarnings.
Re-readthisoperator's
manualand
thesafetyinstructions
periodically.
THE
OPERATOR
Physical
Condition
Operatormustbeingood
physical
conditionandmentalhealth
and
not
underthe influenceof anysub-
stance
(drugs,
alcohol,etc.)which
mightimpairvision,
dexterityor
judgement
[Fig.
3a].
Donotoperatea lawnedgerwhen
fatigued.Bealert
- ifyouget
tired
whileoperatingthemachine,
takea
break.Tirednessmayresult
inloss
ofcontrol.Workingwith
any
power
toolcan
bestrenuous.lf you
have
any
conditionthat
mightbeaggra-
vatedby strenuous
work,check
with
your
doctor
beforeoperating
themachine.
TheAtom
LawnEdgerisequipped
with
vibrationreducing
hand
grips
and main handle
anti-vibration
mountings.These
aredesignedto
reduce
thetransmission
of engine
vibrationsto theoperator'shands.
Replace
hand
grips
andmountings
when
wornordamaged.
Therubberhandles
donot
guaran-
tee that you will not sustain
whitefinger
diseaseorcarpal
tunnel
syndrome.Therefore,
continualand
regular users should monitor
closely
theconditionsof
theirhands
andfingers.lf anyof the above
symptoms
appear,
seekmedical
advice
immediately.
Proper
Clothing
Clothing
mustbesturdy
andsnug-
fitting,
butallowcomplete
freedom
of movement
/see Fig.41.Avoid
loose-fitting
jackets,
flaredor
cuffed
pants,
or
anything
thatcouldtripthe
operator.
Wearoverallsor long
pants
to protect
your
legs.
Donot
wearshorts.
Useof gloves
when
working
withthe
lawnedgeris
rec-
ommended.
Good
footingis most
important.
Wear
sturdyshoes
with
nonslipsoles.
Do not wearsan-
dalsor operate
with barefeet.In
hot or sunnyconditions
always
wear
ahatandlongsleeve
shirt
for
protection
against
skin cancers.
Useofa good
brandof sunscreen
creamis alsorecommended
on
exposed
skinsurfaces.
Replace
immediately
broken
or
cracked
bladecovers
and grass
debrisdeflector.
Never
operatea lawnedger
unless
wearing
goggles
or properly
fitted
safety
glasses
with adequate
top
and
side
protection
which
comply
withANZI287.1
(oryour
applicable
national
standard).
Engine
noisemay damage
your
hearing.
Wearsoundbarriers
(ear
plugsor ear mufflers)to protect
your
hearing.
Continualandregular
users
shouldhavetheir
hearing
checked
regularly.
SAFETY
PRECAUTIONS
(cont'd
rt
Uf
tl
&
FIG
'f
-n-
O
A WARNING
Carelessor improperuse of the
machine
maycauseseriousinjury.
Have
your
Dealershow
you
howto
operate
your
lawnedger.
Safe use of a Lawn Edger in-
volves
1. the
operator
2. the
lawnedger
3. the
useofthelawnedger
A WARNING
Thelawn
edgermustnotbeoper-
atedbyminors.Bystanders,
espe-
ciallychildren
andanimals,should
notbeallowedinthe
areawherea
machineis inuse
(at
least
15
me-
tresaway).
Neverletthe unitrun
unattended
[Fig.
3b].
FIG3a
FIG3b
A WARNING
Proper
eye protection
is a must.
The bladecovermay not protect
theoperatorfromall fastmoving
foreignobjects
eventhough
the
discharge
isdirectedaway
fromthe
operator,
asricochets
andbounce-
backsmayoccur
duringlawnedg-
ingoperations.
A WARNING
Do not lend, rent or sell this
machinewithout
this operator's
manual.
Besurethat
anyoneus-
ingthis unitunderstandsthe in-
formationcontained
inthisman-
ualbefore
use.
A WARNING
Prolongeduseof anyhandheld
powered
machineexposingtheop-
eratorto vibrations
may produce
whitefingerdisease
(Raynaud's
phenomenon)
orcarpaltunnel
syn-
drome.Theseconditionsreduce
thehand's
abilitytofeeland
regu-
latetemperature,
produce
numb-
nessand burning
sensationsand
maycausenerve
andcirculation
amageandtissue
necrosis.
SAFEW
PRECAUTIONS
(cont'd
Fueling
This
Atomunitusesan
oil-gasolinemixturefor
fuel(see
thechapteron
"Fuel"). @
FIG5
SAFETYPRECAUTIONS
(cont'd)
Fuelinginstructions
Refuel outdoors only. Always
switchofftheengineandallowitto
coolbeforerefueling.Relieve
fuel
tank
pressure
bylooseningfuelcap
slowly.Neverremovefuelfillercap
while
engineisrunning.
Selectbare
ground
forfuelingand
moveatleast10feet
(3m)
from
the
fueling
spotbeforestartingtheen-
gine.
Wipeoffanyspilledfuelbe-
forestarting
your
lawnedgerand
checkforleakage.
Alwaystightenfuel fillercap se-
curelyafterfueling.
Starting
Youshould
alwaysinspect
your
unit
before
starting
it. Makesure
the
controls
and safetydevices
are
working
properly.
Asthethrottletriggeris
fittedwitha
%throttlelockto assistinstarting
theengine,never
leavelz throttle
lock
onother
thanforstarting.
For specificstartinginstructions,
seetheappropriatesectionofthis
operatorsmanual.
Placethe ma-
chineonfirm
ground
orothersolid
surfacein an openarea.Maintain
good
balanceandsecurefooting.
Failuretofollowthis
procedure
may
result
in
injury
tohandorfingersor
maydamagethe startermecha-
nism.
Workinginstructions
andimpor-
tantadjustments
Never
operate
your
machineifitis
damaged,improperly
adjustedor
not completely
and securelyas-
sembled.
Atcorrectidle
speedthe
blade
shouldnot
turn.Donotuse
lawn
edgerwith
incorrectidlespeed
adjustment.
Adjustthespeed
your-
self(Page
75)
settingCarburettor
ldle Speed
Adjustment,
or by a
service
dealer.
MAINTENANCE,
REPAIR
AND
STORING
Useonly original
Atom replace-
mentparts
for maintenance
and
repair.Use
of parts
manufactured
byothers
willvoid
warranty,and/or
may
cause
seriousor fatalinjury.
Followthe maintenanceinstruc-
tionsintheappropriatesectionof
this
manual.Anyrepairsshould
be
carriedoutby
anauthorisedservice
dealer.
Check
fuelfillercapfor leaks
at
regularintervals.Usethe
specified
spark
plug
and
makesureitandthe
ignitionleadare alwaysin good
condition.
Rememberthattheriskofforest
or
grass
firesis
greater
in
hotweather.
A WARNING
Nevertoucha hotmuffleror burn
willresult.
Keep
spark
plug
andwireconnec-
tion tightand clean.
Spark
plug
electrode
gapshouldbe checked
witha feeler
gauge
at leastevery
50operating
hoursandresetifnec-
essary.Fit
anewspark
plug
ifelec-
trodes
are badly
pitted
or fouled
withcarbonbuildup.
Storelawn
edgerina dry,highor
locked
location
place
and out of
reach
ofchildren.
A WARNING
Startand operate
your unit out-
doorsinaventilated
area.
A WARNING
Gasoline
(petrol)
is an extremely
flammable
andexplosivefuel.Use
extremecautionwhen handling
gasoline
orfuelmix.Donotsmoke
orbringany
fireorflamenearthe
fuel.
WARNING
The lawnedgeris a one-person
machine.Toreducetheriskofeye
orotherinjury
fromthrownobjects,
ensurethat
bystandersareatleast
15feet
(5m)
away
duringuse.Re-
place
immediately
anywornorbro-
kendebrisdeflectorshieldorblade
cover.lfapproached,release
throt-
tle trigger to immediately
de-
acceleratetheengine. A WARNING
Alwaysstop
the motorand
make
surethat
theblade
isstoppedbe-
fore
adjusting
bladeheight,doing
any maintenance
or repair
work,
cleaning
theunitor
removing
grass
ordebris
fromtheblade.
WARNING
Alwaysallowenginetocoolbefore
refuelling.Accidental
spillageof
gasoline
over hot enginecould
causefireorexplosion
tooccurwith
consequent
possible
disfigurement
or fatalinjury.Washandclean
handsafterfueling.
A WARNING
When
youpull
starter
grip,
do not
p
starterropearound
your
hand.
Do
notallow
grip
tosnapback,but
guide
starterropeslowlybackto
permit
ropetorewind
properly.
l\ wARNTNG
Awornor
damaged
mufflerisafire
hazard
andmaycause
lossofhear-
ing.Check
tosee
thatthe
muffleris
ingood
condition.
Thelawnedger
mustnotbe
operatedifthemuffler
isnotfunctioning
properly,
is
dam-
aged,
or hasbeenremoved.In
order
to reduce
theriskoffire,do
not
modifyor removeany
part
of
the
muffler.
7
A WARNING
Neverstore
themachinewith
gaso-
lineinside
a buildingwherefumes
mayreach
anopenflameorspark,
e.g.
gasor oil firedheaterappli-
ance.
electric
motor
etc.
I
SAFETY
PRECAUTIONS
(cont'd)
Beforestoring
fora longer
period,
alwaysempty
thefueltank.
Keepthe
spacebehind
andbeside
theengine
clearatalltimestoallow
for the escape
of hot and toxic
exhaustfumes.
Operate
your
machine
under
good
visibility
and daylightconditions
only.Workcarefully.
WorkingConditions
When
workingwiththelawn
edger
always
wrap your fingerstightly
aroundeach
handle.Keep
your
handsinthis
position
tohave
your
machineunder
controlatalltimes.
never attemptto operatelawn
edgerwith one handas lossof
controlmayresult
inseriousorfatal
injury.
Makesure
thehandle
grips
arein
good
conditionandfreeof mois-
ture,
pitch,
oil or grease.Use
both
hands,
oneoneachhandle,toop-
erate
andcontrolthe lawnedger.
Do not overreach.
Keep
proper
footing
&balanceatalltimes.
A WARNING
Donottouchhotmotorduringand
immediatelyafteruseasyou
may
burn
yourself.
FuelMix
Prepare
the mixtureof a brand-
name
unleaded
gasoline
and
qual-
itytwo-stroke
(2cycle)engine
oilin
an approvedsafety-type
canister.
Pourintheoilfirst
(eg.
Castrol2T
two stroke oil or equivalent)and
thenadd
gasoline.
Donot
useBIA
or TCW (two cyclewatercooled)
mixoils.
Well knownbrandsof 2 stroke
(2
cycle)engine
oilarerecommended.
Theyareformulated
specially
for2
cycleengines
and guarantees
a
long
enginelife.
For
the
sake
ofyour
health
andthe
environment
unleaded
gasoline
is
recommended.
A WARNING
Pressure
maybuild
upin
thecanis-
ter.Remove
fuel cap slowly
to
avoid
injuryfromfuel spray.
Re-
place
fuelcapsecurely.
Clean the fuel tank and can
fromtimetotime.
Take
carewhenhandling
gasoline.
Avoiddirect
contact
withtheskin
andavoid
inhaling
fuelvaPor.
Change
fuelpickup
filter
at least
once
every
year
ormore
frequently
depending
onuse.
Beforefueling,
clean
thefiller
cap
andtheareaaround
it to ensure
thatnodirt
fallsinto
thetank.Never
mix
the
gasoline
and
oilinthe
fuel
tank
oftheengine.
Always
allowengine
tocool
before
refuelling.
Accidental
spillage
of
gasoline
overa hotengine
could
causefire
orexplosion
tooccur.See
Page6 Safety
Precautions
Fu-
elling.
Fillor addfuelto thetank
only
whenthe edgeris in a horizontal
position
asshown
(Fig.
7).ALLOW
engineto cooldown
foratleast5
minutes
beforeadding
fuel.
FIG6
FUEL
MIX
ANDFUELING
ASSEMBLINGTHELAWNEDGER
Fitcross
bracetohandleswithbracetotouch
ground.
Use4 screws
and4
locknuts
provided
inpacket
[see
A].Fithandleassembly
to edger.Insert
150mm
(6")
bolt(B).Screwlarge3 wingnut(C) so that boltend is
approximatelyflush
(level)
withfaceofcentrebossoflarge
wingnut.This
allowshandle
"platform"
to "float"
withoutvibration.DO NOTOVER-
TIGHTEN
BOLT.
Fitthrottletoright
handhandle
[see
D].Clip
in
throttlecable/ignition
switch
wirewith2 cableclampsattachedtohandle
[see
El
A WARNING
Electrical
shock. Nevertouch
electrical
wires or components
while
theengineis running.They
aresourcesof high
voltage& can
giveyouan electricalshock.Re-
place
immediatelyanyfaultyhigh
tensionleadorspark
plug
cap.
25:lMixChart
GasolineL 1z34
2-cvcle
oilML 480 120 160 200
RecommendedMixing Ratio
Term Gasoline
:Oil
Up
to20hoursuse 20.1
After20hoursuse 25.1
STARTING
&STOPPING
INSTRUCTIONS STARTING
&STOPPING
INSTRUCTIONS
(cont'd
Inferior
qualitygasolines
or oils
may
damage
the engine,sealing
rings,
fuellinesor fueltank,and
6sgulsttor.
Alsocausesroughand
irregular
runningandstarting.
Only
mix sufficientfuelfor a few
weeks
work- store in approved
safety-lype
canisters.
Pour
oil in
first.
Screw
fhefuelcancapontightlY
and
thdroughly
shakethemixture
before
fueling
your
machine.
FIG7
1. Pla6e
lawnedgeron
ground
in
horizontal
position
lsee
Fig.91.
gs surethe ignitionswitchis
'g$". Pullswitchtowardopera-
1s1
to turn
ON.
Switchlocated
on
fight
sideoftrigger
fsee
Fig.
81.
2. Set trigger throttleto 112
THROTTLELOCKby placing
hand
onhandle
grip
and
push-
ingdownsafetyinterlock
with
thumb,
and
pulling
upandhold-
ingtrigger
withfinger.Then
movethumbto holdin 112
throttlebutton,release
trigger,
thenrelease
1/2throttlebutton.
Trigger
throttleisthenengaged
athalfspeedforstarting
(only).
'l'
ItI
FIG9a
3. COLDSTART:Movechoke
leveruptostart
position.
Press
andrelease
primer
3or4times
untilthefuelflows
intotheclear
tube.Place
one foot on the
cross
brace.
FIG9b
Makesure
you havea firm
footing.Holddownmotorwith
lefthandandwithrighthand
pull
thestarter
grip
slowlyuntil
you
feelit engage
- andthen
give
itafast
pull
[Fig.
9].Donot
pull
outstarlerropemorethan
26"
(65cm)
- itmightbreak.
Standbetweenhandlestostart.
Do not let starter
gripsnap
back.
Guideit backslowlyso
thatthestarterropecanrewind
slowly.
PULLTHE STARTERROPE
BRISKLY
until
you hearthe
engine
soundlikeit wantsto
runorrunsthenstops
(normally
1-5
pulls).
Openchoke
gradually
to allow
motortorun.
lfitstops,
re-startandallowthe
engine
to runfora fewmore
secondson lz lhrollle lock
(engine
runsfast).Pullthrottle
trigger (releases% throttle
lock),& allowthrottletriggerto
slowly
pull
backtoengineidle.
Note: ln warmtemperatureor
hotmotorfhissfepmaynotbe
necessary.
HOT OR WARM START:
(Enginehas alreadybeen
startedandwarmedup).Switch
ignition"ON".Set1/2
THROT-
TLE
LOCK
[Fig.
8]. Pullstarter
until
motorrunsandletitrunfor
afewsecondsbeforereleasing
%THROTTLELOCK.This
aI.
lowscoolerfuelto enterthe
carburettor.
Allowthrottletrig-
ger
toslowly
pull
backtoidle.
Note:A built-inautomaticcen-
trifugalclutch disengagesthe
blade from rotating at engine
idlespeed.
Theclutchengages
the blade when the engine
speedisincreased.
Throttle
trigger(engine
accel-
eratorcontrol)is operatedby
pushing
down interlockwith
thumb
and pulling
on trigger
[Fis 8].
FLOODEDENGINE:
(Engine
willnot staft).
lf smokeor fuel
comesfrom exhaustand en-
gine
willnotstart.
i. Check
thatignitionswitchis
"ON',
CHOKELEVERison
RUN
position,
throttleisset
onHALFTHROTTLE
LOCK
position.
ii. Pullstarterropeup to 10
timestoclearengineoffuel
soitcanstart.
iii.lfenginehasexcessive
fuel
thatcannotbecleared
byi&
iiabove,
removespark
plug
from
engineandfromspark
plug
terminal,
crankengine
to clearexcess
fuel,wipe
anddry spark
plug
of all
fuel, re-install
spark
plug
andterminal,andrestart
as
above.
IMPORTANT:
After t hours
use tighten all screws
(especially9 screws around
gear case),checkevery 20
hoursuse.
10.
Tostopmotor
push
switchslide
onthrottletrigger
sideforward.
8.
il
I
il
I
4.
5.
1.
7.
A WARNING
Theblade
willrotatewhenengine
is
idling
fast
(eg.
onstarting
(1/2
throt-
tlelock]
orwhenmotoriscold).
TO STOPMOTORmove
ignition
switch
up intothe "OFF"
position
fpage
10Fig.
8].
lqxtrtoN ,r
swr'cH.{ I
l0 ll
Anti-Vibration
(AV)
Adjustment
Handlenut can be tightened
to
markon knobto obtainbestAV
affecttoreducehandlevibrations.
During
break-in
period
A factorynewmachineshouldnot
be run at high revs (fullthrottle)
withoutanyload.Thisavoidsun-
necessarywearduringthebreak-in
period.
Asall
moving
parts
haveto
bedinduringbreak-in
period,
fric-
tionalresistancesintheengineare
greater
duringthisperiod.
Engine
developsitsmaximum
power
after
about5to15tankfillings.
Whenusing,increaseenginerevs
asloadisincreasedonlawnedger.
Whenlawnedgerisunder
fullload,
fullthrottleistobe
used.
Afterfinishingwork
Storingfor short period
- keep
the unitin a dry place
until
you
needit again.Donot
storewhere
nakedflameorelectrical
machinery
isoperating.
Storingfor a long period
- drain
the
fueltank,runengineuntilcar-
burettoris
dry.
EDGING
OF
LAWN
The edgeris very easyand
simpletouse,andmostopera-
torscanimmediately
adaptto
itsunique
use.
Forsome
people
itmaytakea
fewedgingsto becomeaccus-
tomedtoitsoperation.
Thoroughlyinspect
the area
wheretheedgeristo beused
andremoveallstones,sticks,
wiresandotherforeignobjects.
1.
2.
OPERATING
INSTRUCTIONS
3. Adjustblade
height.Withanew
bladetrysecondholeclosestto
oPerator' HETcHTADJUsTMENT
FIG
10
Withbotharmsfullyextended
downwards
(see
illustration
on
frontcover)
holdbothhandle
grips
firmly.
Withthe engine
running
pull
thethrottletrigger
toincrease
enginespeed.
lf bladeisnotdeepenough,
or
is diggingtoo deep,adjust
bladeheightor
slightlyraiseor
lower
handlestosuitdepth
re-
quired
[Fig. 11].However
it is
alwaysmorecomfortable
and
relaxedto havearms
fullyex-
tended
downwards.
Ascutting
actionbegins,
push
thelawnedgerforwardsothat
thebladecancuttheedge
as
you
moveforward.
OPERATING
INSTRUCTIONS
(cont'd)
7. Continueat a moderate
pace 10.Clutch.The lawn edger
is
equipped
with a centrifugal
clutch.DO NOTrunedgerat
low
speedsorif blade
jammed
at high speeds
as clutch
shoeswill prematurely
wear
outandcausedamage.
FIG12
l\ wARNTNG
Onlyoperateunitwhenmovingfor-
ward. DO NOT operate
walking
backwardsas
youmaytrip,falland
injure
yourself.
A WARNING
To avoid
personal
injury,never
carrythe
edgerwhiletheengineis
running.Stayclearof therotating
blade.
Stoptheengine
prior
tomak-
ingadjustments
and
cleaning.
l3
8.
until
you
arefamiliarwiththe
controls
andthehandlingofthe
lawnedger.
lf bladejams or stops in
ground,
lowerhandles,
or pull
backunit and recommence.
Controlengineand cutting
speedtosuitwork
beingdone.
Whencuttingefficiently,
engine
speed
shouldbe full throttle
underload.
SidewaysTilting
:Lowereither
left or right
handto achieve
9.
4.
5.
6.
angle
cutting.
Toedge
deePer
lift
handles
FIG
11
t2
MAINTENANCE
thefiltertospread
theoiland
to
remove
excessoil
[Fig.
16].
Reinstallthe filter air filter
cover.
Note: lf the unit is operated
witha dry or dirtyfilteror with-
outtheairfilterand/orcarburet-
tor/airfilter cover,you will void
wananty.
Note:Fuel
Filter.When
themo-
torrunsshortoffuel
supply
and
the tank has gasoline in it,
check the fuel filter for block-
age.
CARBURETTOR
ADJUST-
MENT
This unit is equipped
with a
diaphragm-type
slide carburetor
that
hasbeencarefully
calibrated
at
thefactory.
In mostcases
no fur-
ther
adjustmentwill
berequired.
The condition
of the air filteris
importantto the operation
of the
edger.
A dirtyairfilterwillrestrict
theairflow,which
upsetsthe
fuel-
airmixtureinthecarburettor.
The
resulting
symptomsare
often
mis-
taken
foranout-of-adjustment
car-
burettor.
Therefore.check
thecon-
ditionof
theairfilter
beforeadjust-
ing
thecarburettor.
lfthefollowing
conditions
areexpe-
rienced,
it may be necessary
to
adjustthecarburettor:
o Themotor
willnotidle.
. The
motorhesitatesorstallson
acceleration.
. Thelossofmotor
power
thatis
notcorrected
by cleaningthe
airfilter
andmuffler.
AIRFILTER
MAINTENANCE
Note:Cleanandre-oilthe airfilter
Every5 hoursof operation
ordaily.
The air filter is one of the most
importantareas
to maintain.lf it is
not maintained,
you will void the
warranty.Before cleaning,
make
sure
theunitisturnedoff.
FIG16
Washthe
filterindetergent
and
waler
[Fig.75l.Rinse
thefilter
thoroughly
andallow
ittodry.
Applyenough
cleantwo-stroke
oilorSAE
30oiltosaturate
the
filterwhen
squeezed.
Squeeze
1.
2.
l4
MAINTENANCE
(cont'd)
. Themotor
operatesin an er-
ratic or fuel-richcondition
(indicated
by excessiveex-
haust
smokefrom
themuffler).
Note: Carelessadjustments
canseriously
damage
the car-
bureftor
and/ormotor.
ADJUSTINGTHECARBU-
RETTOR
1. Cleanairandfuelfilter
if it is
dirty.RefertoAirFilterMainte-
nance
(Page
74).Throttletrig-
ger
tobeinidle
position.
Fuel Filter:Whenthe motor
runsshort
of fuelsupplyand
the tank has gasoline
in it,
cleanthefuelfilterforblockage
[Fis.17]
2. ThrottleCable:The normal
play
is1-2mm
whenmeasured
at the carburetor
side.Re-
adjustwith
the cable
adjustor
asrequired.
3. Engineldling
Setting:To in-
creasemotoridlespeed,turn
clockwiseldle screw
( ) [Fig.
191lo decrease
motor idle
speed, turn counter(anti)-
clockwise.
Note:
Edger
bladenottorotate
whenmotorisidling.
Note:Throttlecablewireis not
to be pulled tight (againsttrig-
ger throttle). Trigger.tohave
smallinitialmovementbeforeit
pullscable and carby throttle
lever.
Note:Forcingthe high speed
mixturescrew (B) (withscrew-
driver) will damagethe screw
tipandthe seatinthecarburet-
tor body.Closehigh speed
jet
andopen2.5 turns! 1/2turn
[Fis 1e].
Set1/2throttlelock
[Fig.
I page
70l.Startthe motorandlet it
runfor
afew
seconds-
Release1/2throttlelockandlet
the motoridle.
lf the motor
stops,turnthe idlescrew
(A)
clockwise1/8turn at a time
(as required)until the motor
idles.lf idlespeedit too high
turn idle screw (A) counter
(anti)-clockwise.
3.
4.
FIG17
MAINTENANCE
(cont'd)
5. High SpeedScrew Mixture
Adjustment:
The factory
presets
the high
speedmixturescrew(B) at
2.112t 1/2turnsoutfromthe
closed position.
Your unit
should
perform
wellatthisset-
ting.lf additionaladjustment
of
the highspeedmixtureis re-
quired,
contact
your
localau-
thorizedservicedealer.
Note: Theedgerbladeshould
not
rotatewhenthemotoridles.
Note:lf the carburettoradjust-
ments
do not helpthe unit to
run properly, contactyour au-
thorizedservicedealer.
Recom-
mendedidle speedis 3000to
3200RPM.
BLADEREPLACEMENT
1. Stopmotor.Cleanareaaround
dustcoverand pry out with
screwdriver
[Fig.20].
2. Throughdustcoverhole
place
14mmsinglesocketspanner.
On bladeend of shaft
place
17mmspanneron bladenut
[Fig.
21].
3. Unscrew nut counter(anti)-
clockwise
(normal
right hand
thread).
4. Removeonesmallwasher,
one
largewasherandblade.
Before
fittingbladeand
washers,clean
all gritand
grease.
Assemble
these
parts
cleananddry.
Fit
largewasher,newblade
with
flat blade on inside,
large
washer,onesmall
washer,and
nul
[Fig.23l.
Tightennut.
A WARNING
Useonly
Atom blades
(P/N
43105).
Other
bladeshavelarger
sizeholes
(1/2) which will cause out-of-
balance
vibrations
whichwilldam-
age
unitandMUSTNOTBE FIT-
TED.
- - scnewDavea
LEVER3 OFF DUST
COVER ETPOSINO
lilllt| HEX HEAD
FOR U}|SCRE!4NO
BLAOE IIUT
FIG21
A WARNING
Do not run motorwithout
blade
tightenedto bladeshaft
as gear
damage
willoccur.
l6 l7
MAINTENANCE
(cont'd)
5. Clean plastic dust cap and
housing,
press
backby gently
tappinginto
place.
Clean
inside
bladecoverofany
builtupdirt.
CHECK
THESPARK
PLUG
lf motorisdown
onpower,
difficult
to start
or runs
poorly
at idling
speed,check
thespark
plug.
. Allowmotor
to
cooldown.
. Remove
spark
plug.
o Clean
dirty
spark
plug.
. Checkelectrode
gap
- itshould
be0.02"
(0.5mm).
. Rectify faults which have
caused
fouling
ofspark
plug.
Possiblefaults
include:
a
a
a
a
Incorrect
carburettor
setting
Toomuch
oilorwrong
tyPe
of
oilinfuel
mix
Old
fuelmix
Dirtyair
filter.
o Unfavourable
running
condi-
tions (eg. operating
at Part
load).
Donot
cleanthe
spark
plug
inan
abrasive
gritspark
plugcleaner,
as
expensive
damageto themo-
tor could occur
throughloose
grit
damaging
chrome
in
cylinder
bore.
Fita newspark
plug
after
approxi-
mately100
operatinghours
orear-
lier
if electrodes
arebadly
eroded
(recommended type Champion
RCJ-]Y).
CHECKINGEXHAUST
MUFFLER
Tightenexhaust
screws.
lf exhaust
gasket
isleaking,
replace
gasket.
if
themotor
isdown
onpower
check
the muffler.
Allowmotor
to cool
down.
Remove
andscrape
out
ex-
cess
carbonon bothinlet
and
exit
exhaust
or have
thisdoneby a
service
dealer.
FIG22
LOOSEBLADE
Asin1and2 ofBlade
Replacement
andtighten
nutclockwise.
LUBRICATION
OFGEARS
Theoil inthe gear
caseshould
be
topped up accordingto use by
adding light free flowing lithium-
based grease (Castrol EPO)
throughfillhole
in casing
[Fig.
20].
Use a suitable filling gun or
squeezeoil pack(P/N43227).
Re-
move bleedscrew
to allow
grease
to ejectindicating
gearbox is 3/4
full.Refitbleedscrewandpush
in
3-4 more pumps. Refit fill bolt
(tighten
gently).
A WARNING
Over tighteningwill cause plastic
thread
tostrip.
TROUBLE
SHOOTING
PROBLEM CAUSE ACTION
Motorwillnot
run. lgnitionswitch
is
"OFF"............,..... Turn
switch
"ON".
Pushdown.
Fillfuel
tank.
Press
primer
bulb
fully& slowly5
times.
Ilseslartinanrocedrrrewilhout
Primerbulb
wasnot
pushed
enough
times
using
choke.See
page
11
Motor
willnot
idle. Carburettor
misadjusted..... Adiustthroftleidlesoeedadiust-
ingscrew.
Adjustcarburettor.
See
page
15.
Motor
willnot
accelerate. Carburettor
misadiusted...... Arliusi carblrre,ttorSee oaoe 15
Motorruns
roughor
hard
tostart.
Carburettor/crankcase/
cylinder
gaskets/
crankshaftseal
leaking......
Damaged
motor
parts...... Tighten
screws
Replace
gaskets
witha sealant
and
tightenscrews.
Replace
crankshaft
seal,damaged
parts.
Motorlacks
power
orstalls
whencutting.
Diriv air filter Cleanorreplace
airfilter.
See
page
14.
Readjustcarburettor.
See
page
15.
Wrongcarburettor
adjustment
...
Cutting
blade
doesnottum
when
operating.
Bladecover
filledwithdirt/grass
(1lrrlah elinnina Clean.
CullessdeothCheckclutch.
hlada Tighten
nut.
See
page
17.
Gear
caseleak-
ing. Tighten.
Replace.
EtrnLan "f.\" rina
Noisy
gears. Noheavyoilin
gear
case
Looseblade
nutorgear
adjustment Refill.See
page
15.
Reassemble
parts
correctly.
l8
Atom Industries (ATOM)watrants each new ATOM
LawnEdger
forTWELVE
(12)
months
fordomestic
useto
thelollowino
terms
Thiswirranty
extendsto the original
retail
purchaser
onlyand commences
on the date of original
retail
puc
chase.
Anypart
oftheATOMLawn Edgermanufactured
or
suppliedby
ATOMandfound
inthereasonable
judgement
ofATOMto bedetectiveinmaterialor
workmanship
willbe
repairedor
replacedby
anauthorised
ATOMseryice
dealer
without
chargefor
parts
andlabour
TheATOMLawn
Edger,including
any
defective
part,
mustbereturned
to an authorised
seryicedealer
within
the
warranty
period.
Theexpense
ofdelivering
theATOMLawn
Edgerto the dealer
forwarranty
workand
theexpenseof
returninoit backto the owner
after
repairor replacement
will be
-paid
for by the owner.
ATOM'S
responsibility
in
respect
to claimsis limitedto making
therequired
repalrs
orreplacementsand
noclaimot breachof warrantyshall
be cause tor cancellation
or rescissionof the Conkact ot
Saleot anyATOMLawn Edger. Proofof purchase
will be
requrred
bythedealer
to substantiate
anymrranty claim.
All rerranw work must be performed
bv an authorised
AToM seryice
dealer
orbvAt6m
Industries
Thiswarrantyis limitedto NINEry (90)daysfromthe
dateof originalretailpurchase
for any ATOM Lawn Edger
thatis usedforcommercial
purposes
andONE (1)
month
lor rentalourooses.
Thiswatrantydoes notcoveranyATOM LawnEdger
that has beensubject
to misuse,
neglect,
negligenceor
accident,or that has been operated
in anyway contraryto
theoperatinginstructions
as specified
intheATOMOpera-
tor'sManual.
Thiswarranty
doesnotapply
to anydamage
to the ATOM Lawn Edger that is the result of improper
maintenance
orto any
ATOMLawn Edger
thathasbeen
alteredor modifiedso as to adversely
atfectthe products
operation,performance
or durabilityor that has been al-
tered or modified so as to change its intended use The
warrantydoes not extend to repalF made necessaryby
normalwear or by the use of parts or accessotieswhich
are either incompatiblewith the ATOM Lawn Edger or
adversely
affectitsoperation,
performance
ordurability
PLEASE
FILLININFORMATION
BELOWON
PURCHASE
AS THIS WILL ALSO BE REOUIRED
FORANYWAR-
RANTY
DATEOFPURCHASE:
PURCHASED
BY:
Address:
State IPost/Zip
Code:
SOLDBY:
Addressr
State: lPostZip Code:
Operator
Manual
PartNo.43580Printed
inAustralia
Copyrighl
@1997ATOM
INDUSTRIES.
ALLRIGHTS
RESERVED
A separaleLawn
EdgerWorkshop
Manualis available
PartNo.43564also
Engine
ManualPart
No43572
ATOMINDUSTRIES,
9 FREDSTREET,
LILYFIELD,
NSW.2040,
AUSTRALIA
PO
Box513,
Rozelle,NSW,2039,
AUSTRALIA
Phone
withinAuslralia:
(02)
98106691
- International:.
+61
298100194
Fax
withinAustralia:
(02)
9810
6691
- International:
+61
29E10
6691
ATOMINDUSTRIES
is a division
ofSolo Industries
PtyLld (ACN
000583924)
ATOM reseruesthe right to change or improvethe
designof anyATOM Lawn Edger withoutassumingany
obligation
tomodifyany
productpreviously
manufactured.
ALLIMPLIEDWARRANTIES
ARE
LIMITED
INOURA-
TION
TO THE TWELVE (12)MONTH
WARRANry PE-
RIODOR NINEW (90) DAYS FOR PRODUCTSUSED
FOR ANY COMMERCIAL
PURPOSE ACCOROINGLY
ANY SUCH IMPLIEDWARRANTIES
INCLUDING
MER-
CHANTABILITY.
FITNESS
FOR A PARTICULARPUR-
POSE OR OTHERWISE.
ARE DISCLAIMED
IN THEIR
ENTIRETY
AFTER
THEEXPIRATION
OFTHEAPPROPRI.
ATETWELVE
(12)
MONTHS
OR NINEry (90)
DAY
WAR-
RANTYPERIOD ATOM'S OBLIGATION
UNDERTHIS
WARRANry IS STRICTLY
AND EXCLUSIVELY
LIMITED
TO THE REPAIR
OR REPLACENiIENT
OF DEFECTIVE
PARTS,
ANDATOM DOES
NOTASSUMEOR AUTHO-
RISE ANYONETO ASSUMEFOR THEM ANY OTHER
OBLIGATION.
SOME STATES
DO NOTALLOWLIMITA-
TIONSON HOWLONG
ANIMPLIED
WARRANTYLASTS,
SOTHEABOVELIMITATION
MAYNOT
APPLYTOYOU,
ATOMASSUMESNO RESPONSIBILITY
FORINCI.
DENTAL.
CONSEQUENTIAL
OR OTHER
DAMAGESIN.
CLUDING,
BUT NOT LIMITED
TO EXPENSEOF RE-
TURNING
THE ATOM PRODUCTTO AN AUTHORISED
SERVICE
DEALER
AND EXPENSE
OF DELIVERING
IT
BACKTO THE OWNER. MECHANIC'S
TRAVELTIME,
TELEPHONE
ORTELEGRAM
CHARGES,RENTAL
OFA
LIKEPRODUCT
DURING
THE TIMEWARRANTYSER-
VICE
ISBEINGPERFORMED.
TRAVEL.LOSS
OR DAM-
AGETO PERSONAL
PROPERry,
LOSSOF REVENUE,
LOSSOF USEOFTHE PROOUCT,LOSS
OFTIiTE,
OR
INCONVENIENCE,
SOMESTATES
DONOT
ALLOWTHE
EXCLUSION
OR LIMITATION
OF INCIDENTALOR CON-
SEOUENTIAL
DAMAGES,
SO THE ABOVELIMITATION
OREXCLUSION
MAY
NOTAPPLY
TOYOU.
Thiswarrantygivesyou speciticlegal rights,and you
mayalso have
otherrights
whichvary
fromstateto s-tate.
Thrswarrantyapplies
to all ATOM Lawn EdEers
manuiactured
byATOM
G
:
o
o
=
U'
o
E
f
E
62
tlJ s
56
s=
Jo
:*
;*
a-
5(!
FO
20
2
v
v
ATOMLA\ryN
E,DGE,R
GK3-f)PRO-ENGINE
SERVICE
MANUAL
CONTENTS
Specifications
& Standards
SpecialTools
Dissassembly
ofEngine
Fuel
Supply
System
Carburettor
Fuel
Feed
Line
Ignition
System
Recoil
Starter
Clutch
Parts
List
Exploded
View
Page
No
WARNING:FUELISA HIGHLY COMBUSTIBLE
SUBSTANCE.
DRAINALL
FUEL FROM TANK AND KEEPAWAY FROM WORKPLACE IN A SEALED
CONTAINERBEFORE
COMMENCING REPAIRS. MAKE SURE
ALL PARTS
ARECLEANBEFORE
ASSEMBLY.
2-3
3
4-8
9
10
lt
t2
13
t4
l5
t6
ATOM INDUSTRTES
P.O.Box513,
Rozelle
NSW
2039
9Fred
StreetLilvfieldNSW2040
Tel:
(02)
9810
0194
Fax:
(02)
9810
6691
E-mail:
ECIFICATIONS
G3K.D
Pistondisplacement Air
cooled
2-stroke
gasoline
engine
cc 33.6
mm 36x33
Nikki
Flywheel
magneto,
transistorcontrol
Champion
RCJ-8Y
Rewind
starter
Primary
coilshort-circuiting
Mixture
ofalcohol-free
gasoline
and2-cycle
oil
(ratio
25:1)
L 0.65
TECHNICAL
DATA
G3K-D
Maximumoutput kW 1.10
at7000rpm
Maximiumtorque N-m 1.77
at5500rpm
ldling
range rpm 2100
-2300
utchengaging
range rpm 2750
- 3250
stallrange rpm 4250
- 4750
fuelconsump- g/kW-h 620
FUEL
/OIL
RATIO
Gasoline
:Oil
Upto20hoursuse 20 : 1
20hoursuse 25 1
MAINTENANCE
STANDARDS
ITEM
.ENGINE
pressionpressure
G3K-D
STANDARD LIMIT
7.0 5.0
36 36.04
36 35.86
I 9.04
0.045 0.2
0.002T 0.05L
1.5 1.6
0.04 0.15
'1.5 1.4
0.1
-
0.3 0.7
9 898
12 12.03
12 11.95
0.02 0.07
0.1
-
0.3 0.4
REMARKS
Reject
if plating
dam-
aged
inderbore
outerdiameter
pin
bore
rence
between
cylinder
& pistion
Tolerancebetween
piston
hole& pistonpin T=tight;L=loose
ofgroove
for piston
ring
between
groove
and
piston
ring
istonring
width
iston
ringend
gap
iston
pin
outer
diameter
rod
smallendbore
rankshaft
diameteratbearinosection
ftmisalignment
rankshaft
end
play
INTENANCE
STANDARDS
. IGNITION
SYSTEM
ITEM G3K-D
ISTANDARD ALLOWANCE REMARKS
gap
between
core
androtor 10.4 r 0.1
Spark
plug
air
gap 06 ,0.7
Primary
coilresistance C
67 l! 15Vo Reading
betweencore& switch
wireterminal
coif
resistance :::: ! 20o/o Readino
betweencoreand o
MAINTENANCE
STANDARDS
. CARBURETTOR
G3K-D
ITEM STANDARD
IALLOWANCE REMARKS
ldlelimiter
oosition
Levelof metering
lever
Main
jet
# - high
speed
Jetneedle#-stage
Inletvalve
cracking
pressure kg/cm2
,1 A
2.5
596
-2/3 0.
r 0.1
r 0.5
44
-t I
Right
turn:
lean. Leftturn:
rich.
See
page
10
See
page
9 (item
21)
Topstage:
lean. Bottom
stage.rich.
ASTENER
SPECIFICATIONS
.WORKING
UNIT
ITEM THREAD
DIMENSIONS
(metric) TIGHTENING
TORQUE
(kgcm)
Enginemounting
bolt/ EM5x 1.0 50-90
FASTENER
SPECIFICATIONS
. POWER
UNIT
ITEM
Crankcase
halves
fastening
screw
Cylinder
mountingbolt
(Except
forYBC3OD)
Starter
pulley
mountingnut
(YBCSOD
only)
Rotormounting
nut
(YBC30D
&YBC4OD
only)
utch
shoe
mountingbolt
(Except
forYBC3OD)
fflermounting
bolt
(Except
forYBC30D)
mounttng
screw
rtercase
mounting
screw
(YBC3OD
&
YBC4ODonly)
parkplug
THREAD
DIMENSIONS
(metric)
M5x 0.8
M5x0.8
M10x
'1.0
M8
x1.0
M8x10
M6x 1.0
M5x0.8
M5x 0.8
M14x 1.25
TIGHTENING
TORQUE
(kg-cm)
25-40
50-80
200
-300
120
- 180
110
- 170
80
- 120
30-45
20-35
150
-220
CIAL
TOOLS
PARTNUMBER
Puller
assembly
Set
block
Rod
assembly
Stopper
Toremove
rotorand
starter
pulley 1075-96100
1400-9621
0
1600-96300
1
664-96411
lToset
pole
core
gap
Toremove/installpistonpin
To holdcrankshaft
K
12
SEftVICE GUIDE
ENGINEBLOCK
Construction
t1
13
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1. Cylinder
2. Gasket,
cylinder
3. Crankcase,
rotor
slde
4. Crankcase,
starter
slde
5: Gasket,
crankcase
6. Malnbearing
7. Oll seal,slarterslde
8. Oll seal,rotor side
9. Clrclip
10. Piston
11. Piston
ring
12. Plston
pin
13. Circlip
14. Thrust
washer
15. Crankshafl
15.
17.
18.
Key
Shim
Needlebearing
v
A. Disassembly:
l. Separateenginefromworkunit Drainfuel
tankand
cleantheexterior
ofthe eneine.
2. Remove
fuel
tank.aircleaner"carburettor.
muffler
guard.
muffler.
rylinder
cover.starter
case,
fancoverandspark
plug.
NOTE.
Whenremoving
carburettorandmuffler.
takecarenot
todamagethe
gasket.
Ifdarnaged.
replace
withanew
onewithoutfail
3. While holding clutch shoesu'ith :rrod.unfas-
ten securing
bolts with a sockc
4) Unfasten
the
rotor
securing
nut
andremove
rotor
by
using
the
specialtool.
Note:
. Do notattempt
to remove
rotor
by hitting
on
crankshaft.
That
may
disorder
the
crankshaft
di_
mensions.
. When
litting
thepuller,
make
sure
to thread
in
the sidebolts
to equal
depth
over 10mm
or
threads
onrotor
may
be
damaged.
5) Unfasten
thestader
pulley
securing
nutandre_
move
starter
pulley
by
using
the
special
tool.
Note:
Do
not
attempt
to remove
thepulley
byhitting
on
crankshaft.
That
can
damage
the
crjnXinaft.
Extending
the
end
gap,
removepiston
ring.
Remove
circlips
from
both
sides
ofpiston
pin
by
using
apointed
tool.
Dd4'
6) Remove
cylinder
bypulling
it
straight.
Note:
Do
not
twist
cylinder,
orpiston
ring
may
be
broken.
Note:
Take
care
not
todamage
piston.
9) Push
out
piston
pin
with
the
speciallool.
7)
B)
v
t-
Rod
assembly
Note:
Wnen
tapping
onspecial
tool,hold
piston
inhand
soas
not
togive
shock
onconnectingrod.
10)Unfasten
fourscrews,
separatecrankcase
halves
and
pull
out
crankshaft.
Note:
. Makesure
that
key
isremoved
from
crankshaft.
. Do
notusea screwdriver
topry
openthefitting
surface
ofcrankcase
halves.
When
itdifficultto
separate,
lightly
tapon the halves
witha soft
hammer.
Reference:
Removing
oilsealandmainbearing.
1) Oilsealshould
bebroken
otf{rom
crankcase.
2) Mainbearingshould
bepressed
outwith
jigsap'
plied
as showninthefigure.
Note:
Donotre-usesuchanoilsealonceremoved.
Notes:1.
2.
3.
The
crankshaft
isa built-up
type.Donotattempt
todisassemble
without
duefacilities.
lfdefective
be
found
inthecomponent,replaceascrankshaft
complete.
Check
theservicelimitsasnecessary.
Gasketsonceremovedshould
bereplaced
withnewones.
PTOslde Starlerslde
B. Inspection:
Parl Check
point Repair
Cylinder
Piston
Piston
ring
Needle
bearing
Crankcase
Crankshaft
. Carbon
depositsonthe
headandexhaust
port.
. Scoring
or
peeling
ofl
ofplated
bore.
. Carbon
depositsonlhecrown
andinthe
ring
groove.
. Serious
damageor
partial
wearonthesurface.
. Damageor
partial
wear.
. Looseness,
damage
ordiscoloration.
. Damage,wear
orhardeningofoilseals.
. Roughrotationofmainbearing.
. Crackordarnageolcase
body.
. Damage,discolorationorexcessive
wear
ofconnecting
rodeitherend.
. Scrape
otfcarefully.
. Replace.
. Scrape
otfcarefully.
. Replace.
. Replace.
. Replace.
. Replace.
. Replace.
. Replace.
. Replace.
4) Install
bearing
andwashers
loconnectingrod
small
end.
Assemble
piston
with
piston
pin
byusing
the
special
tool.
Then,
secure
piston
pin
with
circlips.
Note:
. Make
sure
to point
the arrowmark
on piston
toward
the
exhaust
side.
. lf
circlipis
distorted,
usenew
one
without
fall.
Cut this sectionoff.
6) Fit
piston
ringto
pistongroove.
Make
sure
thatthe
end
gap
isproperly
located
atthe
positioning
pin.
7) lnstallcylindertocrankcasewhileholding
piston
ring
in
the
groove.
Tighten
evenly
with
fourscrews.
Note:
. Confirmcylinderbore
and
piston
ringarecoated
withoil.
. Usenew
gasket
forcylinder
base
flange.
. Twistingofcylindercandamage
piston
ring
and
cylinderbore.
8) Fitkeyto crankshaftPTO
side.
Install
rotor
with
keywayfitted.Tightenfirmlywith
nut.
Note:
. Checkkey
and
keywayfor
damageordistortion.
lfnecessary,
use
new
parts
withoutfail.
. Keyway
position
isindicated
by
wedge-shaped
mark
onthebossofrotor.
9)
,Tighten
starter
pulley
tocrankshaft.
10)lnstall
other
parts
as
theyare.
Note:
. Payspecial
attentiontocarburetorflange
gasket.
lfdefective,replacewithoutfail.
. Wheninstallingclutchshoes,
facethe arrow
sideto outside.lf reversed,theshoes
willbe
worn
rapidlyaccompanied
withextravibration.
v
v
Exhaustma;k
5) Put
crankshaft
into
crankcase
starterside
andfit
crankcase
sidewith
gasket
inserted.Tighten
the
halves
evenly
withfour
screws.
Note:
. Usenew
gasket.
. Checkthefitting
surfaee
for
chipsofold
gasket.
. Cutoffexcessive
gasket
protruding
atcylinder
base
flange.
1)
2l
Assembly:
Note:
. Cleandisassembled
parts
wellandkeepthem
freefrommetal
orcarbon
chips.
. Apply
grease
to
thelipofoilseals.
. Coatmoving
parts
with
2-cycle
oil.
. Before
actual
assembly,checkfit
ofparts.
Fitthecirclip
inthe
groove
ontheshafthole
(PTO
sideonly).
Press
fit the mainbearing
to the shaft
holeof
crankcase.
Note:
. Make
suretopress
thebearing
straight.
. Donot
useahammer
to
installthe
bearing.
. Make
thenumber
sideoppositeto
theoilseal.
. Before
pressing
in,
coatthebearing
withoil.
3) Coat
the
lipofoil
sealwithheat-proof
grease,
then
fitin
the
shafthole
asshownin
thefigure.
PTOslde Starlerside
PTOslde Starter
side
FUEL
SUPPLYSYSTEM.G3KD
v
v
I
.fuh 23
25
26
27
28
29
30
--o
-@,
-e
1, Screen
3. Cleaner
4. Element
7. Maln
body
8. Rubber
cap
9. Body cap
10. Throttlesprlng
11. Needle
spring
12. Recelve
13. Jel needle
14. Throttlevalve
16. Pumpcover
assembly
17. Pump
dlaphragm
18. Gssket
19. Sprlng
20. ldle
adjusting
screw
21. Maln
adJustlng
screw
23. Needle
valve
24. Hlnge
sprlng
25. Hlnge
26. Hinge
pln
27. Set
screw
28. Gasket
29. Maln
dlaphragm
30. Maln
diaphragm
cover
-\1
,e*:")^-
^Nl
,o__M.^ ./
n @o'' "
l. Fueltank
2. Cap
3. Innercap
4. Gasket
5. Filter
assembly
6. Clip
8. Suction
pipe
9. Check
valve
10.
Primer
pump
ll. Stopper
NOTE:Pipefrom tank goes to fuel pump (left hand side).
Pipefrorn primer goes to right hand side of carburettor
nearmain adjusting screw,
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